Tetra Laval contributes to the lives of people around the world in many positive ways. Our three industry groups – Tetra Pak, Sidel and DeLaval – provide innovative systems that improve the efficiency, quality and safety of food production, processing and packaging.
When Select Milk Producers in the US decided to build a new plant in Littlefield, Texas, it chose Tetra Pak to install all of the processing equipment and automation controls. Scheduled to come on stream in April 2019, the new plant will process raw milk for a variety of dried-milk products, as well as cream for butter.
The Texas plant builds on our previous experience of creating a similar factory for the same customer in Michigan. With a daily raw milk intake of 1.8 million litres, sourced from farms spread across Southwest US, the new plant will be able to produce up to 6,800 kg of milk powder and 7,300 kg of cream for butter production per hour. Select Milk chose the Tetra Pak process because it maintains the high quality of the raw milk while also creating value-added products. This large plant is a major undertaking that reinforces Tetra Pak’s position as a primary supplier in the North American market.
Two of Nestlé Waters’ best performing production lines in North America are found in the Greenwood Plant in the US. Although there are many reasons for their great success, Gebo Cermex’ EIT™ (Efficiency Improvement Tool) can also take part of the credit.
The EIT data acquisition & plant intelligence system – developed in 1996 and currently installed in more than 110 Nestle Waters’ lines worldwide – gives employees at all levels of the organisation real-time access to relevant and actionable information on key performance indicators, for optimised efficiency and improved productivity. In Greenwood, regular reviews of the EIT data helped achieve an impressive reduction of unplanned downtime and improve operators’ awareness.
The dairy industry in the US needs to formulate sustainability metrics that can be presented to retailers and food processors, as consumers increasingly demand products that come from sustainable farming practices. Dairy co-operatives have been early responders, as they have close relationships with member farmers.
DeLaval North America has started an active dialogue with several co-ops on how to help dairy farmers increase sustainability in a cost-efficient manner. The DeLaval solutions that support these demands include DeLaval VMS™, which are generally more energy-efficient and provide higher productivity with better animal welfare. Consumables such as AcidiShine™ detergent and iodine-free OceanBlu™ teat dips promote animal health and food safety – and all are free of NPE.
Back in 1997, engineers worked around the clock to finalise the DeLaval VMS™ to ensure we launched the most advanced milking platform on the market. With a host of patents, the DeLaval VMS™ had the first touch screen, the first teat preparation cup, the first real quarter milking system and the first rear plate to secure hygiene. Celebrating 20 years of automated milking, more than 200 events were held across Europe in 2017. Most of these were open farm days hosted by DeLaval, with up to as many as 500 visitors. “It’s a great opportunity to meet customers to discuss our expertise in automated milking while presenting our product range,” says Edouard Alix, Cluster Solution Manager Automatic Milking Systems.
In an innovative campaign designed to engage children, Al Safi Danone teamed up with Tetra Pak in Saudi Arabia to launch the world’s first personalised carton package for its leading Safio flavoured-milk brand. The Safio MyPack campaign was promoted in shopping malls throughout the country, allowing children to engage in various activities at Safio booths. The 25 most common names for boys and girls were chosen by Al Safi Danone for printing on Tetra Brik Aseptic 200 ml Slim Leaf carton packages for all flavours: chocolate, banana, strawberry and plain. Supported by an integrated marketing campaign that included in-store branding and radio, the Safio MyPack initiative resulted in the production and distribution of some 39 million personalised packs, boosting Safio’s market share from 13 per cent to 16 per cent.
A large 2,000-cow dairy farm in southern China needed to improve their manure treatment efficiency and asked DeLaval for a solution. They required solids with an improved dry matter ratio for better composting, in addition to reducing daily separation time. The farm had three screw separators, but only one of them was running more than 20 hours a day to finish the separation job. However, the moisture level was too high and having only one operational screw separator was not sustainable in the long run.
DeLaval removed the two dysfunctional separators and used the remaining pipeline and pump to install a new DeLaval Manure Separator. The integrated system was installed and operational within one day. With two separators now working together, daily separation time dropped from 20 hours to ten, and the solid level of the DeLaval Manure Separator meets the customer’s requirements. The customer rates the system highly on cost savings, reduced servicing requirements, the design and safety of the equipment, as well as the cleanliness of the machine.
The Cikedokan plant – a Coca-Cola Amatil Indonesia (CCAI) facility near Jakarta – produces carbonated soft drinks, tea and juice in PET bottles and tea in plastic cups. The original line featured manual palletising at its end-of-line, causing many congestion, safety and labour-management issues. Working closely with the team at the customer’s site, Gebo Cermex engineers designed a new automatic palletising solution, enabling the production line to deliver 3,600 cases per hour in the most economical and operationally efficient way. Together with more than 50 per cent line efficiency and higher OEE (overall equipment effectiveness), it allows for a much better management of the labour force.
Sidel has supplied two Sidel Matrix™ Combis to the Sanpellegrino plant in Ruspino, Italy, to help increase production capacity of its famous sparkling mineral water, yet ensuring utmost food safety. Combining blow moulding, filling and capping processes into a single system, the Sidel Matrix Combi reduces operating costs and uses up to 30 per cent less floor space, compared with traditional standalone equipment. In addition, it offers up to 4 per cent higher efficiency levels, faster format changeovers, lower energy consumption and a reduction of operating costs by 8–12 per cent.
The Chinese market has seen a growth in the popularity of ambient drinking yogurt containing particles, such as fruit pieces or grains. Tetra Pak has helped Yili, one of China’s largest dairy producers, to capture this opportunity with the launch of Tetra Top® Ambient Distribution (TTAD), which is based on a non-aseptic filling platform combined with ambient distribution. The Tetra Top® package itself offers premium image and shelf differentiation, with a one-step wide opening that is perfect for the viscosity of the product.
Read more about Tetra Top carton bottles