Process your potential
The world's growing demand for natural, plant-based proteins equals vast opportunities.
Reduce your time to market and sustainably produce high-value plant-based proteins that consistently meet customers' demands for purity and functionality at optimum yield.
From plant to powder we understand and master each step of the process. Our complete processing line technologies give you the flexibility to stay competitive and transform the potential of proteins into pure business.
Prioritize quality
To deliver quality day in and day out, you need high-quality and dependable solutions that will help you deliver optimal products.
Perform sustainably
Minimize your environmental impact while maximizing efficiency, safety – and overall performance.
Pursue excellence
Take advantage of our expertise and achieve excellence across the board. From carrying out simulations to your final product.
The proof is in the process
Whatever your base ingredient, be it soy, potato, pea, or even mung bean, we're here to help optimize every single step of your production process. From the collection and preparation of raw materials to the moment the finalized product leaves your factory floor.
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Quality
Watch our video with Sarah, Application Development Manager for plant-based proteins, and find out how our project managers, process and engineering experts at dedicated GEA test centers can work with you to put quality first, and help you to create new and exciting products for your customers.
Sustainability
In this video, GEA energy expert Riccardo explains how GEA can help you to dramatically reduce reliance on fossil fuels, boost relative energy efficiency and cut CO2 emissions, as well as recycle water and improve productivity in your plant-based protein production process.
Excellence
Meet Conny, Application Sales Manager for starch and proteins, and find out how more than 60 years of GEA expertise supports every aspect of plant design and installation, post-commissioning service and maintenance.
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Key process steps for plant-based protein powders
The most common wet separation is a multi-stage process involving protein extraction, protein precipitation and purification. Key end points are consistent protein quality and high yields, using technologies that ensure hygienic processing and sustainable water management. A membrane filtration unit could optionally be used to isolate specific fractions of the purified protein.
The protein-rich fraction derived from the isolation and purification steps is neutralized and diluted to the required concentration and viscosity.
An indirect UHT plant with tube heat exchanger, steam injection or steam infusion is used to carry out effective heat treatment of protein dispersions.
The dryer is configured to match the final protein powder properties. The configuration can vary from single stage to three stage drying, with or without fines recycling, integrated agglomeration and/or lecithination.
Flash and ring dryers are used for starch and fiber streams drying. Wet material is dispersed into a stream of heated air, which conveys it through a drying column. The heat from the air stream dries the material as it is conveyed.
Conveying of powder from the dryer to powder storage followed by conveying to the powder filling system or other processing unit such as powder mixing. Conveying can be performed by gravity, pneumatic, mechanical or vibratory means as required by the application.
Powder filling into 25kg and big bags using high hygiene automatic powder fillers. Automated bag handling and closing is performed inside an enclosed safe environment to eliminate potential for contamination.
Effluent from the protein isolation process can undergo thermal separation in an evaporator, to produce a concentrate and a clean condensate. Condensate from the evaporator can be further purified in a GEA reverse osmosis (RO) plant to generate a concentrated retentate and a permeate of very high purity.
Effective CIP solutions remove any leftover product from the plant, tank surfaces, heat exchangers, pumps, pipes, etc. Systems with SIP (Sterilize-in-Place) functionality for high microbiologic control can be integrated.
Advanced process control tools enable consistent, and robust process conditions with the highest efficiency levels and minimum energy consumption.
What we do
Our end-to-end solutions have been designed to meet your exact needs. Have a look at some of our offerings below and see how we can help you.
CFD for accurate and efficient product design
Make spray drying plant-based proteins a breeze using Virtual Spray Dryer Testing. Based on computational fluid dynamics (CFD), GEA’s Virtual Spray Dryer Testing solution simulates the performance of the spray drying process with all its complexities. Our solution also provides deep process insights that can be used to make fast, reliable decisions, and we can help you make the most informed choice when it comes to a new investment or equipment upgrade.
Decanters for plant proteins
When it comes to protein extraction and purification, centrifugal decanters might be at the heart of every wet process line – but it is the complete process setup that brings out the best in them. Only the combination of extensive process line expertise with unique decanter features, e.g. Varipond P, make for top yields, high purity proteins, and valuable by-product recovery. In addition, clever recycling of process water minimizes fresh water consumption.
Test facilities for starch and proteins
Ready to work on a new product but looking for a tried and tested process before investing? With access to our test centers in Germany, the US and Denmark – the latter being the largest of its kind – work alongside our process experts to test your product under real-life conditions. This will allow you to select and tailor the best technologies for your needs so you can optimize every part of your production process. And be confident in your ability to achieve the required quality standards and powder characteristics you desire.
