HD21: Up to 25% lower energy consumption
2-in-1 innovation that boosts performance while cutting costs
How can you secure reliable, efficient homogenization performance without adding to the cost of your line? It’s a challenge for many dairy and ice cream producers, especially those with less complicated processing requirements.
We developed our homogenizers for this segment with exactly these challenges in mind. The key is our unique HD21 homogenization device, which offers 2-in1 simplicity to ensure your homogenizer gives you the quality you need without all the bells and whistles. On this page, we explain how the HD21 works – and what sets it apart from more conventional homogenizer configurations.
Traditional setup
Today, the traditional setup for homogenizers used in most types of applications will involve two homogenization devices in a series. These are commonly referred to as the “first-stage” and “second-stage” devices, respectively. In theory, this configuration can be used for either single- or two-stage homogenization. In practice, however, most applications will require two-stage homogenization that uses both of the devices installed.
The pressure required for the first homogenization stage is typically much higher than the pressures the product experiences in the rest of the production line. This large pressure differential can cause vibrations that have a negative effect on the equipment.
Introducing a second stage to adjust the back pressure minimises these challenges. Homogenization is also improved, as the second stage ensures a more uniform and stable emulsion by helping to break down the fat clusters that may have formed after the first stage. Furthermore, a constant and controlled back pressure to the first stage optimises the conditions for the homogenizer.
A proven solution
This setup has become the traditional solution for a reason. In fact, when using highly efficient homogenization technology, it can offer a number of benefits.
Being able to regulate back pressure via the second-stage device means it is possible to optimise the pressure differential according to the specific application in question. It can also be useful when working with many different of types of products that have different properties and different processing needs.
More than you need?
For operations with simpler processing needs, however, the costs associated with a traditional configuration may outweigh the benefits. Putting two homogenization devices in one machine increases the number of parts. This will, of course, be reflected in the investment cost of the homogenizer as well as the maintenance needs and operating costs it requires over time.
For smaller plants and those that produce a limited number of products, this creates an obvious conundrum. As the second device is required to effectively regulate back pressure, how do you design a homogenizer that delivers efficient performance without becoming more than you really need?
One device. Two duties.
Our Tetra Pak homogenization experts have sought to solve this challenge by re-thinking the design of the device itself. Their idea was to combine both the first and second homogenization stages into a single device.
The result was HD21: one homogenization device with two gaps. The second gap acts as an integrated second homogenization stage. As the name implies, the HD21 is therefore a “2-in-1” device – it is handling the job of two devices.
Balancing efficiency and simplicity
Since both stages are integrated into the same device, the back pressure settings are set to a fixed ratio when operating with an HD21. Simplifying the overall homogenizer design, in other words, entails a tradeoff.
To account for this, the HD21 has been designed to maximise homogenization efficiency, based on lessons we have learned from our proven HD100 homogenization device.
HD21 is engineered with a wider diameter than found on most conventional homogenization devices. As a result, the device also has a significantly narrower gap than the conventional alternatives. A narrower gap enables you to achieve the same level of homogenization using lower pressures. The machine can thus be run with up to 25% lower energy consumption* compared to a homogenizer with a conventional homogenization device, allowing for long-term cost savings and more efficient line performance.
*Based on the following production scenario: Pasteurized milk, NIZO 66%, 14 days of shelf life, 2000 L/h and compared to alternative homogenization devices in the market.
Two parts are better than six
The streamlined design of the HD21 not only eliminates the need for a second device. It also reduces the number of parts featured in the device.
Most traditional homogenization devices include – at a minimum – three separate parts. In a conventional setup, that means at least six wear parts that need to be monitored, maintained and replaced with some regularity. The HD21, by contrast, is constructed with just two parts. This translates to just a third of the parts required in the traditional setup, meaning 66% lower spare parts replacement costs for homogenization devices over the lifetime of the equipment.
Or is it 4-in-1?
As with the HD100, the HD21 also utilises our turnable wear part design. This means that every HD21 homogenization device can be used twice. Once one side is worn, the operator simply turns it over so it can be used again. Put simply, each HD21 you buy can be seen as fulfilling the duties required by as many as four separate homogenization devices used in a conventional two-stage machine.
Benefits that match the application
The advantages of HD21 can offer an ideal fit for many smaller dairies and ice cream producers. Eliminating the second-stage device simplifies installation and makes it easier to build the machine with a a skid-mounted, plug-and-play design. As a result, a homogenizer with HD21 can add simplicity to an operation already from day one.
The significant reduction in parts has a positive impact on both the investment cost of the machine as well as maintenance and spare parts needs in the long-run. These trade-offs can be highly advantageous in applications where the benefits of a two-device setup aren’t required.
Which setup is right for you?
HD21 is well suited for many producers, but some scenarios will need the full optimisation possibilities that are only possible with two homogenization devices installed in a series. Not sure which type of setup makes the most sense for your operation? Our experts can work with you to understand your application, and help you to select the best choice based on both today’s needs and where you want to go in the future.
