Tetra Pak’s OneStep processing technology is now enabling milk producers to prepare ultra-high-temperature (UHT) milk from powder in one step, reducing operational cost by up to 40% and carbon impact by more than a half.
The technology removes the multiple steps of pasteurization and intermediate storage in the traditional process of preparing milk from powder before UHT treatment.
Redesigned using the high performing Tetra Pak High-Shear Mixer and Tetra Alfast in-line blending unit, the process mixes skim milk powder with preheated water to make a concentrate, which is then blended with water and fat before UHT treatment.
Producing milk from powder is a common practice in markets such as the Middle East, Far East and Africa, where milk is increasingly seen as a source of protein but there is an insufficient supply of raw milk.
Tetra Pak says this is an expanding, but competitive market, and as the cost of milk powder is high, producers are constantly searching for ways to keep production costs down.
Sadafco, a Saudi Arabian Dairy and one of the largest producers of recombined milk products, piloted the technology with Tetra Pak.
“Thanks to the new solution, we have been able to reduce energy consumption by up to 40%, resulting in a smaller environmental footprint, whilst doubling production capacity,” says Raffaael Reinders, director manufacturing at Sadafco.
“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.”
Sadafco started commercial production on the first OneStep line in December 2013 and has since placed its second order.
Tetra Pak OneStep technology can be used to produce one product, or configured into multiple streams to produce a number of recipes.
It can also be used to produce formulated milk, which combines liquid milk or powder with fat and flavor to create flavored and value added milk or lactic acid drinks.
