Processing Systems for Insect Proteins
Convert insect biomass into high‑quality insect protein powder efficiently and at low temperature. Hosokawa Micron supplies robust processing systems for black soldier fly larvae, mealworms (molitor) and fruit fly larvae, combining separation, drying, milling, classifying and mixing for consistent powder quality in food and feed applications.
Insect larvae are a fast‑growing, sustainable protein source thanks to their high feed‑conversion rate and ability to valorise waste streams from meat, vegetable or brewing industries. To unlock this potential, processors need gentle, high‑throughput drying and powder handling—especially when feeds are wet, cohesive and heat‑sensitive.
A Typical Insect Processing System:
Separator » Cooker » Screw press » Decanter » DMR flash mill dryer » Mixer
- Separator: larvae are separated from frass (vibratory screen separator).
- Cooker: Heat is applied for better shifting and to prevent bacteriological problems further on in the process.
- Screw press: most of the free fluid (water & fat) is pressed out.
- Decanter (3-phase): liquid phase is separated into 3 streams: water-phase, oil-phase and wet press cake (pulp).
- DMR flash mill dryer: pulp is dried, milled and classified in one machine to produce insect-based protein powder with the desired characteristics (e.g. fineness).
- Mixer: Batches of insect-based protein powders of differing qualities can be mixed together to achieve an end product with the desired quality level for the sales market.
Separation into Water, Oil and Pulp
After separation, cooking and pressing, the decanter produces three valuable streams: the oil phase, the water phase and the wet press cake or "pulp". The oil phase can be further processed and purified for use as a nutritious oil or feed additive. The water phase (“stick water”) can be thickened in an evaporator and mixed with the pulp as feed material for the DMR dryer system in order to produce protein powder. This approach maximises yield and allows tight control over the final protein powder specification.
Drying, Milling and Classifying in One Machine
Thanks to its unique design, the DMR flash mill dryer enables the precise adjustment of a wide range of parameters – including the RPM of the mill disc and classifier wheel, the process airflow, the feed rate and the inlet and outlet temperatures – to carefully manage the exposure time inside the drying chamber. This maintains the optimal product temperature as the particles pass upwards from the mill disc at the bottom to the rotating classifying wheel at the top of the chamber. In the case of larvae, for example, it is important to ensure that the product temperature stays below 60 degrees.
The DMR is also available with various mill discs and liners to adjust the particle size and amount of shear. The Hosokawa Micron R&D team will help you to identify the right parameters for your specific application. Besides ensuring that the insect-based proteins retain their beneficial properties, this all-in-one process step can give you an important edge in terms of efficiency, return on investment (ROI) and sustainability.
Mixing
Insect farmers have to meet certain quality criteria with their products. However, the quality of insect harvests can fluctuate due to seasonal influences, for example, which means that each harvest can have a different size or nutritional quality. Hosokawa's batch mixing technology can be used to mix several batches of insects to achieve a consistent overall quality level.
Moreover, all our Conical Paddle Mixers (CPM) and Nauta® mixers can be executed with a liquid injection system in order to add flavourings, colourings or oils during the mixing process.
Need Help Setting up Your Process?
Run trials with your own materials on production-scale equipment at our 2,000 m² Test & Process Development Centre in the Netherlands. Our experienced process specialists work with you to determine the optimal process, equipment or plant setup. We offer lab and production-scale trials, each supported by a detailed technical report covering setup, process parameters and performance insights—helping you choose the best solution with confidence.
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Hosokawa Micron B.V. is committed to sustainable and responsible process technology. Our ISO 14001 certification covers key environmental aspects such as air, soil, energy, waste, water, noise and hazardous substances. With an EcoVadis Silver Medal, we rank among the top 3% of EcoVadis-rated companies in the special machinery industry.
