Dairy Powder Processing

Milk Protein Concentrate (MPC)

We concentrate MPC to higher total solids without the plugging that limits traditional NF/UF.  So you get a steadier feed to drying while keeping thermal exposure low to protect protein functionality, solubility, and flavor. Low-heat separation improves product quality before it ever reaches the dryer.

Value to Operations:

• Higher % Total Solids: Less energy per ton dried and more stable dryer operation
• Better Product Quality via Low-Heat Separation: Minimal thermal/mechanical stress preserves protein integrity, solubility, color, and flavor
• Lower fouling and integrates into existing CIP processes

Whey Protein Concentrate (WPC)

We concentrate WPC to high total solids while keeping thermal exposure low, so delicate whey proteins retain solubility, foaming, and emulsification. Our open-channel flow prevents localized overheating and fouling, delivering repeatable quality, easier cleaning, and cleaner permeate for water reuse.

Value to Operations:

• Higher % Total Solids:  liquid load on the dryer unchanged, less energy per ton dried, and steadier dryer performance
• Better Product Quality via Low-Heat Separation: Minimal thermal/mechanical stress preserves functionality (solubility, foaming, emulsification), flavor, and color
• Lower Fouling: Uniform flow reduces plugging; integrates into existing CIP with tighter, more repeatable  operation
• Cleaner Permeate for Reuse: Improved clarity and consistency support water recycle and downstream hygiene—while reducing overall drying cost per ton

Drying Capacity and Energy Balance

By concentrating dairy protein streams upstream, SmartFlow shifts part of the work from thermal to mechanical separation. This approach increases dryer utilization and with minimal changes in overall plant energy use.

Operational Value:

• Typically achieves 10–30 % additional dryer throughput within the same footprint
• Expanded production without new greenfield construction
• Balanced dryer operation and energy distribution
• Rapid payback

SmartFlow enables dairies to increase dryer throughput and total protein output, including high-value MPC, WPC, MPI, and WPI products.  This allows customers to expand capacity without the need for new greenfield construction.

Automation, Design, and Retrofit Flexibility

Key Benefits

• Compact Modular Skids: Minimal footprint for retrofit or expansion
• Advanced Automation: Simple operator interface, recipe-based CIP, and integrated performance monitoring
• Scalable Design: Begin with either backset or mid-stillage and expand later for combined operation
• Minimal Downtime Installation: Systems bolt into existing circuits without interrupting production

Why Customers Choose SmartFlow

Engineered for Results

• HSTFF™ open-channel technology maintains uniform flow across high-solids, viscous streams
• Optimized shear and channel geometry sustain stable flux under variable loading
• Modular trains enable stepwise expansion with shared automation and components

Designed for Efficiency

• Mechanical dewatering reduces evaporator and dryer energy use
• Clarified permeate improves downstream reliability and strengthens plant water balance through enhanced recycle and reuse capacity
• Integrated process automation ensures simple, repeatable operation

The Result

Cleaner operation, higher yield, lower steam and fuel use, and a scalable path to long-term carbon-intensity (CI) and cost-reduction goals. SmartFlow’s HSTFF™ platform transforms solids management from a maintenance burden into a controllable, high-ROI process variable.