A novel whole-kernel defatting technology for simultaneous production of high-quality edible oil and protein-rich...

Conventional oilseed processing prioritizes oil extraction, relegating protein-rich meals to low-value by-products. Here we report a whole-kernel defatting (WKD) technology using n-pentane that simultaneously yields high-quality peanut oil and protein-rich intact kernels. After seven extraction cycles, WKD removed >99% oil and retained 98.8% kernel integrity, outperforming supercritical CO₂ and n-hexane. The oil contained higher levels of vitamin E, phytosterols, and resveratrol than conventional-pressed oils, with superior oxidative stability. The defatted kernel retained its native protein conformation, achieving a nitrogen solubility index of 86.6%. In mice fed isocaloric diets, mice consuming defatted kernels instead of raw peanuts exhibited over 2.4-fold lower body weight gain and significantly attenuated hepatic lipid deposition. The process yielded a gross profit of $633.7/ton of raw peanuts, 3.5- to 5.9-fold higher than conventional pressing, and also successfully applied to other oilseeds including camellia seeds and walnuts. This work presents a sustainable, high-value oilseed paradigm without low-value meal.