Protein Powder

Milk Intake
Milk arrives at the dairy processor where it is tested for purity, quality, fat content, and proper storage temperature to ensure the milk is free from harmful bacteria. Standardization includes determining the ratio of protein to fat in the milk or standardizing the solids and then weighing the milk.

Coagulation
Coagulation is the process of denaturing the milk proteins to form a gel network that facilitates the separation of milk solids (casein curds) from liquid (whey). However, coagulation itself does not separate curds and whey. Bacterial cultures are added to the milk before coagulation and after pasteurization. Streptococcus, Lactobacillus, and Lactococcus lactis are commonly used starter cultures that convert the lactose in milk to lactic acid via fermentation.

Whey Draining and Pasteurization
After separation, the whey is drained from the curds and then stored and transported to a protein manufacturing facility. After draining, the liquid whey is pasteurized again at 161 degrees Fahrenheit for at least five seconds to further ensure that the whey is free of harmful pathogens.

Whey Filtration
The liquid whey then undergoes filtration using a variety of methods, such as membrane filtration or ion exchange, which allow the whey proteins and other nutrients to selectively pass through while filtering out suspended solids (such as fine casein curd particles that remain from the draining step). In order to raise the concentration of whey protein (to 90% or higher) relative to all other dry matter, the liquid whey may undergo diafiltration, a process that adds water to the liquid whey during filtration to wash out lactose and minerals.

Evaporation and Crystallization
Next, the permeate enters the evaporators, which siphon off more liquid in the whey product, further concentrating the whey proteins and nutrients.
After evaporation, the whey is flash cooled to 85 to 105 degrees Fahrenheit to facilitate the formation and growth of lactose crystals, a process known as nucleation. The whey is then held within the crystallizers for four to eight hours to achieve a uniform distribution of lactose crystals, a characteristic that prevents the final product from absorbing or attracting moisture from the air.

Spray Drying
The whey is then transported to a post-crystallization spray dryer where any remaining water in the whey concentrate is evaporated off and the product is milled into a powdered or flake form. Spray drying prevents the growth of microorganisms in order to protect the consumer and to better preserve the food product. The most widely-used method is drum-spray drying, by which the whey product is run over high-capacity, steam-heated, rotating drums to facilitate the grinding of the whey concentrate and siphoning of the whey's excess liquid in the form of a vapor.

Packaging
After drying, the powdered concentrate is transferred to Permeate Powder Storage, where the powdered whey protein product is then bagged, typically in approximately 25 kg, plastic-lined, industrial bags.