Optimizing Sesame Oil Extraction: How Large-Scale Plants Cut Energy Costs with Solvent Leaching

For large-scale edible oil producers, efficiency isn’t just about yield—it’s about reducing energy consumption while maintaining consistent quality and compliance. In this guide, we explore how solvent leaching using hexane can reduce energy usage by up to 25–30% compared to traditional expeller pressing methods in sesame seed oil production—without compromising on output or safety.

Understanding the Hexane Leaching Process

Hexane-based solvent extraction is widely used in industrial-scale oilseed processing due to its high efficiency in extracting residual oil from crushed seeds. Unlike mechanical pressing—which typically leaves behind 6–10% oil—the solvent method achieves a final residue of less than 1%. This means more oil per ton of raw material, directly improving ROI.

Raw Material Quality Matters: Oil Content & Particle Size

Data from real-world applications show that sesame seeds with an average oil content of 45–52% (based on moisture-adjusted analysis) perform best when ground to a particle size of 0.8–1.2 mm. Smaller particles increase surface area for solvent contact, boosting extraction efficiency by up to 15%. However, overly fine grinding increases viscosity, which can slow down flow rates and raise pumping energy use—a trade-off worth optimizing.

Equipment Design That Drives Efficiency

Modern counter-current continuous extractors feature multiple stages with controlled solvent-to-seed ratios and precise temperature regulation. A well-designed system maintains a solvent recovery rate above 98%, minimizing waste and environmental impact. For example, one Chinese OEM reported a 22% drop in hexane consumption after upgrading their extractor design with better internal baffles and improved heat exchange units.

De-solventization: The Hidden Cost Driver

The drying and desolventizing stage accounts for approximately 40% of total energy use in solvent extraction. Advanced multi-stage flash drying systems now reduce steam consumption by 18–25% through efficient heat reuse and vapor condensation. Additionally, integrated gas detection and explosion-proof ventilation ensure compliance with OSHA and ATEX standards—an essential selling point for international clients.

Real-World Impact: Case Study from Southeast Asia

A major Malaysian oil mill implemented a full-scale solvent extraction line in 2023. Within six months, they achieved:

• Energy savings: 27% reduction in kWh/ton of processed seeds
• Labor cost decrease: 35% fewer operators needed per shift
• Yield improvement: From 92% to 96.5% oil recovery rate

As global food processors face rising pressure to cut emissions and improve margins, solvent leaching offers a proven path forward—not just for sesame oil, but for sunflower, rapeseed, and soybean operations too. With smarter equipment, better process control, and cleaner de-solventizing tech, your plant can stay competitive in both price and sustainability.