Average extracted volume per experimental mode.

Essential oil (EO) distillation units, which are commonly installed on farms, have difficultly accessing knowledge centers. The apparent simplicity of the process hides unwanted losses and deviations that go undetected and, therefore, not corrected. This article proposes improvements to the process that are based on “4.0” technologies in order to detect and correct two important deficiencies, with an impact on the yield, quality and environmental performance. The first deficiency comprises the steam channels that are formed through green mass (channeling), are well known and are considered normal by EO producers. Without detection and correction, this negatively affects the extraction results. The second is the lack of technology that is able to automatically determine the extraction endpoint. Smart sensing, control, self-configuration and the dynamic determination of improved process parameters make up a set of actions undertaken by a smart extraction plant (50-liter capacity). Nineteen experiments using lemongrass (Cymbopogon citratus) exhibited remarkable 24% and 10% improvements in the yield and quality, respectively. Energy consumption and a more than 50% reduction in the processing complete the set of results achieved. In addition to manufacturing costs and the utilization of capacity, better sustainability indicators are positive consequences of this technological updating.