Turning Whey Into Value With Microparticulation: LeanCreme™

Functional Protein Innovation in Dairy Processing

In today’s evolving dairy landscape, the pressure to deliver more nutritious, sustainable and economically resilient products continues to grow. At the same time, the challenge of underutilized whey is still familiar. Many processors rely on drying or selling whey into commodity markets, options that can work, but often limit the value that whey could offer.

How Membrane Filtration and Microparticulation Expand Whey Utilization

Recent advances in membrane filtration and microparticulation are creating new opportunities. By transforming surplus whey into microparticulated whey protein (MWP), dairies can rethink the role of protein in their formulations, shifting from nutrition-only to a multifunctional ingredient that helps shape structure, stability and sensory experience.

LeanCreme™ Converts Whey Streams Into High-Functionality Protein

One solution enabling this shift is LeanCreme™, a process developed by SPX FLOW to convert whey streams into high-functionality MWP tailored for specific dairy and nutrition applications.

Beyond Fat Replacement: Why Protein Functionality Matters

Limitations of Traditional Reduced-Fat Reformulation

Traditional reduced-fat reformulation has relied heavily on starches, stabilizers, or imported protein blends. These can help, but they often fall short on mouthfeel, clean-label expectations, or long-term product stability.

Protein Engineering Improves Dairy Product Performance

This has led to a broader shift in thinking from fat replacement to protein engineering. By designing how proteins behave at the microscopic level, processors can influence:

Functional Properties Controlled Through Microparticulation

• Particle size and distribution
• Hydration and viscosity
• Emulsion and suspension stability
• Flavor release and sensory perception

MWP gives producers a way to build in functionality early in the process, rather than relying on multiple downstream workarounds.

LeanCreme as a Platform for Protein Innovation

How the LeanCreme System Restructures Whey Protein

The LeanCreme System combines ultrafiltration with thermomechanical processing using the APV Shear Agglomerator to restructure whey protein into a soft, fat-mimicking matrix. The result is a practical shift from whey disposal to internal functionalization, allowing dairies to capture more value from what they already produce. LeanCreme supports a more integrated approach to ingredient development, reducing external dependencies and enabling application-specific performance.

Modular Design Enables Integration Into Existing Dairy Processing Lines

Operationally, the process is modular and designed to integrate with existing whey streams, centered around the APV Shear Agglomerator, supported by heating, holding, cooling and optional drying

Operational Benefits of LeanCreme Microparticulation

It helps processors:

• Improve use of internal whey streams
• Reduce external ingredient dependence
• Enable clean-label, protein-forward formulations
• Capture more value on-site instead of exporting whey

Practical Applications Across Dairy Categories

Application-Specific Protein Functionality Across Dairy Products

What sets LeanCreme apart is its focus on application-specific functionality, rather than one-size-fits-all fat mimicry. Depending on the formulation, LeanCreme can enhance texture, improve nutritional density, or simplify ingredient labels.

Dairy and Nutrition Applications Supported by LeanCreme

Use cases include:

• Yogurt and spoonables, smoother texture and fuller body
• Ready-to-Drink (RTD) protein beverages, better suspension and mouthfeel
• Cheese spreads and processed cheese, improved melt and spreadability
• Frozen desserts, protein-enriched formulations with clean creaminess
• Medical and senior nutrition, neutral-tasting, high-quality protein

Each application benefits from a more precise approach to how protein behaves within the matrix and LeanCreme allows that behavior to be dialed in during processing.

LeanCreme and Cavimaster™ Expand Protein Functionality Capabilities

Complementary SPX FLOW Technologies for Protein Processing

This ability to tailor protein structure aligns with other SPX FLOW technologies focused on enhancing functional performance. For example, while LeanCreme uses controlled shear and heat to deliver a creamy, fat-like matrix ideal for body and texture, Cavimaster™ modifies proteins through hydrodynamic cavitation, a high-energy approach better suited for boosting viscosity and refine profile.

Combined Functional Benefits Across Dairy and Nutrition Applications

Together, these solutions give producers a broader toolkit: LeanCreme for creaminess and fat reduction, Cavimaster for texture and mouthfeel. each addressing different functional goals across dairy and nutrition applications.

Each tool addresses different formulation challenges and supports distinct product outcomes.

Supporting Circularity and Sustainability in Dairy Processing

Converting Whey Into High-Functioning Ingredients Improves Resource Efficiency

By transforming whey into high-functioning protein ingredients in-house, processors can:

Sustainability and Efficiency Benefits

• Reduce food waste
• Improve raw material efficiency
• Cut reliance on synthetic or imported fats
• Lower carbon footprint per kg of product

This aligns with broader sustainability and resource optimization goals across the industry.

Enabling Smarter Formulation Through Collaboration

SPX FLOW Innovation Center Supports LeanCreme and Cavimaster Development

SPX FLOW supports LeanCreme and Cavimaster development through its Innovation Center in Silkeborg, Denmark, where pilot trials, formulation support and process validation are available. The goal is to give producers the tools and insights needed to make protein functionality a driver of both innovation and efficiency.

Rethinking the Role of Whey in Modern Dairy Processing

Microparticulation Transforms Whey Into a Strategic Ingredient

Whey isn’t waste, it’s an underleveraged resource. With the right tools and mindset, dairy producers can move beyond traditional constraints and build formulations that are both nutritionally relevant and commercially sustainable.

LeanCreme and Cavimaster Enable Higher-Value Dairy Ingredient Production

Microparticulated whey protein, and processes like LeanCreme and Cavimaster, offer a framework for doing exactly that: turning surplus into structure, protein into performance, and byproduct into business value.