In November 2016, Tetra Pak launched a new version of Tetra Pak® PlantMaster, enabling manufacturers to manage an entire plant through a single control and data management system. The world’s most advanced plant automation and information solution, it is specifically designed for the food and beverage industry, and is based on our extensive production knowledge.
The new release includes Tetra Pak PlantMaster Manufacturing Execution Systems Suite (MES), which provides full end-to-end information management. In our industry, plants often contain equipment from different suppliers that use separate information systems or even require manual data collection. With the new MES, Tetra Pak PlantMaster provides one set of software tools that integrates all operations, from incoming raw materials to finished, palletised products, with any brand of equipment, and across all sites. More streamlined data collection facilitates accurate analysis and, ultimately, improves efficiency.
Customers can take total control of their operations and maximise the value of their production, cutting downtime and waste and reducing operational costs and environmental impact. They can also achieve consistent product quality and full control of food safety, while providing end-to-end traceability from raw material to consumer. This reduces complexity in their management processes and increases productivity, which in turn has a further positive impact on their bottom line.
Tetra Pak PlantMaster can be easily customised to fit each customer’s specific needs: they can choose the modules relevant to their operations today, while enabling quick and easy creation of new functions they may need in the future. It is available globally as an upgrade to existing versions, or as a new installation.
In December 2016, Tetra Pak launched a new version of Tetra Brik® Aseptic 1000 Edge with Bio-based LightCap™ 30: the first aseptic carton package in the world to receive the highest class of Vinçotte certification for its use of renewable materials. The new package is manufactured using a bio-based plastic film and cap, made from polymers derived from sugarcane. Combined with the paperboard, this lifts the share of materials from renewable sources in the package to above 80%, the threshold for four-star certification from Vinçotte, the Belgium-based accreditation agency. Earlier in the year, in April, Tetra Pak surpassed the 200 billion mark for packages carrying the Forest Stewardship Council™ label.
Tetra Pak® Marketing Services are taking off around the globe, supporting growth and market success for food and beverage producers and brand owners. Participating customers work with us on a tailored, collaborative innovation journey using best-in-class tools and creative methods, and leveraging our industry expertise. This joint approach enables us to unlock richer insights into markets and consumer trends; identify mutual growth opportunities; and create new or improved products and solutions.
Read full article Working directly with the customer's brands
Traditional equipment maintenance can be predetermined – run it every 1000 hours or every 500,000 litres – or corrective – fix it when it breaks. But thanks to digitalised services, Tetra Pak is now able to offer Condition Monitoring: a new approach that can predict failures before they occur, allowing customers to plan maintenance and save hours or even days of downtime.
Read full article Predicting breakdowns and helping customers plan maintenance
In September 2016, long-time customer Skånemejerier launched a range of drinking yoghurts in a package that offers a completely new shape for on-the-go consumption: the Tetra Top® 330 Mini Nallo. The package was developed in partnership with Skånemejerier, a dairy cooperative based in southern Sweden, and is designed for chilled, value-added dairy products such as drinking yoghurt, juices and nectars. These are all healthy products with a degree of novelty and indulgence, making them attractive to younger consumers. The fact that the package is made primarily of renewable materials adds to the appeal. The new carton package takes the place of plastic bottles, enabling Skånemejerier to cut their use of plastics by an estimated 45 tonnes a year.
The new and improved Tetra Pak® Ice Cream Filler A3 is designed specifically for small- to medium-sized producers looking to lower operating costs and increase flexibility, with minimal investment. The new filler produces up to 18,000 ice cream cones per hour, with three enhanced components that are also available individually as line upgrades: a cone dispenser with high reliability and size flexibility; an easy-to-operate chocolate sprayer with exceptional accuracy; and a precise lid dispenser, which improves standardisation. These features reduce waste, minimise stops and increase overall speed, while ensuring product quality. The modular design also offers significant production flexibility with simple setup and easy equipment changeovers, which take just minutes.
Separating the expensive fat from milk is an important part of the dairy production process. Fat is then added back to the product to achieve the required percentage through a process called standardisation. An enhanced version of the Tetra Pak® Standardization unit has lifted the precision of this process to a new level, helping dairies to optimise fat content in their products and thereby achieve significant savings. The product has already achieved field success with international dairy cooperative Arla Foods at its plant in Palmers Green, London.
“For us, the big money is in cream,” says Christian Odgaard, Regional Project Manager. “To give cream away is an absolute no-no. We were quickly impressed with the reliability and precision of the Tetra Pak Standardization unit. The difference in higher accuracy is clear to see. A lot of cream is coming back into our tank.”
Arla Foods’ requirements were challenging: to replace three obsolete standardisers, while limiting downtime to three days. “That is exceptional for us,” says Regional Project Manager Josette Bogerman. “I love working with Tetra Pak. They gave us the right guarantees. We would never have had the commitment from anyone else to do it in three days.”
The unit, which is now available to customers worldwide, provides automatic in-line standardisation directly after milk separation, with a capacity of up to 75,000 litres of milk per hour. Highly reliable, the system is based on continuous development and testing of high-performance automation software and advanced flow transmitters and regulation valves. Overall, it delivers a reduction in the variation of “cream giveaway” from +/- 0.020% to +/- 0.015%.
The world’s largest-capacity food-processing homogeniser went into operation in March 2016 with its first customer, Chinese food company YinLu. The Tetra Pak® Homogenizer 500 can produce up to 63,600 litres per hour, offering outstanding product quality at the lowest operational cost available. The machine features Tetra Pak’s pioneering HD EnergyIQ, an innovative homogenising device that operates at pressures around 20% lower than standard machines, while delivering the same quality. The result is a significant reduction in energy consumption, considerably reduced costs, and the highest uptime in the market.
In May 2016, Tetra Pak completed work on the world’s largest biscuit manufacturing plant in Salinas, Mexico that includes 12 production lines of Tetra Pak processing equipment. Tetra Pak Guerin Systems beat stiff competition to win the contract for the greenfield plant for multinational food and beverage maker Mondelez. The new plant produces biscuits and cookies for the North American market, including such well-known brands as Oreo, Ritz, Chips Ahoy and Belvita. While Tetra Pak had previously worked with Mondelez on several powder-handling projects, most recently for a sugar reception expansion, this project also includes handling of liquids, such as oils and syrups.
Guloso in Portugal has become the first brand worldwide to pack whole peeled tomatoes in a carton package, thanks to Tetra Recart® technology. Lighter, safer and easier to transport and use than traditional tomato packaging options, a Tetra Recart® package maintains product quality for 24 months without preservatives or refrigeration. It can also be resealed if the entire product is not used in one go and is made of Forest Stewardship Council™-certified cardboard, a renewable resource. Consumers can easily close it again if the entire product is not used at once.
According to Nuno Saraiva, Marketing Director of Sugal, the company responsible for the Guloso brand: “The Tetra Recart® system offers the tomato segment, conventionally supplied in cans, all the functional, logistical and environmental advantages of carton packages throughout the supply chain.”
In November 2016, Tetra Pak announced its €100 million investment in a new state-of-the-art regional manufacturing facility near Ho Chi Minh City, Vietnam, to serve growing consumer demand in the Asia-Pacific region. The liquid dairy and fruit-based beverage categories markets in the country are forecast to grow at a healthy 5.6% per annum over the next three years, with products packed in Tetra Pak cartons projected to grow at a much faster rate than bottles and cans. The first-ever liquid food carton packaging factory in Vietnam, the new facility is expected to start commercial operations by early 2019, with an expandable production capacity of around 20 billion packs per annum serving customers across the region.