Flowhey®: 60 Years of Expertise Delivering Reliable Whey Powder Across the Globe

For more than six decades, Lactalis Ingredients has refined a unique expertise in whey drying technology. At the heart of this excellence lies the mastery of lactose crystallization.

 This innovation, commercialized under the Flowhey® brand, transforms raw material into stable and high-performance powder — guaranteeing consistent product integrity, regardless of climatic conditions and logistical constraints.

 How can mastering lactose crystallization improve powder stability? Why has this approach become the standard for industrial manufacturers? Explore the science and engineering behind Flowhey®.

An Invisible Challenge, Highly Visible Consequences

To understand Flowhey®, one must first understand the physicochemical challenge it solves.

During spray drying of whey without pre-crystallization, lactose exists predominantly in an amorphous state — an unstable and extremely hygroscopic form. This form can absorb and retain up to 100 times more free water than crystalline lactose, making it particularly vulnerable to hygroscopic fluctuations (Bronlund & Paterson, 2004).

The cascading consequences are immediate and costly:

The powder absorbs moisture and becomes sticky. Particles bond to one another, creating agglomerates. The powder cakes, compacts, and becomes unusable as it is.

Simultaneously, this absorbed moisture considerably increases molecular mobility, accelerating Maillard reactions — non-enzymatic browning reactions that degrade color, flavor, and nutritional value.

For manufacturers operating in high-temperature and high-relative-humidity environments — where temperature fluctuations and extended transit times are unavoidable — these degradation phenomena quickly become uncontrollable, resulting in significant material losses and productivity.

The Solution: Mastering Crystallization

Lactalis Ingredients has developed a technology that masters lactose crystallization in two stages — a controlled pre-crystallization prior to drying, followed by a second stage occurring at the bottom of the spray drying towers on crystallization belts.

Whey is first concentrated through evaporation, creating a lactose-supersaturated solution. This solution is then cooled in crystallization tanks, initiating the crystallization phase in a progressive and controlled manner. Amorphous lactose begins its transformation into alpha-lactose monohydrate crystals.

The pre-crystallized whey is spray-dried. The powder then completes its crystallization on belts located upstream of the fluidized beds, promoting the formation of alpha-lactose monohydrate. This final step achieves crystallization rates up to 90% — far exceeding standard powders.

The result? A fundamentally different powder with exceptional stability.

The Four Pillars of Flowhey® Quality: From Properties to Customer Benefits

This controlled crystallization creates powder with exceptional properties that translate into direct operational benefits:

• High fluidity. Lactose crystallization reduces fine particles and improves powder flow. For manufacturers, this translates to better dosing precision, reduced dust emissions (and thus reduced production lines cleaning), and optimized production rates.
• Non-hygroscopic powder. Unlike amorphous lactose that absorbs moisture, crystalline lactose shows minimal water affinity. The powder maintains its moisture balance, enabling longer and safer storage without degradation in hot/humid climates.
• Absence of caking. Without absorbed moisture, no liquid bridges form between particles. The powder does not stick, does not agglomerate, and maintains fluidity throughout storage — even after months in tropical climates. In production, this significantly reduces line stoppages and limits losses, ensuring better profitability.
• Thermal stability. Even at elevated temperatures, the powder browns only minimally and does not undergo undesirable Maillard reactions. For demanding applications such as sweetened condensed milk, this thermal stability is an advantage that guarantees consistent quality of finished products.

A Range Adapted to Diverse Application Needs

Lactalis Ingredients offers a complete portfolio designed to meet the specific requirements of a multitude of applications.

Flowhey® is the standard reference, ideal for most food applications.

Flowhey® Heatstable offers enhanced thermal stability for high-temperature processes. It excels in demanding applications such as sweetened condensed milk, where powder must remain stable even at extreme temperatures.

Flowhey® D40 is a 40% demineralized whey powder combining high fluidity and controlled mineral composition, improving the taste of finished products.

A Global Solution for All Markets

Flowhey® offers global manufacturers a reliable solution that addresses key operational challenges: improving finished product quality, reducing losses from storage and transport issues, optimizing production efficiency, and ensuring consistent performance across demanding climatic environments.

Need a practical overview of Flowhey® and its key benefits?
Download/View the Lactalis Ingredients Flowhey® infographic.

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Sources:

• Bronlund, J. E., & Paterson, A. H. J. (2004). Moisture sorption isotherms for crystalline, amorphous and partially crystallized lactose. International Journal of Pharmaceutics, 281(1-2), 41-54.