Executive Summary
A global manufacturer of plant-based nutritional ingredients required a fully automated, GMP-compliant Mung Bean Protein Isolate (MBPI) Manufacturing Plant capable of producing premium Mung Bean Protein Isolate (85–90% Protein), Mung Bean Protein Concentrate, Mung Bean Starch, and Dietary Fiber for sports nutrition, vegan foods, dairy alternatives, egg replacement products, bakery applications, and pharmaceutical formulations.
The customer required a turnkey manufacturing facility capable of maximizing protein recovery while preserving native protein functionality, minimizing water and energy consumption, and consistently producing export-quality products 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 an 80 TPD Mung Bean Protein Manufacturing Plant integrating advanced raw material cleaning, dehulling, wet milling, alkaline extraction, membrane filtration, protein precipitation, homogenization, spray drying, PLC-SCADA automation, and fully automated CIP systems.
The plant consistently produces premium-quality mung bean protein with excellent emulsification, foaming capacity, digestibility, neutral taste, and international market acceptance.
Customer Background
The customer supplies mung bean protein ingredients to Sports Nutrition Manufacturers, Vegan Food Companies, Plant-Based Egg Manufacturers, Dairy Alternative Producers, Functional Beverage Companies, Bakery & Confectionery Manufacturers, Nutraceutical Companies, and International Ingredient Exporters. The growing demand for allergen-friendly, clean-label, sustainable protein ingredients encouraged investment in a modern automated manufacturing facility.
Customer Challenges
Before modernization, the customer experienced:
- Low protein recovery
- High starch contamination
- Inconsistent protein functionality
- High water consumption
- Manual processing variability
- High operating costs
- Limited manufacturing capacity
- Difficulty achieving export-quality specifications
- Poor recovery of valuable co-products
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 80 MT/day of Whole Mung Beans
- Producing premium Mung Bean Protein Isolate
- Manufacturing Mung Bean Protein Concentrate
- Recovering food-grade mung bean starch
- Producing dietary fiber
- Maximizing protein recovery
- Reducing water and utility consumption
- Supporting expansion up to 400 TPD
Raw Material
- Botanical Name
- Vigna radiata
- Common Name
- Mung Bean (Green Gram)
- Raw Materials Used
- Whole Mung Beans, Dehulled Mung Beans, Mung Bean Flour
- Major Nutritional Components
- Plant Protein, Starch, Dietary Fiber, Essential Amino Acids, Minerals
- Daily Processing Capacity
- 80,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Plant-Based Egg Products
- Vegan Meat Alternatives
- Dairy-Free Products
- Functional Foods
- Nutritional Beverages
- Bakery Products
- Infant Nutrition
- Clinical Nutrition
- Pharmaceutical Formulations
Process Flow
Process Description
Raw Material Preparation
Whole mung beans undergo cleaning, destoning, magnetic separation, dehulling, and wet milling to produce a uniform slurry suitable for high-efficiency protein extraction.
Protein Extraction
Proteins are selectively extracted under controlled alkaline conditions to maximize yield while preserving their native functional properties.
Advantages include:
- High protein recovery
- Excellent emulsification properties
- Superior foaming capacity
- Low protein denaturation
- Consistent batch quality
Centrifugal Separation
High-speed decanter centrifuges efficiently separate:
- Protein-rich extract
- Starch fraction
- Fiber fraction
This maximizes raw material utilization and improves overall plant profitability.
Membrane Filtration
Ultrafiltration and diafiltration systems purify and concentrate proteins while removing soluble carbohydrates, minerals, and other low-molecular-weight compounds.
Benefits include:
- Higher protein purity
- Lower water consumption
- Improved process efficiency
- Uniform product quality
Protein Precipitation & Neutralization
Controlled pH adjustment enables efficient protein precipitation, followed by neutralization to optimize taste, stability, and functionality.
Spray Drying
The purified protein slurry is spray dried using advanced atomization systems to produce premium free-flowing powder with:
- Excellent dispersibility
- Low moisture
- Neutral flavor
- Long shelf life
Quality Standardization
Each production batch undergoes testing for:
- Protein Content
- Moisture
- Solubility
- Emulsification Capacity
- Foaming Stability
- Particle Size
- Bulk Density
- Heavy Metals
- Microbial Load
- Amino Acid Profile
Major Equipment Supplied
- Raw Material Cleaning System
- Destoner
- Magnetic Separator
- Dehulling Machine
- Wet Mill
- Slurry Preparation Tanks
- Protein Extraction Reactors
- Decanter Centrifuges
- Ultrafiltration & Diafiltration Systems
- Protein Precipitation Tanks
- Neutralization Tanks
- Homogenizer
- HTST Pasteurizer
- Spray Dryer
- Fluid Bed Cooler
- Vibratory Sifter
- Automatic Packing Machine
- PLC-SCADA Automation System
- MCC & Instrumentation
- Automatic CIP System
Automation Features
The intelligent PLC-SCADA platform includes:
- Automatic Recipe Management
- pH Control
- Temperature Monitoring
- Flow Control
- Membrane Pressure Monitoring
- Protein Yield Monitoring
- Batch Traceability
- Alarm Management
- Utility Monitoring
- Production Analytics
- Predictive Maintenance
- Industry 4.0 Integration
GMP & Safety Features
The plant is designed according to international food and nutraceutical manufacturing standards. Features include:
- SS 316L product-contact surfaces
- Hygienic sanitary piping
- Closed production systems
- Automatic CIP & SIP systems
- Dust-controlled powder handling
- Validation-ready engineering
- GMP-compliant layout
- HACCP-ready design
- Cross-contamination prevention
Plant Utilities
- Steam Boiler
- Chilled Water System
- RO Water Plant
- Air Compressor
- Vacuum System
- Cooling Tower
- Electrical Power
- Instrument Air
Sustainability Features
The facility incorporates environmentally responsible engineering through:
- Water recycling systems
- Membrane water recovery
- Heat recovery from spray drying
- Complete utilization of starch and fiber co-products
- Utility optimization
- Low wastewater generation
- Reduced carbon footprint
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher protein recovery
- Premium export-quality mung bean protein
- Additional revenue through starch and fiber recovery
- Reduced operating costs
- Lower water and energy consumption
- Increased manufacturing capacity
- Consistent product functionality
- Improved profitability
- Faster return on investment
- 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, nutraceutical manufacturing systems, food ingredient processing equipment, pharmaceutical process machinery, and advanced food processing facilities. With over 30 years of engineering excellence, we deliver innovative processing technologies, intelligent PLC-SCADA automation, hygienic GMP engineering, and sustainable turnkey solutions for the global plant-protein industry.
Conclusion
The Mung Bean Protein Isolate (MBPI) Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for manufacturing premium mung bean protein ingredients. By integrating advanced wet fractionation, membrane filtration, spray drying, intelligent automation, and GMP-compliant engineering, the facility ensures exceptional product quality, maximum raw material utilization, lower operating costs, and world-class manufacturing performance.
Key Technical Highlights
- Raw Material
- Vigna radiata (Mung Bean / Green Gram)
- Plant Capacity
- 2–400 TPD (customizable)
- Finished Products
- Mung Bean Protein Isolate, Mung Bean Protein Concentrate, Mung Bean Starch, Dietary Fiber
- Technology
- Wet Fractionation + Alkaline Protein Extraction + Membrane Filtration + Protein Precipitation + Spray Drying
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS 304 / SS 316L
- Protein Purity
- Up to 90%
- Compliance
- GMP, WHO-GMP, HACCP, ISO 22000, FSSC 22000, BRCGS, USFDA-ready, EU-GMP-ready, CE-compliant equipment
- Applications
- Plant-Based Foods, Sports Nutrition, Vegan Egg Alternatives, Functional Foods, Clinical Nutrition, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in protein processing, food engineering, and nutraceutical manufacturing
- Complete turnkey solutions from 500 kg/day pilot plants to 400 TPD industrial facilities
- Advanced membrane filtration systems for high-purity protein production
- Intelligent PLC-SCADA automation with complete batch traceability and Industry 4.0 connectivity
- GMP-compliant hygienic engineering with automated CIP/SIP systems
- Energy-efficient processing with heat recovery, water recycling, and by-product valorization
- Complete installation, commissioning, validation, operator training, preventive maintenance, spare parts supply, and lifetime technical support
- Proven expertise in protein processing, herbal extraction, phytochemicals, oleoresins, essential oils, natural colors, nutraceutical ingredients, and pharmaceutical process plants
Want Results Like This For Your Plant?
Mechotech engineers are ready to assess your process and design the right plant for your target output.
Get a Free Consultation
