Project HighWhey: engineering while the plant keeps running
Consumption and Production
HighWhey: an open-heart operation for a greener future
In Workum, the dairy industry is working on one of its most far-reaching sustainability steps: a 35% CO₂ reduction by 2030. The existing evaporator installation has to make way for modern membrane technology, while production keeps running as normal. Batenburg Beenen is handling the engineering, installation work, and software.
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Alex van Dalen
Managing Director
From evaporator to membrane technology
Project HighWhey marks a fundamental shift. The evaporator is being replaced by Reverse Osmosis (RO) and Ultra Filtration (UF) systems. These techniques are significantly more energy-efficient, making HighWhey a key element in the site's sustainability roadmap.
Engineering in a live operation
The work is taking place simultaneously in the new-build area and in the existing plant environment. While new systems are being built up in one location, active processes are being intervened on in another. Downtime is not an option. That makes it comparable to what's called open-heart surgery in the medical world: operating while the heart keeps beating. The margin for error is minimal, the pressure to coordinate is maximal.
Dragan Josipovic, Lead Engineer E&I at Batenburg, recognizes this: "The challenge was complex, the time frame tight, but by working closely together and daring to make choices, we delivered a sustainable result."
Collaboration as the foundation
A project of this complexity demands more than technical knowledge alone. The collaboration between Batenburg and the client required intensive coordination from the very start. Knowledge of the existing environment was essential to responsibly prepare the integration of new systems. During execution, this meant constantly switching between disciplines, levels, and interests. In-house people with deep process knowledge and genuine commitment made the difference.
Martijn Berends, project manager at the client, looks back: "As we got closer to execution, the complexity did create some friction and tension. But that was also part of the project's success."
Software as the connecting thread
Batenburg's role goes beyond cabling and switchgear. Software is the invisible layer connecting all the new systems to the existing plant environment. Integrating the control software for the RO and UF installations requires deep process knowledge that Batenburg has built up over the years in the food & beverage sector. New systems must not disrupt existing processes, which is why testing, validating, and phased commissioning are integral parts of the approach.
The engineering phase started in September 2024, with completion expected in September 2026. Until then, Batenburg's team remains active on site in Workum, paying close attention to detail and staying flexible in response to the challenges that arise daily.
