Advances in Natural Product Extraction Techniques, Electrospun Fiber Fabrication, and the Integration of Experimental Design: A Comprehensive Review

The present review explores the growing interest in the techniques employed for extracting natural products. It emphasizes the limitations of conventional extraction methods and introduces superior non-conventional alternatives, particularly ultrasound-assisted extraction. Characterization and quantification of bioactive constituents through chromatography coupled with spectroscopy are recommended, while the importance of method development and validation for biomarker quantification is underscored. At present, electrospun fibers provide a versatile platform for incorporating bioactive extracts and have extensive potential in diverse fields due to their unique structural and functional characteristics. Thus, the review also highlights the fabrication of electrospun fibers containing bioactive extracts. The preparation of biologically active extracts under optimal conditions, including the selection of safe solvents and cost-effective equipment, holds promising potential in the pharmaceutical, food, and cosmetic industries. Integration of experimental design into extraction procedures and formulation development is essential for the efficient production of health products. The review explores potential applications of encapsulating natural product extracts in electrospun fibers, such as wound healing, antibacterial activity, and antioxidant properties, while acknowledging the need for further exploration and optimization in this field. The findings discussed in this review are anticipated to serve as a valuable resource for the processing industry, enabling the utilization of affordable and environmentally friendly, natural, and raw materials.

Optimization of Solvent Extraction of Lipids from Yarrowia lipolytica towards Industrial Applications

Extraction of intracellular lipids of the oleaginous yeast Yarrowia lipolytica has been systematically studied aiming towards a sustainable extraction process for lipid recovery. Selection of suitable industrial (bulk) solvents and extraction parameters that lead to maximization of lipid recovery are significant issues to be addressed, with industrial applications motivating this study. Biomass from fermentation of Yarrowia lipolytica (MUCL 28849) was used in small laboratory tests to assess different solvent mixtures (i.e., methanol/hexane, isopropanol/hexane, and methanol/ethyl acetate), implementing a systematic design of experiments methodology to identify near-optimum values of key extraction variables (i.e., polar/non-polar ratio, vortex time, dry biomass/solvent ratio) in regard to lipid yield (g lipids/g dry biomass). The methanol/hexane mixture exhibited the highest extraction yield in a wide range of experimental conditions, resulting in the following optimum parameters: polar/non-polar ratio 3/5, vortex time 0.75 h, and dry biomass/solvent ratio 40. Extraction tests on a fifty-times-larger scale (in a Soxhlet apparatus employing the optimal extraction parameters) confirmed the optimization outcome by obtaining up to 27.6% lipids per dry biomass (L/DB), compared to 12.1% L/DB with the reference lipid extraction method employing chloroform/methanol. Assessment of lipid composition showed that unsaturated fatty acid recovery was favored by the methanol/hexane solvent. Fatty acid composition was not affected by the increase in Soxhlet reflux cycles, whilst the lipid yield was notably favored.

Phenanthrene-enriched extract from Eulophia macrobulbon using subcritical dimethyl ether for phosphodiesterase-5A1 inhibition

Eulophia macrobulbon (E.C.Parish & Rchb.f.) Hook.f. contains a natural PDE5A1 inhibitor, phenanthrene, 1-(4'-hydroxybenzyl)-4,8- dimethoxyphenanthrene-2,7-diol (HDP), a potential agent for the treatment of erectile dysfunction. The aim of this study was to improve the extraction efficiency of HDP from E. macrobulbon by using a more environmentally friendly extraction method, subcritical liquid dimethyl ether extraction (sDME), instead of classical solvent extraction (CSE) and ultrasound-assisted extraction (UAE). The efficiency and quality of the extracts obtained were evaluated using the following criteria: %process yield; solvent amount; extraction time; temperature; %HDP content by LC–MS, bioactivity as inhibition of phosphodiesterase-5A1 (PDE5A1) by radio-enzymatic assay; and chemical profiles by LC-QTOF-MS. sDME provided the highest content of HDP in the extract at 4.47%, much higher than the use of ethanol (0.4–0.5%), ethyl acetate (1.2–1.7%), or dichloromethane (0.7–1.4%). The process yield for sDME (1.5–2.7%) was similar to or lower than the other solvents (0.9–17%), but as long as the process yield is not prohibitively low, the concentration is a more important measure for clinical use. The optimal conditions for sDME extraction were: Extraction time, 40 min; 200% water as co-solvent; sample-to-solvent ratio of 1:8; temperature, 35 °C. Phenanthrene aglycone and glycoside derivatives were the major constituents of the sDME extracts and lesser amounts of phenolic compounds and sugars. The inhibition of PDE5A1 by sDME (IC₅₀ 0.67 ± 0.22 µg/ml) was tenfold more potent than ethanolic extract and other extraction methods, suggesting a high probability of clinical efficacy. Thus, sDME was a more efficient, faster, solvent-saving and environmentally friendly extraction method and more selective for phenanthrene when extracted from E. macrobulbon.

Sublimation for Enrichment and Identification of Marker Compounds in Fruits

In this article, we describe the benefits of sublimation for natural product and food chemistry. The direct sublimation of substances from dried plant powders has not received much attention in research in the past, just like the sublimation of substances from dried plant extracts. We used sublimation to study dried sea buckthorn berry powders and dried sea buckthorn berry extracts. The results of the powder sublimations were compared to that of dried chokeberry, wolfberry, and European cornel powder. 52 marker substances of which 27 are specific for sea buckthorn were found in the sea buckthorn powder sublimates using LC/MS. The majority of them are not described in the literature and were obtained by direct sublimation. Accordingly, sublimation can help to identify new plant constituents. Our identification method was validated by the analysis of four commercially available fruit powders. The sea buckthorn powder showed an almost 80% correlation with the determined marker substances, whereas the other fruit powders did not achieve more than 38% correlation. The sublimates of sea buckthorn extracts show additional marker substances compared to the fruit powder sublimate, and we think that both techniques can be used to fight food fraud.

Digital Twin for Extraction Process Design and Operation

Traditional extraction processes of natural product are widespread, especially in regulated industries. Possibilities of extraction development and manufacturing optimization in regulated industries is limited. Regulatory approvals are often based on traditional preparations of phyto-pharmaceuticals. The dependence on traditional processes can result in sub-optimal extraction parameters causing unnecessary costs and product variability. Innovative methods like Quality-by-Design (QbD), including process analytical technology (PAT), open opportunities for manufacturers to cope with regulatory demanded, narrow batch-to-batch variability. In addition, such validated process models represent perfect digital twins which could be utilized for advanced process control and life cycle analysis.

Distinct and Quantitative Validation for Predictive Process Modelling in Steam Distillation of Caraway Fruits and Lavender Flower Following a Quality-By-Design (QbD) Approach

A quality by design (QbD) approach as part of process development in the regulated, pharmaceutical industry requires many experiments. Due to the large number, process development is time consuming and cost intensive. A key to modern process development to reduce the number of required experiments is a predictive simulation with a validated physico-chemical model. In order to expand the process expertise of steam distillation through maximum information, a model development workflow is used in this paper, which focuses on implementation, verification, parametrization and validation of a physico-chemical model. Process robustness and sensitivity of target values can be determined from the developed general model and design of experiments with statistical evaluations. The model validation is exemplified by two different types of plant systems, caraway fruits (Carum Carvi) and lavender flowers (Lavandula).

Process Engineering Accelerating an Economic Industrialization Towards a Bio-Based World

The transition towards a bio-based world is a challenging undertaking. This perspective paper, from an engineering point of view, aims to provide an overview of existing projects and academic disciplines highlighting the potential benefit of increased interdisciplinary exchanges. Furthermore, the current utilization of biomass to produce biogas is discussed, including an economic assessment, showing the need for new strategies of biomass valorization. One solution could be the development of separation processes for the isolation of secondary plant metabolites, which have been especially valuable for pharmaceutical applications, e.g., taxotere ^® and artemisinin. The economic feasibility is demonstrated in a case study, evaluating the purification potential of curcuminoids from Curcuma longa L. Subsequently, the conclusion discusses the limitations of large-scale industrial applications and the need for new separation techniques as a step towards a bio-based world.

Polyphenols from Red Vine Leaves Using Alternative Processing Techniques

The extraction kinetics of polyphenols, which are leached from red vine leaves, are studied and evaluated using a laboratory robot and nonconventional processing techniques such as ultrasonic (US)-, microwave (MW)-, and pulsed electric field (PEF)-assisted extraction processes. The robotic high-throughput screening reveals optimal extraction conditions at a pH value of 2.5, a temperature of 56 °C, and a solvent mixture of methanol:water:HCl of 50:49:1 v/v/v. Nonconventional processing techniques, such as MW- and US-assisted extraction, have the fastest kinetics and produce the highest polyphenol yield. The non-conventional techniques yield is 2.29 g/L (MW) resp. 2.47 g/L (US) for particles that range in size from 450 to 2000 µm and 2.20 g/L (MW) resp. 2.05 g/L (US) for particles that range from 2000 to 4000 µm. PEF has the lowest yield of polyphenols with 0.94 g/L (450–2000 µm), resp. 0.64 g/L (2000–4000 µm) in comparison to 1.82 g/L (2000 to 4000 µm) in a standard stirred vessel (50 °C). When undried red vine leaves (2000 to 4000 µm) are used the total phenol content is 1.44 g/L with PEF.

Natural Products Extraction of the Future—Sustainable Manufacturing Solutions for Societal Needs

The production of plant-based extracts is significantly influenced by traditional techniques and the natural variability of feedstock. For that reason, the discussion of innovative approaches to improve the manufacturing of established products and the development of new products within the regulatory framework is essential to adapt to shifting quality standards. This perspective of members of the DECHEMA/ProcessNet working group on plant-based extracts outlines extraction business models and the regulatory framework regarding the extraction of traditional herbal medicines as complex extracts. Consequently, modern approaches to innovative process design methods like QbD (Quality by Design) and quality control in the form of PAT (Process Analytical Technology) are necessary. Further, the benefit of standardized laboratory equipment combined with physico-chemical predictive process modelling and innovative modular, flexible batch or continuous manufacturing technologies which are fully automated by advanced process control methods are described. A significant reduction of the cost of goods, i.e., by a factor of 4–10, and decreased investments of about 1–5 mil. € show the potential for new products which are in line with market requirements.

Extraction of polyphenols from black tea--conventional and ultrasound assisted extraction

Products from plant raw materials gain increasing importance in food-, cosmetics and pharmaceutical industry. By way of contrast, due to lack of detailed physico-chemical fundamentals, existing production processes are economically not optimal designed. This leads to a need for deeper understanding of the processes and furthermore a systematic process and equipment design for the potentially applicable extraction techniques. Using the example of polyphenol extraction from black tea (Kenya), the conventional and ultrasound assisted extractions are investigated. Here, the state of the art as well as a comparison between the two techniques is in focus. Especially, resulting quasi-equilibria and mass transport kinetics serves as a criteria. The physico-chemical background is discussed taking particle size distributions and scanning electron microscope (SEM) measurements into account. Conclusively, process alternatives are projected and discussed. Hence, the present study makes influences of ultrasound technique on physico-chemical characteristics during extraction a subject of discussion.

Accelerated solvent extraction for natural products isolation

Accelerated solvent extraction (ASE(®)), first introduced in 1995, is an automated rapid extraction technique that utilizes common solvents at elevated temperature and pressure, and thereby increases the efficiency of extraction of organic compounds from solid and semisolid matrices. ASE(®) allows extractions for sample sizes 1-100 g in minutes, reduces solvent uses dramatically, and can be applied to a wide range of matrices, including natural products.

Effects of Solvent/Solid Ratio and Temperature on the Kinetics of Vitamin C Extraction from Musa Acuminata

This work studied on the kinetics of Vitamin C extraction from banana peel at different solvent/solid concentration and temperature. Musa Acuminata was ground into smaller sizes before contacted with methanol as a solvent in an ultrasonic bath. To study the effect of solvent/solid ratio, 4.5, 5.0 and 10.0 ml/g ratio were used for the extraction at fixed temperature. Then, the temperature was varied with the heating element available in the ultrasonic bath at 30, 45 and 60 oC, to study the effect of temperature on the extraction kinetics. It was found that high solvent/solid ratio (10 ml/g) provides more solute-solvent contact and prevents the extracted Vitamin C from coming into contact with the air. Besides, higher temperature (60 oC) contributes sufficient kinetic energy for Vitamin C distribution in the solvent which is important to prevent degradation with air. The best fitted kinetic model for Vitamin C extraction from Musa Acuminata is Ana et al. (2007) with equilibrium concentration of 0.05 g/L and 0.40 g/L.hr extraction rate