Tecnológico de Monterrey turns dairy waste into sustainable protein using microbial communities

Scientists at Tecnológico de Monterrey, in partnership with the Technical University of Denmark (DTU), have developed a method to transform industrial cheese byproduct whey into a sustainable protein source. The project uses microbial communities in a precision fermentation process to produce single-cell protein (SCP) without relying on genetically modified organisms (GMOs), positioning the technique as a potential solution to both food security and environmental challenges.

Whey, the liquid byproduct of cheese manufacturing, often ends up in waterways, contributing to pollution and nutrient overload that can lead to ecological disruptions such as eutrophication. In Mexico alone, it’s estimated that in regions such as Veracruz and Chiapas, more than 100,000 liters of whey are dumped into rivers every day. Globally, the dairy industry generates millions of tons of whey annually, much of which goes unused despite its nutritional potential.

Dr Mario Antonio Torres Acosta, the lead researcher and a biotechnology expert at Tecnológico de Monterrey, explained the scientific foundation of the project. “The use of microbial communities is key in this process. In nature, microorganisms do not function in isolation but in consortia where they complement each other. We leverage this principle to optimize the conversion of waste into a product with high added value.”

The team’s approach uses a combination of yeasts and bacteria to convert the lactose in whey into protein-rich biomass, eliminating the need for genetic modification and helping improve the public perception and regulatory pathway of the product. According to Dr Torres-Acosta, this method could simplify scalability and market entry, especially in regions where GMO regulations are strict or public concern is high.

The result is a functional protein powder with a neutral flavor and promising nutritional and economic attributes. Preliminary economic modeling shows that the cost of producing the SCP could be around US$1,600 per ton, with a market price potentially ranging from US$5,000 to US$7,000 per ton. For comparison, beef protein can cost as much as US$10,000 per ton. The SCP is high in essential amino acids, has good digestibility, and offers a biological value similar to that of animal-derived proteins like meat and milk.

Dr Alberto Santos Delgado, Director of the Informatics Platform at the Novo Nordisk Foundation Center for Biosustainability at DTU, said the integration of computational modeling was critical in designing an efficient and scalable process. “The combination of biotechnology, computational modeling, and precision fermentation allows us to design an efficient, scalable, and economically viable process for single-cell protein production,” he noted.

Unlike microalgae-based proteins, which sometimes face barriers due to their taste and color, yeast-based SCPs offer a more neutral sensory profile. This makes them easier to integrate into various food products, particularly for younger consumers and flexitarians seeking sustainable alternatives that don’t compromise on taste or appearance.

“This is no longer optional,” Dr Torres-Acosta said. “We are facing an unprecedented climate and food security crisis, and developing sustainable protein sources will be key to feeding a growing population.”

The research aligns with Tecnológico de Monterrey’s broader strategy through its Flagship Project on Food Security and Nutrition. The institution has prioritized applied science projects that aim to benefit society by addressing challenges in health, climate, sustainability, and industrial transformation. The SCP project contributes to this goal by providing a circular economy solution – reclaiming a nutrient-rich waste stream and converting it into a food-grade protein.

The university envisions the new protein being deployed in a variety of settings, from nutritional support for vulnerable populations to ingredients for mainstream food processing. The project is part of the university’s ongoing commitment to develop food safety systems, traceability mechanisms, and balanced nutrition strategies that span the entire value chain – from agriculture and production to processing and distribution.

Researchers plan to explore commercial applications and regional deployment models next, especially in countries where dairy production leads to high volumes of residual whey. The team also hopes the research will encourage other institutions to explore microbial consortia and waste valorization as viable pathways for sustainable protein development.