Tetra Pak Targets Energy Efficiency with New Heat Pump

Tetra Pak has introduced an integrated heat pump system aimed at electrifying the pasteurisation process for food and beverage producers.

The launch, part of Tetra Pak's Factory Sustainable Solutions portfolio, targets firms looking to lower carbon emissions and operational expenditures. This technology moves away from traditional methods that often use fossil fuel-powered boilers and electric chillers.

The system works by combining heating and cooling functions. It uses an electric heat pump to capture low-temperature waste heat, which is then upgraded to higher temperatures suitable for pasteurisation. At the same time, the system generates ice for cooling needs.

This integration is designed to create a more efficient energy cycle within the production line. According to Tetra Pak, the system can recover up to 2kWh of heat for every 1kWh of electricity used, making it potentially three times more efficient than conventional boiler setups.

Industrial-scale heat recovery

For food and beverage manufacturers, pasteurisation represents a large portion of energy consumption. Tetra Pak’s system addresses this by recovering and repurposing waste heat that would otherwise be lost. The technology is centred on creating a closed loop where energy is recycled within the pasteurisation and cooling stages.

Tetra Pak has identified several key applications where this technology could provide substantial returns. These include large-scale pasteurisation processes for products such as fruit juice, chilled milk and cheese. It is also applicable for pre-treatment in ambient milk production.

"Food and beverage producers need smarter ways to reduce energy use without compromising performance," explains Nicole Uvenbeck, Director of Factory Sustainable Solutions and OEM Components at Tetra Pak.

The financial and environmental impact

The potential for cost and emission reductions is a key aspect of the new system. For a typical dairy facility processing 60,000 litres of milk per hour and running for 6,000 hours a year, Tetra Pak estimates that annual operating expenses could be reduced by up to US$250,000.

For the same operation, Tetra Pak calculates that CO₂ emissions could be cut by up to 650 tonnes annually. These figures are based on specific process conditions and the efficiency of existing utility systems, meaning actual savings may vary between facilities.

"The new heat pump system delivers up to three times the efficiency of conventional boilers, recovering 2kWh of heat for every 1kWh of electricity," Nicole adds.

She also noted that Tetra Pak works with customers to integrate the system into their existing operations, utilising its processing expertise and global network.

Electrification in food and drink manufacturing

The move towards electrification comes as the food and beverage industry faces pressure from volatile energy markets and stricter emissions regulations. Industrial heat pumps are gaining more attention across European manufacturing as part of a wider push to electrify thermal processes.

However, adoption rates differ depending on the sector and the size of the facility. Tetra Pak's system targets a specific high-energy process in dairy and beverage production, where concentrating heat recovery efforts could be economically viable for large-scale operators.

Fiona Liebehenz, VP of Key Components, Plant Solutions and Channel Management at Tetra Pak, commented on the development.

"By blending advanced technology with a deep understanding of the daily challenges F&B producers face, we've developed a solution designed to make one of the most energy-intensive stages of food production more efficient," says Fiona. Tetra Pak has not released pricing details for the system.