New technology for more efficient milk production

THE OneStep technology can now be used by milk producers to prepare UHT from milk powder in one continuous step, according to Tetra Pak. It basically eliminates pasteurization and intermediate storage in the process of preparing milk from powder before UHT treatment, an innovation that will cut some 40% in production costs, and 50% carbon impact.

With the complete redesign using the high performing Tetra Pak® High-Shear Mixer and Tetra Alfast® in-line blending unit, the cost-effective system can be used in one continuous step to achieve UHT milk. Skim milk powder is mixed with preheated water to make a concentrate, which is then blended with the precise amount of water and fat before undergoing UHT treatment.

Continuous single-stream blending with OneStep technology for recombined milk (Photo: Tetra Pak)
 

Other benefits from the new process are complete automation and continuous operations, reducing milk waste lost between processing steps and improving consistency in product quality.

Another feature of the OneStep is its flexibility to configure into several streams to create various recipes.  The technology enables producers to make formulated milk, flavored milk, lactc acid drinks and value-added milk.

In the Middle East, Africa and Far East, this technology will greatly benefit the dairy market. In these regions, there is insufficient supply of raw milk, while demand is increasing. And as the cost of milk powder is high, producers seek ways to keep costs low. This is where the OneStep comes in.

For example, ​​Sadafco, a Saudi Arabian Dairy and one of the largest producers of recombined milk products, piloted the technology with Tetra Pak.

​​Raffaael Reinders, Director Manufacturing at Sadafco said: “Thanks to the new solution, we have been able to reduce energy consumption by up to 40 percent, resulting in a smaller environmental footprint, whilst doubling production capacity. In addition, the new system has enabled us to reduce production losses by as much as a third. The return on investment for the two lines was less than two years”.

​​Two years ago, Sadafco started commercial production on the first OneStep line and has since placed its second order.

​“We understand that improving efficiency and reducing costs are of great importance to our customers. That is why we worked in close partnership with Sadafco to challenge an industry norm and do things in a different way. The result is this unique OneStep technology, which eliminates storage steps, reduces product losses and maintains consistent product quality. We are now ready to roll out this solution to all customers,” said ​Bengt Eliasson, Manager of Centre of Expertise, Dairy Aseptic.

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