Executive Summary
A leading global producer of premium plant-based nutritional ingredients required a fully automated, GMP-compliant Hazelnut Protein Hydrolysate Manufacturing Plant for manufacturing Enzymatically Hydrolyzed Hazelnut Protein, Bioactive Hazelnut Peptides, Low Molecular Weight Peptide Fractions, Instant Hazelnut Protein Hydrolysate, and Functional Protein Ingredients for sports nutrition, clinical nutrition, medical nutrition, nutraceuticals, pharmaceutical formulations, functional beverages, confectionery nutrition, and premium plant-based food applications.
The customer required a turnkey manufacturing facility capable of producing highly digestible hazelnut protein hydrolysates with accurately controlled Degree of Hydrolysis (DH), enhanced bioavailability, superior solubility, excellent emulsification, improved foaming characteristics, and consistent peptide 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 200 TPD Hazelnut Protein Hydrolysate Manufacturing Plant integrating automated slurry preparation, intelligent enzyme dosing, enzymatic hydrolysis reactors, ultrafiltration, nanofiltration, deoiling systems, vacuum concentration, spray drying, PLC-SCADA automation, nitrogen blanketing, and fully automated CIP/SIP systems.
Customer Background
The customer supplies hazelnut protein hydrolysates to Sports Nutrition Manufacturers, Clinical Nutrition Companies, Functional Food Manufacturers, Plant-Based Beverage Producers, Nutraceutical Companies, Pharmaceutical Manufacturers, Premium Vegan Protein Brands, and International Food Ingredient Exporters. Growing demand for premium nut-derived proteins and clean-label functional ingredients encouraged the customer to establish a technologically advanced hazelnut protein hydrolysate manufacturing facility for export markets.
Customer Challenges
Before modernization, the customer experienced:
- Variable enzymatic hydrolysis efficiency
- Residual oil affecting protein purity
- Batch-to-batch quality variation
- Inconsistent peptide molecular weight distribution
- High manufacturing costs
- High utility consumption
- Limited automation
- Stringent export quality requirements
- Lower protein recovery
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 200 MT/day of Hazelnut Protein
- Producing premium hazelnut protein hydrolysates
- Manufacturing customized peptide fractions
- Achieving precise Degree of Hydrolysis
- Maximizing protein recovery
- Reducing manufacturing costs
- Supporting future expansion up to 2,000 TPD
Raw Material
- Botanical Name
- Corylus avellana
- Common Name
- Hazelnut
- Raw Materials Used
- Hazelnut Protein Isolate, Hazelnut Protein Concentrate, Defatted Hazelnut Meal, Food-Grade Proteolytic Enzymes, Purified Water
- Major Nutritional Components
- Plant Protein, Bioactive Peptides, Essential Amino Acids, Arginine, Glutamic Acid, Functional Peptide Fractions
- Daily Processing Capacity
- 200,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Clinical Nutrition
- Functional Foods
- Plant-Based Dairy Alternatives
- Nutraceutical Products
- Pharmaceutical Formulations
- Protein Beverages
- Meal Replacement Products
- High-Protein Snack Foods
- Functional Bakery Products
Process Flow
Process Description
Protein Slurry Preparation
Premium hazelnut protein isolate or concentrate is dispersed in purified water using automated high-shear mixing systems to prepare a homogeneous slurry. Controlled hydration maximizes enzyme accessibility while preserving protein functionality.
Enzymatic Hydrolysis
Selected food-grade proteolytic enzymes hydrolyze hazelnut proteins into highly digestible bioactive peptides under optimized pH, temperature, enzyme dosage, and reaction time.
Advantages include:
- Improved digestibility
- Enhanced amino acid absorption
- Superior peptide bioavailability
- Excellent water solubility
- Improved emulsification
- Better foaming characteristics
- Enhanced functional performance
Membrane Purification
Advanced ultrafiltration and nanofiltration systems separate peptides according to molecular weight while removing residual oil, carbohydrates, enzyme residues, pigments, salts, and other impurities.
Benefits include:
- High peptide purity
- Uniform peptide molecular weight distribution
- Excellent nutritional quality
- Consistent export-grade quality
- Superior functional properties
Vacuum Concentration & Spray Drying
The purified peptide solution is vacuum concentrated and spray dried into a premium free-flowing powder featuring:
- Instant dispersibility
- Low moisture content
- Uniform particle size
- Excellent flowability
- Long shelf life
Quality Standardization
Each production batch undergoes comprehensive testing for:
- Degree of Hydrolysis (DH)
- Protein Content
- Peptide Molecular Weight Distribution
- Solubility Index
- Moisture Content
- Bulk Density
- Amino Acid Profile
- Residual Oil Content
- Heavy Metals
- Microbiological Quality
- Particle Size Distribution
Major Equipment Supplied
- Automated Raw Material Feeding System
- Protein Slurry Preparation Tanks
- High-Shear Mixing System
- Enzymatic Hydrolysis Reactors
- Intelligent Enzyme Dosing System
- Plate Heat Exchanger
- Decanter Centrifuge
- Ultrafiltration System
- Nanofiltration System
- Deoiling & Polishing Filtration System
- Vacuum Evaporator
- Spray Dryer
- Fluid Bed Cooler
- Nitrogen Flushing System
- Automatic Packing Machine
- Metal Detector
- PLC-SCADA Automation System
- MCC & Intelligent Instrumentation
- Fully Automatic CIP & SIP System
Automation Features
The advanced PLC-SCADA automation platform provides:
- Automated recipe management
- Online Degree of Hydrolysis monitoring
- Intelligent enzyme dosing
- Automatic pH and temperature control
- Membrane performance monitoring
- Batch traceability
- Utility monitoring
- Alarm management
- Predictive maintenance
- Industry 4.0 integration with remote diagnostics
GMP & Safety Features
- SS316L product-contact surfaces
- Hygienic sanitary piping
- Fully enclosed processing systems
- Fully Automatic CIP & SIP systems
- HEPA-filtered drying air
- Hygienic powder conveying systems
- Nitrogen-protected product handling
- GMP-compliant facility design
- HACCP-compliant manufacturing
- Validation-ready engineering
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
- Energy-efficient enzymatic hydrolysis
- Closed-loop water recycling
- Advanced membrane water recovery
- Heat recovery from evaporation and spray drying
- Reduced wastewater generation
- Maximum protein utilization
- Reduced carbon footprint
- Zero-waste manufacturing philosophy
- Sustainable hazelnut protein processing
Customer Benefits
Following successful commissioning, the customer achieved:
- Premium hazelnut peptide production
- Improved digestibility and bioavailability
- Consistent export-quality products
- Reduced operating costs
- Lower utility consumption
- Increased production capacity
- Faster return on investment
- Expanded product portfolio
- Enhanced profitability
- Stronger global competitiveness
Plants Used In This Project
Why Mech O Tech LLP?
MECH O TECH LLP is a globally recognized manufacturer of turnkey protein hydrolysate plants, plant protein processing systems, botanical extraction plants, nutraceutical processing equipment, pharmaceutical manufacturing systems, and advanced food ingredient production facilities. With over 30 years of engineering excellence, MECH O TECH LLP delivers complete EPC solutions integrating enzymatic hydrolysis, membrane purification, PLC-SCADA automation, hygienic GMP engineering, installation, commissioning, validation, operator training, and lifetime technical support.
Conclusion
The Hazelnut Protein Hydrolysate Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for manufacturing premium hazelnut-derived protein hydrolysates and bioactive peptide ingredients. Through advanced enzymatic hydrolysis, membrane purification, intelligent automation, and GMP-compliant engineering, the plant ensures exceptional digestibility, consistent product quality, superior production efficiency, and sustainable industrial manufacturing for global nutrition and plant-based food industries.
Key Technical Highlights
- Raw Material
- Corylus avellana (Hazelnut Protein Isolate, Hazelnut Protein Concentrate, Defatted Hazelnut Meal)
- Plant Capacity
- 10–2,000 TPD (Customizable)
- Finished Products
- Hazelnut Protein Hydrolysate, Bioactive Hazelnut Peptide Powder, Functional Protein Ingredients
- Technology
- Enzymatic Hydrolysis + Ultrafiltration + Nanofiltration + Deoiling & Polishing Filtration + Vacuum Concentration + Spray Drying
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS304 / SS316L
- Protein Recovery
- >97%
- 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, Plant-Based Dairy Alternatives, Nutraceuticals, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in protein hydrolysate and plant protein processing technologies
- Complete turnkey EPC solutions from 10 TPD pilot plants to 2,000 TPD commercial production facilities
- Advanced enzymatic hydrolysis, membrane purification, peptide fractionation, spray drying, and hygienic process engineering
- 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 manufacturing with water recycling, heat recovery, and maximum raw material 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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