Executive Summary
A leading international food ingredient manufacturer required a fully automated, GMP-compliant Sesame Protein Isolate (SPI) Manufacturing Plant capable of producing premium Sesame Protein Isolate (88–93% Protein), Sesame Protein Concentrate, Cold-Pressed Sesame Oil, Sesame Lignan Concentrate, and Sesame Fiber for sports nutrition, functional foods, plant-based beverages, bakery products, dairy alternatives, nutritional supplements, and pharmaceutical applications.
The customer required a turnkey manufacturing facility capable of maximizing protein recovery from cold-defatted sesame meal, preserving natural antioxidants such as sesamin and sesamolin, minimizing oxidation, reducing water and energy consumption, and consistently producing export-quality ingredients compliant 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 150 TPD Sesame Protein Manufacturing Plant integrating advanced seed cleaning, dehulling, cold pressing, protein extraction, membrane filtration, lignan recovery, vacuum concentration, spray drying, PLC-SCADA automation, and fully automated CIP systems.
The facility consistently produces premium sesame protein with excellent digestibility, superior emulsification properties, pleasant flavor, and exceptional international market acceptance.
Customer Background
The customer supplies sesame-derived ingredients to Sports Nutrition Manufacturers, Functional Food Companies, Bakery Ingredient Manufacturers, Plant-Based Beverage Producers, Nutraceutical Companies, Health Supplement Manufacturers, Pharmaceutical Companies, and International Ingredient Exporters. The growing global demand for allergen-friendly, clean-label, plant-based proteins encouraged investment in a state-of-the-art sesame protein manufacturing facility.
Customer Challenges
Before modernization, the customer experienced:
- Low protein recovery
- Oxidation during processing
- Variable protein functionality
- High utility consumption
- Inconsistent product quality
- Limited manufacturing capacity
- High operating costs
- Underutilization of sesame oil and lignans
- Difficulty meeting export-quality specifications
Project Objectives
MECH O TECH LLP engineered a turnkey solution capable of:
- Processing 150 MT/day of Sesame Seeds
- Producing premium Sesame Protein Isolate
- Recovering Cold-Pressed Sesame Oil
- Recovering Sesame Lignans
- Producing Sesame Fiber
- Maximizing raw material utilization
- Reducing production costs
- Supporting expansion up to 750 TPD
Raw Material
- Botanical Name
- Sesamum indicum
- Common Name
- Sesame Seed (Til)
- Raw Materials Used
- Whole Sesame Seeds, Hulled Sesame Seeds, Cold-Pressed Sesame Cake, Defatted Sesame Meal
- Major Nutritional Components
- Plant Protein, Healthy Oils, Sesamin, Sesamolin, Dietary Fiber, Essential Amino Acids, Minerals
- Daily Processing Capacity
- 150,000 kg/day
Finished Product
Available Options
Applications
- Sports Nutrition
- Functional Foods
- Plant-Based Milk
- Protein Powders
- Bakery Products
- Nutritional Beverages
- Dairy Alternatives
- Clinical Nutrition
- Health Supplements
- Pharmaceutical Formulations
Process Flow
Process Description
Raw Material Preparation
Sesame seeds are cleaned, destoned, magnetically separated, dehulled, and cold pressed to recover premium edible oil. The resulting protein-rich meal is finely milled for downstream extraction.
Cold Oil Pressing
Mechanical cold pressing preserves the nutritional quality of sesame oil while producing protein-rich meal.
Advantages include:
- Premium oil quality
- High oil recovery
- Reduced oxidation
- Improved protein concentration
- Higher overall profitability
Protein Extraction
Protein is extracted under carefully controlled conditions to preserve its functional and nutritional properties.
Benefits include:
- High protein recovery
- Excellent digestibility
- Superior emulsification
- Good foaming properties
- Consistent batch quality
Membrane Filtration
Advanced ultrafiltration and diafiltration systems remove:
- Soluble sugars
- Minerals
- Low molecular weight compounds
- Pigments
Benefits include:
- Higher protein purity
- Lower water consumption
- Better product consistency
- Improved processing efficiency
Lignan Recovery
Specialized extraction and purification systems recover valuable sesame lignans such as sesamin and sesamolin, widely used in nutraceuticals and functional food formulations.
Vacuum Concentration & Spray Drying
The purified protein stream is gently concentrated and spray dried into a premium free-flowing powder with:
- Excellent dispersibility
- Low moisture
- Long shelf life
- Superior functional properties
- Neutral flavor profile
Quality Standardization
Each production batch undergoes comprehensive testing for:
- Protein Content
- Moisture
- Solubility
- Particle Size
- Bulk Density
- Oil Residue
- Heavy Metals
- Microbial Load
- Amino Acid Profile
- Functional Properties
Major Equipment Supplied
- Raw Material Cleaning System
- Destoner
- Magnetic Separator
- Dehulling Machine
- Cold Oil Press
- Meal Mill
- Slurry Preparation Tanks
- Protein Extraction Reactors
- Decanter Centrifuges
- Ultrafiltration & Diafiltration Systems
- Lignan Recovery Unit
- Vacuum Concentrator
- 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 provides:
- Automatic Recipe Management
- Temperature Monitoring
- pH Monitoring
- Flow Monitoring
- Membrane Performance Monitoring
- Protein Yield Monitoring
- Batch Traceability
- Utility Monitoring
- Alarm Management
- Production Analytics
- Predictive Maintenance
- Industry 4.0 Integration
GMP & Safety Features
The plant is engineered according to international hygienic food manufacturing standards. Features include:
- SS 316L product-contact surfaces
- Hygienic sanitary piping
- Fully enclosed processing 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
- RO Water Plant
- Chilled Water System
- Cooling Tower
- Air Compressor
- Vacuum System
- Electrical Power
- Instrument Air
Sustainability Features
The plant incorporates environmentally responsible engineering through:
- Complete utilization of sesame seeds
- Recovery of premium edible oil and lignans
- Water recycling systems
- Heat recovery from spray drying
- Utility optimization
- Low wastewater generation
- Reduced environmental footprint
Customer Benefits
Following successful commissioning, the customer achieved:
- Higher protein recovery
- Premium export-quality sesame protein
- Additional revenue from sesame oil and lignans
- Reduced production costs
- Lower water and energy consumption
- Increased production capacity
- Consistent product quality
- Faster return on investment
- Improved profitability
- Enhanced 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 processing plants. 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 food ingredient industry.
Conclusion
The Sesame Protein Isolate Manufacturing Plant from MECH O TECH LLP provides a complete turnkey solution for producing premium sesame protein ingredients, cold-pressed sesame oil, sesame lignan concentrates, and dietary fiber. By integrating advanced extraction technology, membrane filtration, spray drying, intelligent automation, 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
- Sesamum indicum (Sesame Seed)
- Plant Capacity
- 5–750 TPD (Customizable)
- Finished Products
- Sesame Protein Isolate, Sesame Protein Concentrate, Cold-Pressed Sesame Oil, Sesame Lignan Concentrate, Sesame Fiber
- Technology
- Cold Pressing + Protein Extraction + Membrane Filtration + Lignan Recovery + Vacuum Concentration + Spray Drying
- Automation
- PLC-SCADA with Industry 4.0 Integration
- Construction Material
- SS 304 / SS 316L
- Protein Purity
- Up to 93%
- Compliance
- GMP, WHO-GMP, HACCP, ISO 22000, FSSC 22000, BRCGS, USFDA-ready, EU-GMP-ready, CE-compliant equipment
- Applications
- Functional Foods, Sports Nutrition, Plant-Based Foods, Bakery Products, Nutraceuticals, Pharmaceutical Ingredients
Why Global Manufacturers Choose MECH O TECH LLP
- 30+ years of engineering excellence in protein processing, edible oil extraction, nutraceutical manufacturing, and food process engineering
- Complete turnkey solutions from 500 kg/day pilot plants to 750 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 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, edible oil processing, nutraceutical manufacturing, pharmaceutical process equipment, essential oil plants, oleoresin plants, and advanced food ingredient manufacturing systems
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