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The dairy industry is undergoing a technological transformation, with innovations spanning from farm to factory to fridge. From cutting-edge high-pressure processing to AI-driven pasture management, these advancements are not just boosting supply chain efficiency but also driving sustainability and safety. FoodBev's Siân Yates finds out how dairy manufacturers can harness the latest technologies to stay ahead of the curve and meet the rising demand for quality and environmental responsibility.

As consumer expectations evolve and the demand for sustainable, high-quality dairy products intensifies, the dairy manufacturing industry finds itself at a crossroads. With the pressure mounting to meet rigorous food safety standards, reduce environmental footprints and deliver products that appeal to a more health-conscious audience, the industry is stepping up its innovation game.

Advances in technology are reshaping every stage of dairy production, from farm operations to the final packaging process. High-pressure processing (HPP), AI-driven pasture management, energy-efficient evaporators and real-time contaminant detection systems are just some of the innovations driving the dairy industry forward. These technologies are transforming how dairy manufacturers operate, enabling them to meet both consumer demands and regulatory expectations.

High praise for HPP

HPP has become a key technology in dairy manufacturing, offering a non-thermal method to enhance food safety without compromising product quality. By subjecting dairy products to ultra-high pressure, HPP inactivates harmful pathogens while preserving the natural taste, nutritional value and texture.

This makes it particularly appealing for dairy products like fresh cheeses and milk-based beverages, which must maintain freshness while extending shelf life. The latest systems are making it more efficient for largescale production and reducing bottlenecks in highvolume operations.

HPP technology manufacturer Quintus, for example, recently unveiled the industry’s largest HPP system – the QIF 600L – with a 600-litre cycle capacity, capable of processing up to 9,140lbs (4,150kg) per hour. This high capacity boosts efficiency, reducing cycles and lowering energy and labour costs.

The system features up to 12 intensifiers and offers flexible processing to meet varying production demands. Its integrated AI-driven condition monitoring predicts maintenance needs, minimising downtime. Designed for user ease, the QIF 600L’s components are easily accessible for maintenance, while its SmartPress software ensures seamless operation and direct access to support. The system’s scalability and efficiency make it a game-changer for dairy manufacturers.

Meanwhile, Hiperbaric has developed the Hiperbaric 525 and 1050, two advanced HPP systems used in dairy manufacturing. The 525 is a compact, versatile system for small to medium-scale operations, processing up to 525 litres per cycle, offering flexibility and efficiency. The 1050 is designed for large-scale production, handling up to 1,050 litres per cycle, ideal for high-volume dairy products. Each of these systems uses HPP technology to preserve products without heat or preservatives, maintaining nutritional value and fresh taste.

In addition, Hiperbaric’s EcoCycle technology reduces energy consumption by up to 40%, enhancing sustainability in dairy operations.

Adding to this, JBT’s Avure range of HPP systems is helping producers deliver dairy products that are fresher, safer and longer-lasting. By using only pressurised cold water, Avure systems avoid the taste and texture changes caused by heat, chemicals or irradiation, while retaining key sensory qualities such as flavour, colour and nutritional content.

Because HPP is applied in the product’s final packaging, it also eliminates post-processing contamination risks and inactivates pathogens like Salmonella, E. coli and Listeria, helping manufacturers avoid costly recalls. reduced cooling costs and minimal water use – all while being compatible with 95% of existing set-ups and installable in under six hours.

Temperature control is critical at the farmgate, where even small deviations can affect milk quality. Companies like Anderson-Negele are developing hygienic temperature sensors and digital transmitters designed specifically for dairy environments, helping farmers maintain optimal cooling and prevent bacterial growth.

These sensors feature stainless steel construction, CIP/SIP compatibility and versatile process connections for tanks, pipelines or retrofits. Digital outputs allow integration into automated systems, giving real-time visibility, and supporting traceability and optimisation.

By monitoring temperature with this level of precision, dairy operations can reduce thermal stress on milk, protect flavour and freshness and ensure high-quality products downstream. With rising operational costs and pressure to meet sustainability goals, the demand for smart, farm-ready technologies like these is only expected to grow.

Intelligent control at the farmgate

Energy efficiency on the farm is also receiving a high-tech upgrade. Technidrive, a provider of intelligent drive and control systems, recently delivered its 1,000th bespoke dairy control solution, marking a major milestone for on-farm innovation.

Its flagship technologies, TechniVac and TechniFlow, are designed to help dairy farmers across the UK and Ireland enhance energy efficiency, milk quality and operational performance.

TechniVac, a vacuum pump system, automatically adjusts output to match real-time demand during milking – reducing energy use by up to 60% while delivering quieter, low-maintenance operation. TechniFlow, meanwhile, enables variable-speed control during milk transfer, ensuring gentle flow, reduced cooling costs and minimal water use – all while being compatible with 95% of existing set-ups and installable in under six hours.

Temperature control is critical at the farmgate, where even small deviations can affect milk quality. Companies like Anderson-Negele are developing hygienic temperature sensors and digital transmitters designed specifically for dairy environments, helping farmers maintain optimal cooling and prevent bacterial growth.

These sensors feature stainless steel construction, CIP/SIP compatibility and versatile process connections for tanks, pipelines or retrofits. Digital outputs allow integration into automated systems, giving real-time visibility, and supporting traceability and optimisation.

By monitoring temperature with this level of precision, dairy operations can reduce thermal stress on milk, protect flavour and freshness and ensure high-quality products downstream.

With rising operational costs and pressure to meet sustainability goals, the demand for smart, farm ready technologies like these is only expected to grow.

Advanced inspection technologies

The role of advanced inspection systems in the dairy sector is increasingly crucial. Traditional methods, such as metal detection, often struggle with non-homogeneous dairy products like grated cheese, where contaminants are harder to detect.

Anritsu has addressed this challenge with its dual-energy X-ray inspection systems, specifically designed to detect contaminants in products with varying shapes and textures.

These systems use two different X-ray spectra to scan dairy products more comprehensively, allowing for a detailed analysis and improved contaminant detection. In addition to identifying contaminants, they also measure fill levels accurately, ensuring consistent product weight and preventing costly giveaways. The systems are equipped with antibacterial surfaces to reduce contamination risks.

Meanwhile, Eagle Product Inspection’s Pack 400 HC is designed specifically for the dairy industry, combining hygienic design with robust contaminant detection. The system can identify glass shards, dense plastic, rubber, metal fragments and mineral stones in products packaged in cartons, pouches, boxes or plastic containers.

Beyond detecting foreign materials, the Pack 400 HC also performs essential quality checks such as fill level verification, mass measurement and package integrity, ensuring caps and closures are correctly placed on drinkable yogurts or identifying voids in blocks of cheese.

With advanced PXT photon-counting, dualenergy X-ray technology and Eagle’s SimulTask PRO interface, the system enhances inspection accuracy and operational efficiency. It can also integrate with network-based TraceServer technology to store images and data, supporting traceability and regulatory compliance.

Built to withstand harsh washdown environments, the Pack 400 HC features welded stainless-steel plates, tool-less belt removal and a cabinet designed to deflect water, meeting NAMI sanitary design standards and IP69 ingress protection.

By integrating these advanced inspection technologies, dairy processors can enhance product safety while optimising production processes, leading to improved product quality and increased profitability.

Tackling membrane fouling with a gentler touch

Membrane fouling remains a persistent issue for dairy processors, often leading to reduced throughput, higher operational costs and increased cleaning downtime. Traditional chemical cleaning solutions can be harsh, potentially damaging membranes or raising concerns around environmental safety.

In response, Pure Bioscience has developed a new membrane treatment method using its existing antimicrobial product, called Pure Hard Surface.

Originally designed as a surface disinfectant, the product has now been adapted for use in reverse osmosis and ultrafiltration systems, offering a simplified and less abrasive approach to cleaning and sanitising membranes.

Unlike conventional treatments, Pure Hard Surface requires no mixing or protective gear and is applied as a ready-to-use solution. It has been shown to penetrate membranes quickly, removing fouling and helping to restore flow efficiency – all without oxidation or degradation of the membrane itself.

ZwitterCo has launched its Evolution membrane range for dairy and food processing. Using patented ‘Zwitteronic’ chemistry, these antifouling membranes fully recover performance with simplified cleaning programmes, enabling processors to clean faster, use fewer chemicals and reclaim valuable production time.

Available in ultrafiltration, superfiltration and reverse osmosis configurations, Evolution membranes are compatible with existing systems and offer substantial operational savings. Early adopters report cutting total cleaning costs by more than 50%, reducing water use by over 30%, and saving an hour for every step removed from their cleaning routines. This makes the technology a major step forward in sustainable and efficient membrane processing.

A more sustainable sector

Sustainability is an increasingly pressing concern for dairy manufacturers, particularly as energy costs rise and environmental regulations tighten. To meet these challenges, companies are turning to innovative technologies that not only improve energy efficiency but also reduce the environmental impact of their operations.

GEA Group’s eZero evaporator is a new solution for energy-efficient dairy production, achieving CO2-free operation and supporting the industry’s push to reduce carbon footprints. By cutting energy consumption by up to 60% compared to traditional systems, the eZero evaporator helps manufacturers lower costs while significantly reducing their environmental impact.

Its compatibility with existing for easy integration without the need for costly infrastructure overhauls, making it a practical upgrade for modernising operations. Additionally, the inclusion of an ammonia heat pump optimises heat transfer, further boosting energy efficiency and reinforcing the system’s commitment to sustainability.

In addition to GEA’s eZero evaporator, other advancements in sustainable dairy production are also gaining traction. Developed by Denmark-based Lyras, raslysation is a non-thermal pasteurisation method that uses UV light to deactivate microorganisms in liquid dairy products. It significantly reduces resource usage, consuming 60-80% less water and 60-90% less energy compared to traditional methods. This increases product yield by preserving bioactivity and reducing the need for additional processing. Additionally, raslysation helps maintain the nutritional quality of dairy products, enhancing taste and extending shelf life.

Another example is Tetra Pak, which has been developing energy-efficient pasteurisation systems that reduce both energy consumption and water use. These systems are designed to lower the environmental impact of dairy production by focusing on key areas such as energy recovery, water conservation and waste reduction.

Tetra Pak has also introduced more sustainable packaging solutions, such as using more recycled materials and offering solutions that use less energy throughout their lifecycle.

With increasing pressure from regulators and consumers alike to adopt more sustainable practices, these innovations are helping dairy manufacturers not only meet environmental standards but also achieve cost savings in the process. By investing in technologies like these, dairy businesses can continue to produce high-quality products while contributing to the broader goal of sustainability in the food production industry.