Executive Summary
A leading European plant-based ingredient manufacturer required a fully automated, GMP-compliant Faba Bean Protein Isolate (FBPI) Manufacturing Plant capable of producing premium Faba Bean Protein Isolate (88–92% Protein), Faba Bean Protein Concentrate, Faba Bean Starch, and Dietary Fiber for meat alternatives, dairy substitutes, protein beverages, sports nutrition, bakery products, infant nutrition, and pharmaceutical applications.
The customer required a turnkey manufacturing facility capable of maximizing protein recovery while preserving protein functionality, minimizing anti-nutritional factors, reducing water and energy consumption, and consistently producing export-quality ingredients meeting 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 160 TPD Faba Bean Protein Manufacturing Plant integrating advanced raw material cleaning, dehulling, wet milling, alkaline extraction, decanter centrifugation, ultrafiltration, diafiltration, protein precipitation, homogenization, spray drying, PLC-SCADA automation, and fully automated CIP systems.
The facility consistently produces premium-quality faba bean protein ingredients with excellent emulsification, gelation, foaming properties, neutral flavor, and outstanding international market acceptance.
Customer Background
The customer supplies faba bean protein ingredients to Plant-Based Meat Manufacturers, Dairy Alternative Producers, Sports Nutrition Companies, Functional Food Manufacturers, Bakery Ingredient Suppliers, Nutraceutical Companies, Pharmaceutical Manufacturers, and International Ingredient Exporters. The rapidly expanding demand for sustainable, non-soy, allergen-friendly protein ingredients encouraged investment in an advanced automated manufacturing facility.
Customer Challenges
Before modernization, the customer experienced:
- Low protein extraction efficiency
- Presence of anti-nutritional compounds
- Variable protein functionality
- High water consumption
- High operating costs
- Batch-to-batch inconsistency
- Limited manufacturing capacity
- Difficulty meeting export-quality specifications
- Poor recovery of starch and fiber
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 160 MT/day of Faba Beans
- Producing premium Faba Bean Protein Isolate
- Manufacturing Faba Bean Protein Concentrate
- Recovering food-grade starch
- Producing dietary fiber
- Maximizing raw material utilization
- Reducing production costs
- Supporting expansion up to 800 TPD
Raw Material
- Botanical Name
- Vicia faba
- Common Name
- Faba Bean (Broad Bean)
- Raw Materials Used
- Whole Faba Beans, Dehulled Faba Beans, Faba Bean Flour
- Major Nutritional Components
- Plant Protein, Starch, Dietary Fiber, Essential Amino Acids, Minerals
- Daily Processing Capacity
- 160,000 kg/day
Finished Product
Available Options
Applications
- Plant-Based Meat
- Dairy Alternatives
- Sports Nutrition
- Functional Foods
- Bakery Products
- Nutritional Beverages
- Infant Nutrition
- Clinical Nutrition
- Gluten-Free Foods
- Pharmaceutical Formulations
Process Flow
Process Description
Raw Material Preparation
Whole faba beans are cleaned, destoned, magnetically separated, dehulled, and wet milled into a uniform slurry to optimize protein extraction.
Protein Extraction
Proteins are extracted under carefully controlled alkaline conditions to maximize recovery while preserving native functionality.
Advantages include:
- High protein yield
- Excellent emulsification
- Superior foaming characteristics
- Excellent gel strength
- Low protein denaturation
Solid-Liquid Separation
High-efficiency decanter centrifuges separate:
- Protein-rich extract
- Starch fraction
- Fiber fraction
Efficient separation ensures maximum recovery of valuable co-products.
Membrane Filtration
Ultrafiltration and diafiltration systems concentrate proteins while removing:
- Soluble carbohydrates
- Minerals
- Anti-nutritional compounds
- Low molecular weight impurities
Benefits include:
- Higher protein purity
- Reduced water consumption
- Improved product consistency
- Enhanced process efficiency
Protein Precipitation & Spray Drying
After controlled precipitation and neutralization, the purified protein is homogenized, pasteurized, and spray dried into a premium free-flowing powder with:
- Excellent dispersibility
- Neutral flavor
- Low moisture
- Long shelf life
Quality Standardization
Each production batch is tested for:
- Protein Content
- Moisture
- Solubility
- Gel Strength
- Emulsification Capacity
- Particle Size Distribution
- Bulk Density
- Heavy Metals
- Microbial Load
- Amino Acid Profile
Major Equipment Supplied
- Raw Material Cleaning System
- Destoner
- Magnetic Separator
- Dehulling Machine
- Wet Mill
- Slurry Preparation Tanks
- Protein Extraction Reactors
- Decanter Centrifuges
- Ultrafiltration & Diafiltration Systems
- Protein Precipitation Tanks
- Neutralization Tanks
- Homogenizer
- HTST Pasteurizer
- Spray Dryer
- Fluid Bed Cooler
- Vibratory Sifter
- Automatic Packing Machine
- PLC-SCADA Automation System
- MCC & Instrumentation
- Automatic CIP System
Automation Features
The intelligent PLC-SCADA platform provides:
- Automatic Recipe Management
- pH Monitoring & Control
- Temperature Monitoring
- Flow Monitoring
- Membrane Performance Monitoring
- Protein Yield Monitoring
- Batch Traceability
- Utility Monitoring
- Alarm Management
- Production Analytics
- Predictive Maintenance
- Industry 4.0 Integration
GMP & Safety Features
The facility is designed according to international food and nutraceutical manufacturing standards. Features include:
- SS 316L product-contact surfaces
- Hygienic sanitary piping
- Closed processing systems
- Fully automated CIP & SIP systems
- Dust-controlled powder handling
- Validation-ready engineering
- GMP-compliant layout
- HACCP-ready design
- Cross-contamination prevention
Plant Utilities
- Steam Boiler
- RO Water Plant
- Chilled Water System
- Cooling Tower
- Air Compressor
- Vacuum System
- Electrical Power
- Instrument Air
Sustainability Features
The plant incorporates environmentally responsible engineering through:
- Water recycling systems
- Heat recovery from spray drying
- Membrane water reuse
- Complete utilization of starch and fiber co-products
- Utility optimization
- Low wastewater generation
- Reduced environmental footprint
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher protein recovery
- Premium export-quality faba bean protein
- Additional revenue through starch and fiber recovery
- Lower production costs
- Reduced utility consumption
- Increased manufacturing capacity
- Consistent product functionality
- Faster return on investment
- Improved profitability
- Enhanced global competitiveness
Plants Used In This Project
Why Mech O Tech LLP?
MECH O TECH LLP is a globally recognized manufacturer of turnkey protein processing plants, food ingredient manufacturing systems, nutraceutical processing equipment, pharmaceutical process machinery, botanical extraction plants, and advanced food processing facilities. With over 30 years of engineering excellence, we deliver innovative processing technologies, intelligent PLC-SCADA automation, hygienic GMP engineering, and sustainable turnkey solutions for the global food ingredient industry.
Conclusion
The Faba Bean Protein Isolate Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for producing premium faba bean protein ingredients, starch, and dietary fiber. Through advanced wet fractionation, membrane filtration, spray drying, intelligent automation, and GMP-compliant engineering, the facility delivers exceptional product quality, maximum raw material utilization, reduced operating costs, and world-class manufacturing performance.
Key Technical Highlights
- Raw Material
- Vicia faba (Faba Bean / Broad Bean)
- Plant Capacity
- 5–800 TPD (Customizable)
- Finished Products
- Faba Bean Protein Isolate, Faba Bean Protein Concentrate, Faba Bean Starch, Dietary Fiber
- Technology
- Wet Fractionation + Alkaline Protein Extraction + Membrane Filtration + Protein Precipitation + Spray Drying
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS 304 / SS 316L
- Protein Purity
- Up to 92%
- Compliance
- GMP, WHO-GMP, HACCP, ISO 22000, FSSC 22000, BRCGS, USFDA-ready, EU-GMP-ready, CE-compliant equipment
- Applications
- Plant-Based Foods, Sports Nutrition, Dairy Alternatives, Functional Foods, Bakery Products, Clinical Nutrition, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in plant protein processing and food engineering
- Complete turnkey solutions from 500 kg/day pilot plants to 800 TPD industrial facilities
- Advanced membrane filtration and purification technologies for premium protein production
- Intelligent PLC-SCADA automation with complete production traceability and Industry 4.0 connectivity
- GMP-compliant hygienic engineering with fully automated CIP/SIP systems
- Energy-efficient processing with water recycling, heat recovery, and complete by-product utilization
- Complete installation, commissioning, validation, operator training, preventive maintenance, spare parts supply, and lifetime technical support
- Proven expertise in protein processing, botanical extraction, nutraceutical manufacturing, pharmaceutical process equipment, essential oil plants, oleoresin plants, and advanced food ingredient manufacturing systems
Want Results Like This For Your Plant?
Mechotech engineers are ready to assess your process and design the right plant for your target output.
Get a Free Consultation
