Manufacturing Procedure (Tongkat Ali Powder Extract)

1. Root Extraction

   Tongkat Ali plants can be found in many parts of the Malaysian Rain Forest. To extract the root, the plant is manually uprooted. This process is normally done in the morning. Then the root is seperated from the stem at the spot. At the end of the day, the roots are gathered at the collection point. The roots are then washed to get rid of the soil and then are immediately transported to the factory.

2. Washing, Cleansing & Drying

   Tongkat Ali roots are washed for the second time to ensure they are really clean. The roots are then cut and chipped and oven dried at 60°C for 4 hours.

3. Flaking & Drying

   The dried roots are the fed into the pulverizing machine that will produce root flakes of about 1mm to 5mm in size. The root flakes are then dried further and then packed and stored in the storage area.

4. Extraction Process

   Flaked roots are then extracted with reverse osmosis water (1kg of root/10 liters of R.O. water). The extraction process is carried out at 100°C for 6 hours. The extracts are then micro-filtered & magnet-filtered. The extracts are then stored in a deep freezer (-40°C). The frozen extract is then freeze dried to yield the powdered extract. The powdered extract is then packed in vacuum packing and kept in dry area until required for production.

5. Mixing

   Powdered extract is transferred to a G.M.P. factory. The powdered extracts are then mixed with fillers using Food Grade Stainless Steel Mixing Tank for 15 minutes.

6. Capsuling

   After mixing, the resulting mixture will be encapsulated using the fully automated encapsulation machine at the factory. The machine will automatically vacuum polish the capsules.

7. Bottling & Sealing

   The capsules are sent for quality inspection before sending them to the bottling machine.

8. Product Specification

   The extraction yield results will vary for each batch, but the average yield is approximately 1%. The yield is very much influenced by a number of factors, and the main factors are as follows:

   1. Age of Tongkat Ali root: the older, the more yield.
      
   2. Source of Tongkat Ali root: Tongkat Ali from Pulau Perhentian has the highest extraction yield, followed by Pahang. The yield from Tongkat Ali roots from Kedah is only about 0.65%.
      
   3. The duration of extraction process: the optimum yield is 6 hours of extraction.
      
   4. Extraction temperature: optimum yield is obtained at boiling temperature (100°C).

   A typical extraction result is as follows:

   Process Tongkat Ali root : 10 kg R.O. Water : 100 liters Extraction at 100°C : 6 hours Concentrate & freeze-dried : 1 day Result : 100g of Tongkat Ali extract (1% yield)