Bioactive Extract Production from Citrullus Clocynthis Fruit via Microwave-Assisted Extraction: Experimental Optimization, Process Design and Economics with Uncertainty Quantification

Purpose Despite a huge pharmacological and medicinal significance of Citrullus Colocynthis fruit (CCF) extract as claimed by previous researchers, the extract production is limited to laboratory endeavour. Therefore, this study is aimed at developing optimal process conditions, scale-up process design with its associated economics for CCF microwave-assisted extraction in view of translating the traditional CCF extraction from backyard production enterprise to wealth creation industrial factory. Method A series of 17 experimental runs, with extraction factors such as microwave irradiation power (520 – 1040 W), extraction time (2- 10 min) and solid–liquid ratio (0.4 – 1 g/100 ml), were designed, analysed and optimized using response surface methodology. ASPEN Batch Process Developer (ABPD) V10 was used to perform process simulation, scale-up design and economics, while Monte Carlo simulation of Oracle Crystal Ball software was used to investigate profitability uncertainty. Results Extraction optimum conditions gave yield (24.4%), TPC (2.23 mg GAE/g dry extract) and CO 2 emission (0.001 kg) at irradiation time 2.67 min and microwave power 520 Watt with solid–liquid ratio 0.4 g/100 ml, respectively. The scale-up simulation results gave 0.0045 kg, 0.09 kg and 0.43 kg batch size for 5L, 100L and 500L extractor capacities, respectively. Cost of manufacturing for CCF extract production for 5L, 100L and 500L capacities are US$2721, US$192 and US$ 74 accordingly. The ROI and NPV certainty quantification for 500L production capacity show 57.09% and 50.44%, respectively. Conclusion The study demonstrated that 500L production capacity for CCF extract is the most economically feasible and plausible with USD 25256, 3.8 yrs and 26% for NPV, PBT and ROI, respectively. Graphical abstract