Long gone are the days of one-size-fits-all protein powders. These days, you can pop into the supermarket or do a quick search online, and many varieties, purities, and strengths are available. By now, we should all know that a high-protein diet works wonders when paired with consistent exercise, but do we know what goes into those pre- and post-workout protein shakes and powders and how they’re actually made? 

Before we delve into all the processes of how protein powder is made, let's first identify the numerous varieties available to us.

The 7 Types of Protein Powders

Whey Protein

Thought to be the most popular protein powder, whey protein is a by-product of milk. It enters your bloodstream faster than any other protein, allowing it to boast the highest level of the amino acid leucine, providing muscles with the necessary fuel to get through a workout and build muscle. If you aim to build muscle, whey protein is considered the most effective when consumed within an hour after exercise.

Whey Concentrate

Whey concentrate is a particular form of whey protein, including some lactose and fat, but can be up to 88% pure protein that is more flavoursome and less expensive thanwhey isolate.

Whey Isolate

This type of whey protein has been removed of all carbs and fat, producing a powder that can be up to 98% protein.

Casein Protein

Both casein and whey are high-quality proteins naturally found in milk, but they work in different ways to support your active lifestyle. Casein digests slowly, making it a popular choice for athletes and wellness enthusiasts looking for sustained protein release, especially before bedtime. In contrast, whey protein is absorbed more quickly by the body, which is why it’s often enjoyed right after exercise to help kickstart recovery.

Soy Protein

Soy protein is a plant-based protein source made from ground soybeans that have been carefully dehulled and defatted. It digests at a moderate rate, similar to egg white protein. It is naturally rich in the amino acids glutamine and arginine, which may help support immune health, digestive function, and cognitive wellbeing.

As a complete protein, soy contains all the essential amino acids your body needs, making it one of the most effective plant-based options for building and maintaining muscle. However, if you have a history of estrogen-related cancers or concerns about testosterone levels, it’s a good idea to consult your healthcare provider or consider varying your protein sources.

Egg White Protein

Egg white protein is simply pure egg whites gently dried and transformed into a convenient, high-quality powder. It digests at a moderate pace, slower than whey protein but faster than casein, making it a versatile addition to your nutrition routine.

While egg white protein may not be as effective as whey or casein for muscle protein synthesis, it remains an excellent choice for post-workout recovery or as a nutritious addition to your smoothie. Additionally, it is naturally dairy-free, making it ideal for individuals with dairy allergies or those who prefer to avoid milk-based proteins.

Pea Protein

Pea protein, derived from yellow peas, is one of the most easily digestible plant proteins. This makes it an excellent option for people with sensitive stomachs or those looking to avoid dairy and soy. Although pea protein is naturally low in two essential amino acids, you can easily complete its amino acid profile by pairing it with other plant-based proteins, such as hemp or rice.

For those seeking a higher protein content,pea protein isolate is a great choice. If you prefer a slightly lower protein option,pea protein powder is also an excellent selection and is often available in organic varieties.

Hemp Protein

Hemp protein is made from nutrient-rich hemp seeds and is an excellent option for those looking to enhance their overall nutrition. While it contains slightly less protein per serving (typically 10 to 15g per scoop) than whey or soy protein, hemp protein compensates with a substantial amount of fibre and naturally occurring omega-3 fatty acids, which are beneficial for digestive health and overall well-being.

To create a complete amino acid profile, consider pairing hemp protein with other plant-based sources, such as rice or pea protein. Hemp protein is ideal for those who want to increase their intake of wholesome nutrients without needing high levels of protein for muscle building.

How is Protein Powder Made?

Whey Protein Concentrate Process

Whey protein concentrate is produced through a series of steps that begin with fresh milk sourced from dairy farms:

1. Milk Collection and Pasteurisation: Milk is pasteurised from cows to eliminate harmful bacteria. During cheese production, a coagulant is added to the milk, which causes it to separate into curds (used for cheese) and liquid whey.

2. Separation and Filtration: The liquid whey, containing proteins, fats, and carbohydrates, is separated from the curds. It is then filtered using ultrafiltration or microfiltration techniques to concentrate the protein and remove most fats and lactose.

3. Concentration: Through these filtration processes, the whey protein is concentrated to the desired protein content, typically between 70% and 80% for whey protein concentrate.

4. Drying: The concentrated whey protein liquid is then spray-dried. This process involves atomising the liquid into small droplets and drying them with hot air, resulting in a fine powder while preserving the protein’s nutritional quality. 

5. Finishing and Packaging: The resulting whey protein concentrate powder is tested for purity and quality. Flavourings or other ingredients may be added before packaging it for sale.

This process ensures that whey protein concentrate retains its nutritional value, making it suitable for supplements and food products.

Whey Protein Isolate Process

The production of whey protein isolate is very similar to the production of whey protein concentrate, the main difference being the filtration step. As mentioned previously, whey protein concentrate is filtered to allow for a 70-80% protein content. In contrast, whey protein isolate is filtered further to remove almost all fat and lactose to produce a 90% protein content or higher.

In some cases of whey protein isolate production, ion exchange chromatography technology is used, where proteins are selectively separated based on their electrical charge, further increasing purity.

Casein Protein Process

Casein protein is made from skim milk using two primary methods: acid precipitation and rennet coagulation. Here’s how each process works:

Acid Casein Production

1. High-quality skimmed milk undergoes pasteurisation and is then acidified to reach the isoelectric point of casein, which typically occurs at a pH of 4.3 to 4.6. This acidification can be achieved using mineral acids, such as hydrochloric or sulfuric acid, or by adding lactic acid bacteria for biological acidification. 

2. Acid coagulates casein, separating it from the liquid whey. Once the casein curds have formed, they are drained of whey and washed multiple times with water to eliminate residual lactose, minerals, and whey proteins. This washing usually takes place in several stages at controlled temperatures.

3. After washing, the curds are pressed to remove excess moisture and milled into smaller particles. Finally, the casein is dried, often in two stages at different temperatures to reduce the moisture content to about 12% before being ground into a fine powder for packaging.

Rennet Casein Production

1. Pasteurised skim milk is first heated, after which rennet (an enzyme, typically chymosin) is added to coagulate the casein. This process forms a gel that is then cut and gently heated to deactivate the enzyme, followed by further stirring and cooking.

2. Next, the whey is drained, and the casein undergoes several washing stages to purify it, similarly to the acid process. After washing, the casein is dewatered, dried, and ground into powder.

Both methods aim to eliminate as much fat, whey proteins, lactose, and minerals as possible, resulting in a high-quality, pure casein protein powder.

Soy Protein Process

To create soy protein, soybeans are first dehulled, flaked, and defatted using a gentle extraction process. The resulting soybean flakes are mixed with an alkaline solution to draw out the protein. Next, the mixture is spun in a centrifuge to remove fibre. Finally, the protein-rich liquid is dried into a fine powder. The result? A powder that’s around 90% pure protein.

While the process involves a few scientific steps, the key takeaway is simple: soy protein is a powerhouse of nutrition. It’s also the only vegan protein source that’s “complete,” meaning it provides all nine essential amino acids your body can’t make on its own and must get from food.

Egg White Protein Process

Egg white protein is produced through a straightforward yet carefully controlled process:

1. Egg Breaking and Separation: Fresh eggs are sent to a processing facility, where they are cracked open. The yolks are separated from the whites, and only the egg whites are used for protein production.

2. Filtration: The liquid egg whites are filtered to remove any remaining shell fragments or impurities.

3. Pasteurisation: The egg whites are pasteurised to ensure safety and eliminate bacteria.

4. Spray Drying: The pasteurised egg whites are then spray-dried. In this process, the liquid egg whites are sprayed into a chamber with heated air, quickly evaporating the water, leaving behind a fine egg white protein powder.

5. Agglomeration (Optional): Sometimes, a small amount of an ingredient, such as sunflower lecithin, is added to improve the powder's solubility and mixing properties.

6. Packaging: The resulting egg white protein powder is ground (if necessary) and packed in a hygienic environment, ready for use in supplements and food products.

This process preserves the quality of the protein and ensures that the final product is easy to mix and store.

Pea Protein Process

Pea protein is derived from yellow split peas, rather than the green peas typically served with meals. The process begins by removing the peas' outer shells, then grinding and milling them into a fine flour. This flour then undergoes a wet filtration process, separating the starch and fibre, leaving behind the valuable protein and essential vitamins and minerals. Finally, these nutrients are carefully distilled and dried to produce a pure, high-quality pea protein powder.

Hemp Protein Process

Hemp protein powder is made from whole hemp seeds, which have their oil carefully removed using a cold expeller press. What remains is a nutrient-rich hemp seed meal that is finely milled into a natural protein powder. 

Due to its minimal processing, hemp protein retains more of its original nutrients and typically contains about 50% protein. This makes it a wholesome, plant-based option for those seeking to enhance their daily nutrition.

The Bottom Line

The journey from raw ingredient to protein powder is a carefully crafted process, with each step tailored to the specific source, be it whey, pea, soy, or hemp. Understanding how these powders are made can empower you to choose the right protein for your lifestyle, whether taste, dietary requirements, or fitness ambitions guide you.

By shedding light on the production methods behind your favourite protein powders, we hope this guide helps you make informed, confident choices on your wellness journey.

At Nutristrength, we pride ourselves on providing high-quality, pure and simple nutrition for everyone, from whey protein isolate and delicious vegan varieties to food. Check out our protein range today, or check out ourblogs and recipes for more guidance and inspiration.