The Rise of New Plant-Based Beverages
The plant-based category is one that is continuously evolving with new base products being trialled that add to the list of plant-based alternatives in the market.
Plant-based beverages such as soya, almond (nut) and oat are typically the top three products in most markets, while a myriad of other products derived from ingredients such as rice, hemp seeds, pea and many more are being introduced. This presents both an opportunity and a challenge to beverage manufacturers.
Collaborate with Tetra Pak experts with unrivalled knowledge to revitalize your soya-based product range
Understanding the Rice Beverage Trend
Asia-Pacific has a strong history in the production and consumption of rice, with it being the staple of many meals across multiple cultures in the region. Today, rice is no longer considered for food consumption only, but also as a great plant-based beverage option.
For manufacturers, processing requirements of rice-based beverages will vary depending on the starting raw material. When rice grains are used, a grinding solution is required to allow for conversion into a slurry. Multiple rice grain types can be used for beverages, and polished rice is the most commonly used ingredient – both long and short grains, but at times brown rice or other varieties may also be used.
Use of rice flour will eliminate the need for a grinding solution, however an effective mixing solution would be recommended in order to create a uniform slurry.
As rice is naturally high in carbohydrates, the next crucial step is the gelatinisation of the starch. In this phase, the starch will then be broken down by use of specific enzymes. Following this is separation of the larger particles from the slurry, which will provide a smoother mouthfeel. These are critical process steps for end-product quality and as such, correct process design is imperative.
Many of the other plant-based ingredients may require a similar processing setup, but with some slight variations. For example, a legume-based ingredient may also need a step involving anti-nutritional factor inhibition so that the final beverage product is healthy and safe for consumption.
At Tetra Pak, we have been applying our vast learning in elimination of anti-nutritional factors from soya, to design a fit-for-purpose solution that is also flexible for other ingredients. We also have extensive experience in understanding process technology and its impact on product quality. Whether it’s a new line solution or a modification requirement to an existing plant-based line, we can support you.
Meeting Manufacturing and Processing Flexibility
The growth and rapid development of alternatives in the plant-based category provides consumers with a wealth of options. This includes taste and nutrition options, as well as increased variety. However, the breadth of new plant-based alternatives poses key challenges for manufacturers.
Downstream processing
While a major part of the focus is on the extraction process for plant-based beverages, it is also important to focus on the other downstream processing – mixing, blending, ultra-high-temperature (UHT) and aseptic filling.
High Shear Mixer
Mixing is a critical operation for number of reasons. Firstly, the majority of plant-based beverages are clean label products, where mixing can play a very significant role in helping disperse different phases together before the product is treated further. Secondly, through effective mixing and by option to apply vacuum air incorporation to process can be reduced which is critical to further improve the product quality.
Tetra Pak® High Shear Mixer
Fast and reliable ingredients mixing
A complete mixing solution, the efficient mixing system reduces mixing time and produces homogeneous and lump-free products of superior quality, easily adaptable to a wide variety of product recipes and enable quick and easy product changes.
Capacity: 5,000 – 40,000 l/hr
Applications: Perfect for all kinds of plant-based beverages, involving mixing of ingredients such as stabilizers, vegetable oils, emulsifiers etc.
Homogenisation
The process of homogenisation has an equally critical role to play in plant-based beverages. As many plant-based beverages are clean label products, homogenisation acts to stabilise the product, extending its shelf life while also delivering an improved mouthfeel. Good knowledge of the product and homogenisation design is critical for this to be successfully achieved in conjunction with operational factors such as running and repair costs.
Tetra Pak® Homogenizers
Pioneering design for lower pressure and energy savings with smart automation
Tetra Pak® Homogenizers reduce particle size and improve product quality. Available in non-aseptic and aseptic versions with a wide range of capacities and pressures, and for products with different viscosities.
Capacity: 55 l/h to 63,600 l/h
Cost Effective Maintenance: Lowest operational, utility service and spare parts costs
Operational Efficiency: Highest homogenizer uptime
Applications: Efficient homogenization of both low and high acid products; wide range of applications
UHT Treatment
Plant-based beverages have different heating requirements based on their initial microbial load, product properties (viscosity, thermal conductivity etc.) and ultimately flavour and sensory properties. Tetra Pak UHT solutions can not only help you achieve high -quality food safety, but also deliver the right product sensory properties, along with optimum operational running hours.
Tetra Pak® UHT Solutions
Application: Tetra Pak® UHT Solutions are processing unit for highly efficient, continuous ultra-high temperature treatment of plant based beverages. The UHT solutions are available in number of different process configurations – e.g. Indirect (Plate or Tubular Heat exchanger) or Direct UHT.
Whether it is a direct or indirect UHT unit, the common elements are: an aseptic design, a heat exchanger to heat the product to desired temperature and holding for a specific period of time. The end result is a product that can be stored at ambient temperatures. Tetra Pak® UHT solutions are suitable for plant based beverages such as soy, oat, nuts and other dairy alternative milk, plant based cream, plant based yoghurt drinks and formulated plant based beverage products. Combinations with other non-dairy applications such as juice, tea and coffee are also possible.
Tetra Pak® UHT Solutions are available as a stand-alone unit or as part of a complete line solution.
Capacity: 1 000 - 40 000 litres/hour
Key Highlights:
- Consistent product quality
- Minimized product losses thanks to low-loss balance tank function
- Improved uptime as a result of optimized cleaning
- Maximized operational efficiency due to minimized energy consumption
- Guaranteed performance
