Executive Summary
A leading international manufacturer of plant-based nutritional ingredients required a fully automated, GMP-compliant Faba Bean Protein Hydrolysate Manufacturing Plant capable of producing premium Enzymatically Hydrolyzed Faba Bean Protein, Bioactive Peptide Powder, Low Molecular Weight Peptide Fractions, Instant Protein Hydrolysates, and Functional Protein Ingredients for sports nutrition, clinical nutrition, elderly nutrition, infant nutrition ingredients, functional beverages, nutraceuticals, and pharmaceutical applications.
The customer required a turnkey manufacturing facility capable of producing highly digestible protein hydrolysates with a precisely controlled Degree of Hydrolysis (DH), high peptide bioavailability, excellent solubility, superior dispersibility, and consistent molecular weight distribution while complying with GMP, WHO-GMP, HACCP, ISO 22000, FSSC 22000, BRCGS, USFDA, and international food safety standards.
MECH O TECH LLP successfully designed, engineered, manufactured, supplied, installed, and commissioned a 180 TPD Faba Bean Protein Hydrolysate Plant integrating automated protein slurry preparation, enzymatic hydrolysis reactors, intelligent enzyme dosing, membrane fractionation, vacuum evaporation, spray drying, PLC-SCADA automation, nitrogen blanketing, and fully automated CIP/SIP systems.
Customer Background
The customer supplies protein hydrolysates to Sports Nutrition Companies, Clinical Nutrition Manufacturers, Functional Beverage Producers, Infant Nutrition Ingredient Suppliers, Pharmaceutical Companies, Nutraceutical Manufacturers, Protein Supplement Brands, and International Ingredient Exporters. Growing demand for rapidly absorbed plant-derived peptides encouraged investment in an advanced hydrolysate manufacturing facility.
Customer Challenges
Prior to modernization, the customer faced:
- Inconsistent peptide profiles
- Variable enzyme efficiency
- Low digestibility
- Poor powder solubility
- High utility consumption
- Batch-to-batch variation
- Limited production capacity
- High manufacturing costs
- Difficulty meeting export specifications
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 180 MT/day of Faba Bean Protein
- Producing premium protein hydrolysates
- Manufacturing customized peptide fractions
- Achieving precise Degree of Hydrolysis
- Maximizing protein utilization
- Reducing operating costs
- Supporting expansion up to 1,200 TPD
Raw Material
- Botanical Name
- Vicia faba
- Common Name
- Faba Bean
- Raw Materials Used
- Faba Bean Protein Isolate, Faba Bean Protein Concentrate, Food-Grade Proteolytic Enzymes, Purified Water
- Major Nutritional Components
- Plant Protein, Bioactive Peptides, Essential Amino Acids, Branched-Chain Amino Acids (BCAAs), Functional Peptide Fractions
- Daily Processing Capacity
- 180,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Clinical Nutrition
- Medical Foods
- Functional Beverages
- Protein Supplements
- Geriatric Nutrition
- Infant Nutrition Ingredients
- Pharmaceutical Nutrition
Process Flow
Process Description
Protein Slurry Preparation
Premium faba bean protein is dispersed in purified water using automated high-shear mixing systems to ensure complete hydration and uniform processing.
Enzymatic Hydrolysis
Selected food-grade enzymes hydrolyze protein into bioactive peptides under accurately controlled temperature, pH, enzyme dosage, and reaction time.
Advantages include:
- Improved digestibility
- Rapid amino acid absorption
- High peptide bioavailability
- Excellent solubility
- Controlled peptide profile
Membrane Peptide Fractionation
Advanced ultrafiltration and nanofiltration systems separate peptides according to molecular weight.
Benefits include:
- Uniform peptide fractions
- Improved product purity
- Removal of residual carbohydrates
- Excellent batch consistency
- Superior nutritional performance
Spray Drying
The concentrated hydrolysate is converted into a premium free-flowing powder featuring:
- Instant solubility
- Low moisture
- Excellent dispersibility
- Mild flavor
- Long storage stability
Quality Standardization
Every production batch is tested for:
- Degree of Hydrolysis (DH)
- Protein Content
- Peptide Distribution
- Solubility
- Moisture
- Bulk Density
- Particle Size Distribution
- Amino Acid Profile
- Heavy Metals
- Microbiological Quality
Major Equipment Supplied
- Protein Slurry Preparation Tanks
- High-Shear Mixing System
- Enzymatic Hydrolysis Reactors
- Automated Enzyme Dosing System
- pH & Temperature Control System
- Plate Heat Exchanger
- Decanter Centrifuge
- Ultrafiltration System
- Nanofiltration System
- Vacuum Evaporator
- Spray Dryer
- Fluid Bed Cooler
- Automatic Packing Machine
- Metal Detector
- PLC-SCADA Automation System
- Nitrogen Blanketing System
- Fully Automatic CIP & SIP System
Automation Features
The intelligent PLC-SCADA platform provides:
- Automatic recipe management
- Degree of Hydrolysis monitoring
- Automated enzyme dosing
- Temperature and pH control
- Membrane performance monitoring
- Batch traceability
- Utility monitoring
- Alarm management
- Predictive maintenance
- Industry 4.0 integration
GMP & Safety Features
- SS316L product-contact surfaces
- Hygienic sanitary pipeline design
- Closed-loop processing
- Fully Automatic CIP & SIP systems
- HEPA-filtered drying air
- Hygienic powder transfer systems
- Validation-ready engineering
- GMP-compliant layout
- HACCP-compliant processing
- Cross-contamination prevention
Plant Utilities
- Steam Boiler
- RO Water Plant
- Chilled Water System
- Cooling Tower
- Vacuum System
- Air Compressor
- Electrical Power
- Instrument Air
- Nitrogen Generation System
Sustainability Features
- Low-energy enzymatic processing
- Water recycling systems
- Energy-efficient membrane separation
- Heat recovery from evaporation and drying
- Low wastewater generation
- Maximum protein utilization
- Reduced carbon footprint
- Zero-waste manufacturing philosophy
- Sustainable pulse protein processing
Customer Benefits
Following successful commissioning, the customer achieved:
- Premium bioactive peptide production
- Excellent digestibility and bioavailability
- Consistent peptide profiles
- Higher export competitiveness
- Reduced manufacturing costs
- Lower utility consumption
- Increased production capacity
- Faster return on investment
- Improved profitability
- Entry into premium clinical nutrition markets
Plants Used In This Project
Why Mech O Tech LLP?
MECH O TECH LLP is a globally recognized manufacturer of turnkey protein hydrolysate plants, protein processing systems, botanical extraction plants, nutraceutical process equipment, pharmaceutical processing systems, and advanced food ingredient manufacturing facilities. With over 30 years of engineering excellence, MECH O TECH LLP delivers complete EPC solutions integrating enzymatic hydrolysis, advanced membrane technology, PLC-SCADA automation, hygienic GMP engineering, validation support, installation, commissioning, and lifetime technical assistance.
Conclusion
The Faba Bean Protein Hydrolysate Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for producing premium plant-derived protein hydrolysates and bioactive peptide ingredients. Through advanced enzymatic hydrolysis, membrane peptide fractionation, intelligent automation, and GMP-compliant engineering, the plant delivers superior digestibility, consistent product quality, excellent process efficiency, and sustainable industrial manufacturing.
Key Technical Highlights
- Raw Material
- Vicia faba (Faba Bean Protein Isolate/Concentrate)
- Plant Capacity
- 5–1,200 TPD (Customizable)
- Finished Products
- Faba Bean Protein Hydrolysate, Bioactive Peptide Powder, Instant Protein Hydrolysate, Functional Peptide Ingredients
- Technology
- Enzymatic Hydrolysis + Ultrafiltration + Nanofiltration + Vacuum Concentration + Spray Drying
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS304 / SS316L
- Protein Recovery
- >96%
- Compliance
- GMP, WHO-GMP, HACCP, ISO 22000, FSSC 22000, BRCGS, USFDA-ready, EU-GMP-ready, CE-compliant Equipment
- Applications
- Sports Nutrition, Clinical Nutrition, Functional Foods, Medical Nutrition, Nutraceuticals, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in protein hydrolysate processing and food engineering
- Complete turnkey EPC solutions from 5 TPD pilot plants to 1,200 TPD industrial facilities
- Advanced enzymatic hydrolysis, peptide fractionation, and membrane purification technologies
- Intelligent PLC-SCADA automation with complete production traceability and Industry 4.0 integration
- GMP-compliant hygienic engineering with fully automated CIP/SIP systems
- Energy-efficient processing with water recycling, heat recovery, and maximum protein utilization
- Complete installation, commissioning, validation, operator training, preventive maintenance, spare parts supply, and lifetime technical support
- Proven expertise in protein processing, hydrolysate production, botanical extraction, nutraceutical manufacturing, pharmaceutical process equipment, essential oil plants, oleoresin plants, and advanced food ingredient manufacturing systems
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