Extractor
El extractor CONTEX de GEA ayuda a los productores de todo el mundo a producir extractos de primera clase.
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.
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.
El extractor CONTEX cuenta con una verdadera extracción continua a contracorriente. Los sólidos se introducen por gravedad o se dosifican por volumen en el extremo inferior del recipiente de proceso y luego se transportan hacia arriba a través del extractor mediante dos tornillos helicoidales en espejo que giran en sentido contrario con un deslizamiento controlado. Los sólidos pasan por dos cilindros superpuestos que giran a la mitad de la velocidad de los tornillos.
El líquido de extracción fresco entra en el extremo superior y, por gravedad controlada por la inclinación, fluye como una corriente sumergida hacia la mitad inferior de la sección transversal y por el sólido de rotación lenta, en una verdadera extracción en contracorriente, bien controlada con un flujo de pistón casi ideal en ambas fases. La velocidad de los tornillos se ajusta para proporcionar el tiempo de residencia necesario para el sólido. El flujo de líquido se ajusta de forma independiente para obtener una concentración óptima del extracto.
En el extremo inferior, el extracto sale a través de filtros especiales de autolimpieza y un depósito de control de nivel. El sólido extraído se apretará ligeramente en el extremo superior y se descargará continuamente. El tiempo de permanencia en el extractor es de aproximadamente 0,5 a 2 horas, según el producto.
El CONTEX está disponible en unidades de hasta 2.700 litros (2,7 m3) y capacidades de hasta 500-1000 kg/h de materia prima.
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.
The system delivers additional benefits, such as lower building height requirements as standard, as well as being at a safer, more accessible level for operators in terms of inspection and maintenance. The system is able to operate 24/7, significantly reducing both sanitation and maintenance intervals that require scheduled downtime and also the risk of human error.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.
Available in six standard sizes (27, 180, 300, 830, 1400 and 2750 liters), the CONTEX system adapts seamlessly from pilot-scale testing to full-scale production. Able to efficiently process a wide variety of raw materials, including coffee, barley, tea, health foods and natural medicines, the system delivers maximum flexibility against ever-evolving industry needs.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.
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.
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.
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:
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.
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