AbstractBACKGROUNDHigh levels of aspalathin, an antidiabetic dihydrochalcone, in green rooibos underpins interest in the production of a standardised extract. Elements of a quality‐by‐design approach were applied to optimise extraction conditions, aiming at the delivery of a dry matter yield (DMY) ≥ 160 g kg−1 and an extract with an aspalathin content (AC) ≥ 80 g kg−1.RESULTSHot water extraction parameters, namely extraction time, extraction temperature and water‐to‐plant material ratio, were optimised for DMY and aspalathin extraction efficiency (AEE) using Design of Experiments. Good polynomial prediction models were obtained and multiresponse desirability plots indicated 37 min, 93 °C and 23:1 as optimal conditions. Even when using 30 min and 10:1 instead for practical reasons, the target DMY and AC values could be achieved with the caveat that plant material with an AC ≥ 30 g kg−1 is used. Particle size distribution and stem content were identified as contributing to variation in the AC of raw material.CONCLUSIONBy setting raw material specifications in terms of AC, as well as applying practical optimum extraction conditions, 160 g kg−1 extract with an AC ≥ 80 g kg−1 could be consistently achieved from green rooibos plant material. © 2017 Society of Chemical Industry