Executive Summary
A leading manufacturer of premium plant-based nutritional ingredients required a fully automated, GMP-compliant Sesame Protein Hydrolysate Manufacturing Plant for producing Enzymatically Hydrolyzed Sesame Protein, Bioactive Sesame Peptides, Low Molecular Weight Peptide Fractions, Instant Sesame Protein Hydrolysate, and Functional Protein Ingredients for sports nutrition, clinical nutrition, functional foods, medical nutrition, nutraceuticals, pharmaceutical formulations, and premium vegan food applications.
The customer required a turnkey manufacturing facility capable of producing highly digestible sesame protein hydrolysates with accurately controlled Degree of Hydrolysis (DH), enhanced bioavailability, superior solubility, excellent emulsification, improved foaming characteristics, and consistent peptide molecular weight distribution while 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 Sesame Protein Hydrolysate Manufacturing Plant integrating automated slurry preparation, intelligent enzyme dosing, enzymatic hydrolysis reactors, ultrafiltration, nanofiltration, decolorization systems, vacuum concentration, spray drying, PLC-SCADA automation, nitrogen blanketing, and fully automated CIP/SIP systems.
Customer Background
The customer supplies sesame protein hydrolysates to Sports Nutrition Manufacturers, Clinical Nutrition Companies, Functional Food Manufacturers, Plant-Based Beverage Producers, Nutraceutical Companies, Pharmaceutical Manufacturers, Vegan Protein Brands, and International Food Ingredient Exporters. Growing demand for allergen-managed, high-protein, plant-derived functional ingredients encouraged the customer to establish a modern sesame protein hydrolysate manufacturing facility.
Customer Challenges
Before modernization, the customer experienced:
- Inconsistent protein hydrolysis
- Variable peptide molecular weight distribution
- Dark product colour due to natural pigments
- Batch-to-batch quality variation
- High utility consumption
- Limited automation
- High manufacturing costs
- Export compliance challenges
- Lower protein recovery
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 250 MT/day of Sesame Protein
- Producing premium sesame protein hydrolysates
- Manufacturing customized peptide fractions
- Achieving precise Degree of Hydrolysis
- Maximizing protein recovery
- Reducing operating costs
- Supporting future expansion up to 2,000 TPD
Raw Material
- Botanical Name
- Sesamum indicum
- Common Name
- Sesame Seed (Til)
- Raw Materials Used
- Sesame Protein Isolate, Sesame Protein Concentrate, Defatted Sesame Meal, Food-Grade Proteolytic Enzymes, Purified Water
- Major Nutritional Components
- Plant Protein, Bioactive Peptides, Essential Amino Acids, Sulfur-Containing Amino Acids, Functional Peptide Fractions
- Daily Processing Capacity
- 250,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Clinical Nutrition
- Functional Foods
- Plant-Based Foods
- Medical Nutrition
- Nutraceutical Products
- Pharmaceutical Formulations
- Protein Beverages
- Meal Replacement Products
- High-Protein Bakery Products
Process Flow
Process Description
Protein Slurry Preparation
Premium sesame protein isolate or concentrate is dispersed in purified water using automated high-shear mixing systems to obtain a homogeneous slurry for efficient enzymatic hydrolysis.
Enzymatic Hydrolysis
Selected food-grade proteolytic enzymes hydrolyze sesame proteins into highly digestible bioactive peptides under precisely controlled pH, temperature, enzyme dosage, and reaction time.
Advantages include:
- Improved digestibility
- Enhanced amino acid absorption
- Superior peptide bioavailability
- Excellent solubility
- Improved emulsification
- Better functional properties
- Consistent peptide profile
Membrane Purification
Advanced ultrafiltration and nanofiltration systems separate peptide fractions according to molecular weight while removing carbohydrates, pigments, salts, enzyme residues, and unwanted impurities.
Benefits include:
- High peptide purity
- Uniform molecular weight distribution
- Excellent nutritional quality
- Consistent export-grade quality
- Superior product functionality
Vacuum Concentration & Spray Drying
The purified peptide solution is vacuum concentrated and spray dried into a premium free-flowing powder featuring:
- Instant dispersibility
- Excellent flowability
- Low moisture content
- Uniform particle size
- Extended shelf life
Quality Standardization
Each production batch undergoes comprehensive testing for:
- Degree of Hydrolysis (DH)
- Protein Content
- Peptide Molecular Weight Distribution
- Solubility Index
- Moisture Content
- Bulk Density
- Amino Acid Profile
- Heavy Metals
- Microbiological Quality
- Particle Size Distribution
Major Equipment Supplied
- Automated Raw Material Feeding System
- Protein Slurry Preparation Tanks
- High-Shear Mixing System
- Enzymatic Hydrolysis Reactors
- Intelligent Enzyme Dosing System
- Plate Heat Exchanger
- Decanter Centrifuge
- Ultrafiltration System
- Nanofiltration System
- Activated Carbon Treatment System
- Vacuum Evaporator
- Spray Dryer
- Fluid Bed Cooler
- Nitrogen Flushing System
- Automatic Packing Machine
- Metal Detector
- PLC-SCADA Automation System
- MCC & Intelligent Instrumentation
- Fully Automatic CIP & SIP System
Automation Features
The PLC-SCADA automation system provides:
- Automated recipe management
- Online Degree of Hydrolysis monitoring
- Intelligent enzyme dosing
- Automatic pH and temperature control
- Membrane performance monitoring
- Batch traceability
- Utility monitoring
- Alarm management
- Predictive maintenance
- Industry 4.0 integration with remote diagnostics
GMP & Safety Features
- SS316L product-contact surfaces
- Hygienic sanitary piping
- Fully enclosed processing systems
- Fully Automatic CIP & SIP systems
- HEPA-filtered drying air
- Hygienic powder conveying systems
- Nitrogen-protected product handling
- GMP-compliant facility design
- HACCP-compliant manufacturing
- Validation-ready engineering
Plant Utilities
- Steam Boiler
- RO Water Plant
- Chilled Water System
- Cooling Tower
- Vacuum System
- Air Compressor
- Electrical Power
- Instrument Air
- Nitrogen Generation System
Sustainability Features
- Energy-efficient enzymatic hydrolysis
- Closed-loop water recycling
- High-efficiency membrane purification
- Heat recovery from evaporation and spray drying
- Reduced wastewater generation
- Maximum protein utilization
- Reduced carbon footprint
- Zero-waste manufacturing philosophy
- Sustainable sesame protein processing
Customer Benefits
Following successful commissioning, the customer achieved:
- Premium sesame peptide production
- Improved digestibility and bioavailability
- Consistent export-quality products
- Reduced operating costs
- Lower utility consumption
- Increased production capacity
- Faster return on investment
- Expanded product portfolio
- Enhanced profitability
- Stronger global competitiveness
Plants Used In This Project
Why Mech O Tech LLP?
MECH O TECH LLP is a globally recognized manufacturer of turnkey protein hydrolysate plants, plant protein processing systems, botanical extraction plants, nutraceutical processing equipment, pharmaceutical manufacturing systems, and advanced food ingredient production facilities. With over 30 years of engineering excellence, MECH O TECH LLP delivers complete EPC solutions integrating enzymatic hydrolysis, membrane purification, PLC-SCADA automation, hygienic GMP engineering, installation, commissioning, validation, operator training, and lifetime technical support.
Conclusion
The Sesame Protein Hydrolysate Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for manufacturing premium sesame-derived protein hydrolysates and bioactive peptide ingredients. Through advanced enzymatic hydrolysis, membrane purification, intelligent automation, and GMP-compliant engineering, the plant delivers exceptional digestibility, consistent product quality, superior production efficiency, and sustainable industrial manufacturing for global nutrition and plant-based food industries.
Key Technical Highlights
- Raw Material
- Sesamum indicum (Sesame Protein Isolate, Sesame Protein Concentrate, Defatted Sesame Meal)
- Plant Capacity
- 10–2,000 TPD (Customizable)
- Finished Products
- Sesame Protein Hydrolysate, Bioactive Sesame Peptide Powder, Functional Protein Ingredients
- Technology
- Enzymatic Hydrolysis + Ultrafiltration + Nanofiltration + Activated Carbon Decolorization + Vacuum Concentration + Spray Drying
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS304 / SS316L
- Protein Recovery
- >97%
- Compliance
- GMP, WHO-GMP, HACCP, ISO 22000, FSSC 22000, BRCGS, USFDA-ready, EU-GMP-ready, CE-compliant Equipment
- Applications
- Sports Nutrition, Clinical Nutrition, Functional Foods, Medical Nutrition, Plant-Based Foods, Nutraceuticals, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in protein hydrolysate and plant protein processing technologies
- Complete turnkey EPC solutions from 10 TPD pilot plants to 2,000 TPD commercial production facilities
- Advanced enzymatic hydrolysis, membrane purification, peptide fractionation, spray drying, and hygienic process engineering
- 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 manufacturing with water recycling, heat recovery, and maximum raw material utilization
- Complete installation, commissioning, validation, operator training, preventive maintenance, spare parts supply, and lifetime technical support
- Proven expertise in protein processing, hydrolysate production, botanical extraction, nutraceutical manufacturing, pharmaceutical process equipment, essential oil plants, oleoresin plants, and advanced food ingredient manufacturing systems
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