45 Years of Experience
Dairy Industry Solutions
In modern dairy economics, whey accounts for up to 90% of the original milk volume and retains more than 50% of its nutritional value. At Sanchelima International, whey is not managed as a disposal stream but as a strategic raw material. Our engineering is focused on the fractionation, concentration, and stabilization of whey components to maximize return per 0.26 gal (1 L) processed—ranging from basic recovery systems to the production of high‑value protein concentrates and isolates in powder form.
Pre‑Treatment and Stabilization
Whey valorization begins with pre‑treatment, a critical step prior to any thermal operation. Residual fat and suspended solids are recovered using high‑efficiency standardizing separators, generating whey cream as a directly marketable by‑product, while filtration systems remove curd fines and protect downstream equipment. HTST pasteurization is then applied to ensure biological stability, carefully managing thermal load to preserve the functional integrity of soluble serum proteins.
Whey valorization begins with pre‑treatment, a critical step prior to any thermal operation. Residual fat and suspended solids are recovered using high‑efficiency standardizing separators, generating whey cream as a directly marketable by‑product, while filtration systems remove curd fines and protect downstream equipment. HTST pasteurization is then applied to ensure biological stability, carefully managing thermal load to preserve the functional integrity of soluble serum proteins.
Direct‑Consumption Whey Products and Cheese Applications
For plants seeking rapid return on investment and direct‑consumption products, we implement flocculation modules for Ricotta production. These systems precipitate whey proteins through precise control of temperature and acidity, producing spreadable or culinary cheeses with exceptional yields. Sweet or acid whey is converted into finished product within hours. Beyond fresh cheese, whey proteins can be valorized as functional ingredients for pasta filata cheese production, such as Oaxaca‑style cheese and mozzarella‑type pizza strands. By reusing whey proteins that would otherwise be discarded, producers reduce disposal costs and generate a high‑value ingredient without additional raw‑material expense, enabling product innovation, portfolio diversification, and access to new markets.
For the industrial ingredients market, whey processing is scaled using membrane concentration technologies. Nanofiltration and Reverse Osmosis remove water and reconcentrate solids, significantly reducing the energy demand of downstream evaporation. When demineralized whey (D90) is required—particularly for infant nutrition applications—electrodialysis demineralization is integrated to selectively remove salts without compromising protein functionality.
Evaporation, Crystallization, and Drying
The final stage is drying, traditionally the most challenging due to whey’s fouling tendency and hygroscopic behavior, especially in acid whey. Our solution combines forced‑circulation evaporation, engineered for viscous and difficult fluids, with controlled crystallization of concentrated whey to ensure correct formation of α‑lactose monohydrate. This control guarantees that, after spray drying, the resulting powder is free‑flowing, non‑caking, and compliant with international solubility and export standards.
RAW WHEY STORAGE SILOS
FINES SEPARATOR
HEATING AND COOLING SYSTEM
RAW WHEY CLARIFICATION
RAW WHEY SKIMMING
CLARIFIED AND SKIMMED WHEY STORAGE TANK
MEMBRANE SYSTEM NANOFILTRATION
ELECTRODIALYSIS SYSTEM
ELECTRODIALYZED WHEY CONCENTRATE STORAGE TANK
ALFA-FLASH EVAPORATION
CRYSTALLIZATION
THREE-STAGE VERTICAL DRYER
(DWPC) DEMINERALIZED WHEY PROTEIN CONCENTRATE (DWPI) DEMINERALIZED WHEY PROTEIN ISOLATE
From By-Product to Premium Ingredient: Strategic Valorization of Acid Whey
The diagram above illustrates a profitability strategy to transform acid whey (typically an operational challenge in Greek yogurt and cream cheese production) into high-value commodities: Demineralized Protein Concentrates (DWPC) and Isolates (DWPI).
Unlike conventional lines, this solution integrates critical Electrodialysis and Forced-Circulation Evaporation technologies. This configuration allows us to overcome the barriers of acidity and mineral load, delivering a thermally stable protein and a powder with superior solubility, suitable for the most demanding sports nutrition markets.
This is engineering designed for financial robustness: it maximizes return per liter of milk processed, ensures operational continuity and delivers a final product of export quality.
Acid Whey Valorization: Process Line for Demineralized Concentrates and Isolates (DWPC / DWPI)
This process line represents an integrated solution to transform a complex by-product—acid whey from Greek yogurt, cottage cheese or cream cheese—into high commercial value ingredients: Demineralized Whey Protein Concentrate (DWPC) and Isolate (DWPI).
Historically, acid whey processing has presented technical challenges due to its high mineral content, acidity and salinity. Our engineering integrates membrane separation, electrodialysis and multi-stage drying technologies to overcome these barriers. The result is a continuous, stable process that mitigates fouling issues and delivers a functional, thermally stable, highly soluble powder suited to the most demanding sports nutrition and dietary supplement markets.
Technical Process Description
1. Pre-treatment and Fines Recovery The process starts with the reception of raw acid whey. The first critical phase is solids recovery using a rotary filter designed specifically as a curd fines saver (Cheese Curd Fines Saver Separator). This stage not only cleans the whey to protect downstream equipment but also recovers remaining curd, adding immediate value back to the cheese line before whey processing. The whey is then clarified and skimmed by centrifugal separation with thermal control, ensuring a fat-free base for maximum protein purity.
2. Demineralization and Selective Concentration (Nanofiltration + Electrodialysis) The core of purification begins with a Nanofiltration system that removes monovalent salts (sodium, potassium, chlorides) and allows lactic acid to pass through, retaining almost all lactose and concentrating total solids (protein + lactose) to 18–22%. To guarantee the functional quality of the final product, the concentrate goes through an Electrodialysis system. This stage is decisive for thermal stability: it removes bivalent cations such as calcium and magnesium, which are responsible for protein denaturation and aggregation during heating. By replacing these ions, we achieve a thermostable protein (Heat-Stable Whey Protein), an essential characteristic for applications in beverages and supplements that require pasteurization or cooking without precipitation.
3. Forced-Circulation Evaporation (Alfa Flash) Thermal concentration is carried out in an Alfa Flash Plate Evaporator. Unlike traditional falling-film evaporators that struggle with acid whey viscosity, this forced-circulation technology handles high-viscosity, high-fouling and shear-thinning fluids. Its compact, self-cleaning design ensures continuous operation with minimal downtime for maintenance, bringing the product to the required concentration while meeting zero or low liquid discharge standards.
4. Crystallization and Stabilization With the concentrate at 50–60% solids, crystallization acts as the critical point of physical stabilization. This stage forces the transition of lactose from an amorphous, hygroscopic state to a stable crystalline state (α-lactose monohydrate). Precise control in this phase is what prevents the final powder from caking during storage, ensuring the free-flow of the finished product.
5. Three-Stage Drying (Multi-Stage Dryer - MSD) The final stage uses a Three-Stage Dryer, the most efficient configuration to preserve the molecular structure of high-value globular proteins. By decoupling rapid evaporation from final heat treatment, the system gently dries the product in fluidized beds. This results in a DWPC/DWPI powder with excellent instant rehydration properties, no lumps or sediment, meeting end-consumer quality expectations.
