Process optimization, scale-up studies, economic analysis and risk assessment of phenolic rich bioactive extracts production from Carica papaya L. leaves via heat-assisted extraction technology

This work investigated the influence of process variables of extraction temperature (35–55 °C), solid to liquid ratio (1:20–1:50 g/mL) and time (100–200 min) on the total phenolic content (TPC) and yield (EY) of Carica papaya leaves (CPL) extracts using Box-Behnken experimental design available in D...

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Bibliographic Details
Published in:	Heliyon Vol. 8; no. 4; p. e09216
Main Authors:	Adeyi, Oladayo, Oke, Emmanuel O., Okolo, Bernard I., Adeyi, Abiola J., Otolorin, John A., Nwosu-Obieogu, Kenechi, Adeyanju, James A., Dzarma, Goziya William, Okhale, Samuel, Ogu, Denilson, Onu, Precious N.
Format:	Journal Article
Language:	English
Published:	England Elsevier Ltd 01-04-2022 Elsevier
Subjects:	Carica papaya leaves Heat-assisted extraction technology Integrated process design Process optimization Techno-economic analysis Unit production cost Techno-economic analysis Process optimization Heat-assisted extraction technology Integrated process design Carica papaya leaves Unit production cost
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Summary:	This work investigated the influence of process variables of extraction temperature (35–55 °C), solid to liquid ratio (1:20–1:50 g/mL) and time (100–200 min) on the total phenolic content (TPC) and yield (EY) of Carica papaya leaves (CPL) extracts using Box-Behnken experimental design available in Design Expert software. Bi-objective process optimization was also carried out using the desirability function algorithm. The optimum process variables were later used to design an integrated process for the production of CPL extracts with the assistance of SuperPro Designer software. Scale-up studies and economic analysis for CPL extracts production were investigated in the range of 0.638–20.431 × 103 kg CPL extracts/y to determine the most economically feasible production capacity based on the minimum unit production cost (UPC) of CPL extracts. The risk and sensitivity analyses of the most economically feasible production scale were carried out using the Monte Carlo simulation in Oracle Crystal Ball software. Process variables had notable influences on the TPC and EY of CPL extracts. The extraction temperature of 35 °C, solid to liquid ratio of 40.25 g/mL and time of 100 min gave the optimum TPC of 74.65 mg GAE/g d.b and EY of 18.76 % (w/w). HPLC results indicated that CPL extracts were rich in gallic, betulinic, chlorogenic, ellagic, ferulic and caffeic acids. The designed integrated process showed similar behavior with the laboratory scale of 0.18758 g CPL extracts/batch. The preliminary techno-economic analysis indicated that plant capacity has a strong dependence on the material & energy demands and process economics. Plant capacity of 19.857 × 103 kg CPL extracts/y possessed the least UPC and was selected as the most economically feasible scale. The certainty of obtaining base case UPC value of 525.21 US$/kg CPL extracts was 75.20%. Sensitivity analysis showed that extracts recovery, CPL/water, centrifuge purchase cost, extraction time, extractor purchase cost and extraction temperature contributed -5.3 %, +42.8%, +4.0%, +47.1%, +0.1%, and +0.5%, respectively to the variance in UPC of CPL extracts. ▪ •Carica papaya leaves (CPL) extracts are rich in polyphenols.•Heat assisted extraction technology was capable of recovering CPL extracts.•Industrial extracts scale-ups were achievable using SuperPro Designer software.•Plant capacity of 19.857 × 103 kg extracts/y was selected most economical scale.•The 525.21 US$/kg extracts unit production cost base case certainty was 75.20%. Heat assisted extraction technology; Integrated process design; Techno-economic analysis; Carica papaya leaves; Process optimization; Unit production cost.
ISSN:	2405-8440 2405-8440
DOI:	10.1016/j.heliyon.2022.e09216