In only two years, Tetra Pak has increased its use of renewable electricity from 20 per cent to 50 per cent. This achievement was possible through a combination of initiatives, including the purchase of International Renewable Energy Certificates (I-RECs) and solar power installations at our own facilities. Tetra Pak factories in Sweden, Denmark, Finland and South Africa use electricity from 100 per cent renewable sources and 17 major sites now run exclusively on renewable electricity. Mario Abreu, Vice President Sustainability at Tetra Pak says, “Renewable energy is an important step on our journey to reduce the carbon footprint of our operations and help tackle climate change.”
A new plant management service, Tetra Pak® Plant Secure, is a game-changer when it comes to delivering profitability improvements for customers. It starts with a detailed audit of all the equipment and systems across the customer’s value chain. Tetra Pak then applies its unique industry expertise to identify opportunities and implement improvements throughout the entire operation, based on clear financial and production targets. Pilot projects have been carried out in the Americas and Europe, delivering results that exceeded expectations. An US-based dairy producer reduced operational costs by more than 10 per cent in the first year and the project continues to deliver savings. Tetra Pak® Plant Secure is being rolled out to all food and beverage companies worldwide.
The successful US-based water brand JUST Water was awarded “Best Packaging Solution” at the 2018 Global Bottled Water Congress in Evian, France. JUST Water uses the Tetra Top® carton bottle made from 82 per cent renewable resources: primarily FSC™ certified paperboard and renewable plastic derived from sugar cane. “This package allows us to provide our customers with a better solution, while fulfilling our global mission of reducing plastic pollution,” says Ira Laufer, CEO of the producer JUST Goods.
The newly launched Tetra Pak® Homogenizer 250 was designed to meet the need for a mid-range capacity and high level of automation. It offers efficient homogenization of both low- and high-acid products, including pasteurized milk, ESL milk and other beverages. In a comparative trial, the Tetra Pak® Homogenizer 250 can render the same flow rate at a lower speed than the competitor model tested. This reduces the strain on movable parts and thereby the cost for spare parts and maintenance by up to 32 per cent, and increasing equipment uptime in the process. Results of the trial indicated that total cost of ownership of the homogenizer were at least 10 per cent lower than the leading competitor.
The Tetra Pak® Extrusion Wheel has a patented new design that produces stick ice cream products with large inclusions, such as whole nuts, real fruit segments or cookie dough chunks, while doubling the capacity. The wheel can be added to existing lines and uses an innovative vertical rotating design that is synchronised to produce up to 12,000 products per hour and lane. In addition to smoothing the surface of each stick, it also reverses the process by filling the ice cream around the stick rather than inserting it at the end, which renders a more uniform result. With the Tetra Pak® Extrusion Wheel, producers can respond faster to growing consumer trends for novel and high-quality ice creams.
Kara, the market-leading coconut cream in Indonesia produced by PT Pulau Sambu, was the first to launch the Tetra Classic® Aseptic 65 Cube in the Indonesian market in 2019. This launch was also a worldwide premier. The archipelago nation often has massive logistical challenges, especially beyond Java island. This packaging format supports distribution to remote areas, saving 20 per cent in distribution and logistics costs. Better storage and shelving possibilities with the Tetra Classic® Aseptic 65 Cube are also expected to reduce rejects from leakages by up to 50 per cent.
Tetra Pak packaging material plant in Izmir, Turkey, has received the world’s top award for manufacturing excellence. Appraised by the Japan Institute of Plant Maintenance (JIPM), the World-Class Total Production Maintenance award is bestowed on facilities that have achieved outstanding levels of production quality, reliability, efficiency and environmental performance. Upon receiving the award, Tetra Pak Turkey Factory Director Selami Ulusoy said, “The commitment we show to outstanding product quality, while maintaining the highest standards in operational performance and sustainability, is truly reflected in this achievement. In the last five years alone, we have invested more than EUR 60 million in this plant, and will continue to do so, especially in digitalisation and new technologies.”
Tetra Pak has launched a suite of new packaging material effects, known as Tetra Pak® Artistry, that enable food and beverage producers to revitalise the look and feel of their products. These effects help brands attract shoppers’ attention without switching to a new packaging format or investing in new equipment. The suite includes: Tetra Pak® Reflect with holographic effects, Tetra Pak® Metallized to create a metallic look, Tetra Pak® Sculpt with an embossed surface texture, and Tetra Pak® Craft with the natural look of bare paperboard with wood fibres. The whole range will be available for the majority of Tetra Pak® packages formats and offered to customers worldwide.
Tetra Pak has equipped one of the largest cheese plants in southern Russia, with investments totalling € 78 million. Agrokompleks is a major Russian producer of raw milk and the plant’s expected annual capacity is 575 tons of milk per day, with the possibility to extend up to 675 tons. This is a strategically important project for Tetra Pak and the biggest processing contract ever signed in the region. The installed Tetra Pak® equipment will produce semi-hard, mozzarella, fresh and pasta filata cheeses; butter, whey and skimmed milk powder.
PepsiCo in Russia has introduced an innovative package from Tetra Pak for their juice and nectar brand, Fruktovy Sad, to enhance shelf visibility and product sales. Tetra Brik® Aseptic 1000 ml Ultra Edge was successfully field tested with PepsiCo in July 2018. The project scope includes the rebuilding of four Tetra Pak® A3/Flex lines at the Lebedyan plant in Russia. With a capital investment of more than € 2 million, annual packaging material sales are expected to reach 100 million packages.
Tetra Pak has cut the energy use of its separators by 40 per cent by incorporating Encapt™, a breakthrough pressure management technology, into the systems’ design. The Encapt technology lowers the atmospheric pressure around the spinning bowl and the system is supervised by sensors that keep air friction to a minimum – and less friction means less energy required. Tetra Pak® Separators with Encapt™ technology coupled with AirTight technology offer customers operational flexibility for different speeds and flow rates, lower operational costs and a smaller environmental footprint.