How to profit from whey demineralization

How to profit from whey demineralization

Demineralize and concentrate whey using electrodialysis with our RALEX® membranes

Did you know...

You can demineralize WPC and WPI by MEGA electrodialysis.

Successful implementations of electrodialysis in dairy by MEGA

Successful implementations of electrodialysis in dairy by MEGA

Arla Foods, Denmark

R&D Cooperation
High quality whey based ingredient product
D90 demineralization degree

The Danish company Arla Foods has implemented several units into their manufacturing process. Thanks to the extensive cooperation of our technologists with Arla’s Food Process Engineers and R&D managers, we were able to deliver turnkey solutions with maximal optimization of the manufacturing process. Arla has been able to obtain a high-quality whey-based ingredient product with a 90% mineral removal.

For more successful applications, please, ask for the full reference list..

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

90+ running references with more than 6.900 tons of concentrated whey processed every day. Ask for the full reference list.

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 profit on selling or internal reusing of processed whey.
Demineralized whey can be used in infant formula, nurse nutrition, sports nutrition, ice cream and yoghurts or as animal feed. Process all types of cow, buffalo or goat dairy by-products.

  • Sweet and acid whey
  • UF permeate
  • Delactosed whey
  • Skimmed milk
  • Mother liquor
  • Whey protein concentrates and isolate

Find out more about UF permeate demineralization
Find out more about whey processing
MEGA Electrodialysis Application Overview

Electrodialysis application overview

Electrodialysis can be incorporated into different processes in the dairy business. Download the Application overview and get in touch with our sales managers to enhance your processes.

Electrodialysis explained

Electrodialysis units RALEX® by MEGA

Electrodialysis is an electric field gradient driven process enabling separation of mineral matters from feed solutions. It moves dissociated ions through ion-permselective membranes and forms two different flows - desalted flow called diluate and a concentrated flow called concentrate. Our RALEX® electrodialysis units provide a wide range of demineralization options and easy maintenance.

  • Flexible Technology for D50, D70, D90
  • CIP without steam or enzymes
  • Certified Quality

Go to Electrodialysis applications
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.

What we do

Products

Sweet whey is a by-product of hard and semi-hard cheese production. It naturally contains a significant number of minerals and organic anions (acids). All minerals together represent ash content which is approximately 8.0-8.5% ODB considered typical for natural sweet whey with total solids 5.5-6.5% (TS). Demineralization by MEGA electrodialysis enables to decrease the ash and acids content to obtain a product with a much better taste and the possibility of a further use.

MEGA electrodialysis units can process natural whey or whey concentrated up to 22% TS - 18 - 22% TS by evaporation (EV) or pressure membrane processes as reverse osmosis (RO) or nanofiltration (NF). This is preferred due to the higher conductivity of the feed after the concentration and the optimal efficiency of MEGA ED units. Thanks to the concentration and higher conductivity of the feed MEGA electrodialysis units can achieve high demineralization rates like D90 (1% Ash ODB) without using ion exchange.

Continue to whey protein powder       Contact us for a similar solution
Continue to whey protein powder       Contact us for a similar solution

Acid whey is a by-product of greek yogurt, soft cheese or quark production. Due to the high acidic properties with pH ranging from 4.7–5.3 caused by a high number of organic ions (lactate and citrate) and a large mineral content of approximately 9–11% ODB, considered typical for natural acid whey, with total solids 5.5-6.5% (TS) make it difficult for further processing. It can’t be evaporated without using special techniques with high operational costs and due to very low sensory attributes it can’t be reused internally either.

Electrodialysis is an elegant solution for all these issues. It goes hand in hand with the removal of minerals and especially of organic ions (acids). MEGA electrodialysis units can achieve pH values according to the customer’s needs by removing the organic ions (acids) and integrated pH correction. The results of the demineralization process of acid whey make the final product suitable for food grade products.

MEGA electrodialysis units can process natural acid whey or whey concentrated up to 22% TS - 18 - 22% TS by reverse osmosis (RO) or nanofiltration (NF), which is preferred due to the partial removal of monovalent ions and organic ions. Thanks to the higher conductivity of the feed after the concentration, MEGA ED units can work at the maximum efficiency to achieve high demineralization rates like D90 (1% Ash ODB) without using ion exchange even for acid whey.

Continue to whey protein powder       Contact us for a similar solution
Continue to whey protein powder       Contact us for a similar solution

After ultrafiltration of whey, up to 95% of the solution is rejected as permeate despite its high lactose content. The reason for rejection is a very high mineral content from 9% up to 12 % ODB and high acidity after the whey is filtrated.

By processing of the UF permeate with electrodialysis you can produce an edible food-grade lactose for further use in confectionery, bakery or animal feed. That means that you can expand your product portfolio and increase your revenue by utilizing a by-product of cheese production.

The electrodialysis process also minimizes the evaporator and spray dryer scaling issues of an untreated UF permeate. And in that way partially prevents costs connected with the after-treatment maintenance which makes it a very effective solution for multiple parts of your production process and provides you with cost-effective advantages.

Continue to UF permeate demineralization       Contact us for a similar solution
Continue to UF permeate demineralization       Contact us for a similar solution

Delactosed whey (DLW) or Mother Liquor (ML) is produced from concentrated whey which has been partly delactosed by crystallization. It is a saturated lactose solution (45-50% ODB) with a content of protein (26-33% ODB), organic acids and mineral substances (10-12% ODB), the total amount of dry matter is 40%. Due to a high volume of salts and acids, DLW/ML can’t be further reused as an animal feed.

The electrodialysis is an effective solution for reducing the salts and acids concentration after the original content of dry matter is diluted down to 18-22% in order to assure better hydrodynamic conditions of the electrodialysis process. The demineralized product can be reused in lactose production in order to increase the volume of the product. It means that it can be used either directly in liquid or spray dried.

Contact us for similar a solution
Contact us for similar a solution

Products & Technologies

Low capacity ED units RALEX® EWDU Series P

Nanofiltration unit MEGA

Our new unit has a number of advantages, the main one being low power consumption due to improved hydraulics. Compact design and complete factory assembly simplify on-site installation. An integrated CIP system with a microcontroller management allows you to select the optimal sanitization program, taking into account the characteristics of the membranes used, the processed raw materials and the used CIP chemicals.

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 a 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%.

MEGA electrodialysis reversal stacks EDR-II unit dimensions
One-stack unit Two-stack unit
Dimensions (L×W×H m) 4.8×1.2×2.5 6.7×1.2×2.5
MEGA newest RALEX® EWDU unit

RALEX® EWDU 10xEDR-20/200

The new generation unit EWDU 10xEDR-20/200 merges all the experience and the best parameters from the previous types of electrodialysis units which have been operated as highly reliable demineralization technology around the globe for almost 30 years. MEGA has designed the new ED unit as compact as possible keeping good spatial requirements and maintenance conditions. Our modular system is brought to perfection by extending the unit from 4 up to 10 stacks. The unit offers performance higher by tens of percent and OPEX of the demineralization process is significantly lower in comparison to the units being used until these days. Achievable rate of demineralization is 50%, 70% and 90%.

MEGA industrial autonomous electrodialysis processing unit dimensions
Ten-stack unit
Dimensions (L×W×H m) 8.1×6.0×4.0
Why to choose MEGA whey demineralization EDR technology

Why to choose MEGA whey demineralization EDR technology

  • The achievable rate of demineralization varies from 40 % to 90+ %.
  • Customized design.
  • Low process temperature.
  • Reversible operation mode.
  • Long lifetime of membranes.
  • Reliability.
Ask our experts for help with your project

Our case studies

Dolomites Milk - Demineralization of sweet whey for nutrition formulas

Dolomites Milk, Italy

Demineralization of sweet whey for nutrition formulas

MEGA was approached by Dolomites Milk to help solve the challenge of processing large volumes of sweet whey of varying compositions from local farmers.

MEGA developed a tailor-made technology solution while maintaining the client's requirement for future expandability and flexibility in the design of the industrial unit.

Dolomites Milk has expanded its unit to full size in a very short time and is now producing demineralised whey at various desalination levels of DWP 40, DWP 50, DWP 70 and DWP 90. The company is selling its products from non-GMO ingredients to producers of nutrition formulas such as infant formula and sports nutrition, and bakery, chocolate, pastry products manufacturing etc.

Dolomites Milk highlights

Large daily volumes Expanding production capacity Variable desalination levels
View case study Dolomites Milk
View case study Dolomites Milk
MEGA Electrodialysis EWDU 8xEDR-II/250 Galacteum

Galacteum, Spain

NF cheese sweet whey demineralization

The Spanish company Galacteum, as one of the dairy industry-leading companies, was looking to expand their already broad product portfolio in order to get the highly valuable products from NF cheese sweet whey.

After extensive cooperation with MEGA's technologists, Galacteum purchased an electrodialysis unit, high-tech solutions for the demineralization of whey-based dairy by-products. The EWDU 8xEDR-II/250 unit enables it to process 50 to 100 t/day of sweet NF whey from cheese production with different degrees of desalination up to D90+.

Galacteum opted for electrodialysis due to its highly efficient separation and cleaning with low operating costs and thanks to the flawless daily operation of the MEGA unit, it does not have to deal with annual operating costs (OPEX) at all.

Galacteum highlights

Low OPEX NF sweet whey Variable demineralization levels
View case study Galacteum
View case study Galacteum
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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
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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 regular 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 regular 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

Key Account Manager

+420 606 387 947 michal.jirdasek@mega.cz
Ales Platzer

Ales Platzer

Sales Manager

+420 702 176 317 ales.platzer@mega.cz