Improve Protein Functionality for High-Performance Dairy Products

APV® Cavimaster™ systems help dairy producers create functional whey protein ingredients for high-protein beverages, dairy ingredients and nutritional products. Cavimaster™ improves protein performance and enables producers to maximize the value of whey streams while developing differentiated products with enhanced texture, stability and sensory characteristics.

The technology supports product innovation, resource utilization and high-protein product development across a wide range of dairy applications.

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Protein Functionalization for Product Innovation and Resource Utilization

Consumer demand for high-protein products continues to create new opportunities for dairy producers. Many producers are looking for ways to improve protein performance, maximize whey utilization and create differentiated products with strong sensory characteristics.

Cavimaster™ uses cavitational processing to apply thermal and mechanical energy simultaneously, transforming whey proteins into functional particles with tailored characteristics. This approach enables producers to create high-value ingredients for nutritional beverages, dairy ingredients and protein-enriched products while improving the utilization of available raw materials.

APV technologies build on decades of dairy processing expertise and a large global installed base, helping producers achieve reliable performance from pilot trials through commercial production.

Processing Advantages

Cavimaster™ helps dairy producers improve protein functionality while supporting efficient and reproducible production.

Key benefits include:

Improved protein functionality
Enhanced suspension stability
Improved mouthfeel and sensory performance
Support for high-protein product development
Reduced reliance on stabilizers and additives
Increased value from whey streams
Consistent product quality and performance
Minimized fouling and extended production runs

Protein Functionality Benefits

High Protein Beverages | Maintain protein suspension and product consistency throughout shelf life while supporting a smooth drinking experience.
Nutritional Products | Support reproducible functionality across demanding formulations with high protein content.
Dairy Ingredients | Create application-specific whey protein ingredients for downstream processing and formulation.
Clean-Label Development | Reduce reliance on stabilizers while maintaining texture and product stability.

How the Cavimaster Process Works

Cavimaster combines indirect heating and controlled cavitational processing to functionalize whey proteins and create ingredients with tailored performance characteristics.

Indirect Preheating
An APV plate heat exchanger heats the product to the required preheating temperature, typically between 50°C and 65°C, using efficient heat transfer and high heat recovery.
Cavitational Processing
The product then passes through the APV Cavitator, where high-speed impellers generate controlled steam cavitation. The spinning action creates internal liquid friction (disk friction), which generates heat within the product, while engineered openings create hydrodynamic cavitation and high shear forces.

This combination of direct product heating and controlled cavitation enables precise denaturation and aggregation of proteins such as WPI and WPC while maintaining tight control over particle size and functionality.
Cooling and Product Stabilization
The system cools the product through regenerative and final cooling stages before downstream processing or drying. The Cavimaster process helps producers create uniform, stable products with enhanced functional properties, improved texture and clean-label appeal. Because thermal energy is generated within the product itself, the process minimizes fouling and supports long, reliable production runs.

Why Producers Choose APV

APV combines decades of dairy processing expertise with a large global installed base and extensive knowledge of whey, dairy ingredient and protein processing applications. Our Innovation Centers allow producers to evaluate formulations, validate product performance and optimize processing conditions before commercial implementation. Lifecycle services, including OEM spare parts, preventive maintenance, diagnostics, operator training and process optimization, help maximize reliability, product quality and long-term value.

Applications

Cavimaster™ systems are commonly used in:

High-protein dairy beverages
Ready-to-drink nutritional beverages
Sports nutrition products
Medical nutrition products
Functional dairy ingredients
Protein-enriched dairy products

The Cavimaster System can be configured based on process requirements. Common options include:
Operating temperature	Up to ~110°C (±1°C) in final heating
Compatible feedstocks	WPI and WPC
Heating capacity	Configurable to meet throughput and residence time
Particle size adjustment	Via impeller and dasher speed control
Run time	Designed for ≥8 hours of continuous operation before CIP in most applications

Options

To adapt to different product types and plant requirements, the Cavimaster™ System can be equipped with:

Twin-screw pump for viscous product handling
Scraped surface heat exchangers for precise post-treatment cooling and particle refinement
Mobile or pilot-scale systems for in-plant validation and development
Automation packages including data logging, recipe control, and integration with SCADA
Sanitary design options meeting 3-A, PMO, or other compliance standards
Continuous cavitational processing
Automated process control
Hygienic dairy design
Configurable capacities
Integration with upstream and downstream processing systems
Designed for commercial dairy ingredient production

Frequently Asked Questions

How does Cavimaster™ improve protein functionality? +

Cavimaster™ uses controlled cavitational processing to modify whey proteins and improve their functionality in applications requiring enhanced stability, texture and sensory performance.

Which products are best suited for Cavimaster™? +

Cavimaster™ is particularly well suited for high-protein beverages, nutritional products, dairy ingredients and other applications where protein functionality plays a critical role in product performance.

How does Cavimaster™ support whey valorization? +

Cavimaster™ transforms whey proteins into higher-value functional ingredients, creating additional opportunities for product development and resource utilization.

Can Cavimaster™ help reduce reliance on stabilizers? +

Yes. Cavimaster™ improves protein functionality, which can enhance texture and stability naturally and reduce the need for stabilizers and other formulation aids.

How does Cavimaster™ differ from LeanCreme™? +

LeanCreme™ is optimized for applications where texture, creaminess and viscosity are primary objectives. Cavimaster™ is designed for applications where protein functionality, stability and performance are key requirements.

Can producers evaluate formulations before investing? +

Yes. Innovation Center trials allow producers to validate functionality, optimize formulations and assess commercial feasibility before scale-up.

What lifecycle support is available? +

Lifecycle services include OEM spare parts, preventive maintenance, diagnostics, operator training and process optimization to help maximize long-term system performance and reliability.