In an era where the global dairy industry faces unprecedented challenges, volatile markets, stringent environmental regulations, and increasing water scarcity, the way we manage by-products is becoming a defining factor of competitiveness and sustainability. Whey, the liquid fraction generated during cheese production, contains over 90% water, enriched with valuable nutrients and organic matter. Yet in most facilities worldwide, this stream is still treated as a waste problem rather than a strategic asset. Every cubic meter discarded not only represents lost water but also a missed opportunity to reduce costs, generate value, and strengthen environmental credentials.
This project turns that equation on its head. By recovering and reusing water from whey through a combination of ultrafiltration, reverse osmosis, and food-grade disinfection, the plant can reclaim up to 80–90% of the water contained in this by-product. For a facility producing 100,000 liters of whey daily, this means more than 30,000 m³ of high-quality water per year, enough to supply the annual needs of 200 households, returned to the process or other productive uses. The transformation goes beyond quantity: the approach reduces wastewater volumes, decreases the energy and chemicals required for treatment, and enables a circular management of both water and nutrients.
The market context is clear: in regions where the dairy sector is under pressure to demonstrate sustainable water stewardship, solutions that integrate Volumetric Water Benefit Accounting (VWBA 2.0) principles, additionality, intentionality, and traceability, are no longer optional. This initiative is fully aligned with those principles, delivering verifiable Water Benefits (A-2: avoided consumption, and A-6: safe onsite reuse) and measurable quality improvements under WQBA standards. Physical traceability is ensured through inline monitoring of flow and quality parameters, while digital traceability is provided by a georeferenced, auditable system capable of supporting corporate ESG disclosures and third-party verification.
More than a technical upgrade, this is a strategic repositioning: turning a regulatory liability into a high-visibility sustainability asset. It demonstrates leadership in Water Positive action, aligning with ODS 6 (Clean Water and Sanitation), ODS 12 (Responsible Consumption and Production), and ODS 13 (Climate Action), while strengthening operational resilience and brand value in an increasingly resource-conscious market.
The dairy industry generates vast volumes of whey as a by-product of cheese production. While the protein-rich fraction of whey has commercial value, the aqueous portion, often called “whey permeate” after protein extraction, is typically seen as an effluent. In most plants, this stream is sent to wastewater treatment, where its high organic load and volume increase operational costs and environmental impact. In regions with water stress, this practice intensifies pressure on freshwater sources and limits the sector’s ability to grow sustainably.
This project addresses that challenge head-on by installing a dedicated water recovery system that processes whey through sequential ultrafiltration and reverse osmosis stages, followed by chlorine-free disinfection to meet internal process water standards. The recovered water is reintegrated into non-critical production stages, such as cleaning-in-place (CIP), cooling systems, and auxiliary processes, or even returned to the potable water circuit if regulatory compliance is achieved. The residual concentrate, enriched with lactose and minerals, is valorized as an ingredient for animal feed or as a substrate for biogas production, closing the loop on resource use.
The technical opportunity is twofold:
The benefits are immediate and scalable: in the first year alone, the system is expected to recover more than 30,000 m³ of process-ready water and cut effluent volumes by the same amount. Over a decade, that represents over 300,000 m³ saved, a Water Positive outcome equivalent to recharging a small aquifer.
The actors involved include the dairy plant operator, the technology provider specialized in membrane filtration and food-grade water treatment, the project structurer ensuring VWBA/WQBA alignment, and the third-party verifier certifying additionality and traceability. Together, they create a model that any medium-to-large dairy operation can replicate, particularly in regions where water stress intersects with strong dairy production.
For companies seeking to lead in ESG performance, secure supply chain resilience, and comply with increasingly demanding water regulations, this is more than a technical upgrade—it is a narrative of transformation. Acting now means converting a persistent operational burden into a measurable, reportable, and marketable advantage that positions the company at the forefront of a new era in sustainable dairy processing.
The project includes the implementation of a dedicated treatment line for whey condensate, designed with an advanced physical-mechanical approach that avoids the use of chemicals and adapts to the intermittent and variable flows typical of this stream. The system incorporates a multi-layer filtration stage to remove suspended particles and organic solids, followed by a thermal stabilization unit to homogenize temperature and remove volatile compounds through controlled thermal conditioning.
Next, an advanced oxidation process (AOP) reactor is used to degrade residual organic molecules using controlled oxidative species (such as hydroxyl radicals), without forming toxic byproducts. The final stage involves high-intensity UV disinfection, ensuring microbiological safety before storage and recirculation of the treated water.
This solution, modular and energy-efficient in design, is inspired by selective electromagnetic separation technologies, continuous flow operation, and automatic self-cleaning protocols, allowing seamless integration with the plant’s existing SCADA systems. With a recovery efficiency of up to 90%, the treated water exhibits stable conductivity, low microbial load, and absence of critical compounds, complying with internal standards for safe reuse in non-potable applications such as CIP, cooling towers, and equipment washing.
The implementation of the whey condensate reuse system at the plant is structured in four sequential phases, each with specific technical objectives, key activities, and associated control parameters:
Technologies or actions applied: Modular system for treating whey condensate, based on advanced physical separation, thermal stabilization, and non-chemical oxidation. A compact, scalable, and energy-efficient solution tailored for high-load industrial environments. Adaptable to variable flows and compliant with internal sanitary standards.
Technical Diagnosis and Design: This phase includes exhaustive mapping of whey condensate generation points within the plant, identifying intermittent flows and operational conditions for each line. Representative samples are taken for physico-chemical (conductivity, TDS, temperature, volatile compounds) and microbiological (total coliforms, mesophiles) analysis. Based on these results, the treatment system is dimensioned and quality parameters defined according to intended internal uses (CIP, cooling, auxiliary services).
Installation of the Treatment Line: This stage involves installing the technology modules in series. Multi-layer prefiltration removes particles above 50 microns, followed by a thermal stabilization unit that maintains constant temperatures, eliminates volatiles, and avoids thermal shocks in subsequent stages. The AOP reactor is calibrated based on the expected organic load to perform advanced oxidation without generating toxic byproducts. A dual-pass UV disinfection unit ensures the microbiological safety of the treated effluent, validated through log-reduction testing.
Operational Integration: Once stabilized, the treatment system is connected hydraulically and electronically to the plant’s internal circuits. Treated water is directed to intermediate tanks and distributed based on process needs. The system is integrated into the SCADA platform, allowing real-time monitoring of flow, pressure, and temperature, with alarms for deviations. Contingency protocols are also configured for automatic diversion if microbiological or conductivity parameters deviate.
Monitoring and Maintenance: The system includes a continuous monitoring plan with in-line sensors measuring conductivity, turbidity, TDS, and temperature at key points. Composite samples are analyzed weekly to validate water quality, and internal audits verify energy consumption (kWh/m³), contaminant removal efficiency, and system integrity. Automatic cleaning and quarterly predictive and corrective maintenance cycles are included.
Controls and measurements by phase:
Monitoring Plan:
Partnerships and implementing actors:
This project aims to transform the internal water management of the plant by recovering, treating, and reusing condensate water generated during the whey evaporation process. This stream, commonly referred to as “cow water,” constitutes a technically recoverable fraction of the total water flow, characterized by its low dissolved solids content and minimal microbiological load. Despite its favorable characteristics, its potential has historically been underutilized due to the lack of specific water valorization strategies.
Through a comprehensive technical and operational analysis, it was determined that this stream can be treated using state-of-the-art technologies based on advanced physical processes, without requiring chemical inputs or generating secondary waste. These technologies, such as multi-layer filtration, thermal stabilization, advanced oxidation processes (AOP), and dual-pass UV disinfection, effectively remove particles, eliminate volatile compounds, and ensure the microbiological safety of the treated water. The resulting water quality allows for safe reuse in non-potable applications such as CIP cleaning, tray washing, indirect cooling, and thermal service supply, thus replacing potable water in those uses.
The project implementation is structured into four successive technical stages. First, the system is diagnosed and designed through detailed characterization of the condensate’s flow, composition, and destination. Second, a modular and scalable treatment line is installed and adapted to the plant’s existing infrastructure. The third stage integrates the system into daily operations, linking it with SCADA and internal distribution systems. Finally, a predictive monitoring and maintenance plan is established, including in-line sensors, microbiological quality control, and energy efficiency assessment.
Methodologically, the project is structured under the Volumetric Water Benefit Accounting (VWBA 2.0) framework, by generating measurable savings of blue water, and the Water Quality Benefit Accounting (WQBA) approach, by reducing the load on effluent treatment systems. This dual contribution—both in demand reduction and discharge quality improvement, makes it possible to quantify and validate the project’s positive water impact. Furthermore, the initiative aligns with the Sustainable Development Goals (SDGs), by integrating innovation, industrial sustainability, resource efficiency, and strategic partnerships for transforming the plant’s water management model.
