Executive Summary
A leading international nutraceutical ingredient manufacturer required a fully automated, GMP-compliant Horse Gram Protein Isolate (HGPI) Manufacturing Plant capable of producing premium Horse Gram Protein Isolate (90–94% Protein), Horse Gram Protein Concentrate, Defatted Horse Gram Flour, Dietary Fiber, Polyphenol-Rich Extract, and Functional Plant Protein Ingredients for sports nutrition, clinical nutrition, functional foods, nutraceuticals, pharmaceutical formulations, and specialty health products.
The customer required a turnkey manufacturing facility capable of maximizing protein recovery from Horse Gram (Macrotyloma uniflorum), while reducing naturally occurring anti-nutritional factors such as phytic acid, tannins, trypsin inhibitors, and enzyme inhibitors, preserving functional protein properties, minimizing utility consumption, and consistently producing export-quality ingredients 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 250 TPD Horse Gram Protein Manufacturing Plant integrating advanced cleaning, grading, dehulling, thermal conditioning, anti-nutritional factor reduction, protein extraction, membrane filtration, vacuum concentration, spray drying, PLC-SCADA automation, nitrogen blanketing, and fully automated CIP systems.
The facility transforms one of the world's most nutrient-dense legumes into premium export-quality protein ingredients while ensuring sustainable processing and maximum raw material utilization.
Customer Background
The customer supplies horse gram-derived ingredients to Sports Nutrition Manufacturers, Functional Food Companies, Nutraceutical Manufacturers, Clinical Nutrition Companies, Pharmaceutical Manufacturers, Plant-Based Protein Brands, Health Supplement Companies, and International Ingredient Exporters. Growing global demand for sustainable, climate-resilient plant proteins encouraged investment in a modern horse gram protein processing facility.
Customer Challenges
Before modernization, the customer experienced:
- Low protein recovery
- Presence of anti-nutritional compounds
- Variable protein functionality
- High energy consumption
- Limited processing capacity
- Inconsistent export quality
- Poor utilization of by-products
- High operating costs
- Product quality variation
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 250 MT/day of Horse Gram
- Producing premium Horse Gram Protein Isolate
- Reducing anti-nutritional compounds
- Recovering valuable polyphenols
- Manufacturing Defatted Horse Gram Flour
- Producing Dietary Fiber
- Maximizing raw material utilization
- Supporting expansion up to 2,000 TPD
Raw Material
- Botanical Name
- Macrotyloma uniflorum
- Common Name
- Horse Gram
- Raw Materials Used
- Clean Horse Gram Seeds, Dehulled Horse Gram, Horse Gram Flour, Defatted Horse Gram Meal
- Major Nutritional Components
- Plant Protein, Polyphenols, Dietary Fiber, Iron, Calcium, Potassium, Essential Amino Acids
- Daily Processing Capacity
- 250,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Functional Foods
- Clinical Nutrition
- Plant-Based Foods
- Nutraceuticals
- Pharmaceutical Products
- Protein Supplements
- Functional Beverages
- Food Fortification
- Specialty Protein Blends
Process Flow
Process Description
Raw Material Preparation
Horse gram seeds are cleaned, graded, dehulled, and conditioned to obtain a high-quality protein-rich raw material suitable for efficient extraction.
Anti-Nutritional Factor Reduction
MECH O TECH LLP employs scientifically optimized processing to reduce phytic acid, tannins, and trypsin inhibitors while maintaining nutritional integrity.
Advantages include:
- Improved digestibility
- Enhanced mineral bioavailability
- Better protein functionality
- Consistent export quality
- Increased consumer acceptance
Protein Extraction
Optimized extraction technology maximizes protein recovery while preserving native protein functionality.
Benefits include:
- High protein recovery
- Excellent emulsification
- Superior foaming capacity
- High water-holding capacity
- Excellent digestibility
Membrane Filtration
Advanced ultrafiltration and diafiltration systems remove:
- Soluble carbohydrates
- Residual anti-nutritional compounds
- Minerals
- Color bodies
- Low molecular weight impurities
Benefits include:
- Protein purity up to 94%
- Lower water consumption
- Improved production efficiency
- Excellent batch consistency
Vacuum Concentration & Spray Drying
The purified protein solution is concentrated and spray dried to produce a premium free-flowing powder featuring:
- Excellent dispersibility
- Low moisture
- Mild flavor
- Long shelf life
- Outstanding functional performance
Quality Standardization
Each production batch undergoes testing for:
- Protein Content
- Moisture
- Phytic Acid
- Tannin Content
- Trypsin Inhibitor Activity
- Solubility
- Particle Size
- Heavy Metals
- Microbial Load
- Functional Properties
Major Equipment Supplied
- Seed Cleaning & Grading System
- Dehulling Machine
- Thermal Conditioning Unit
- Fine Grinding System
- Anti-Nutritional Reduction System
- Protein Extraction Reactors
- Decanter Centrifuges
- Ultrafiltration & Diafiltration Systems
- Vacuum Concentrator
- Homogenizer
- Spray Dryer
- Fluid Bed Cooler
- Metal Detector
- Automatic Packing Machine
- PLC-SCADA Automation System
- Nitrogen Blanketing System
- MCC & Instrumentation
- Fully Automatic CIP System
Automation Features
The intelligent PLC-SCADA platform provides:
- Automatic recipe management
- Protein yield monitoring
- Anti-nutritional reduction monitoring
- Temperature & pH control
- Membrane performance monitoring
- Batch traceability
- Utility monitoring
- Alarm management
- Predictive maintenance
- Industry 4.0 integration
GMP & Safety Features
- SS 316L product-contact surfaces
- Hygienic sanitary piping
- Fully enclosed processing systems
- Automatic CIP & SIP systems
- Dust-controlled powder handling
- Nitrogen-protected product storage
- Validation-ready engineering
- GMP-compliant layout
- HACCP-compliant design
- Cross-contamination prevention
Plant Utilities
- Steam Boiler
- RO Water Plant
- Chilled Water System
- Cooling Tower
- Air Compressor
- Vacuum System
- Electrical Power
- Instrument Air
- Nitrogen Generation System
Sustainability Features
- Complete utilization of horse gram
- Recovery of valuable polyphenol-rich fractions
- Water recycling systems
- Heat recovery from spray drying
- Energy-efficient membrane technology
- Low wastewater generation
- Biomass utilization
- Reduced carbon footprint
- Zero-waste manufacturing philosophy
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher protein recovery
- Premium export-quality horse gram protein
- Improved digestibility and nutritional quality
- Additional revenue from polyphenol-rich extracts
- Lower operating costs
- Reduced utility consumption
- Increased production capacity
- 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, edible oil processing systems, nutraceutical manufacturing facilities, botanical extraction plants, pharmaceutical process equipment, and advanced food ingredient manufacturing systems. With over 30 years of engineering excellence, we deliver innovative processing technologies, intelligent PLC-SCADA automation, hygienic GMP engineering, and complete EPC solutions for the global food processing industry.
Conclusion
The Horse Gram Protein Isolate Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for producing premium horse gram protein ingredients through advanced anti-nutritional factor reduction, protein extraction, membrane filtration, and intelligent automation. The plant ensures maximum protein recovery, superior functionality, international regulatory compliance, and sustainable utilization of one of the most nutritious pulse crops.
Key Technical Highlights
- Raw Material
- Macrotyloma uniflorum (Horse Gram)
- Plant Capacity
- 10–2,000 TPD (Customizable)
- Finished Products
- Horse Gram Protein Isolate, Horse Gram Protein Concentrate, Defatted Horse Gram Flour, Horse Gram Dietary Fiber, Polyphenol-Rich Extract
- Technology
- Anti-Nutritional Factor Reduction + Protein Extraction + Membrane Filtration + Vacuum Concentration + Spray Drying
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS 304 / SS 316L
- Protein Purity
- Up to 94%
- Compliance
- GMP, WHO-GMP, HACCP, ISO 22000, FSSC 22000, BRCGS, USFDA-ready, EU-GMP-ready, CE-compliant Equipment
- Applications
- Sports Nutrition, Functional Foods, Clinical Nutrition, Plant-Based Foods, Nutraceuticals, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in plant protein processing and food engineering
- Complete turnkey EPC solutions from 500 kg/day pilot plants to 2,000 TPD industrial facilities
- Advanced anti-nutritional factor reduction, membrane filtration, and protein 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 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, edible oil processing, essential oil plants, oleoresin plants, and advanced food ingredient manufacturing systems
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