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

Batch blending:

Total cost, $          
Per year Steam Electricity Fresh Water Caustic Acid
Production 0 5564 0 0 0
CIP 643 99 866 980 0

In-line blending:

Total cost, $          
Per year Steam Electricity Fresh Water Caustic Acid
Production 0 7141 0 0 0
CIP 482 125 649 601 0

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 condensate 7 950  l/h 195 kg/h
Tetra Pak Homogenizer          750     l/h 50   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/campaigns/yoghurt-products/precision-pasteurization

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 year 46 [weeks/year]
Production volume per week 2 100 [m3/week]
Annual production volume 96 600 [m3/year]

 

Non-production    
Tetra Pak    
Pre-sterilisations 3 [/week]
Sterile water re-circulations 3 [/week]
Sterile water circulation time 6 [h/week]
         of which in Hibernation 6 [h/week]
Aseptic Intermediate Cleanings 3 [h/week]
Cleanings In Place 3 [h/week]

 

Utility Consumption   Cost  
Steam 4305 [ton/year] 189435 [EUR/year]
Electricity 739 [MWh/year] 73891 [EUR/year]
Chilled water 0 [MWhr/year] 0 [EUR/year]
Tower water 37 [MWhr/year] 75 [EUR/year]
Fresh water 30381 [m3/year] 79599 [EUR/year]
Compressed air 41519 [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]
Sewage 34687 [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 year 46 [weeks/year]
Production volume per week 2 100 [m3/week]
Annual production volume 96 600 [m3/year]

 

Non-production    
Tetra Pak    
Pre-sterilisations 3 [/week]
Sterile water re-circulations 3 [/week]
Sterile water circulation time 6 [h/week]
         of which in Hibernation 0 [h/week]
Aseptic Intermediate Cleanings 3 [h/week]
Cleanings In Place 3 [h/week]

 

Utility Consumption   Cost  
Steam 4413 [ton/year] 194172 [EUR/year]
Electricity 741 [MWh/year] 74092 [EUR/year]
Chilled water 0 [MWhr/year] 0 [EUR/year]
Tower water 70 [MWhr/year] 140 [EUR/year]
Fresh water 31285 [m3/year] 81966 [EUR/year]
Compressed air 41519 [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]
Sewage 35698 [m3/year] 8567 [EUR/year]
Sum utility cost     382341 [EUR/year]