ii. 
Case study benchmark comparing batch blending and in-line blending:

Batch blending:

Total cost, $     
Per yearSteamElectricityFresh WaterCausticAcid
Production05564000
CIP643998669800

In-line blending:

Total cost, $     
Per yearSteamElectricityFresh WaterCausticAcid
Production07141000
CIP4821256496010

In-line blending increases electricity costs by 26% but reduces:

  • Steam by 25%
  • Fresh water by 25%
  • Caustic by 39%

iii.
Figures comparing cooling water and steam consumption of the Tetra Pak Homogenizer 400, which handles temperatures up to 125°C vs. a homogenizer that requires low temperature condensate (60°C) and thus consumes much more cooling water and steam:

 Cooling water Steam
Homogenizer requiring low temperature condensate7 950  l/h195 kg/h
Tetra Pak Homogenizer         750     l/h50   kg/h


Formula for cooling water calculation:

E = E1+E2+E3
Where;
E1: Cooling energy from 140°C to 100°C (steam)
E2: Evaporation energy from 100°C(steam) to 100°C(fluid)
E3: Cooling energy from 100°C(fluid) to 60°C
Cooling energy:
E1 , E3 = m*c*ΔT
Evaporation energy:
E2 = m*h
Heat capacity:
Cw (water) = 4.18 kJ/kg*°C
Cs (steam) = 1.97 kJ/kg*°C
Specific evaporation heat:
h=2 260 kJ/kg

m =mass in kg
ΔT=temperature change in °C
c = specific energy in kJ/kg*oC
h = specific evaporation heat      

iv.
When the homogenizer is equipped with this option, temperature sensors ensure that it only uses exactly the amount of water needed to maintain the right temperature, and no more.

vii.
Read more about hibernation mode in Tetra Pak heating units at https://www.tetrapak.com/solutions/categories/dairy/fermented-dairy-products

viii.

Calculation tool comparing total cost of ownership for a Tetra Pak heating unit with or without hibernation mode, showing a cost savings of approximately €7,600 annually:

UHT unit D
Estimation tool
Cost of ownership with hibernation mode
General input Production Scenario
*Bold numbers indicate available information.

Production  
Production weeks per year46[weeks/year]
Production volume per week2 100[m3/week]
Annual production volume96 600[m3/year]

 

Non-production  
Tetra Pak  
Pre-sterilisations3[/week]
Sterile water re-circulations3[/week]
Sterile water circulation time6[h/week]
         of which in Hibernation6[h/week]
Aseptic Intermediate Cleanings3[h/week]
Cleanings In Place3[h/week]

 

UtilityConsumption Cost 
Steam4305[ton/year]189435[EUR/year]
Electricity739[MWh/year]73891[EUR/year]
Chilled water0[MWhr/year]0[EUR/year]
Tower water37[MWhr/year]75[EUR/year]
Fresh water30381[m3/year]79599[EUR/year]
Compressed air41519[Nm3/year]830[EUR/year]
Caustic (50 w/w%)14876[kg/year]16662[EUR/year]
Acid (60 w/w%)4223[kg/year]5912[EUR/year]
Sewage34687[m3/year]8325[EUR/year]
Sum utility cost  374729[EUR/year]


UHT unit D
Estimation tool
Cost of ownership with hibernation mode
General input Production Scenario
*Bold numbers indicate available information.

Production  
Production weeks per year46[weeks/year]
Production volume per week2 100[m3/week]
Annual production volume96 600[m3/year]

 

Non-production  
Tetra Pak  
Pre-sterilisations3[/week]
Sterile water re-circulations3[/week]
Sterile water circulation time6[h/week]
         of which in Hibernation0[h/week]
Aseptic Intermediate Cleanings3[h/week]
Cleanings In Place3[h/week]

 

UtilityConsumption Cost 
Steam4413[ton/year]194172[EUR/year]
Electricity741[MWh/year]74092[EUR/year]
Chilled water0[MWhr/year]0[EUR/year]
Tower water70[MWhr/year]140[EUR/year]
Fresh water31285[m3/year]81966[EUR/year]
Compressed air41519[Nm3/year]830[EUR/year]
Caustic (50 w/w%)14876[kg/year]16662[EUR/year]
Acid (60 w/w%)4223[kg/year]5912[EUR/year]
Sewage35698[m3/year]8567[EUR/year]
Sum utility cost  382341[EUR/year]