Executive Summary
A leading global manufacturer of plant-based nutritional ingredients required a fully automated, GMP-compliant Lentil Protein Hydrolysate Manufacturing Plant capable of producing premium Enzymatically Hydrolyzed Lentil Protein, Bioactive Peptide Powder, Low Molecular Weight Peptide Fractions, Instant Protein Hydrolysates, and Functional Protein Ingredients for sports nutrition, clinical nutrition, medical foods, infant nutrition, nutraceuticals, and pharmaceutical applications.
The customer required a turnkey manufacturing facility capable of producing highly digestible lentil protein hydrolysates with precisely controlled Degree of Hydrolysis (DH), enhanced bioavailability, superior solubility, excellent emulsification properties, and consistent peptide 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 Lentil Protein Hydrolysate Manufacturing Plant integrating automated slurry preparation, enzymatic hydrolysis reactors, intelligent enzyme dosing, ultrafiltration, nanofiltration, vacuum concentration, spray drying, PLC-SCADA automation, nitrogen blanketing, and fully automated CIP/SIP systems.
Customer Background
The customer supplies lentil protein hydrolysates to Sports Nutrition Manufacturers, Clinical Nutrition Companies, Medical Food Producers, Functional Beverage Manufacturers, Nutraceutical Companies, Pharmaceutical Manufacturers, Infant Nutrition Ingredient Suppliers, and International Ingredient Exporters. Growing demand for rapidly digestible plant proteins and clean-label peptide ingredients encouraged investment in an advanced lentil protein hydrolysate manufacturing facility.
Customer Challenges
Before modernization, the customer faced:
- Variable peptide profiles
- Inconsistent enzyme performance
- Poor protein solubility
- High processing costs
- Limited production capacity
- Batch-to-batch variation
- High utility consumption
- Difficulty meeting global export specifications
- Limited product diversification
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 200 MT/day of Lentil Protein
- Producing premium protein hydrolysates
- Manufacturing customized peptide fractions
- Achieving precise Degree of Hydrolysis
- Maximizing protein utilization
- Reducing operating costs
- Supporting future expansion up to 1,500 TPD
Raw Material
- Botanical Name
- Lens culinaris
- Common Name
- Lentil
- Raw Materials Used
- Lentil Protein Isolate, Lentil 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
- 200,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Clinical Nutrition
- Medical Foods
- Functional Beverages
- Protein Supplements
- Geriatric Nutrition
- Infant Nutrition
- Pharmaceutical Formulations
- Functional Bakery Products
- High-Protein Ready-to-Drink Beverages
Process Flow
Process Description
Protein Slurry Preparation
Premium lentil protein isolate is dispersed in purified water using high-shear mixers to create a homogeneous slurry for efficient enzymatic hydrolysis.
Enzymatic Hydrolysis
Food-grade enzymes convert lentil proteins into bioactive peptides under tightly controlled pH, temperature, enzyme concentration, and reaction time.
Advantages include:
- Improved digestibility
- Rapid amino acid absorption
- Enhanced peptide bioavailability
- Superior solubility
- Excellent functional characteristics
Membrane Fractionation
Advanced ultrafiltration and nanofiltration systems separate peptides according to molecular weight while removing residual carbohydrates, salts, and impurities.
Benefits include:
- Uniform peptide profile
- High product purity
- Excellent nutritional value
- Consistent batch quality
- Improved functional performance
Vacuum Concentration & Spray Drying
The purified peptide solution is concentrated under vacuum and spray dried into a premium free-flowing powder with:
- Instant dispersibility
- Excellent solubility
- Low moisture
- Mild taste
- Extended shelf life
Quality Standardization
Every production batch is tested for:
- Degree of Hydrolysis (DH)
- Protein Content
- Peptide Molecular Weight Distribution
- Solubility
- Moisture
- Bulk Density
- Amino Acid Profile
- Heavy Metals
- Microbiological Quality
- Particle Size Distribution
Major Equipment Supplied
- Protein Slurry Preparation Tanks
- High-Shear Mixing System
- Enzymatic Hydrolysis Reactors
- Automated Enzyme Dosing 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:
- Automated recipe management
- Degree of Hydrolysis monitoring
- Intelligent enzyme dosing
- Real-time pH and temperature control
- Membrane fouling monitoring
- Batch traceability
- Utility monitoring
- Alarm management
- Predictive maintenance
- Industry 4.0 integration
GMP & Safety Features
- SS316L product-contact surfaces
- Hygienic sanitary process piping
- Fully enclosed processing systems
- Fully Automatic CIP & SIP systems
- HEPA-filtered drying air
- Hygienic powder conveying 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 hydrolysis
- Closed-loop water recycling
- Energy-efficient membrane separation
- Heat recovery from evaporation and spray drying
- Minimal 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 absorption
- Consistent peptide quality
- Improved export competitiveness
- Reduced manufacturing costs
- Lower utility consumption
- Increased production capacity
- Faster return on investment
- Improved profitability
- Entry into high-value clinical and sports 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, plant protein processing systems, botanical extraction plants, nutraceutical process 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 separation, PLC-SCADA automation, hygienic GMP engineering, installation, commissioning, validation, operator training, and lifetime technical support.
Conclusion
The Lentil Protein Hydrolysate Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for manufacturing premium plant-derived protein hydrolysates and bioactive peptide ingredients. Through advanced enzymatic hydrolysis, membrane fractionation, intelligent automation, and GMP-compliant engineering, the plant ensures exceptional digestibility, superior product quality, high process efficiency, and sustainable industrial production.
Key Technical Highlights
- Raw Material
- Lens culinaris (Lentil Protein Isolate/Concentrate)
- Plant Capacity
- 5–1,500 TPD (Customizable)
- Finished Products
- Lentil Protein Hydrolysate, Bioactive Peptide Powder, Instant Lentil 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 and plant protein processing technologies
- Complete turnkey EPC solutions from 5 TPD pilot plants to 1,500 TPD commercial production facilities
- Advanced enzymatic hydrolysis, membrane fractionation, and peptide purification systems
- 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, nutraceutical manufacturing, botanical extraction, pharmaceutical process equipment, essential oil plants, oleoresin plants, and advanced food ingredient manufacturing systems
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