From Cow to Shaker Bottle: How Whey Protein Is Made (& Why It Matters)

How long have you been using protein supplements? Have you ever stopped to wonder and ask yourself how whey protein is made? 

After being in the supplement industry for well over a decade, I asked myself that question quite a few times before I finally got to see the actual process with my own two eyes.

And let me tell you… It’s AMAZING.

When you stop to think about it, you have protein powder available as whey protein isolate, whey protein concentrate, and many other forms that all come from cow’s milk. It’s quite fascinating when you break it all down.

In this article, we are going to dive deeper and answer the question of how whey protein is made and why it should matter to you when looking for the highest quality protein powder.

Disclaimer: This article is for informational purposes only and is not meant to treat or diagnose any condition. It is recommended that you speak with your doctor before starting any exercise program, making changes to your nutrition plan, or adding any new supplements into your current regimen.

What Is Whey Protein and Where Does It Come From?

Whey protein comes from cow’s milk on dairy farms. Cows produce milk that goes through the cheese-making process. The process yields curds for cheese and liquid whey that forms whey protein concentrate.

Here’s a shocking fact for you: Nearly nine pounds of whey are formed for every pound of cheese made. Cow’s milk gets pasteurized to kill harmful bacteria and alter protein structure slightly without losing all of its health benefits.

What we are left with through this process is whey protein isolate and whey protein concentrate that help boost muscle growth and enhance muscle recovery. And as we all know, quality whey protein powder supplies essential amino acids (EAAs) such as leucine, lysine, and tryptophan.

Let’s unpack exactly how whey protein is made and ends up in your shaker bottle as a protein powder. 

Step-by-Step: How Whey Protein is Made

When asking the question of how whey protein is made, it’s not as simple as taking a cow’s milk and drying it into a powder form. There are many other steps that it goes through to be ready for your shaker bottle. 

Below is the process in which cow’s milk goes through to turn into protein supplements.

Step 1: Milk collection and pasteurization

Milk comes from cows’ milk that holds around 3.5% protein, 4% fats, and 4.6% lactose. Cattle get milked anywhere from two to three times each day, with some farms using robotics to milk cows up to four times daily.

High-quality milk begins its journey at trusted cattle farms and then makes its way in refrigerated tankers cooled to no higher than 45°F until it reaches a pasteurization facility.

Operators heat the raw milk to 155-175°F to kill harmful bacteria, using processes that keep dairy products safe for you.

Step 2: Separation of whey from curds

Enzymes, such as rennet, are used to help the milk proteins coagulate. Once coagulated and solidified, the formed curds are then separated from the liquid whey. They speed up the cheese-making process and break down milk proteins. 

Membrane filtration (MF) is then used to help trap the whey protein while removing the bacteria and fat.

Ion exchange methods further purify whey isolate and whey protein concentrates. This process turns curds and whey into a clean and pure whey protein powder.

Step 3: Filtration (micro, ultra, or cross-flow methods)

Microfiltration, ultrafiltration, and cross-flow filtration work to remove fat and lactose from liquid whey protein. These methods use membranes that trap unwanted components while keeping beneficial nutrients intact.

The system focuses on protein concentration and filters out extra milk solids. What you are left with is a whey protein that supports your training and recovery.

This filtration step sets the stage for high-quality concentrate, isolate, or hydrolyzed whey protein.

Step 4: Drying into a powdered form

In the fourth step, a spray dryer is used to remove the water from liquid whey. This precise process is key as it helps maintain 90% whey protein in the powder. High amounts of raw whey are used to yield quality batches.

This method is used to preserve the nutritional integrity and stability of whey protein, while also providing supplement manufacturers with a form that can last longer on the shelf. 

The drying process allows the whey protein to hold on to its high nutritional value despite being converted from a liquid to a powder. Overall, the drying step is a stable method that addresses issues such as milk allergies and unwanted carbohydrates.

Step 5: Blending and flavoring (optional)

When it comes to making whey protein, this is probably going to be the step that, while optional, is our favorite. 

Why?

Because who doesn’t love a great-tasting protein powder?

This step is where everything gets blended and flavored. Flavoring upgrades your whey protein and provides you with a delicious and enjoyable experience. As you can imagine, NutraBio adds flavoring to make the product enjoyably smooth, leaving you with a mouth-watering protein shake that you look forward to drinking every day. 

That being said, in order to get a flavor you’ll enjoy, you will find natural flavoring agents mixed in during this step.

Step 6: Packaging for retail or bulk distribution

The final whey protein powder is tested for purity before it is packaged. Quality checks utilize protein purification techniques, including anion exchange and chromatographic methods, to ensure you receive the highest-quality whey protein powder possible.

Air-resistant containers are then used to hold the protein powder and help keep it fresh.

The packaging process achieves safe products that avoid issues like unwanted coagulation or crystallization (because no one likes to open their tub of protein and find it all clumpy).

Once the packaging step is complete, all of the protein powder is then sent out directly for retail or in bulk distribution.

Different Types of Whey: Concentrate, Isolate, and Hydrolysate