Tetra Pak extends OneStep technology to production from powder

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

The company said that producers can now prepare UHT milk from powder in one continuous step, reducing operational costs by up to 40%, 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. A complete redesign using the high-performing Tetra Pak High-Shear Mixer and Tetra Alfast in-line blending unit has enabled the whole process to be 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, Tetra Pak said, 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, the firm added.

Saudi Arabian Dairy Sadafco, one of the largest producers of recombined milk products, piloted the technology with Tetra Pak.

Sadafco director manufacturing Raffaael Reinders said: “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. 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 for Tetra Pak, 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.”