Aug 17, 2025
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by Michal Jetelina

How whey protein is made: from the farm to your shaker

Aug 17, 2025
0 comments
by Michal Jetelina

Introduction to whey concentrate production

Whey protein is a by-product of cheese production and is one of the highest quality sources of animal protein . Its production and composition vary depending on the methods used , which affects its nutritional value and protein structure , fat content and even taste .

Depending on the type of stage and type of technological processing , four types of whey concentrate can be created, which are most often used in sports nutrition for the final production of protein powder, as you know. These are whey concentrate , whey isolate , whey hydrolysate . To give you an idea, more than 160 kg of whey solution is needed to produce 1 kg of whey concentrate in powder.

This article puts all the important information into context and provides a comprehensive overview of the topic of whey protein production in one place. After reading the article, you will know what all needs to happen in order to mix your favorite protein after training . The article is divided into the following chapters, which you can use for easier orientation.

First step: separating the whey from the milk
Step two: whey protein purification
Step three: whey protein concentration
Step four: converting liquid to powder
Step five: flavoring, production and packaging
The game of brands: the reality of the Czech and European market
In conclusion: the choice and quality of whey proteins

Step One: Separating the Whey from the Milk

The production of whey protein begins with pasteurization of cow's milk to remove all unwanted bacteria . During pasteurization, the milk is brought to boiling point (70-80 °C) and then immediately cooled to 4 ° . After pasteurization, approximately 20% whey protein and 80% casein remain in the milk.

A key step in this process is the use of the enzyme chymosin , also known as rennin, which is essential for the production of most types of cheese. Chymosin's job is to coagulate, or curdle, the milk , separating the solid and liquid casein particles from the liquid part of the milk.

The action of chymosin is therefore directed at casein , specifically its variant kappa-casein, present on the surface of milk micelles . When chymosin cleaves certain bonds in kappa-casein, the micelle structure changes , leading to the aggregation of milk proteins , particularly casein, into solid particles . After coagulation, solid casein particles are formed, from which cheese is made , and are separated from the liquid part , known as whey . Whey contains whey proteins, lactose, vitamins and minerals, and is further processed to produce whey proteins.

The process of separating casein from whey.

Source: foodunfolded.com

Step two: whey protein purification

The next step is the pre-purification process of the liquid whey , during which the quality and purity of the final product are ensured. The pre-purification process usually includes two phases:

Removal of fats and solids: First, the fats and solids need to be removed from the whey. This is usually done by centrifugation or microfiltration. The goal is to obtain the purest whey solution possible.

Removal of lactose and minerals: Whey contains high amounts of lactose and minerals. To produce whey protein, these components need to be reduced, which is often done through ultrafiltration. Ultrafiltration allows these small molecules to be removed while the proteins remain in solution.

Schematic of the whey microfiltration process during the whey protein production process.

Source: agropur.com

Step three: whey protein concentration

After removing unwanted components, the whey proteins are concentrated. This process is usually carried out using several methods (or combinations thereof) depending on how pure the protein concentrate is to be and what product is to be produced. Ultrafiltration , diafiltration , microfiltration , nanofiltration, electrodialysis, reverse osmosis, cross flow microfiltration (CFM) , ion exchange , or hydrolysis may be used.

The methods can also be used in sequence with the aim, for example, of reducing the residual fat percentage in the concentrate as much as possible or of preserving the integrity of the protein structure as much as possible. Each of the above protein concentration methods has its specific advantages and disadvantages and is used for different types of products.

In the standard production of whey protein , which is used for sports nutrition , membrane filtration (e.g. ultrafiltration, cross-flow microfiltration) is used in the vast majority of cases to produce whey concentrate . If the ion exchange method is also used in the process, whey isolate is produced. In the production of whey hydrolysate, a chemical process known as enzymatic hydrolysis is chosen instead of ion exchange. The production of pure protein combines filtration, ion exchange and hydrolysis .

Batch ultrafiltration technology in whey protein production.

Source: Hilton C. Deeth and Nidhi Bansal (2019)

The result of these technological processes is a liquid solution of concentrated proteins, which form the basis of products for

Whey Protein Concentrate (WPC) : The abbreviation WPC is often accompanied by the number 75, 80. This number expresses the protein content per 100g of pure raw material. The fat percentage ranges between 6-8%.
Whey Protein Isolate (WPI) / Clear Whey Isolate : The protein content in isolates is typically over 90%. The fat content is around 1-2% with minimal carbohydrates.
Whey hydrolysate: The protein content in hydrolysates ranges between 75-80% in 100 g of pure raw material. However, they have the best bioavailability and fastest digestibility.

The solution then travels to the fourth stage, where drying takes place. But before we get there, let's summarize the basic information about the methods used.

Ultrafiltration (UF) uses membranes with small pores to separate proteins from smaller molecules such as lactose , minerals and water . Proteins, due to their larger molecular weight , remain on one side of the membrane, while smaller molecules pass through.

Advantages: Efficient separation of proteins from smaller components; preserves the functional and nutritional properties of proteins; widely applicable and scalable method.
Disadvantages: Risk of membrane clogging, requiring regular cleaning and maintenance; can be costly for large volumes or highly concentrated solutions.

Cross-Flow Microfiltration is a more technologically advanced method and its use ensures higher quality and purity of the final product . During the process , the liquid flows parallel to the membrane surface , rather than directly through it. This reduces the risk of membrane clogging, as larger particles are constantly “washed away” from the membrane surface.

Advantages: less prone to membrane clogging and fouling than traditional filtration; effective for separating larger particles such as fats and bacteria; better for preserving protein structure and functionality.
Disadvantages : higher equipment and maintenance costs; less efficient for separating proteins from smaller molecules than ultrafiltration.

Ion exchange enters the process if the result is to be whey isolate . This is a process that selectively isolates specific protein components. Raw whey is sent through a column that collects the proteins and separates them based on differences in their overall charge . The remainder (lactose and minerals) is washed away and further processed into another component. Ion exchange collects all the functional and nutritional proteins in the whey, including bioactive proteins such as immunoglobulins and lactoferrin. The resulting whey protein therefore has less fat and lactose than whey concentrates and also dissolves better , for example.

Advantages: Highly selective for specific proteins; effective in removing impurities.
Disadvantages: May denature some proteins; requires specific conditions for each type of protein.

Schematic of the ion exchange process during the whey protein production process.

Source: agropur.com

Hydrolysis is a biochemical process in which long chains of amino acids in whey concentrate are broken down into shorter peptide chains. Hydrolysis is performed using enzymes, acids, or alkalis. Enzymatic hydrolysis is the most commonly used method because it is more specific and gentle on proteins.

The length of hydrolysis can vary and affects the degree of protein breakdown and the properties of the final product.

Benefits: improves digestive availability and biological activity of proteins; Reduces the allergenic potential of some proteins; Enables the creation of specific peptides with targeted functional properties.
Disadvantages: denaturation (change in structure) of proteins may occur, affecting their functional properties; The hydrolysis process can be expensive due to the need for enzymes or chemicals; Possible changes in the taste and aroma of the final product.

A very popular form of treatment is the so-called Clear Whey Isolate , which is produced by acidifying and purifying whey protein at a low pH . The protein is further often hydrolyzed to achieve higher bioavailability by breaking down and shortening peptide bonds. In simple terms, we can imagine that the proteins are “pre-digested” during the process.

Higher stages of the technological process are designed to almost completely remove excess fats and carbohydrates and thus achieve a higher protein content in 100 g of pure powder. Significant shortening of peptide bonds allows for easier absorption of protein peptides into the bloodstream. Pure protein , like any other isolate or hydrolysate, is therefore best drunk immediately after training. In the case of pure protein, you have the advantage that it does not taste like milk and is wonderfully refreshing.

Cross-flow ultrafiltration , cross-flow microfiltration , and ion exchange are physical methods that focus on separating proteins based on molecular size . In contrast, hydrolysis is a chemical process that changes the structure of the proteins themselves . The choice of method depends on the desired properties of the final product and the specific needs of the manufacturing process.

Step four: converting liquid to powder

The drying process in the production of whey concentrate is a key stage during which the liquid form of whey is converted into a powdered product suitable for long-term storage, easy distribution and possible further processing (e.g. flavoring). The most widespread and most used method is spray drying .

This technological process involves spraying concentrated liquid whey into hot air in a drying chamber . Water molecules are rapidly evaporated from the concentrate droplets, creating a powdered product. Spray drying allows for rapid and efficient evaporation of water molecules and maintains high protein quality . This process is sensitive to thermal regulation, and therefore temperature and humidity are constantly tightly controlled to prevent thermal denaturation of the proteins .

In the final stage, the powder is weighed into bags, most often 25kg, by an automatic packaging machine and stored. For export, the bags are placed on a pallet and prepared for transport to a facility that specializes in flavoring and repackaging into consumer packaging.

Whey concentrate in powder form packed on a pallet.

Source: proteinfactory.com

Step five: flavoring, production and packaging

In the fifth step, secondary processing takes place. The input is a white, unflavored powder , and the output is the protein that we know - it is flavored , sweetened , colored , and packaged in consumer packaging, most often in bags or cans in various weights from 400-2000 g.

Flavoring and sweetening

Your favorite protein flavor is provided by either artificial or natural flavors , colors and sweeteners . In order for all the ingredients to mix well in the shaker, it is often necessary to add completely harmless lecithin (most often soy or sunflower). In some cases, a harmless anti-caking agent is also added to the proteins - e.g. silicon dioxide , which prevents lumping or reduces foaming in the case of clear whey isolate.

All flavoring ingredients are added to the protein in a certain ratio according to the preferences of the brand's development department , which continuously tastes and tests samples in the search for the best flavor - or at least they should. Once the flavor and solubility are satisfactory, production begins .

Production and packaging

The primary raw material and flavoring ingredients are then literally poured into a so-called homogenizer, which can be imagined as a large mixer. Rotation in different directions ensures that the resulting loose mixture is truly homogenized and all added ingredients are well mixed with the pure whey base . This ensures that each dose of protein in the package tastes the same when mixed with the recommended amount of water or milk . From the homogenizer, the mixture is then packaged into consumer packages according to the selected weight . The product is then placed on a pallet again and transported to the brand's warehouse . After an online order, it is picked from the warehouse, packaged and transported to a distribution point or to your home by the service of your choice .

Source: homogenizer.cz

The game of brands: the current reality of the Czech and European market

Currently, on the Czech and European markets, we can find proteins that are in the vast majority of cases flavored with artificial flavors , colors and artificial sweeteners such as sucralose , acesulfam K , aspartame , sodium cyclamate , etc. These proteins often have a very artificial taste and leave a typical "tail" at the end.

The production of such proteins is very cheap and easy . It is also a widespread but not entirely legal practice to use thickeners such as guar gum , xanthan gum or various forms of cellulose .

A minimal percentage of brands choose to flavor their products with natural flavors , colors , and sweeteners of natural origin . The reason is that they do not fully control the secondary production process and cannot influence the individual ingredients and recipes that will be used in the final product.

However, this is not the case with hyve. Hyve has 100% control over the production process . If an ingredient doesn't seem or work the way we want it to, we simply replace it with another natural alternative .

Conclusion: selection and quality of whey proteins

The basis of the vast majority of whey proteins is whey concentrate , isolate, clear isolate or hydrolysate. This basis is qualitatively completely identical or very similar. The very high standards for the production and quality of these raw materials apply equally to all producers of the primary raw material . And this is precisely why milks of different brands also taste the same or very similar and have a similar nutritional composition.

The reason is that primary agriculture , especially the dairy industry and its products, is one of the most important and most strictly controlled sectors in the entire European Union and the output quality is clearly defined and standardized .

However, this does not apply to secondary processing in the case of the production of flavored whey proteins , during which flavoring ingredients of various and often inferior qualities are added to the high-quality raw material .

These are mainly artificial sweeteners , flavors and colors . Yes, the proteins that you take into your body from these drinks are the same in both cases, without much difference , but artificial sweeteners , flavors and colors can have negative effects on the body. Brands offering products with artificial ingredients are telling you three things

they do not have production completely under their direct control
they don't take all the ingredients in their products seriously
to maximize the margin per unit produced, they combine production with other brands in large production plants, which achieve significant economies of scale; standardized and very simple recipes with predefined flavor profiles are used; the result is practically the same content for all participating brands; only the packaging differs

On the other hand, brands like hyve, which have complete control over their production, ensure that the customer not only gets the perfect source of protein, but that the flavoring ingredients are not controversial or potentially harmful to health . We have 100% control over the recipe, as well as all the ingredients that we use in the final product .

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