Resource Efficient Innovations Database (REID)

Reducing product losses in UHT dairy production

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Reducing product losses in UHT dairy production
Tetra Pak has launched a new direct heating unit for UHT dairy production which significantly cuts product losses
In Use – First announced in November 2010.

Product Waste Reduction, Resource efficiency (e.g. filling line efficiency)

Product Categories
Drinks, Food

Relevant Materials
Not Applicable

Relevant Packaging Formats
Not Applicable

Supply Chain Phase


Tetra Pak has launched a new direct heating unit (the Tetra Therm Aseptic VTIS) for UHT dairy production which can significantly cut product losses. Direct heating units, as opposed to indirect units, use steam injection to speed up the heating and cooling process so that the impact of heat on product quality is minimised. Run at higher operational cost than indirect units, such heating systems are designed to be used in the manufacture of premium dairy and soy products.
The company claims the direct heating unit cuts product loss by up to 40 per cent compared to current industry standards and boosts running time by up to 60 hours. To deliver these improvements a number of design changes have been introduced. Running times between cleanings have been increased from 30 hours with previous generations to up to 60 hours due to an improved steam injector and holding cell design.
Other significant changes include a new double tank system, with one tank for product and one for water, which is designed to reduce product loss in the mix phase. This system makes it possible to completely empty the main balance tank of water before filling it with new product. The flash cooling system has also been updated so that it includes a new conically designed topped vessel and built-in spray condenser, rather than a conventional external condenser. Finally, steam consumption has been cut by 5 per cent compared to previous models thanks to a preheating process that uses heat-treated product rather than hot water to transfer heat to the cool inlet product.

Potential Benefits

As well as providing environmental benefit through reduced product losses, and compared to the previous generation of direct UHT heaters, the Tetra Therm Aseptic VTIS reduces overall operating cost by 15 per cent. Improved running time is one of the biggest changes in the new system, reducing operating costs significantly.

Intellectual Property

This machine is the proprietary technology of Tetra Pak. The Tetra Therm Aseptic VTIS can be configured to match the specific needs of customers and is available on its own or as part of a Tetra Lactenso Aseptic dairy production solution.

Consultant View

This technology is an example of how improved processing techniques can provide environmental benefits as well as delivering significant cost benefits, in this case in the form of reduced energy consumption, reduced water consumption and improved production efficiency.

Contacts and Further Information

Company contact details:
Tetra Pak International SA Headquarters
70 Avenue Général-Guisan Case Postale
Tel: +41 21 729 2111
Technology Contact:
Fredrick Gunnarsson (Product Manager for Tetra Therm Aseptic VTIS )
Tel: +46 46 36 1456

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