Executive Summary
A leading international plant protein manufacturer required a fully automated, GMP-compliant Moth Bean Protein Isolate (MBPI) Manufacturing Plant capable of producing premium Moth Bean Protein Isolate (90–94% Protein), Moth Bean Protein Concentrate, Defatted Moth Bean Flour, Dietary Fiber, Polyphenol-Rich Functional Extracts, and Specialty Plant Protein Ingredients for sports nutrition, clinical nutrition, functional foods, nutraceuticals, pharmaceutical formulations, and high-protein food products.
The customer required a turnkey manufacturing facility capable of maximizing protein recovery from Moth Bean (Vigna aconitifolia), reducing naturally occurring anti-nutritional compounds such as phytic acid, tannins, raffinose-family oligosaccharides, and trypsin 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 220 TPD Moth Bean Protein Manufacturing Plant integrating advanced cleaning, grading, dehulling, 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 converts a drought-resistant pulse crop into premium export-quality protein ingredients while ensuring sustainable processing, maximum product recovery, and excellent functional performance.
Customer Background
The customer supplies moth bean-derived ingredients to Sports Nutrition Manufacturers, Functional Food Companies, Nutraceutical Manufacturers, Clinical Nutrition Companies, Plant-Based Protein Brands, Pharmaceutical Companies, Health Supplement Manufacturers, and International Ingredient Exporters. Growing global demand for sustainable pulse proteins and climate-resilient crops encouraged investment in an advanced moth bean protein manufacturing facility.
Customer Challenges
Before modernization, the customer experienced:
- Low protein recovery
- Anti-nutritional compounds affecting digestibility
- Variable protein functionality
- High energy consumption
- Limited production capacity
- Product quality inconsistency
- Poor by-product utilization
- High operating costs
- Limited export opportunities
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 220 MT/day of Moth Beans
- Producing premium Moth Bean Protein Isolate
- Reducing anti-nutritional compounds
- Recovering valuable dietary fiber
- Manufacturing Defatted Moth Bean Flour
- Maximizing protein recovery
- Reducing operating costs
- Supporting expansion up to 1,500 TPD
Raw Material
- Botanical Name
- Vigna aconitifolia
- Common Name
- Moth Bean
- Raw Materials Used
- Clean Moth Beans, Dehulled Moth Beans, Moth Bean Flour, Defatted Moth Bean Meal
- Major Nutritional Components
- Plant Protein, Dietary Fiber, Polyphenols, Iron, Calcium, Potassium, Essential Amino Acids
- Daily Processing Capacity
- 220,000 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
- High-Protein Bakery Products
Process Flow
Process Description
Raw Material Preparation
Moth beans are cleaned, graded, dehulled, and conditioned to ensure efficient protein extraction while maintaining nutritional integrity.
Anti-Nutritional Factor Reduction
MECH O TECH LLP employs scientifically optimized thermal and aqueous processing to reduce naturally occurring anti-nutritional compounds while preserving protein functionality.
Advantages include:
- Improved digestibility
- Enhanced mineral bioavailability
- Better taste profile
- Consistent export-quality products
- Superior functional properties
Protein Extraction
Advanced alkaline extraction and isoelectric precipitation technology maximize protein recovery with excellent functional characteristics.
Benefits include:
- High protein recovery
- Excellent emulsification
- Good foaming properties
- High water-holding capacity
- Superior digestibility
Membrane Filtration
High-performance ultrafiltration and diafiltration systems remove:
- Soluble carbohydrates
- Anti-nutritional compounds
- Minerals
- Low molecular weight impurities
- Color pigments
Benefits include:
- Protein purity up to 94%
- Reduced water consumption
- Excellent production efficiency
- Outstanding batch consistency
Vacuum Concentration & Spray Drying
The purified protein solution is concentrated under vacuum and spray dried to obtain a premium free-flowing powder with:
- Excellent dispersibility
- Low moisture
- Mild flavor
- Long shelf life
- Outstanding functionality
Quality Standardization
Every production batch is analyzed for:
- Protein Content
- Moisture
- Phytic Acid
- Tannin Content
- Trypsin Inhibitor Activity
- Solubility
- Particle Size Distribution
- Bulk Density
- Heavy Metals
- Microbial Load
Major Equipment Supplied
- Seed Cleaning & Grading System
- Dehulling Machine
- Conditioning Unit
- Fine Grinding Mill
- 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
- Fully 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 moth beans
- Recovery of valuable dietary fiber
- 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 moth bean protein
- Improved digestibility and nutritional value
- Additional revenue from dietary fiber products
- 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 Moth Bean Protein Isolate Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for producing premium moth bean protein ingredients through advanced anti-nutritional factor reduction, protein extraction, membrane filtration, and intelligent automation. The plant ensures maximum protein recovery, excellent functional performance, international regulatory compliance, and sustainable utilization of this highly nutritious drought-resistant legume.
Key Technical Highlights
- Raw Material
- Vigna aconitifolia (Moth Bean)
- Plant Capacity
- 10–1,500 TPD (Customizable)
- Finished Products
- Moth Bean Protein Isolate, Moth Bean Protein Concentrate, Defatted Moth Bean Flour, Moth Bean Dietary Fiber, Polyphenol-Rich Functional 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 1,500 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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