Executive Summary
A leading global manufacturer of plant-based nutritional ingredients required a fully automated, GMP-compliant Pea Protein Isolate (PPI) Manufacturing Plant capable of producing premium Pea Protein Isolate (80–90% Protein), Pea Protein Concentrate, Pea Starch, and Pea Fiber for sports nutrition, vegan foods, dairy alternatives, meat analogues, bakery products, infant nutrition, and pharmaceutical applications.
The customer required a turnkey manufacturing facility capable of maximizing protein recovery while preserving protein functionality, minimizing water and energy consumption, and ensuring consistent export-quality production in compliance with GMP, WHO-GMP, HACCP, ISO 22000, FSSC 22000, BRCGS, USFDA, and international food safety standards.
MECH O TECH LLP successfully designed, manufactured, supplied, installed, and commissioned a 120 TPD Pea Protein Isolate Manufacturing Plant integrating advanced raw material cleaning, milling, wet fractionation, alkaline extraction, decanter centrifugation, membrane filtration, isoelectric precipitation, homogenization, spray drying, PLC-SCADA automation, and CIP systems.
The facility consistently produces premium pea protein with excellent digestibility, solubility, emulsification properties, and international market acceptance.
Customer Background
The customer supplies plant-based protein ingredients to Sports Nutrition Companies, Vegan Food Manufacturers, Plant-Based Meat Producers, Dairy Alternative Manufacturers, Functional Beverage Companies, Bakery & Snack Manufacturers, Pharmaceutical Companies, and International Ingredient Exporters. The rapid expansion of the global plant-based protein market created demand for a modern, energy-efficient, high-capacity manufacturing facility capable of producing premium pea protein ingredients.
Customer Challenges
Prior to modernization, the customer experienced:
- Low protein extraction efficiency
- High starch contamination
- Variable protein functionality
- High water consumption
- Long production cycles
- High energy costs
- Manual production inconsistencies
- Limited production capacity
- Difficulty meeting international quality specifications
Project Objectives
MECH O TECH LLP developed a turnkey solution capable of:
- Processing 120 MT/day of Yellow Peas
- Producing premium Pea Protein Isolate
- Manufacturing Pea Protein Concentrate
- Recovering food-grade pea starch
- Producing high-quality pea fiber
- Reducing water and utility consumption
- Meeting international food safety standards
- Supporting future expansion up to 600 TPD
Raw Material
- Botanical Name
- Pisum sativum
- Common Name
- Yellow Pea
- Raw Material Used
- Whole Yellow Peas, Dehulled Peas, Pea Flour
- Major Nutritional Components
- Plant Protein, Starch, Dietary Fiber, Essential Amino Acids, Minerals
- Daily Processing Capacity
- 120,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Protein Powders
- Functional Foods
- Vegan Meat Alternatives
- Dairy-Free Products
- Nutritional Beverages
- Bakery Products
- Infant Nutrition
- Clinical Nutrition
- Pharmaceutical Formulations
Process Flow
Process Description
Raw Material Preparation
Yellow peas are cleaned, destoned, magnetically separated, dehulled, and milled into uniform flour to maximize extraction efficiency.
Wet Protein Extraction
The pea flour is mixed with purified process water.
Controlled alkaline extraction dissolves proteins while leaving starch and fiber largely insoluble.
Advantages include:
- High protein recovery
- Excellent protein functionality
- Minimal denaturation
- High process efficiency
- Consistent batch quality
Centrifugal Separation
High-efficiency decanter centrifuges separate:
- Protein-rich liquor
- Pea starch
- Pea fiber
This allows complete utilization of raw material while improving profitability.
Membrane Filtration
Ultrafiltration and diafiltration concentrate proteins while removing:
- Soluble sugars
- Minerals
- Low molecular weight impurities
Benefits include:
- Higher protein purity
- Reduced water consumption
- Better product consistency
- Lower operating costs
Isoelectric Precipitation
Protein is precipitated by precisely controlling pH using automated dosing systems.
Neutralization & Homogenization
The precipitated protein is neutralized and homogenized to improve functionality, taste, dispersibility, and stability.
Pasteurization & Spray Drying
The slurry is pasteurized before spray drying.
Advanced spray drying technology produces free-flowing powder with:
- Excellent dispersibility
- Low moisture
- High shelf life
- Superior solubility
Quality Standardization
Each production batch is tested for:
- Protein Content
- Moisture
- Solubility
- Emulsification Capacity
- Bulk Density
- Particle Size
- Microbial Load
- Heavy Metals
- Amino Acid Profile
- Functional Properties
Major Equipment Supplied
- Raw Material Cleaning System
- Destoner & Magnetic Separator
- Dehulling Machine
- Hammer Mill
- Slurry Preparation Tanks
- Protein Extraction Reactors
- Decanter Centrifuges
- Ultrafiltration System
- Diafiltration System
- Precipitation Reactors
- Neutralization Tanks
- Homogenizer
- HTST Pasteurizer
- Spray Dryer
- Fluid Bed Cooler
- Vibratory Sifter
- Automatic Packing System
- PLC-SCADA Automation System
- MCC & Instrumentation
- Automatic CIP System
Automation Features
The intelligent PLC-SCADA platform includes:
- Fully Automated Recipe Management
- pH Control
- Temperature Monitoring
- Flow Control
- Membrane Pressure Monitoring
- Protein Yield Monitoring
- Batch Traceability
- Utility Consumption Monitoring
- Alarm Management
- 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
- Fully enclosed processing
- 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 plant incorporates sustainable engineering through:
- Water recycling systems
- Membrane water reuse
- Heat recovery from spray drying
- Utility optimization
- Complete utilization of starch and fiber co-products
- Low wastewater generation
- Reduced carbon footprint
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher protein extraction efficiency
- Premium export-quality protein
- Additional revenue from starch and fiber recovery
- Lower production costs
- Reduced water and energy consumption
- Increased manufacturing capacity
- Consistent product functionality
- Improved profitability
- Excellent 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, botanical extraction equipment, pharmaceutical process machinery, and advanced food processing facilities. With over 30 years of engineering excellence, we deliver high-performance processing technologies, intelligent PLC-SCADA automation, hygienic GMP engineering, and sustainable turnkey solutions for the global food industry.
Conclusion
The Pea Protein Isolate (PPI) Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for manufacturing premium pea protein ingredients. By integrating advanced wet fractionation, membrane filtration, spray drying, intelligent automation, and GMP-compliant engineering, the plant delivers exceptional product quality, maximum raw material utilization, lower operating costs, and world-class manufacturing performance.
Key Technical Highlights
- Raw Material
- Pisum sativum (Yellow Pea)
- Plant Capacity
- 5–600 TPD (customizable)
- Finished Products
- Pea Protein Isolate, Pea Protein Concentrate, Pea Starch, Pea Fiber
- Technology
- Wet Fractionation + Alkaline Extraction + Membrane Filtration + Isoelectric 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
- Sports Nutrition, Functional Foods, Plant-Based Meat, Dairy Alternatives, Clinical Nutrition, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in protein processing, nutraceutical manufacturing, and food process engineering
- Complete turnkey solutions from 500 kg/day pilot plants to 600 TPD industrial facilities
- Advanced membrane filtration technology for high-purity protein production
- Intelligent PLC-SCADA automation with complete production traceability
- GMP-compliant hygienic engineering for food, nutraceutical, and pharmaceutical industries
- Energy-efficient processing with heat recovery, water reuse, 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 extracts, phytochemicals, essential oils, oleoresins, natural colors, nutraceutical ingredients, and pharmaceutical process plants
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