Benefits
Tetra Pak® Aseptic Dosing unit F is a unique and innovative new technique where functional ingredients are injected with high precision into the base product after the final heat treatment, just before filling.
The flexible system ensures the stability and survival of heat sensitive functional ingredients and avoids the need to overdose these expensive ingredients.
The Tetra Pak Aseptic Dosing unit F is fully automated and installed between processing and the filling machines. It can serve one or several filling machines.
Quick facts
Unit for automatic aseptic in-line dosing of ingredients
Capacity
Dosing range 0.5 – 30 l/h; product range 1 000 – 20 000 l/h
Applications
Dose sensitive ingredients like enzymes e.g. lactase, vitamins, minerals, Omega 3, probiotics, flavours, colours in everything from plain milk to formulated products
Ride the trends and capture significant savings
- Set your innovation free with ultimate flexibility – Diversify your range and ride the trends thanks to unrivalled accuracy, integrated automation and expert support
- Reduce costs and utility consumption – Fast payback time with huge savings on ingredients, cleaning and maintenance, plus higher equipment utilisation/output
- Rely on high consistent quality and aseptic food safety – Thanks to unrivalled accuracy, lower heat load,
full control and traceability
Features
Automated dosing control
Get ultimate flexibility and consistent quality
Ensure consistent product quality and maximum ingredient utilisation with automated and guaranteed dosing control. To ensure that exactly the right amount of ingredients is injected into the base product, a weighing system monitors the ingredients and flow transmitters monitor the base product as they enter the filling machine. Accuracy is further enhanced with varying diameters of hoses for specific recipes.
‘Just in time’ production
Last step dosing boosts flexibility
Make changeovers in minutes and thanks to the 'Just in time' production method, the dosing unit is positioned just before the filling machine. Ingredients are dosed in the last step and at the last minute before packaging. It is extremely quick and simple to switch from one added ingredient to another. All the operator must do is change the ingredient bag in the dosing unit, and the packaging material in the filling machine.
Ingredient injection
Save on cleaning, maximise output
The rationalised, efficient process means there is no need to clean entire line between products. The dosed ingredients do not come into contact with any of the upstream processing equipment there is no need for intermediate cleaning in place between production runs with different products. This delivers significant savings on cleaning and enables higher equipment utilisation/output. Energy and detergent consumption are also reduced.
Closed ingredients system
Flexible, safe in-line delivery
The ingredients to be dosed are packed separately in advance, and quality checked before being sent to your production plant in ready-to-use 5 or 10 litre aseptic bags. When dosing, the closed ingredient package is connected to the product line via an aseptic transfer hose.
Recipe management system
Secure food safety, enable traceability
Operators scan the barcode on ingredients and hose kit. The recipe management system confirms that the correct ingredients are dosed into each product. Dosing takes place via a sterile hose, connected to the ingredients bag. A sterile needle injects the ingredient into the base product while maintaining aseptic conditions. An advanced information system provides total traceability, with all data stored for analysis in case of an issue.
Product quality control
Twice the shelf life
In the production of UHT lactose-reduced milk, aseptic dosing means less lactase is added to the product, and this in turn means less sugar content in the milk. Less sugar content reduces the browning of the milk (caused by the Maillard reaction). This typically doubles product shelf life.
Turn consumer demand into profit with flavoured and functional recombined recipes
Consumers are increasingly choosing flavoured and functional dairy drinks and they’re willing to pay premium prices for them. Learn how to formulate recipes that meet this growing demand and improve your profitability. Whether you’re exploring the potential of your existing recombined milk line solutions or have a product in mind, we can help you go from concept to a commercial launch.
1 Calculation based on scenario comparing conventional batch production of 2,600,000 litres/year in 52 batches, where lactase consumption is reduced by 93%, from 3 millilitres per litre to 0.24 millilitres per litre.
2 Calculation based on scenario comparing conventional batch production of 2,600,000 litres/year in 52 batches, where flavour consumption is reduced by 20%, from 2 millilitres per litre to 1.6 millilitres per litre.
3 Calculation based on scenario comparing adding flavours in conventional batch production, where 5 different flavoured milks are produced in a day, running 15 hrs/day, with 10,000 l/h in the steriliser and a 20,000 litre aseptic tank.