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Tetra Pak OneStep Technology Improves Efficiency for Milk Production from Powder

30 November 2015

Tetra Pak has extended the application of its OneStep processing technology to milk production from powder; offering a solution that has only been available previously for production from raw milk.

Producers can now prepare UHT milk from powder in one continuous step, reducing operational cost by up to 40 per cent, and cutting carbon impact by more than a half.

Tetra Pak’s OneStep technology removes the multiple steps of pasteurisation and intermediate storage in the traditional process of preparing milk from powder before UHT treatment. Thanks to a complete redesign using the high performing Tetra Pak® High-Shear Mixer and Tetra Alfast® in-line blending unit, the whole process is now streamlined into one continuous step: 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. 

In addition to simplifying and accelerating milk preparation, the OneStep technology enables complete automation and continuous operations, reducing milk waste traditionally lost between processing steps and improving consistency in product quality.  

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 good source of protein but there is an insufficient supply of raw milk. 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. Tetra Pak’s OneStep technology helps producers to achieve just that. 

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”.
Sadafco started commercial production on the first OneStep line in December 2013 and has since placed its second order. 

Bengt Eliasson, Manager of Centre of Expertise, Dairy Aseptic said: “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.”
 
Tetra Pak OneStep technology can be used to produce one single product, or configured into multiple streams to produce a number of recipes, giving customers full flexibility in production. It can also be used to produce formulated milk, which combines liquid milk or powder with fat and flavour to create flavoured and value added milk or lactic acid drinks. 


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