Executive Summary
A leading global food ingredient manufacturer required a fully automated, GMP-compliant Mango Kernel Protein Isolate (MKPI) Manufacturing Plant capable of producing premium Mango Kernel Protein Isolate (90–93% Protein), Mango Kernel Protein Concentrate, Cold-Pressed Mango Kernel Oil (Mango Butter), Defatted Mango Kernel Flour, Mango Kernel Dietary Fiber, and specialty functional ingredients for sports nutrition, bakery, confectionery, plant-based foods, nutraceuticals, cosmetics, and pharmaceutical applications.
The customer required a turnkey manufacturing facility capable of utilizing mango processing by-products efficiently, maximizing protein recovery from defatted mango kernel meal, preserving valuable lipids and natural antioxidants, minimizing oxidation, reducing 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 Mango Kernel Protein Manufacturing Plant integrating advanced kernel cleaning, drying, crushing, oil recovery, protein extraction, membrane filtration, vacuum concentration, spray drying, PLC-SCADA automation, nitrogen blanketing, and fully automated CIP systems.
The facility transforms mango processing waste into multiple high-value food, cosmetic, and nutraceutical ingredients while supporting sustainable manufacturing and circular economy initiatives.
Customer Background
The customer supplies mango kernel-derived ingredients to Sports Nutrition Manufacturers, Functional Food Companies, Bakery & Confectionery Industries, Cosmetic Manufacturers, Nutraceutical Companies, Pharmaceutical Companies, Plant-Based Food Manufacturers, and International Ingredient Exporters. Growing demand for sustainable plant proteins and value-added fruit by-products encouraged investment in an advanced mango kernel protein manufacturing facility.
Customer Challenges
Before modernization, the customer experienced:
- Disposal of large quantities of mango kernels
- Low protein recovery
- High residual fat in meal
- Variable protein purity
- Oxidation of kernel oil
- High utility consumption
- Limited production capacity
- Poor by-product utilization
- High production costs
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 250 MT/day of Mango Kernels
- Producing premium Mango Kernel Protein Isolate
- Recovering Cold-Pressed Mango Kernel Oil (Butter)
- Manufacturing Defatted Mango Kernel Flour
- Producing Mango Kernel Dietary Fiber
- Maximizing raw material utilization
- Reducing operating costs
- Supporting expansion up to 1,500 TPD
Raw Material
- Botanical Name
- Mangifera indica
- Common Name
- Mango Kernel
- Raw Materials Used
- Fresh Mango Kernels, Dried Mango Kernels, Mango Kernel Cake, Defatted Mango Kernel Meal
- Major Nutritional Components
- Plant Protein, Stearic Acid, Oleic Acid, Natural Antioxidants, Dietary Fiber, Essential Minerals, Essential Amino Acids
- Daily Processing Capacity
- 250,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Functional Foods
- Plant-Based Foods
- Bakery Products
- Confectionery
- Nutraceuticals
- Cosmetics
- Pharmaceutical Products
- Food Fortification
- Specialty Food Ingredients
Process Flow
Process Description
Raw Material Preparation
Mango kernels are cleaned, washed, dried, crushed, and conditioned for efficient oil recovery and protein extraction while preserving nutritional quality.
Mango Kernel Oil Recovery
MECH O TECH LLP utilizes advanced cold pressing technology to recover premium mango kernel oil suitable for food and cosmetic applications.
Advantages include:
- Premium cosmetic-grade butter
- High oxidative stability
- Excellent fatty acid profile
- Increased profitability
- Superior product quality
Protein Extraction
The defatted kernel meal undergoes optimized alkaline extraction and isoelectric precipitation, followed by advanced purification.
Benefits include:
- High protein recovery
- Excellent solubility
- Superior emulsification
- Good digestibility
- Consistent product quality
Membrane Filtration
Advanced ultrafiltration and diafiltration remove:
- Soluble carbohydrates
- Residual fats
- Minerals
- Low molecular weight impurities
- Off-flavor compounds
Benefits include:
- Protein purity up to 93%
- Reduced water consumption
- Higher production efficiency
- Excellent batch consistency
Vacuum Concentration & Spray Drying
The purified protein slurry is concentrated under vacuum and spray dried to obtain a premium free-flowing powder offering:
- Excellent dispersibility
- Low moisture
- Mild flavor
- Long shelf life
- Superior functional properties
Quality Standardization
Each production batch undergoes testing for:
- Protein Content
- Moisture
- Residual Fat
- Fatty Acid Profile
- Solubility
- Particle Size Distribution
- Bulk Density
- Heavy Metals
- Microbial Load
- Functional Properties
Major Equipment Supplied
- Raw Material Cleaning System
- Continuous Dryer
- Kernel Crusher
- Cold Oil Press
- Fine Grinding 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
- Oil recovery 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 oil 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 mango processing waste
- Recovery of premium mango kernel butter
- 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 mango kernel protein
- Additional revenue from mango kernel butter
- Reduced waste disposal costs
- 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 Mango Kernel Protein Isolate Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for producing premium mango kernel protein ingredients, mango kernel butter, defatted flour, and dietary fiber. By integrating advanced oil recovery, protein extraction, membrane filtration, 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
- Mangifera indica (Mango Kernel)
- Plant Capacity
- 20–1,500 TPD (Customizable)
- Finished Products
- Mango Kernel Protein Isolate, Mango Kernel Protein Concentrate, Cold-Pressed Mango Kernel Oil (Mango Butter), Defatted Mango Kernel Flour, Mango Kernel Dietary Fiber
- Technology
- Cold Oil Recovery + 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 93%
- Compliance
- GMP, WHO-GMP, HACCP, ISO 22000, FSSC 22000, BRCGS, USFDA-ready, EU-GMP-ready, CE-compliant Equipment
- Applications
- Sports Nutrition, Functional Foods, Bakery, Confectionery, Nutraceuticals, Cosmetics, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in protein processing and food engineering
- Complete turnkey EPC solutions from 500 kg/day pilot plants to 1,500 TPD industrial facilities
- Advanced membrane filtration, protein purification, and edible oil processing 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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