Final report chili oleoresin project usaid amd 045 14 may 2018

U.S. PAKISTAN PARTNERSHIP FOR AGRICULTURAL MARKET DEVELOPMENT
US-Pakistan Partnership for Agricultural
Market Development (AMD)
“
”
14 may 2018

1. Background.
Based on our previous working experience
on oleoresin extraction, we developed a
research methodology to investigate the
local market requirements and develop
specifications to finalize/customize an
appropriate size pilot plant to be used in
manufacturing of oleoresin based on
current technologies and available units.

2. Types of oleoresins.
Specification Capsicum Chili/pepper Paprika
Odor / taste Very pungent &
aromatic
Pungent &
Aromatic
Aromatic
Color Light red to red Red Deep red
SHU 80000-500000 80000-500000 Negligible
Capsicine 0.6-3.9 0.6-3.9 Negligible
Color Units (cu) < 4000 < 20000 40000-150000

Our current engagement in chili oleoresin.
We are engaged in manufacturing oleoresin extracts
with chili and turmeric as main raw materials, have
developed oleoresin capsicum and chili oleoresin
from dandi cut chili, paprika oleoresin from sweet
verity chili and turmeric oleoresin for curcuminoids.
Our main products are oleoresin capsicum for
pungency & oleoresin turmeric for curcuminoids.
Oleoresin capsicum does have a color value
however the finished products are usually
concerned with the biological activities of capsaicin
(pungent principle).

3. Research methodology.
I. Current status of industry.
II. Types of raw material Availability.
III. Budget.
IV. Current technologies available in extraction of oleoresin.

Evaluation of Current status of industry.
• Understand demand of Grantees.
• Understand Local demand of Potential
Customers.
• Types of oleoresin products consumed in local
market.

Type of raw material Availability.
• Dandi Cut moderate yield, Pungency values 30000 -
45000* and color values 35-65 ASTA*.
• Hybrid moderate yield, Pungency values 60000-75000 and
color values 35-65 ASTA*.
• Talhar Sweet chili moderate yield, Pungency values 4000-
5000 and color values 100-130 ASTA*.
*Values provided by NFL

Budget.
A Financial budget of Rs.
9000000 is allocated for the
purchase of oleoresin plant by
USAID-AMD.

Current technologies available in extraction of oleoresin.
• Low temperature:
I. SCFE (Super Critical fluid extraction).
II. Subcritical (Hydrocarbon extraction).
• Solvent Extraction

Low temp. Super critical Fluid extraction (SCFE).
• Preferred technology by customers Oleoresin Industry in
Developed countries & uses CO2 as solvent.
• High initial investment and low processing cost.
• No solvent residue and low temperature application.
• Not preferred in paprika oleoresin industry due to poor
solubility of pigments in CO2.

Low Temperature Subcritical Hydrocarbon extraction.
• New technology mostly applied in manufacturing of
cannabis extracts.
• Uses propane or butane or a combination with high initial
investment.
• Practically very low level of solvent residue, low solvent
requirement and Low temperature application.
• Issues with Compatibility with other raw materials.

Comparison of different techniques available for Chili oleoresin extraction
Parameters SCFE Subcritical Solvent
Temperature Low Low Moderate
Temp duration Less Less more
Yield Low Adequate Good
Capsaicin Adequate Low Good
Color Low Adequate Good
Investment Very High High Economical
Process cost Low Low High
Compatibility* Low -
moderate
Low - moderate Good
Residual solvent No Negligible Considerable
*compatibility with other raw materials

Solvent Extraction.
• Most widely used technology.
• Uses various solvents and combinations.
• Adequate data for processing of all raw materials
available.
• Increased processing cost due to solvent concentration
and recovery as compared to SCFE and Hydrocarbon.
• Suitable for all types of extracts, oleoresin and oils.
• Solvent residue is major concern and require careful
processing to keep residual solvent under limit.

Pilot Plant selection.
On the basis of above researched factors a suitable
size Solvent extraction plant is to be
selected/customized from vendors having
technological capabilities, experience and willingness
to develop a pilot size oleoresin extraction plant. It was
indicated by USAID-AMD that pilot may preferably
selected from European or American origin. However
we have also included plants of Chinese origin for
comparison.

Typical Solvent Extraction Process.

Process flow in Solvent Extraction.
Pre-Processing
(Grinding)
Extraction with
suitable solvent/s
Filtration/separation
of liquid extract from
raw material
Concentration of
extract (solvent
removal)
Collection of extract

Key Customized Features required for pilot size
oleoresin extraction plant.
• Easy to handle Plug and Play.
• Easy material input and output handling.
• Must perform extraction efficiently.
• Must have adequate equipment to concentrate &
distill off residual solvent from extract.
• Following units are under consideration for
customization Preferably supplied from
experienced and renown companies.

1. 100 L Pilot Extraction Plant Germany (SOL01) Devex.
• Connect - Plug – Produce: Plant is ready for operation, after
connection to the local utility supplies.
• For development of oleoresin a small pilot Extraction/concentration
plant provides the ideal solution for developing product in a reliable
and easy to use configuration, or for small batch processing.
• The plant consists of 1x100 L extraction vessels, 200 L extract
collection tank, a plate evaporator with a downstream centrifugal
separator. A vacuum pump is connected to the condenser, and the
vacuum can be adjusted. The evaporation temperature can be
adjusted according to the product specific boiling curve through the
applied vacuum.
• Supplier Location: Germany Price : Euros 89,950/USD $106800

200 L Pilot Extraction Plant Germany

2. Herbal Extractor, Concentrator, Storage Tank
STCTL (SOL02 ).
Model DT-0.5m3 ,The whole unit includes Extractor,
Single effect concentrator 200 L/hr., Extract storage
tanks.
Price: USD 32200 China.

2. Herbal Extractor, Concentrator, Storage Tank
STCTL(SOL02 )

2.
• Normal temperature & pressure extraction,
dynamic recycling extraction, countercurrent
extraction & other processes. This device can
perform as dynamic continuous countercurrent
recycling extra-dynamic continuous
countercurrent extractor. It consist of 200 L
cryogenic extractor, vacuum concentrator and
chiller.
• Total Price Fob shanghai 35,000 USD

200L multifunctional extraction & concentrating machine China.

3. MAXI 50 PE-R 200 Lt heater vessel &
concentrator HP 10 Italy (SOL03) Timatic.
Equipment is high efficiency, latest developed small
dynamic extraction unit. It is composed of 50 L extracting
tank, evaporating concentrator 10 L/hr. and process
piping, with dynamic heat reflux extraction, vacuum
concentration and solvent recovery as a whole.
Unit Price USD 91466. FOB Italy

3. MAXI 50 PE-R 200 Lt heater vessel &
concentrator HP 10 Italy (SOL03).

3. MAXI 50 PE-R 200 Lt heater vessel & concentrator
HP 10 Italy (SOL03).

4. 200L multifunctional Dynamic versatile extraction &
concentrating machine China (SOL07 ).
• Normal temperature & pressure extraction, dynamic
recycling extraction, countercurrent extraction & other
processes. This device can perform as dynamic
continuous countercurrent recycling extra-dynamic
continuous countercurrent extractor. It consist of 200 L
cryogenic extractor, vacuum concentrator and chiller.

5. High Efficiency Low Temperature Extraction &
Concentration Production Line (SOL04).
• Based on soxhlet principle it consist of 600 Liters extraction tank,
concentrator evaporator 800 L/hr., It can extract 400-600 kg raw
material in single batch.
• Price : 95,500 USD/set FOB China.

5. High Efficiency Low Temperature Extraction &

6. LPMIE High Efficiency Low Temperature Extraction &
• 200L multi-function hot reflux extraction and
concentrate tank unit.
• Residue discharged from side of tank.
• Explosion-proof electric control cabinet
• Price: USD23000.00 FOB China

6. LPMIE High Efficiency Low Temperature Extraction &

7. RGMCL 500L herb extractor and concentrator
(SOL06)
• Unit composed of extractor, concentrator, condenser,
receiver and pipes, valves, meters and so on
• It is heated by steam, button control system
• Material contact parts are mirror polished, it is
stainless steel in compliance with GMP standard.
• Price: USD21500.00 FOB China

7. RGMCL 500L herb extractor and concentrator
(SOL06)

• Normal temperature & pressure extraction, dynamic
recycling extraction, countercurrent extraction & other
processes. This device can perform as dynamic
continuous countercurrent recycling extra-dynamic
continuous countercurrent extractor. It consist of 200 L
cryogenic extractor, vacuum concentrator and chiller.

Efficacy Comparison of different solvent plants under evaluation.
Reference #
Sol: solvent,
HC: Subcritical
Location Model Type
Ext. tank
Effective
Volume
Raw
material
capacity per
batch kg
(Approx.)
Batch
time hrs.
(Approx.)
Finished
Product
per batch
kg
(Approx.)
Finished
product
per day
(8 hours)
kg
(Approx.)
Price
SOL01 Germany
200L-
180017
Solvent 100 L 10 2 1 4 $106800
SOL02 China DT-0.5m3 Solvent 500 L 50 2 5 15-20 $32,200
SOL03 Italy 50 L Solvent 50 L 10 10 1 1-2 $91466
SOL04 China
LTQ-
6m3/1500
Solvent 600 L 500 8 50 50 $95,500
SOL05 China LPMIE 200 Solvent 200 L 20 2 2 8 $23000
SOL06 China 500 L Solvent 500 L 50 2 5 20 $21500
SOL02 China
200 L
MHUECM
Solvent 200 L 20 1 2 15 $50,000

5. Hydrocarbon subcritical extractor (HC01) 4.5 kg.
• Based on low temperature hydrocarbon subcritical
extraction, this unit processes more than 10 lbs. of
material per run with an average 60 minute recovery
time making it ideal for small scale commercial
production.
• Location: USA
• Price: USD 138404

Hydrocarbon subcritical extractor (HC01).

6. Hydrocarbon subcritical extractor 40 kg (HC02).
extraction, this unit processes more than 90 lbs. of
material per run with an average 4 hour recovery time
making it ideal for medium scale commercial production.
• Location: USA

7. Hydrocarbon subcritical extractor 4.50 kg (HC03).
extraction, this unit can processes more than 3 kg of
material per run with an average 60 minute recovery time
making it ideal for small scale commercial production.
• Location: USA
• Price: USD $60,000

Hydrocarbon subcritical extractor 4.50 kg (HC03)

extraction, more than 130 kg of material may be
processes per run with an average 6-8 hour recovery
time making it ideal for medium scale commercial
production.
• Location: China

Hydrocarbon subcritical extractor 150 kg (HC04).

Efficacy Comparison of different plants under evaluation.
Reference #
Sol: solvent,
HC: Subcritical
Location Model Type
Ext. tank
Effective
Volume
Raw
material
capacity
per batch
kg (Aprx.)
Batch
time
hrs.
Aprx.
Finished
Product
per batch
kg (Aprx.)
Finished
product
per day
(8 hours)
kg (Aprx.)
Price
SOL01 Germany
200L-
180017
Solvent 100 L 25 2 2.5 10 $106800
SOL02 China
200 L
MHUECM
Solvent 200 L 20 0.5 2 30 $50,000
SOL03 Italy 50 L Solvent 50 L 20 10 2 2 $91466
SOL04 China
LTQ-
6m3/1500
Solvent 600 L 500 8 50 50 $95,500
HC01 USA X 10 Subcritical 14L x 2 4.5 1 0.45 3.15 $138,404
HC02 USA PX 40 Subcritical 180L 40 4 4 8 $258,590
HC03 USA
10LB
Active PSI
Subcritical 10 L 3 1 0.3 2.1 $60,000
HC04 China
150L
LTSEE
Subcritical 150 L 150 8 15 15 USD 90500

Conclusions.
As of the information available following conclusions may be
derived:
1. Raw material Availability & oleoresin Demand.
2. Extraction unit from EU Germany.
3. Extraction unit from EU Italy.
4. Extraction unit from China.

Raw material Availability & oleoresin Demand.
1. Availability: There is substantial quantity to raw material
available for Capsicum and chili pepper oleoresin and
adequate raw material for paprika oleoresin is available
and new varieties of sweet chili should be introduced for
cultivation.
2. Demand: There is adequate demand of chili oleoresin
specially paprika oleoresin.

Extraction unit from EU Germany.
This is an excellent well developed plug and play unit
with all the parameters well suited for manufacturing of
extraction, with only minor customization required if
needed. Only compatibility of various solvents is to be
evaluated and manufacturer confirms to update us in
this regard if a purchase decision is made. Vacuum
pump can create adequate pressure for removal of
solvent under permissible limits.
Back-to-Basics Training Series

Extraction unit from EU Italy.
• This is also an innovative effort, an excellent well
developed computer controlled unit based on high
pressure extraction technology with all the
parameters well suited for manufacturing of oleoresin
with only minor customization required if needed.
Compatibility of various solvents is to be evaluated
and manufacturer confirms to update us in this regard
if a purchase decision is made. It consist of a
separate concentration unit and both units are to be
connected to perform complete processing. Vacuum
pump can create pressure for removal of solvent.

Extraction units from China.
• We have evaluated several units from china. The
working capacity to cost ratios are better from
Europeans. However the technology is relatively
inferior.
• Durability is also questionable.
However a few plants have shown good parameters and
these plants can be further customized/upgraded to
improve the performance as well as durability to match
EU plants.

Recommendation
• Italian unit may fits in budget but needs to proper
evaluated to finalize it for extraction.
• Supplier has recommended us to visit them to
properly evaluate the plant.
• Chinese plant can also be improved, customize and
upgraded to compete for durability with plants of EU
origin.
• An initial lab scale unit can be developed from
Chinese supplier to test it for oleoresin than go for
pilot size plant.

Thank you for selecting
AHL for Chili oleoresin
Project.

Final report chili oleoresin project usaid amd 045 14 may 2018

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Final report chili oleoresin project usaid amd 045 14 may 2018