Extraction using High Power Ultrasonics:
Cavitus Ultrasonic Extraction System (UES)

The Problems Solved

The extraction of organic compounds from agricultural products, plants and seeds has classically been based upon the judicious combination of solvent, heat and/or agitation to optimise process kinetics (rate) and/or yield. The problems associated with these technologies are well-known:

• Not only do the majority of solvents have low boiling-point and highly flammable/explosive characteristics, requiring specialised transportation, very particular health/safety precautions and explosion-proof production facilities, which increase input, capital expenditure and maintenance costs, but also they can change the consistency, flavour and mouth-feel of the extracted product;
• Heat, likewise, requires specialised handling, can change the consistency, flavour and mouth-feel of the extracted product, increases input and maintenance costs, and often involves substantial capital expenditure; and
• Mechanical agitation methods, in addition to changing the consistency, flavour, mouth-feel of the extracted product, and increasing input and maintenance costs, also incurs substantial capital expenditure.

The Technology

Classified as a non-thermal technology, HPU offers an innovative and cost-effective alternative for increasing process kinetics and yield, when compared with commonly-used extraction process technologies. Also, it overcomes the historic limitations of low-power ultrasound in extraction applications of high-volumes and/or continuous flow.

The energy generated from collapsing cavitation bubbles caused by the expansion and contraction of entrained gas in liquids improves mass transfer to and from interfaces, as well as into the interior of materials. At high intensities, HPU extraction can disrupt cell walls and cause the release of cellular materials.

Solution and Benefits

Cavitus has developed a proprietary processing system platform for HPU extraction with application across a wide range of agricultural products, plants and seeds. Cavitus' solution can be adapted for a stand-alone system or used as a retro-fit/'bolt-on' system to a conventional manufacturing process running conventional extraction technologies. Although the design is common, the process parameters are optimised for the specific agricultural material, and the desired combination of yield and processing rate improvement. Benefits vary between agricultural products, but typically include: Potential to use aqueous based solvents - 'Green Label' Lower maintenance costs Energy cost savings Less solvent usage Better raw-material utilisation/yield Faster kinetics/processing speed Elimination of downstream processing step Lower temperature kinetic effect Better product quality (more consistency)

Please click here to download a PDF overview of the Cavitus System for Extraction of Grape Must.

Applications

In a case study from commercial processing of carrot juice waste (pomace and carrot peel) to recover high-value alpha and beta carotene using water as the solvent, the application of HPU increased the yield more than 300%. At a flow rate of 150 litres per minute, conventional extraction provided less than 10% yield, whereas HPU offered a 38% yield for alpha carotene and 32% for beta carotene.

Other results achievable with Cavitus' pat. Pend. solution include:

Material		Extractable	% yield increase vs. conventional process	% kinetics increase vs. conventional process
Grape Must	Water	Anthacyanins,Color	+ 30%	-
Ground Coffee	Water	Coffee	+ 10%	-
Tea	Water	Tea colour, Polyphenols	+ 20%	-
Corn Germ	Hexane	Corn Oil	-	+ 75%
Citrus Peel	Water	Citrus oil	+ 30%	-
Ginger	Liquid CO2	Gingerol	+ 35%	-

Case Study

Using the example of grape must extraction for wine-making, a vertical market application currently in Alpha prototype development by the Company, the specific benefits identified by customers in the U.S.A. and Australia include:

• Reduced downstream processing time (shorter ferments and elimination of clarification step)
• Decreased energy cost from above
• Low maintenance costs (no moving parts)
• Increased asset productivity (increased throughput in fermentation tanks)
• Better raw-material utilisation (higher yield of compounds contributing to flavour)
• Better product quality (higher consistency from greater flavour and color compounds)

Technical Specifications

Cavitus anticipates that its grape must extraction processing system will enter Beta trials with customers in the first half of 2009, at which time the Company will release technical specifications.

Pricing and Availability

Pricing will be available in the 2nd Half of 2009. Our design price target is aimed to provide customers with a payback within 24 months.