Unlock the potential of your existing liquid dairy lines

Are rising energy and water costs, emissions targets and product loss putting pressure on your margins? Dairy producers face these challenges while many lines are still far from end‑of‑life. By optimising existing liquid dairy processing lines with today’s proven, in-market solutions can unlock efficiency gains, cut greenhouse gas emissions and resource use, and strengthen current assets, across four major liquid dairy line types1

At a glance – the reviewed reductions line improvements can deliver

Fact illustration: 47% reduced CO2

Greenhouse gas emissions impact of line upgrades

Greenhouse gas emissions impact of line upgrades

Improving existing liquid dairy processing lines with a defined set of decarbonisation and recovery solutions can reduce greenhouse gas emissions by 47%1 (on average; 40-49% range) versus 2019 best‑practice lines.

Facts illustration: up to 45% reduced water use

Water savings from recovery and optimisation

Water savings from recovery and optimisation

Implementing water‑saving and recovery solutions across the same liquid dairy lines can reduce water use by 45%1 (on average; 32-49% range) compared to 2019 best‑practice lines. 

Facts illustraion: up to 57% lower wastewater

Less product lost to wastewater

Less product lost to wastewater

Recovery solutions and process optimisation can cut product losses to wastewater by 57%1 (on average; 17-65% range) compared to 2019 best-practice lines.

Facts illustration: 4 daily lines

Reviewed across four liquid dairy line types

Reviewed across four liquid dairy line types

The assessment uses a Carbon Trust review methodology and covers four major liquid dairy processing lines: pasteurized milk, fermented yoghurt, indirect UHT milk and direct UHT milk.

Printed infographic dairy line facts and figures

Explore the facts and figures in our dairy line

Explore the facts and figures in our dairy line

See how our solutions can impact greenhouse gas emissions, water use and product losses. Explore the results and what they could mean for your operations.

How the assessment was carried out with the Carbon Trust

What was compared

What was compared

The assessment compared Tetra Pak’s 2019 best‑practice liquid dairy processing lines with upgraded lines that include a defined suite of market‑available decarbonisation and recovery solutions, across four major line types.

How impact is calculated

How impact is calculated

The assessment uses an avoided‑emissions / net carbon impact approach to quantify the change in emissions from reduced electricity, heat and cooling demand, while also accounting for the emissions from the solutions themselves (embodied and use-phase). 

Role of the Carbon Trust

Role of the Carbon Trust

Tetra Pak worked with the Carbon Trust to review and update the model and methodology for avoided greenhouse gas emissions to follow best practice, including clearer documentation of assumptions, a data‑quality assessment and sensitivity analysis on key parameters. 

Scope and limitations

Scope and limitations

Results are based on modelled global scenarios and will vary by geography and specific site implementation. They are specific to Tetra Pak 2019 best‑practice lines (baseline scenario) versus upgraded Tetra Pak solutions and are not intended as a generic industry benchmark.

Dairy processing assessment

Download the reviewed assessment

See exactly how the assessment was carried out. The methodology report details the baseline vs solution scenarios, the suite of commercially available solutions, the avoided emissions calculation, data quality checks and sensitivity analysis across the four liquid dairy line types.

Brochure,  a glass of milk, and a Tetra Brik Aseptic package on a table
Dairy processing assessment

Summary: Methodology and results

Get a concise overview of the assessment. This summary explains the scope, key assumptions and core results for improving existing liquid dairy processing and filling lines with commercially available solutions, including emissions, water and production loss reductions. 

Dairy processing assessment reports

Turning findings into business value for your dairy lines

Upgrading existing liquid dairy processing lines with the assessed suite of market‑available solutions turns the assessment findings into a practical business lever.  It can allow you to reduce emissions, water use and product loss while improving the performance and utilisation of current assets, rather than investing in full line replacement. This can help strengthen margins and resilience by lowering energy and water spend, reducing waste and making better use of existing capex.

People in meeting, dairy line on large screen

Improve, don’t replace: the technologies that deliver savings

Behind these results is a defined suite of market‑available solutions applied across four liquid dairy line types. Here, we focus on three key solution families: heat pumps, OneStep technology and filtration and recovery solutions.

Highlift heat pump

Heat pumps – reduce fuel use and heat‑related emissions

Electrically powered heat pumps recover and upgrade waste heat to provide process heating – and often cooling – using electricity instead of fossil fuels. They can reduce boiler and chiller demand across upgraded liquid dairy lines, helping to lower energy use and heat‑related emissions.

Production line with OneStep technology

OneStep technology – fewer steps, lower costs, greater flexibility

OneStep technology combines several pre‑treatment and UHT process steps into a single continuous operation for UHT milk and yoghurt. This integrated concept can cut electricity and steam use, reduce water consumption and product loss, and support faster, more flexible production with lower operating costs compared with conventional multi-step processing

Filtration equipment

Filtration and recovery – use less water, waste less product

Filtration and recovery solutions, including white water recovery, CIP recoveries and a water filtering station, recover water and product from process and cleaning streams. They help reduce freshwater intake, cleaning‑chemical use and effluent loads, so more product can be sold instead of going down the drain.

Watch how OneStep drives your efficiency​

OneStep technology makes the production process faster and more energy-efficient. In a single unbroken step, raw milk is pre-heated, separated, standardized and homogenized, before undergoing UHT treatment and regenerative cooling, and then transferred to the aseptic tank. By removing the pasteurization and intermediate storage steps, the processing time is shortened from as much as two days to just a few hours.

Watch how OneStep drives your efficiency​

OneStep technology makes the production process faster and more energy-efficient. In a single unbroken step, raw milk is pre-heated, separated, standardized and homogenized, before undergoing UHT treatment and regenerative cooling, and then transferred to the aseptic tank. By removing the pasteurization and intermediate storage steps, the processing time is shortened from as much as two days to just a few hours.