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This industrial-grade nicotine extraction production line is specifically designed for high-end separation and purification applications in tobacco deep processing, biomedicine, and next-generation tobacco products (such as e-liquid). The production line integrates advanced liquid-liquid extraction, precision separation,senbo fluid and molecular distillation technologies to efficiently and safely extract high-purity nicotine from tobacco raw materials or crude extracts. Featuring key advantages such as a high degree of automation, closed-loop solvent recycling, and green environmental protection, the entire system consistently delivers pharmaceutical-grade or industrial-grade nicotine products with purities ranging from 99.5% to 99.99%. This enables enterprises to achieve industrial upgrading from traditional processing to high-value-added biological extraction.
Pretreatment & Extraction Unit
Includes a multi-functional dynamic extraction tank (equipped with agitation and CIP cleaning system) and a high-speed centrifugal extractor, responsible for initial leaching of raw materials and efficient liquid-liquid separation.
Concentration & Purification Unit
Consists of a vacuum concentrator, cold settling tank, and ion exchange/resin purification column, used to remove most of the moisture and impurities while performing initial enrichment.
Rectification & Refining Unit
Centers on a wiped-film molecular still and rectification column, tasked with the final high-purity purification process to produce the finished product.
Auxiliary & Environmental Protection Systems
Includes solvent storage tanks, vacuum buffer tanks, water treatment system (RO reverse osmosis), as well as waste gas and wastewater treatment modules, ensuring production continuity and environmental friendliness.
High-Efficiency Centrifugal Extraction Technology
The core extraction unit employs advanced centrifugal extractors (e.g., LC series), which utilize a centrifugal force field generated by high-speed rotation to achieve second-scale phase separation between the aqueous phase and the organic phase (e.g., ethyl acetate system). Compared with traditional batch extraction, the single-stage extraction efficiency exceeds 99.9%, while the mixing and separation time is significantly reduced.
Molecular Distillation Refining Process
To address the heat-sensitive nature of nicotine, the production line is equipped with wiped-film molecular distillation equipment at the terminal stage. Under high vacuum conditions, low-temperature separation is achieved based on the differences in molecular free paths of different substances. This effectively removes residual solvents, pigments, and heavy component impurities, ensuring extremely high purity and excellent color of the final product while avoiding thermal degradation caused by high temperatures.
Closed-Loop Green Solvent System
The production line is equipped with high-efficiency solvent recovery and rectification units (e.g., alcohol distillation columns, condensation recovery systems), achieving a solvent recovery rate of over 95% and up to 99%. The fully enclosed pipeline operation not only significantly reduces solvent consumption and production costs but also strictly complies with environmental standards for fugitive emissions of volatile organic compounds (VOCs).
Intelligent Temperature Control and Material Assurance
The entire line is controlled by a PLC-based intelligent control system, supporting multi-stage gradient temperature control from 40°C to 75°C, with real-time monitoring and automatic adjustment of the process curve. All material contact parts are made of 316L stainless steel and solvent-resistant fluoropolymer coatings, complying with GMP and ASME standards, ensuring long equipment life and no risk of heavy metal contamination.
Raw Material Processing Capacity
Supports flexible configuration, with daily tobacco leaf processing capacity ranging from 100 kg to 5,000 kg. The annual processing capacity of a single core piece of equipment can reach 100,000 tons, meeting the demands of large-scale industrial production.
Final Product Specifications
| Nicotine sulfate | Purity approx. 40% |
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| High-purity nicotine | Purity ≥ 99.5%, up to 99.99% |
| Tobacco flavor/absolute (extract) | High-concentration extract retaining the characteristic tobacco flavor |
| Extraction Efficiency | Overall nicotine extraction rate ≥ 95%, with some processes achieving over 97.89%. |
| Equipment Material | Main body constructed of SS304/SS316L stainless steel. |
Project Design
The company designs optimal overall solutions that not only meet client requirements but also align with investment plans. We possess a highly experienced team specializing in process and equipment design, comprised of multiple disciplines including process systems, purified ventilation, HVAC & plumbing, integrated plant piping, automation control systems, and 3D structural installation design. Senbofluid All designs are executed in compliance with GMP, FDA, and ASME standards, meeting the stringent requirements of industries such as biopharmaceuticals and food processing.
Equipment Manufacture
The Manufacturing Center utilizes production drawings approved and signed by the client as the sole basis for manufacturing. All equipment fabricated on-site is subject to verification by our Quality Control Supervisor to ensure compliance in accordance with stringent regulations. Concurrently, detailed in-process inspections are conducted to guarantee that all suppliers adhere to the mandated quality standards established by Senbo.
Project Construction
Standardized and professional construction serves as the paramount guarantee for achieving design objectives. Senbo possesses an experienced construction management team and installation crew, renowned for their meticulous attention to detail and relentless pursuit of perfection.
Tunkey Project Installation
We offer comprehensive one-stop solutions, covering the design and construction of process systems, purification and ventilation, HVAC (heating, ventilation, and air conditioning), plumbing and drainage, as well as integrated pipelines across the facility. This integrated approach eliminates the challenges of cross-disciplinary coordination and overlapping construction phases for your project.
Automatic Control
We have established the Automation Installation Engineering Division, leveraging our deep understanding of the pharmaceutical and food industries' processes and our professional automation team. We are committed to delivering the highest quality intelligent integrated services through professional, comprehensive digital solutions for our clients.
Personnel Training, Verification and After-sales service
Senbo has an experienced GMP validation team that provides clients with systematic validation systems and training. Our professional after-sales service team operates across the globe
1.Extraction tank (Stirring device optional):
The dynamic extraction tank can be used for atmospheric pressure, micro pressure, water decoction, warm imrnersion and cold immersion conditions in herbal & plant, food and chemical industries. The equipment is equipped with a stirring device to make the material extraction sufficient and increase the extraction rate.
2.Concentrator:
The products mainly adapted to the concentrated production professional traditional herbal & plant health care products. natural seasonings food additives food. chemical industry and other industries. Senbofluid He can provide different proportions of extracts with different drying production methods t has advantages of wide application range. easy operation and low maintenance rate.
3.Cooling sedimentation tank:
It is applied to the freeze-precipitation of herbal & plant, oral liquid, food health products, etc, freezing or normal temperature precipitation of suspension, solid- liquid phase separation, and separation of wax and lipid substances.
4.Molecular (wiped film) distillation:
Is the best thermal separation machine for heat-sensitive material because it is the gentlest type, causing the least amount of thermal degradation of product. It is a process of separation, purification and concentration of natural products, complex and thermally sensitive molecules. Senbo molecular distillation units are wildly used for purification of oils, such as garlic oil, cod liver oil in chemical and pharmaceutical industries. The whole molecular distillation system includes supporting chillers, heaters, vacuum pumps and all accessories.
The materials are transported from the feed tank to the jacketed main evaporator. The main evaporator is continuously heated. The built-in scraper evenly scrapes the materials into a layer of flowing liquid film for instant evaporation. The light component materials begin to vaporize and adsorb on the built-in condensing coil, flow into the receiving bottle along the outer wall of the condensing pipe, and the heavy component materials flow into the receiving bottle along the inner wall of the main evaporator.
5.Solvent rectification column:
The rectification column is a tower gas-liquid contact device for rectification. Using the characteristics of different volatility of each component in the mixture, the light component (low boiler) in the liquid phase is transferred to the gas phase, and the heavy component (high boiler) in the gas phase is transferred to the liquid phase, thereby achieving the purpose of separation. The equipment is widely used in solvent recovery in plant extraction, Chinese medicine, food, and chemical industries.
6.Preparation of liquid phase system (HPLC):
Industrial preparation liquid phase system is characterized by high efficiency, rapidity, high degree of automation, explosion-proof, etc. It is widely used in the separation and purification of pharmaceutical intermediates, biomedicine, synthetic drugs, natural products, fine chemicals, food additives and other fields. Industrial preparation of liquid phase systems can effectively improve production efficiency, improve automation, and improve product purity and yield.
7.Vacuum Belt Dryer:
The vacuum belt dryer is suitable for continuous drying of raw materials, semi-finished products and finished products such as roots, stems and leaves. It can also be used for continuous drying of aquatic products and other agricultural and sideline products and crops. It is especially suitable for materials with high water content and high heat sensitivity
8.Solvent mixing system:
A solvent mixing system is an automated or semi-automated system that integrates storage, transfer, metering, mixing, quality control, distribution, and safe handling functions. Senbofluid Its core purpose is to efficiently, safely, and uniformly blend one or more solvents (or solvent-containing materials) with other components according to precise formulations to prepare solutions or mixed solvents that meet specific process requirements.
9.Dual Cartridge Filter:
The Dual Filtration System, also known as a Parallel Filtration System or a One-in-Use/One-on-Standby Filtration System, consists of two identical filters connected in parallel. Through an ingenious valve configuration, it enables the function of "one unit in operation while the other is on standby/maintenance." Its core purpose is to ensure the continuity and stability of production by allowing the switching, cleaning, or replacement of filter elements without the need for shutdowns or disruption to the main process flow.
10.CIP Cleaning System:
Is to control the opening and closing of the steam valve by measuring the temperature sensor; to control the opening and closing of the water valve by measuring the level of the liquid through the pressure transmitter; to control the pneumatic diaphragm pump dosing acid/ alkali by measuring the conductivity meter. The overall control process is water fillingto the tank --acid tank (alkali tank ) PH adjust- water heating - hot water washing - alkali washing - hot water washing - acid washing - hot water washing
11.Reactor:
Operating Principles
Firstly turn on the stirrer motor and reducer, under the drive of stirring shaft rotary, the scrapper stirrer; propeller, frame stirrer will all start rotary. The Polystyrene plate connected with spring installed on the scrapper stirrer sweeps the material stick on the inner tank wall, between the level beam of frame stirrer and the shaft has 45 degrees angle, which will form pushing force
Operating Procedures
Input solid material after the stirrer starting, otherwisethe solid material may deposit to the dead angle under the stirrer supporting bearing, the bottom sectorial scrapper can blend the material to dissolve it evenly. Afterwards turn on the steam, the steam heats the product inside tank through the jacket baffle plate and jacket covers, the condensate water is discharged through the condensate outlet. Observe the temperature of the probe, adjust the stirrer speed and direction, Turn off the steam after the reaction finished, open the bottom valves to discharge. After discharging, turn on the CIP cleaning ball to clean the tank inside surface, all reaction procedures finish.
Characteristics
Continuously feeding, auto discharging, high reaction efficiency;
Compound stirring system, easy to clean, product not easy to get coked
Aroma recycle device can collect the aroma produced during the reaction process
12.Resin Adsorption System:
(Automation Control System) Based on the advanced DCS distributed control strategy, the workstation realizes the control and data acquisition of pumps, valves and various online detectors. It can easily complete multicolumn series and parallel operation to ensure the stability and accuracy of the process.
13.Utility Systems:
As a professional manufacturer of plant extraction, concentration, and drying production line equipment, we deeply understand that stable, efficient, and clean utilities are the cornerstone for ensuring the reliable operation of core processes, improving product quality, and achieving energy conservation and reduced consumption. Therefore, we not only supply core production equipment but are also committed to delivering a fully integrated and perfectly matched overall utilities solution.(Descriptions of some equipment are provided below.)
13-1.Cooling water tower:
The exterior of the tower body is made of imported gel coat, and the interior is made of high-quality glass fiber reinforced plastic. The applicable temperature of the normal temperature cooling tower packing is 0-60 degrees, which water distribution capacity is strong and the resistance is small.
13-2.Water Softener
Harmless to the human body
Can work in low temperature, long life.
Can be filled with various filter materials
Made of Fiberglass Shell
Beautiful appearance
Suitable for commercial and industrial water treatment
Excellent corrosion resistance
Widely used places:
Media tanks for water and waste water purification treatment, such as media filters, water softeners, can be used in food environmental protection and other fields
13-3.Industry Steam Generator Boiler
Biomass steam generator is a kind of small boiler with circulating water pipe.Senbofluid Water circulation is smooth, heating area layout is scientific and reasonable, heat conduction is fast, steam pressure rises fast.Automatic feed, blower induction fan frequency regulation, boiler automatic operation, according to the load changes can automatically adjust the amount of fuel, steam output stability.With pressure, water level, smoke exhaust temperature and other protection and alarm measures to ensure safe operation of the boiler.
