Simple steps to making the simple choice:
What to think about when investing in your first homogenizer
For smaller dairy and ice cream operations, entering a new market is about striking a balance. The design of an initial processing line must be able to support reliably profitable production from the start, but also pave the way for long-term growth potential. This means special attention must be paid to each and every piece of technology used in the line.
For equipment like a homogenizer, which plays a critical role in ensuring the correct product quality, making the right choice at the start can seem like a major challenge. Today there is a huge range of homogenization solutions to choose from, with different types of technologies that provide different advantages – and different drawbacks. We asked Tetra Pak’s homogenization application experts what new actors in the dairy and ice cream industries should consider when making their initial homogenizer investment. Their advice when evaluating your alternatives can be summed up in three words: keep it simple.
Check all the boxes
Of course, all businesses want to avoid complexity in their operations. But what does “simplicity” mean in the context of selecting a homogenizer?
“It’s about focusing on your needs,” explains Pavlos Kouroutsidis, a Homogenizer Application Specialist at Tetra Pak. “You want to find technology and a supplier that can help you optimize your homogenization according to your demands, and that won’t give you more than what you really need.”
To start with, this means checking the basics. Make sure your homogenizer is well suited to your dairy or ice cream applications, but also that it complies with the legislative food safety requirements and certification standards in the markets where you plan to sell. Such things may seem straightforward, but as Pavlos explains, mistakes can be costly.
“It can be easy to take some things for granted, but you want to make sure that you’re checking all of the important boxes,” he says. “For example, if you work in North America, are all the product contact components of your homogenizer 3-A certified? Are the electrical systems up to code? Something as small as this could lead to a failed inspection, resulting in costly downtime or even forcing you to replace the machine you just installed.”
Don’t make pressure assumptions
Once you’re confident that your options check the fundamental boxes, there are a number of other factors you may consider. One of the most important, however, is homogenization pressure. Our experts stress that this is one area where “not having more than you need” can have a major impact on the success of your operations.
“When evaluating technology, many people start with a specific pressure in mind, but this is really a backwards way of approaching it,” says Johan Gotthardsson, Homogenizer Portfolio Manager at Tetra Pak. “They may assume they need a pressure of 200 bar, for example. But when we talk to them, we learn this may be because of experiences with older technologies or what they are hearing and seeing in the market. They may not understand that they can actually run at 180, 170 or even lower and still achieve the same level of homogenization for their products.”
Rather than starting from a set pressure, you want to identify capacity and product quality requirements. That is to say: how much do you need to produce, and how small do you need to make the fat globules and particles in the product to satisfy the quality demands of your consumers?
“Homogenization pressure is an indicator of how well you can optimize the performance of the machine,” Johan explains. “The goal is to lower the pressure as much as possible while still meeting capacity requirements and reducing fat globules to the optimal size. A more efficient machine, configured in the right way, will enable you to get the results you need at a lower pressure.”
This measure of efficiency has a direct relationship to the total cost of ownership of the homogenizer. Higher pressure drives up energy consumption and increases wear and tear, leading to a wide range of long-term cost considerations. Being able to run at a lower pressure can therefore mean significant savings over time.
“When buying a first homogenizer, many producers will be looking primarily at the initial investment cost,” Johan notes. “But there is a risk that if you only focus on CAPEX, you may end up with less efficient technology, and this will lead to much higher costs in the long run. To enable profitable production, it’s equally important to consider factors like homogenization pressure that influence the operating costs.”
Avoid the bells and whistles
As the example of homogenization pressure shows, “more” is not always necessarily better. This is also the case when thinking about the overall design and configuration of the homogenizer. When setting up a dairy or ice cream line, it is important to avoid technologies that don’t address your actual needs.
“For a producer entering the market, you want to keep it simple,” Johan says. “You want a plug-and play solution that’s going to be easy to install and incorporate into your line, and easy for your new operators to use on a daily basis. Especially if you’re only producing a limited number of products, you won’t need the high level of automation used in larger, more complex operations.”
The same principle is true when comparing different types of potential homogenization technologies. Consider the respective benefits and drawbacks of different homogenizer models both in terms of the potential complexity they could add to your operation, as well as how relevant they may be for what your needs are today.
“Pressure system designs are a good example,” explains Johan. “Many homogenizers use a pneumatic pressure system. These require automation and a high degree of configuration, as well as an amplifier that is needed to ramp up the pressure in between runs. A hydraulic pressure system, by contrast, keeps things much simpler. There’s no automation or ramp-up-time between runs – it’s a simple on/off switch and you’re ready to go.”
At the same time, putting today’s needs in focus does not preclude the possibility to be ready for tomorrow. In Pavlos’ view, the “right” choice of homogenizer is one that lays the best groundwork for profitable growth.
“To keep costs low in the beginning, we always recommend buying just what you need today,” he says. “But you should have the option to be able to rebuild the machine if your needs change. For example, you should be able to increase the pressure if it turns out you need more pressure, or to add more advanced features if they become relevant. So, it’s important to choose a homogenizer solution with a flexible design and work with a supplier that can give you a possibility of reconfigurations and upgrades later on.”
Remember: you’re buying more than a homogenizer
Considering your supplier’s capabilities is not only about having the flexibility for future growth. It’s also something that can be highly relevant to making the right choice for your initial line setup.
“It’s important to remember that you’re not just buying a piece of equipment,” says Johan. “You’re buying the complete package, including the knowledge, experience and resources that your supplier brings to the table from the start.”
In terms of “keeping it simple,” a supplier that understands your type of production can help you make smart decisions from day one. Whether it’s about optimizing performance to reduce pressure or identifying the features that make most sense for your needs, working with someone that has extensive application experience can prove invaluable in guiding your decision.
A more knowledgeable supplier will also bring experience working in different markets and with dairy and ice cream producers of different sizes. To get the best advice for your situation, you want to collaborate with somebody who has worked with companies like yours as well as larger producers.
“You of course want to work with a supplier that takes your needs seriously – no matter if you’re a big customer or a small customer,” concludes Pavlos. “But it’s also important that they have a mix of references. Hopefully this is a start of a long journey where you will grow over time. Somebody who knows what it takes can be on that journey with you, supporting you as you expand and as your needs become more complex.”
HD21: Up to 25% lower energy consumption
Tetra Pak® Homogenizers 15C and Tetra Pak® Homogenizer 20C are built with the highly efficient HD21 – a single homogenization device with an integrated second stage. In contrast to two-stage homogenizers that require two devices in a series, this means a reduced number of parts and a smaller footprint. With the added benefit of turnability for double parts lifetime, the use of the HD21 device can help secure significant long-term savings.
