Arla Foods Ingredients Expands Whey Processing, Norwegian Venture Goes Into Production

Arla Foods Ingredients starts 2013 with much more to offer customers. Following the start up of its expanded whey processing plant in Denmark, production capacity has taken a large upward leap. So much so, that site management has even exceeded its own expectations.

25 Jan 2013 --- Arla Foods Ingredients starts 2013 with much more to offer customers. Following the start up of its expanded whey processing plant in Denmark, production capacity has taken a large upward leap.

So much so, that site management has even exceeded its own expectations.

The explanation lies in the optimisation of the existing plant that has taken place while building work was underway last year. Efficiency improvements mean the overall processing capacity for the speciality protein Lacprodan Alpha-10 has now increased 120% overall – instead of the 80% originally planned.

At the same time, processing capacity for Lacprodan CGMP-20 has increased ten-fold, on top of the doubling of capacity implemented in early 2012. A wide range of food applications will also gain from the increased production of functional milk proteins.

According to site director, Erik Vesløv, customers are already waiting in line to buy the extra volumes.
“We had wondered how we would bridge the gap when we moved from one capacity to another. Fortunately, it looks like our expansion has followed customer demand,” he says.

During the course of the building work, the plant has gained a new spray-drying tower and advanced filtration equipment. Testing was completed at the end of December.

The plant requires 25% more raw whey protein in order to reach full capacity. This is to be supplied by the new joint venture processing facility, established by Arla Foods Ingredients and German dairy company DMK.

New whey processing facilities are ready for start up at two dairies in Norway, where Arla Foods Ingredients had a well-functioning partnership with the dairy company TINE since 2008.

During 2013, the plants will bring fresh supplies of whey protein concentrate and whey permeate to the global market.

Arla Foods Ingredients has supplied the whey processing expertise to ensure the efficient production and high quality of the whey products, which will be sold through the company’s global sales network.
TINE has invested in the production facilities, including a complete whey processing plant at its dairy in Jaeren, which thereby has become Norway’s biggest, and a new spray-drying plant at its Verdal dairy. Both plants have spray-drying towers for both whey protein and permeate.

Whey raw materials will be supplied by TINE from its annual production of 46,000 tonnes of yellow cheese.
Innovative ingredient ideas can provide food manufacturers with all kinds of benefits. But first manufacturers have to hear about them, understand the difference they make, and try them out on their own production lines.

Trine Trúgvason is operating engineer for the Arla Foods Ingredients pilot production line where promising milk-based ingredients are produced on a small scale until promising sales warrant investment in a capacity expansion.

“Pilot production gives us an opportunity to show the market what an ingredient can do on a bigger scale than the test batches produced in the laboratory,” she says.

“Customers can then run trials right up to commercial scale, making it easier for them to bring their own new products to market.”

Located at Arla Foods Ingredients’ whey processing facility in Denmark, the pilot production line was given a makeover in early 2012, achieving a higher level of automation and the capacity to treat 380 tonnes of milk a week.
“These investments reflect the high priority given to pilot production, where we try things out and gather experience,” Trúgvason remarks.

One of the products currently in successful pilot production is Lacprodan CGMP-20, a bioactive whey peptide suitable for the diets of people with the rare genetic disorder phenylketonuria (PKU).

Increasing customer interest led to a doubling of capacity earlier this year. During 2013, pilot production will cease on completion of a new commercial-scale Lacprodan CGMP-20 line.

Several other products are also currently in pilot production, where processes are adjusted and optimised to ensure a smooth production scale-up when sales show sufficient potential.

“We are the link between laboratory tests and large-scale production. It’s up to us to develop and adjust the process. At the same time, we still have to live up to specifications as we sell our products to customers,” says Trúgvason.