Development of a system for the production of Jambu alcoholic extract concentrated in spilanthol based on a multimode microwave cavity at a semi-industrial scale for continuous processing

• Grant number: 25/04267-9
• Support Opportunities: Research Grants - Innovative Research in Small Business - PIPE
• Start date: September 01, 2025
• End date: August 31, 2027
• Field of knowledge: Engineering - Mechanical Engineering - Mechanical Engineering Design
• Principal Investigator: Letícia Megumi Ishibaru
• Grantee: Letícia Megumi Ishibaru
• Pesquisadores principais: Davidson da Costa Luz ; Jose Lavaquial Biosca Neto ; Marcos Aurélio Corrêa Machado
• Associated research grant: 23/14418-9 - Development of a multimode microwave cavity-based extraction system for continuous production of alcoholic Jambu extract, AP.PIPE

Abstract

The present project aims at scaling up an innovative microwave-based extraction system for the continuous production of natural extracts. The validation of this technology will be carried out using Jambu to obtain alcoholic extracts enriched with spilanthol. The proposed technology seeks to overcome the limitations of conventional methods and enhance the efficiency of industrial extraction processes, standing out for its preservation of bioactive compounds and lower solvent consumption compared to traditional techniques and commercially available equipment.During the PIPE Phase 1 project, entitled "Development of an extraction system based on a multimode microwave cavity for the production of alcoholic Jambu extract in continuous processing" under number 2023/14418-9, a laboratory-scale prototype was developed and tested using a multimodal cavity in a continuous process, ensuring an efficient and sustainable system.The extraction of plant compounds faces challenges related to the preservation of thermolabile molecules and volatile compounds, as well as the optimization of yield and extract quality. Traditional methods often lead to the degradation of desired compounds, in addition to having high energy consumption and batch operation, which hinders continuous processing on an industrial scale. The microwave-based technology developed by Innovatus differentiates itself by enabling rapid and uniform volumetric heating, ensuring higher energy efficiency and better temperature control during the process. Furthermore, the use of a multimodal cavity allows for more homogeneous and scalable operation, reducing operational costs and preserving the integrity of the produced extracts.Based on the experience gained in Phase 1, which resulted in the patent filing BR 10 2024 017835-1, Phase 2 aims to increase the system's capacity to 12 kW, using computational modeling and finite element techniques to optimize the equipment's design and performance. Mechanical fabrications with different materials will be integrated, along with advanced microwave engineering solutions to ensure process efficiency on a larger scale, as well as methods for measuring the dielectric properties of the reaction medium using a vector network analyzer.The adoption of this system not only contributes to the production of high-quality extracts with low levels of undesirable compounds but also promotes a sustainable solution for the natural extracts industry. Thus, the proposed development aims to consolidate a differentiated and efficient technological alternative, aligned with industrial demands and capable of offering high productivity and sustainability to the sector. (AU)