Save time and money while increasing flux in your WPI process.
The manufacturing of WPI requires multiple membrane systems utilizing ultrafiltration (UF), microfiltration (MF), and nanofiltration (NF) to drive protein content high. While conventional membranes have worked in this process, novel anti-fouling zwitterionic membranes are now available to minimize the build-up of organics as a gel layer on the membrane surface. By using anti-fouling Evolution membranes, users can maximize productivity with a higher average sustainable flux and a simplified cleaning program that saves an hour or more of time each day.
Application Details
WPI is a premium protein powder that contains at least 90% protein. It is used in nutritional supplements and drinks, snacks, baked goods, and products featuring increased protein content (e.g. high-protein ice cream, protein-fortified nut butters, etc.). To maximize protein content, WPI processing involves additional membrane steps targeted at removing 95-98% of lactose and fat.
Manufacturing begins with blended skimmed whey that has been pasteurized, clarified, and separated. The pretreated whey is then fed to the first UF system with multiple stages of membranes to concentrate the whey to a certain amount. After this first UF, whey protein concentrate is fed to an MF system targeted at removing fat.
Following MF, the permeate is then fed to a second UF system to further increase protein content, with tighter membrane elements towards the back-end of the system. Finally, many plants have a separate NF system that is fed the retentate from the second UF and maximizes protein content. Diafiltration (DF) is utilized throughout these systems to wash out smaller components and increase protein retention. The resulting NF retentate stream is then dried and finalized as WPI.
Permeate from the UF systems can be sent to lactose concentration systems for further processing. Additionally, the high-fat retentate from the MF can be sent for further processing into products like whey protein phospholipid concentrate (WPPC).
Membranes Used in WPI Manufacturing
Conventional UF membranes used in WPI processing feature a polyethersulfone (PES) chemistry that has not had a significant change in performance in decades. Now, with the novel zwitterionic anti-fouling membrane chemistry used in Evolution membranes, whey processors can experience a significant step-change in productivity and cleanability. Evolution Protein Concentration Membrane (PCM) elements and Evolution Superfiltration (SF) elements are available as drop-in replacements for conventional UF membranes and provide distinct value.
Conventional NF membranes used in WPI feature a piperazine polyamide chemistry that cannot be cleaned with chlorine. Evolution SF elements offer a direct replacement for these NF elements and can be cleaned with chlorine. Click here to learn more about Evolution SF for NF replacement.
Higher Operating Flux on WPI
- WPI process at large whey processor
- Final concentration system
- Feed total solids in 28-30% range
- Elements installed in July; data is after 6 months in operation
- Evolution SF running in parallel with conventional UF
- No measurable difference in permeate
Maximize productivity
By utilizing an anti-fouling membrane chemistry, Evolution PCM and SF membranes minimize gel layer formation at the membrane surface, allowing users to maximize productivity through the membrane.
Decrease cleaning costs by 50% or more
Evolution PCM and SF elements eliminate multiple steps from a cleaning program, saving money on chemicals, water use, and utilities—all while supporting more sustainable operations.
Minimize cleaning time
Evolution PCM and SF can reduce cleaning time by an hour or more per day—giving operators precious time back to focus on other critical tasks and producing more.
Simple implementation
Evolution PCM and SF elements are direct replacements for industry-standard products—no system modifications or new CAPEX required.
Podcast: ZwitterCo Unfiltered
ZwitterCo Unfiltered: Real Talk on Membrane Filtration is a candid, experience-driven podcast exploring real-world membrane applications across food processing, water, and wastewater treatment.
Reduce your cleaning costs by 50%.
With Evolution membranes, your cleaning programs are easier and shorter, enabling more uptime for operators to focus on other important tasks. With easier cleanings and less chemicals, plants enjoy significantly reduced time and labor required for maintenance.
Minimize gel layer formation, maximize productivity.
Evolution membranes feature the highest resistance to organic fouling, which reduces gel layer formation at the membrane surface and leads to higher sustainable average flux. This leads to more output, more uptime, more time for maintenance, and protection against equipment failure for dairy processors.
Simplified & sustainable operations.
Evolution membranes simplify cleaning programs and require fewer chemicals, while also reducing freshwater demand, energy consumption, and amount of wastewater generated.
- Reduced pumping
- Less water
- Less heating of CIP solutions
- Decreased chemical usage
- Reduced energy requirements
Improve your OPEX.
In whey protein concentration applications, Evolution membranes significantly reduce freshwater demand through their simplified cleaning process.
Reduced Operating Costs
With lower cleaning costs, decreased water usage, less wastewater generated, and lower energy requirements, Evolution membranes offer a significant decrease in OPEX.
Increase in Uptime
Evolution membranes offer more uptime due to shorter cleaning programs, freeing operators to work on other priorities.
Mott Case Study
Speak with our engineers to discover ways that ZwitterCo can support positive changes at your plant. With our help, you can reduce your hauling and avoid heavy OPEX spend on plant expansion.
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Industrial Wastewater Reuse
ZwitterCo has only polymeric membranes that can filter high strength organic streams without rapid and irreversible fouling. More description here to describe the kind of solutions we offer for NMP.
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Challenging Surface Water Treatment
Write a description about how we solve challenging surface water treatment problems. EMP for pure water.
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High Value Protein & Co-Product Separation
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Remove Bulk Organics
Remove tough to fight organics, such as fats, oils, grease, and protein.
Fully Chlorine-Intolerant
Can endure aggressive cleaning without wear and tear
Runs at Low Pressure
Runs at low pressure by not removing salt, sugar, alcohol’s or other small molecules.
Replaces Biological Systems
Replace biological systems or coagulation/flocculation processes commonly used to treat organics.