Executive Summary
A leading global food ingredient manufacturer required a fully automated, GMP-compliant Peanut (Groundnut) Protein Isolate Manufacturing Plant capable of producing premium Peanut Protein Isolate (90–94% Protein), Peanut Protein Concentrate, Cold-Pressed Peanut Oil, Defatted Peanut Flour, and Peanut Dietary Fiber for sports nutrition, plant-based dairy, protein beverages, bakery products, confectionery, nutraceuticals, and pharmaceutical applications.
The customer required a turnkey manufacturing facility capable of maximizing protein recovery from cold-defatted peanut meal, minimizing aflatoxin risks through advanced quality assurance systems, preserving protein functionality, reducing water and energy 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 Peanut Protein Manufacturing Plant integrating advanced cleaning, grading, dehulling, blanching, cold oil pressing, protein extraction, membrane filtration, vacuum concentration, spray drying, PLC-SCADA automation, and fully automated CIP systems.
The facility consistently produces premium peanut protein ingredients with excellent digestibility, high solubility, superior emulsification properties, and exceptional international market acceptance.
Customer Background
The customer supplies peanut-derived ingredients to Sports Nutrition Manufacturers, Plant-Based Dairy Producers, Functional Food Companies, Bakery & Confectionery Industries, Nutraceutical Manufacturers, Health Supplement Companies, Pharmaceutical Manufacturers, and International Ingredient Exporters. Increasing global demand for economical, sustainable, high-protein food ingredients encouraged investment in a modern peanut protein manufacturing facility.
Customer Challenges
Before modernization, the customer experienced:
- Low protein recovery
- Residual oil in protein meal
- Aflatoxin control challenges
- Variable product quality
- High utility consumption
- Limited production capacity
- High operating costs
- Inconsistent export quality
- Poor by-product utilization
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 250 MT/day of Peanut Kernels
- Producing premium Peanut Protein Isolate
- Recovering Cold-Pressed Peanut Oil
- Manufacturing Defatted Peanut Flour
- Producing Peanut Dietary Fiber
- Maximizing raw material utilization
- Ensuring stringent food safety compliance
- Supporting expansion up to 1,500 TPD
Raw Material
- Botanical Name
- Arachis hypogaea
- Common Name
- Peanut (Groundnut)
- Raw Materials Used
- Shelled Peanut Kernels, Blanched Peanuts, Cold-Pressed Peanut Cake, Defatted Peanut Meal
- Major Nutritional Components
- Plant Protein, Healthy Unsaturated Oils, Dietary Fiber, Vitamin E, Essential Amino Acids, Minerals
- Daily Processing Capacity
- 250,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Plant-Based Milk
- Protein Powders
- Functional Foods
- Bakery Products
- Confectionery
- Nutritional Beverages
- Clinical Nutrition
- Nutraceuticals
- Pharmaceutical Formulations
Process Flow
Process Description
Raw Material Preparation
Premium peanut kernels undergo cleaning, grading, destoning, dehulling, blanching, and optical sorting to eliminate damaged kernels and foreign materials before oil extraction.
Cold Oil Recovery
Mechanical cold pressing efficiently recovers premium edible peanut oil while producing protein-rich defatted meal.
Advantages include:
- Premium edible oil recovery
- Reduced oxidation
- High-quality protein meal
- Improved process economics
- Better product consistency
Protein Extraction
The protein extraction system is optimized to maximize yield while preserving native protein functionality.
Benefits include:
- High protein recovery
- Excellent solubility
- Superior emulsification
- Excellent water-binding capacity
- Consistent product quality
Membrane Filtration
Advanced ultrafiltration and diafiltration systems remove:
- Soluble carbohydrates
- Residual oil traces
- Minerals
- Low molecular weight impurities
Benefits include:
- Protein purity up to 94%
- Excellent batch consistency
- Reduced water consumption
- Enhanced process efficiency
Vacuum Concentration & Spray Drying
The purified protein slurry is concentrated and spray dried into a premium free-flowing powder featuring:
- Excellent dispersibility
- Low moisture
- Pleasant roasted flavor profile (optional)
- Long shelf life
- Superior functional characteristics
Quality Standardization
Each production batch undergoes comprehensive analysis for:
- Protein Content
- Moisture
- Residual Oil
- Aflatoxin Compliance
- Solubility
- Particle Size
- Bulk Density
- Heavy Metals
- Microbial Load
- Amino Acid Profile
Major Equipment Supplied
- Raw Material Cleaning System
- Destoner
- Dehuller
- Blanching System
- Optical Color Sorter
- Cold Oil Press
- Fine Grinding System
- Slurry Preparation Tanks
- Protein Extraction Reactors
- Decanter Centrifuges
- Ultrafiltration & Diafiltration Systems
- Vacuum Concentrator
- Homogenizer
- HTST Pasteurizer
- Spray Dryer
- Fluid Bed Cooler
- Vibratory Sifter
- Automatic Packing Machine
- PLC-SCADA Automation System
- MCC & Instrumentation
- Fully Automatic CIP System
Automation Features
The intelligent PLC-SCADA platform provides:
- Automatic recipe management
- Protein yield monitoring
- Temperature & pH control
- Membrane performance monitoring
- Optical sorting integration
- Batch traceability
- Utility monitoring
- Alarm management
- Predictive maintenance
- Production analytics
- 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
- Allergen management design
- Validation-ready engineering
- GMP & HACCP-compliant layout
- Cross-contamination prevention
Plant Utilities
- Steam Boiler
- RO Water Plant
- Chilled Water System
- Cooling Tower
- Air Compressor
- Vacuum System
- Electrical Power
- Instrument Air
- Nitrogen Blanketing System (Optional)
Sustainability Features
- Complete utilization of peanut kernels
- Recovery of premium edible peanut oil
- Water recycling systems
- Heat recovery from spray drying
- Energy-efficient membrane technology
- Low wastewater generation
- Reduced carbon footprint
- Circular manufacturing process
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher protein recovery
- Premium export-quality peanut protein
- Additional revenue from peanut oil and flour
- Lower operating costs
- Reduced utility consumption
- Increased production capacity
- Improved food safety compliance
- Faster return on investment
- Enhanced profitability
- Greater international 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 intelligent PLC-SCADA automation, hygienic GMP engineering, sustainable processing technologies, and complete EPC solutions for the global food processing industry.
Conclusion
The Peanut (Groundnut) Protein Isolate Manufacturing Plant from MECH O TECH LLP delivers a complete turnkey solution for producing premium peanut protein ingredients, cold-pressed peanut oil, defatted peanut flour, and dietary fiber. Through advanced extraction technology, membrane filtration, intelligent automation, comprehensive food safety systems, 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
- Arachis hypogaea (Peanut/Groundnut)
- Plant Capacity
- 10–1,500 TPD (Customizable)
- Finished Products
- Peanut Protein Isolate, Peanut Protein Concentrate, Cold-Pressed Peanut Oil, Defatted Peanut Flour, Peanut Dietary Fiber
- Technology
- Cold Pressing + 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, Plant-Based Dairy, Functional Foods, Bakery, Confectionery, Nutraceuticals, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in protein processing, edible oil extraction, and food process engineering
- Complete turnkey EPC solutions from 500 kg/day pilot plants to 1,500 TPD industrial facilities
- Advanced membrane filtration and purification technologies for premium protein production
- Intelligent PLC-SCADA automation with complete production traceability and Industry 4.0 connectivity
- GMP-compliant hygienic engineering with fully automated CIP/SIP systems
- Integrated allergen management and stringent food safety 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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