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ii.
Case study benchmark comparing batch blending and in-line blending:
Batch blending:
Total cost, $ | |||||
Per year | Steam | Electricity | Fresh Water | Caustic | Acid |
Production | 0 | 5564 | 0 | 0 | 0 |
CIP | 643 | 99 | 866 | 980 | 0 |
In-line blending:
Total cost, $ | |||||
Per year | Steam | Electricity | Fresh Water | Caustic | Acid |
Production | 0 | 7141 | 0 | 0 | 0 |
CIP | 482 | 125 | 649 | 601 | 0 |
In-line blending increases electricity costs by 26% but reduces:
iii.
Figures comparing cooling water and steam consumption of the Tetra Pak Homogenizer 400, which handles temperatures up to 125°C vs. a homogenizer that requires low temperature condensate (60°C) and thus consumes much more cooling water and steam:
Cooling water | Steam | |
Homogenizer requiring low temperature condensate | 7 950 l/h | 195 kg/h |
Tetra Pak Homogenizer | 750 l/h | 50 kg/h |
Formula for cooling water calculation:
E = E1+E2+E3
Where;
E1: Cooling energy from 140°C to 100°C (steam)
E2: Evaporation energy from 100°C(steam) to 100°C(fluid)
E3: Cooling energy from 100°C(fluid) to 60°C
Cooling energy:
E1 , E3 = m*c*ΔT
Evaporation energy:
E2 = m*h
Heat capacity:
Cw (water) = 4.18 kJ/kg*°C
Cs (steam) = 1.97 kJ/kg*°C
Specific evaporation heat:
h=2 260 kJ/kg
m =mass in kg
ΔT=temperature change in °C
c = specific energy in kJ/kg*oC
h = specific evaporation heat
iv.
When the homogenizer is equipped with this option, temperature sensors ensure that it only uses exactly the amount of water needed to maintain the right temperature, and no more.
v.
Tetra Pak Sustainability report 2021, page 22
vii.
Read more about hibernation mode in Tetra Pak heating units at https://www.tetrapak.com/campaigns/yoghurt-products/precision-pasteurization
viii.
Calculation tool comparing total cost of ownership for a Tetra Pak heating unit with or without hibernation mode, showing a cost savings of approximately €7,600 annually:
UHT unit D
Estimation tool
Cost of ownership with hibernation mode
General input Production Scenario
*Bold numbers indicate available information.
Production | ||
Production weeks per year | 46 | [weeks/year] |
Production volume per week | 2 100 | [m3/week] |
Annual production volume | 96 600 | [m3/year] |
Non-production | ||
Tetra Pak | ||
Pre-sterilisations | 3 | [/week] |
Sterile water re-circulations | 3 | [/week] |
Sterile water circulation time | 6 | [h/week] |
of which in Hibernation | 6 | [h/week] |
Aseptic Intermediate Cleanings | 3 | [h/week] |
Cleanings In Place | 3 | [h/week] |
Utility | Consumption | Cost | ||
Steam | 4305 | [ton/year] | 189435 | [EUR/year] |
Electricity | 739 | [MWh/year] | 73891 | [EUR/year] |
Chilled water | 0 | [MWhr/year] | 0 | [EUR/year] |
Tower water | 37 | [MWhr/year] | 75 | [EUR/year] |
Fresh water | 30381 | [m3/year] | 79599 | [EUR/year] |
Compressed air | 41519 | [Nm3/year] | 830 | [EUR/year] |
Caustic (50 w/w%) | 14876 | [kg/year] | 16662 | [EUR/year] |
Acid (60 w/w%) | 4223 | [kg/year] | 5912 | [EUR/year] |
Sewage | 34687 | [m3/year] | 8325 | [EUR/year] |
Sum utility cost | 374729 | [EUR/year] |
UHT unit D
Estimation tool
Cost of ownership with hibernation mode
General input Production Scenario
*Bold numbers indicate available information.
Production | ||
Production weeks per year | 46 | [weeks/year] |
Production volume per week | 2 100 | [m3/week] |
Annual production volume | 96 600 | [m3/year] |
Non-production | ||
Tetra Pak | ||
Pre-sterilisations | 3 | [/week] |
Sterile water re-circulations | 3 | [/week] |
Sterile water circulation time | 6 | [h/week] |
of which in Hibernation | 0 | [h/week] |
Aseptic Intermediate Cleanings | 3 | [h/week] |
Cleanings In Place | 3 | [h/week] |
Utility | Consumption | Cost | ||
Steam | 4413 | [ton/year] | 194172 | [EUR/year] |
Electricity | 741 | [MWh/year] | 74092 | [EUR/year] |
Chilled water | 0 | [MWhr/year] | 0 | [EUR/year] |
Tower water | 70 | [MWhr/year] | 140 | [EUR/year] |
Fresh water | 31285 | [m3/year] | 81966 | [EUR/year] |
Compressed air | 41519 | [Nm3/year] | 830 | [EUR/year] |
Caustic (50 w/w%) | 14876 | [kg/year] | 16662 | [EUR/year] |
Acid (60 w/w%) | 4223 | [kg/year] | 5912 | [EUR/year] |
Sewage | 35698 | [m3/year] | 8567 | [EUR/year] |
Sum utility cost | 382341 | [EUR/year] |