How is Protein Powder Made

We've all seen protein powder on the shelves of supplement stores and gyms, even supermarkets, but have you ever wondered how protein powder is made? This dietary fitness supplement is produced by transforming raw food sources into concentrated, easily digestible protein. Once you learn the science behind how protein powder is made, you may think twice about which protein supplements you take.

What is Protein Powder, and Why is It So Popular?

Protein powder is a dietary supplement that extracts protein from natural sources like dairy, eggs, and plants. This concentrated product contains around 60% to 95% protein, with the rest consisting of fats, carbohydrates, and sometimes additives. It's widely used for muscle repair, growth, and overall recovery. 

Its popularity in Australia has surged among athletes, bodybuilders, and individuals on calorie-restricted diets because it's easy to hit your daily protein goals without adding hundreds or even thousands of extra calories to your meal plan. Plus, since it's a powder, it makes for a great meal on the go for commutes to & from work, trips, and when you're a bit short on time. One of our favourite performance supplements, protein powder, helps build muscle mass during bulking periods, repair muscles post-workout, support weight management, and maintain lean muscle mass during periods of calorie restriction.

How Is Protein Powder Made?

Making protein powder involves transforming raw protein sources into a concentrated powder. While the process can vary depending on the type of protein and the manufacturer, the general steps remain the same.

1. Sourcing Raw Protein Materials

Protein powder production starts with carefully selecting raw materials, such as milk for whey and casein proteins, soybeans for soy protein, or peas for pea protein. The quality of these raw ingredients directly affects the nutritional value and purity of the final product.

There are even multiple ways to source a singular type of protein. Whey, for example, is one of the purest and most common forms of protein, but not all whey protein powders are made equal. High-quality whey protein powders are made from grass-fed cows and are minimally processed and un-denatured to maintain their natural structure. 

One step further, there are differences between how protein powders and protein powder concentrates are made. Protein powder concentrates undergo less processing than protein isolates, resulting in a lower protein percentage (typically 70-80%) and higher amounts of fats and carbohydrates than isolates (90%+ protein).

2. Filtration and Extraction

Once the raw material is selected, whether animal-based or plant-based, the next step is to extract the protein. For dairy-based proteins like whey, this involves separating the protein from the liquid byproducts of milk during the cheese-making process. Plant proteins, like soy or pea, are typically processed using water or enzymes to separate the protein from carbohydrates and fats.

Microfiltration and ultrafiltration further purify whey protein by removing unwanted fats and lactose. Plant-based proteins undergo filtration to isolate the protein and remove non-protein components, such as fibre and starch.

3. Drying and Powder Formation

Once the protein has been extracted and undergone ultrafiltration or microfiltration to remove impurities, it's concentrated into powder form via drying. 

Spray drying is generally used for whey protein. The liquid whey is sprayed into a chamber with hot air, causing the water to evaporate, leaving behind a fine protein powder. The temperature must be exact to prevent protein denaturation.

Some premium protein powders use freeze-drying (lyophilisation) instead, which better preserves the protein's structure and nutritional value. Plant-based proteins undergo air-drying or milling to turn them into powder while maintaining nutrients. For some plant proteins, methods like cold-pressing (for seeds) might be used before drying.

4. Flavouring and Packaging

Once the protein is in powder form, manufacturers blend in flavourings, sweeteners, and other additives to improve taste and texture. This blending process ensures uniform distribution of all ingredients. Before packaging, the product undergoes rigorous quality control testing to verify protein content, purity, and safety.

The powder is packaged in airtight containers, including plastic tubs, foil-lined bags, or pouches. These containers are designed to protect the powder from moisture and light. The top manufacturers flush the packaging with nitrogen before sealing, which removes oxygen to extend the powder's shelf life. Instead of a few months, they can last for up to 12-18 months.

Each package is labelled with nutritional information, ingredient lists, and any required regulatory details. Manufacturers also typically add batch codes or lot numbers for traceability. 

Different Types of Protein Powder

Dairy-Based Proteins: Whey and Casein

Whey protein is sourced during cheese production and is the world's most commonly consumed protein powder. It's fast-digesting, making it ideal for quick muscle recovery after workouts. Depending on the level of processing, it's available as a concentrate, isolate, or hydrolysate.

Casein protein digests more slowly, gradually releasing amino acids over several hours, making it a favourite for overnight muscle repair. Most athletes supplement just with whey because they want to start repairing muscles immediately. Bodybuilders generally consume casein, but it's one that athletes should consider cycling the day before or the day of their rest day when they have extra time between training sessions.

Plant-Based Proteins: Soy, Pea, and Hemp

Plant-based proteins have evolved significantly in the last 5-10 years. Soy, peas, and hemp are the primary sources. Still, the industry has evolved into making protein powders from rice, pumpkin seeds, sunflower seeds, and even algae. 

Soy protein is a complete protein containing all essential amino acids. In contrast, pea protein is rich in branched-chain amino acids supporting muscle repair. Hemp protein is nutrient-dense, containing essential fatty acids and fibre.

Other Animal-Based Proteins: Egg and Collagen

Egg white protein is easily digestible, low in fat and carbohydrates, and contains all nine essential amino acids. It's particularly rich in leucine, a crucial amino acid for muscle protein synthesis.

While not a complete protein, collagen protein is often mixed into dairy-based and plant-based powders. It's derived from animal connective tissues like bones, skin, and cartilage and is rich in specific amino acids such as glycine, proline, and hydroxyproline. These amino acids help improve skin elasticity, joint flexibility, and bone strength and have been linked to improved gut health.

Benefits of Protein Powder

• Muscle Growth & Repair: Packed with amino acids, protein powder is excellent for injury recovery, as it helps accelerate muscle repair and regrowth.
• Convenience: It's a quick and easy way to meet daily protein requirements without consuming large amounts of food.
• Weight Management: Protein powder can help maintain muscle mass during calorie restriction, essential for long-term weight management.
• Versatility: Protein powders can be mixed into smoothies, shakes, and even recipes to boost protein intake without altering the flavour too much.

How to Choose the Right Protein Powder for Different Goals

Muscle Building

Regarding protein for muscle growth, whey protein isolate or hydrolysate are your best bet because of their high protein content and rapid absorption. These forms are designed to quickly deliver essential amino acids to your muscles after exercise, promoting efficient repair and growth. 

Weight Management

If you want protein powder to lose weight, casein protein might be a better option. Its slow digestion keeps you fuller for longer and helps prevent muscle breakdown overnight. Combined with other weight loss supplements, it can also aid in maintaining lean muscle mass while supporting fat loss.

Vegan or Plant-Based Diet

Pea or soy protein are excellent choices for those following a plant-based diet. They offer a complete amino acid profile and are ideal for those who prefer non-dairy options. 

Frequently Asked Questions

What is Protein Powder?

Protein powder is a concentrated source of protein made from various food sources, including dairy, plants, and eggs, to supplement dietary protein intake. It is famous for its role in muscle building and overall fitness.

How is Protein Powder Made?

Protein powder is made by extracting protein from food sources and filtering out fats and carbohydrates. The protein is then dried into a powder, often spray drying or milling techniques. The process ensures high protein concentration and nutritional integrity.

What Are the Main Types of Protein Powder?

The main types are protein concentrates, isolates, and hydrolysates. Concentrates contain 60–80% protein, isolates have 90–95%, and hydrolysates are pre-digested proteins for faster absorption.

How Do I Choose the Right Protein Powder?

Consider your dietary goals. For muscle building, opt for whey isolate or hydrolysate. For weight management, choose casein protein. If you're on a plant-based diet, soy or pea protein are great options.