Tetra Pak introduces first-of-its-kind low energy processing line for juice, nectar and still drinks

Tetra Pak has launched a new, first-of-its-kind low-energy processing line for juice, nectar and still drinks (JNSD) to take beverage processing to a new level of efficiency. Innovatively using a unique combination of Pasteurization, Filtration and UV Light technology to treat beverages in two separate streams, which are aseptically blended together into the final beverage.

Instead of pasteurizing the whole volume of the product, the new production line separates out water and pasteurizes only the concentrate. Water is treated separately with Filtration and UV Light which requires a lot less energy. In the new JNSD line customers reduce energy consumption up to 67% and water consumption used for cleaning-in-place, sterilisation and product change-over is cut up to 50%.

Maria Norlin, Subcategory Manager JNSD & Other Beverages, Tetra Pak said: “We realised that we needed to rethink JNSD processing and find a more sustainable solution, that at the same time still provides a high level of food safety & quality assurance for our customers. The launch of our new low-energy JNSD processing line, ‘Best Practice Line for JNSD with Aseptic Blending', illustrates how we are innovating with traditional processing methods in pursuit of more sustainable and efficient solutions. Our decision to split the existing JNSD line into two separate processing streams for treatment allows us to offer our customers processing options that can help them achieve their climate goals, and enables the industry to contribute towards global sustainability efforts.”

“After many years of low growth, we see new opportunities for our customers on the horizon, as people increasingly search for ways to lead a healthier lifestyle, and this trend has accelerated during the spread of Covid-19. We hope this new production line can help customers capture the growth opportunities in a more cost-efficient way” added Norlin. 

Tetra Pak food and drink scientists and processing engineers set ambitious goals for rethinking and redesigning the JNSD processing line. In 2019 a white paper was released outlining the production concept, which was presented at the International Fruit and Vegetable Juice Association Technical Workshop in March 2019.

In October 2019 at the Juice Summit, the presentation of the new production concept was recognised with the IFU 2019 Innovation Award.

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ABOUT TETRA PAK

Tetra Pak is a world leading food processing and packaging solutions company. Working closely with our customers and suppliers, we provide safe, innovative and environmentally sound products that each day meet the needs of hundreds of millions of people in more than 160 countries. With over 25,000 employees around the world, we believe in responsible industry leadership and a sustainable approach to business. 

Our promise, “PROTECTS WHAT’S GOOD™," reflects our vision to commit to making food safe and available, everywhere.

More information about Tetra Pak is available at www.tetrapak.com 

• Traditional processing methods rely on energy-intensive heat treatments which typically blend all ingredients with water before pasteurization to deactivate harmful microorganisms.
• The launch comes after a pilot test found that the new line decreased water consumption by 50%, surpassing an internal target set at 25%. It also reduced water used in cleaning in place (CIP) and sterilization in place (SIP) by about 50%.
  • Energy: If the concentrate-to-water ratio is 1:4, energy use can be cut by 67% or more. Assuming a system with 32,000 litres/hour capacity, steam €30 per tonne, with electricity costing 15 cents per kW/h, the annual operating costs are approximately €138,000. Water treatment with filtration and UV estimated at €12,000, heat treatment of concentrate at €34,000: annual operating cost approx. €46,000. Therefore, energy consumption is reduced by 67%, giving an annual saving of €92,000.
  • Water: The system volume in the new JNSD line is half that of the current solution. The amount of water required for product changes, cleaning in place, and sterilization in place can be reduced by 50%. Current solution: System volume: 2,000 litres. Total = 96,000 litres/week.
  • The new Tetra Pak JNSD line: Water treatment with system volume: concentrate 700 litres, water + 300 litres. Total = 48,000 litres/week.

• The current best-practice line starts with a premix step before moving on to the pasteurization step for the concentrate and a separate water treatment step in the water treatment unit. The Tetra Pak^® Water Treatment unit FUV includes pre-filtration, main filtration and a UV treatment step. The two streams (concentrate and water) are then blended in the Tetra Pak^® Aseptic Tank LV combined with aseptic blending function before being sent to filling.
• This innovation contributes to the company’s overall commitments to minimise our environmental impact across the value chain. Forty percent of our total climate impact comes from equipment used by customers. We are constantly striving to improve energy efficiency, reduce food waste and minimise the impact on resources such as land and water. Tetra Pak has committed to reducing operational GHG emissions by at least 40% by 2030 and 58% by 2040, from a 2015 baseline, working with the Science Based Targets (SBT)​
• Tetra Pak has over 60 years expertise in the processing and packaging of orange juice beverages. Publishing an Orange Book in 1997, which has since been evolved with continued research into the area of juice production working with experts across the industry. The entire Orange Book is now available online.

© Press Release 2020