Whey processing is crucial for the future cheese industry
According to figures published by The Department for Environment, Food and Rural Affairs (Defra) last year, income fell on almost all farm types in England in 2024 – which resulted in profit margins becoming increasingly squeezed. Subsequently, farmgate milk prices – the market value minus the selling cost – have risen, with this trend set to continue.
Amidst these challenges, cheese producers have had to find innovative ways to earn money, beyond the curd. This is where whey, which was originally a by-product of cheese production, comes in – it has become an important product in itself. By reducing carbon emissions, water usage and costs, whey processing could play a key role in allowing British cheese producers to navigate these pressures in the months and years ahead.
Most types of cheese require ten kilograms of milk to produce a kilogram of cheese, leaving producers with roughly nine kilograms of whey. Previously it had been considered an unnecessary by-product, leading to it commonly being left as waste or used as animal feed. However, this is no longer the case.
Whey – and sweet whey in particular – has proven to be a significant value stream and continues to grow in profitability. Producers are now learning about the potential of whey – not only as an additional source of income to aid traditional and large-scale cheese producers financially – but also as a means of reducing carbon emissions and water usage. This is the result of a more complete understanding of the nutritional value of whey as a source of lactose, protein and minerals.
For the past three decades, companies such as Tetra Pak have been investing in developing new technologies and innovations, which effectively process whey, allow it to be utilised in a myriad of ways. These new technologies enable approaches range from filtering and centrifugation to spray drying. This means it is now possible to create a range of powders derived from whey, which can not only be used in supplements but as stabilisers too. Whey protein concentrate (WPC) offers a key example, being a high-value ingredient in products such as baby food, sports drinks, and senior nutritional supplements.
Reverse osmosis, a process made possible with these innovations, successfully removes the water from whey. This process resolves one of the main challenges preventing the dairy industry from making the most of this byproduct: whey’s high water content (94%).
Additionally, producers can reuse the separated wastewater for industrial heating, cooling systems, and cleaning processes. Reverse osmosis, therefore, reduces the need for fresh water in cheese production processes. Passing the whey through a membrane filtration process and removing water content ahead of transport also decreases the volume and weight of product to be moved, further reducing expenses and lowering carbon emissions.
Today, this reverse osmosis process is becoming increasingly accessible to smaller, more traditional producers, thanks to modern technology. This enables more cheesemakers to explore existing opportunities for profit through whey processing while bolstering their sustainability credentials.
The partnership with leading Danish cheese producer, Mammen Dairies, showcases the key benefits that whey processing can bring.
Through this partnership, Tetra Pak and Mamman Dairies have installed a reverse osmosis membrane filtration system which effectively concentrates whey protein from cheese production. Through this system, Mammen Dairies have seen a significant difference to their bottom line as well as their carbon emissions. The overall reduction in the number of truckloads of whey protein they need to transport each day saves up to 150 tonnes of diesel and 460,000 kilometres of road travel.
Furthermore, the water extracted by the filtration system is being reused in factory operations. Its built-in reverse osmosis polisher means that water can now be purified and also used for cleaning the dairy equipment. Through recovering the demineralised process water, the cheese producer has impressively decreased its water intake by a massive 143 tonnes per day.
Whey processing is becoming an essential part of doing business for cheese producers across Europe and beyond. Beside the potential financial gains, British cheese producers are also working towards increasingly ambitious sustainability targetscreating increasingly ambitious sustainability targets. The utilisation of processes and technologies that lower CO2 emissions and water usage could play a helpful role in meeting these goals.
UK cheese producers could increase their profits by investing in these technologies, while also appealing to a new generation of consumers who often shop with sustainability front of mind. Innovations such as whey processing technology will play an important role in keeping the cheese industry afloat during difficult economic headwinds, ensuring that cherished British cheeses remain firmly on market shelves and kitchen tables for years to come.
