Demineralize and concentrate whey using electrodialysis

Process by-products into valuable goods for reuse or sale

Demineralize and concentrate whey using electrodialysis with our custom RALEX® membranes

Custom solution based on in-house RALEX® membranes, stacks and units.

50+ running references with more than 11.500.000 liters of whey processed every day.

Regional offices and service partners around the world ensure tailored care for different customers.

Dairy demineralization by MEGA

More ingredients, less waste

More ingredients, less waste

We deal with all whey and other milk by-products issues. You save money on waste disposal and make money on selling or internal reusing of processed whey.

Lab & pilot testing

Lab & pilot testing

Verify the separation process with your feed samples. Testing can be done on a small scale in the Membrane Innovation Centre or on site using our pilot units.

Electrodialysis explained

Electrodialysis explained

Electrodialysis is an electric field gradient driven process enabling separation of mineral matters from feed solutions while moving dissociated ions through ion-permselective membranes and forming two different flows - desalted flow called diluate and a concentrated flow called concentrate.

What we do

Products

Sweet whey is a by-product of cheese production. It has a high mineral content of 8-10 % in TDS which results in low sensoric properties and overall low value of whey. Demineralization by electrodialysis turns the low value whey into a sweet substance ready for internal reuse or up to pharmeceutical quality for use in infant nutrition.

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Acid whey is a by-product of greek yoghurt, soft cheese or quark production. The high acidity with pH 4.7 - 5.3 and high mineral content of 9 - 11 % in TDS make it difficult to process. It can’t be evaporated without using special techniques and due to very low sensoric properties can’t be reused internally either.

Electrodialysis solves all the issues. After processing, the product is the same after demineralization of sweet whey and can be used in pharmaceutical-grade or food-grade products. ED can reach pH level according to customers’ needs by removing the lactic acid.

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After ultrafiltration of whey, up to 95 % of the solution is rejected as permeate despite its high lactose content. The reason for rejection is very high mineral content of up to 12 % in TDS and high acidity when acid whey is filtrated.

By electrodialysis of UF permeate you prepare an edible food-grade lactose for use in confectionery, bakery or livestock feeding. Electrodialysis process removes the evaporator and spray dryer scaling issues of an untreated UF permeate.

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Delactosed whey is a byproduct of lactose production. It has a high protein, high ash and low lactose content. After demineralization it can be usedfor powder production or livestock feeding, depending on the grade of demineralization.

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Lactulose syrup is a feed solution of lactulose after isomerisation by chemical catalysers. There is a high mineral content due to the agents of catalysers. Electrodialysis allows their removal to receive the final product, which is then used in pharmaceutical applications.

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Mother liquor is a by-product of evaporation and crystallization in lactose production. Due to a very high mineral content its sensoric properties are unpleasant and also blocks crystallization.

Electrodialysis removes the salts, which allows you to put the demineralized mother liquor back to production and increase yield.

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Our case studies

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Milkavita, Belarus

Large scale whey demineralization and drying

This project allows to internally reuse dairy by-products in the food industry and make milk processing a waste-free production. The new production site is so effective, that it processes not only its own whey, but also whey from other factories in the surrounding regions in Belarus. The whey is processed into two main outputs. Demineralized whey powder for the food industry and high quality demineralized whey fat concentrate for livestock feeding. The MEGA technology is universal and can be set to produce LD50, SD70 or SD90.

The Demineralized whey powder is requested in Russia, China, India and South-East Asia, which gives Milkavita new export opportunities.

Milkavita highlights

All types of whey 500 tons per day New export
Ask about this project
Ask about this project

Products & Technologies

RALEX® products

Low-capacity ED units RALEX® EWDU Series P

Low capacity ED units RALEX® EWDU Series P

Electrodialysis low capacity unit for demineralization of various types of whey and for other dairy applications. Compact autonomous processing unit with control system for operating and control of process parameters. Capacity modification with one or two electrodialysis stacks EDR-II. Operating in batch mode. Capacity is designed upon customer’s request. Achievable rate of demineralization is 50 %, 70 % and 90 %.

RALEX® EWDU nx EDR-II 2S two-stage

Two-stage RALEX® EWDU nx EDR-II 2S

Industrial scale unit for demineralization of various types of whey and for other dairy applications by electrodialysis. EWDU units have been designed with extensibility in mind. They can be supplied with fewer stacks at first and later extended to six or even eight stacks if the market situation requires, all without re-engineering the whole unit. Industrial autonomous processing unit with control system for operating and control of process parameters and automatic chemical CIP. Achievable rate of demineralization is 50 %, 70 % and 90 %.

RALEX® EWDU nx EDR-II 1S single-stage

Single-stage RALEX® EWDU nx EDR-II 1S

Innovated industrial scale unit for demineralization of various types of whey and for other dairy applications by electrodialysis. The single-stage unit is 15 % more efficient and requires even smaller footprint. Extensible EWDU units can be supplied with fewer stacks at first and later extended to six or even eight stacks if the market situation requires, all without re-engineering the whole unit. Industrial autonomous processing unit with control system for operating and control of process parameters and automatic chemical CIP. Achievable rate of demineralization is 50 %, 70 % and 90 %.

We care about you

MEGA Care saves your money.
Get all the care you need.

24/7 Specialist Hotline
Remote technology diagnostics
Periodical post-warranty checks

MEGA Care reduces downtimes to the necessary technological minimum by active monitoring, prevention and remote adjustments in advance. Periodical inspections at the point of installation provide three days of exhaustive evaluation during reular production, membrane samples are sent to MEGA laboratory for testing to show early signs of scaling or fouling. Inspections to gather hands-on data together with overall parameters monitoring bring necessary information to ensure reliable performance.

More about MEGA Care

MEGA Care reduces downtimes to the necessary technological minimum by active monitoring, prevention and remote adjustments in advance. Periodical inspections at the point of installation provide three days of exhaustive evaluation during reular production, membrane samples are sent to MEGA laboratory for testing to show early signs of scaling or fouling. Inspections to gather hands-on data together with overall parameters monitoring bring necessary information to ensure reliable performance.

More about MEGA Care

Interested? Contact us.

Michal Jirdasek

Michal Jirdasek

Sales Manager

+420 606 387 947 michal.jirdasek@mega.cz
Jurij Popp

Jurij Popp

Sales Manager

+420 602 418 761 jurij.popp@mega.cz
Katerina Knapcikova

Katerina Knapcikova

Sales Manager

+420 602 122 605 katerina.knapcikova@mega.cz
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