CONTEX Extraktor

Efficient, scalable coffee and herbal product extraction

GEA's continuous extraction solutions are engineered to redefine efficiency for the coffee and herbal extract industries. Designed specifically to deliver optimal yield and precision control, the GEA CONTEX system provides a reliable, automated and scalable alternative to traditional batch extraction - delivering higher-quality extracts with minimal resource use across both hot and cold brew processes. It is also applicable to a wide range of health and herbal products, such as leaves, stems and roots. 

Overcoming extraction challenges

Traditional batch extraction can be slow, inconsistent and require significant resources. GEA’s continuous extraction technology streamlines the process, significantly reducing extraction times while improving extract quality, flavor and aroma retention. By automating key steps and ensuring a continuous, controlled flow, our system enhances throughput, maintains consistency and minimizes waste - offering a cost-effective solution for high-volume, efficient production.

Der CONTEX-Extraktor verfügt über eine echte kontinuierliche Gegenstromextraktion. Die Feststoffe werden durch Schwerkraft oder volumendosiert am unteren Ende des Prozessbehälters zugeführt und dann durch zwei gegenläufige, spiegelbildliche Schnecken mit kontrolliertem Schlupf durch den Extraktor nach oben transportiert. Der Feststoff durchläuft zwei sich überlappende Zylinder, die etwa mit der halben Schneckengeschwindigkeit rotieren.

Die frische Extraktionsflüssigkeit tritt am oberen Ende ein und fließt durch die neigungsgesteuerte Schwerkraft als eingetauchter Strom in die untere Hälfte der Querschnittsfläche und durch den langsam rotierenden Feststoff in echter, gut kontrollierter Gegenstromextraktion mit nahezu idealer Kolbenströmung in beiden Phasen. Die Drehzahl der Schnecken wird so eingestellt, dass die erforderliche Verweilzeit des Feststoffs gewährleistet ist. Der Flüssigkeitsstrom wird unabhängig eingestellt, um eine optimale Konzentration des Extrakts zu erreichen.

Am unteren Ende tritt der Extrakt durch spezielle selbstreinigende Filter und einen Behälter mit Niveauregulierung aus. Der extrahierte Feststoff wird am oberen Ende leicht gepresst und kontinuierlich ausgetragen. Die Verweilzeit im Extraktor beträgt ca. 0,5 bis 2 Stunden, je nach Produkt.

Der CONTEX ist in Einheiten von bis zu 2.700 Litern (2,7 m3) und Kapazitäten von bis zu 500-1000 kg/h Rohmaterial erhältlich.

What sets it apart?

Unlike conventional extractors, CONTEX integrates four extraction stages into a seamless, automated process. The counter-current design optimizes temperature control and residence time, maximizing product recovery while minimizing energy and water consumption. Our expert use of advanced automation maintains a focus on ease of use for operators, at the same time maintaining consistently high extraction performance in both hot and cold brew processes. 

Precision engineering for maximum yield

Our continuous extraction system features an inclined trough with heat transfer jackets for precise temperature control. Raw materials enter at the lower end and are transported upwards via a double helicoidal conveyor, ensuring even transport of the material to be extracted. Meanwhile, the extraction liquid flows downward in a counter-current motion, optimizing percolation and yield.

Benefits

• High extraction efficiency with minimal liquid waste
• Reduced operating costs through optimized process control
• Scalable design from pilot testing to full production
• Uniform and repeatable extraction performance
• High solids content for consistent, high-quality output
• Self-cleaning filters to minimize product loss and downtime.

Key features and advantages

• Fully continuous process – eliminates batch-related downtime for uninterrupted extraction
• Counter-current extraction – maximizes efficiency with four integrated extraction stages
• Higher solids concentration – produces 8-10% solids extract, reducing post-extraction water removal needs
• Versatile applications – ideal for coffee, tea, chicory, roasted barley and plant-based materials
• Cold brew capability – enables extraction at lower temperatures for expanded product possibilities
• Automated and easy handling – reduces human error and labor costs, ensuring process consistency
• Lower energy and water consumption – optimized resource use compared to batch systems.

A more resource-efficient approach to extraction

Resource-efficiency is an important consideration in our continuous extraction solutions. In the CONTEX, the system’s counter-current extraction method reduces water consumption while maximizing extract concentration, lowering the need for additional decanters and concentration stages. By optimizing energy use, for example through the use of advanced heat exchange technology, and minimizing waste, our technology supports resource-efficient production without compromising performance.

Safety and reliability at every step

Process safety is at the core of GEA’s continuous extraction technology. Integrated safeguards ensure stable process control, while automated monitoring reduces the risk of operational errors. The self-cleaning system minimizes contamination risks and maintenance downtime, ensuring a hygienic and efficient production environment.

Maximum efficiency, minimum waste

Our advanced plug-flow optimization ensures high extraction yields while significantly reducing raw material and water consumption. The adjustable slope of the extractor allows you to fine-tune the filling of the extraction, further enhancing efficiency. With a higher solids concentration output, the system minimizes post-extraction water removal requirements - delivering superior performance with lower resource input.

Testing extraction before you scale for maximum confidence

GEA’s state-of-the-art test center offers a 27-liter pilot plant for in-depth process validation. This facility allows you to optimize your extraction process before scaling up to full production, ensuring a tailored and efficient solution. 

Our advanced facility can measure extraction yield, and can also interrogate downstream processes. This includes identifying optimal drying conditions, and simulating the full evaporation and freeze drying processes as part of a complete line evaluation. From roasted beans to final product, nothing is left to guesswork.

Dedicated GEA experts operate in-house to ensure every stage of the process is optimized, and once test results are fully validated are able to provide written performance guarantees for added peace of mind.

Our test center services include:

• Extraction yield measurement from customer-provided samples
• Simulation of full production lines – from raw material to final product
• Drying condition optimization for spray drying, freeze drying, and evaporation
• Advanced powder analysis – assessing compressibility, moisture content and aroma management
• Performance guarantees based on validated test results.

Ongoing service and support

At GEA we stand by our technology with comprehensive in-house service and support. From process optimization and on-site maintenance to remote monitoring and troubleshooting, our expert teams ensure continuous performance and reliability. With tailored service agreements and global technical assistance, customers can rely on GEA for long-term efficiency and innovation in extraction technology.