In the UK, Tetra Pak Processing Systems is normally associated with the supply of advanced new processing equipment or with entire new processing units.

In practice the company also has experience of managing projects with re-used equipment, or with a combination of existing and new components.

For example, Tetra Pak Processing has successfully completed a major dairy project in Lockerbie where Arla Foods wanted to refurbish, rebuild and move existing equipment from two closed dairies into a new building. The dairy also needed new processing modules, a modern automation system and utility facilities.

Arla Foods is one of Europe’s largest food production companies and the new facility was designed to process 350,000 litres of milk in a 24-hour working day. The product range includes extended shelf-life milk, skimmed, semi-skimmed and standard milk along with cream.

Planning and preparation work at the closed dairies was crucial because completion of the different areas in the new building had to be synchronized with deliveries and installation work. Delaying access could have jeopardized the start of commercial production.

“Tetra Pak Processing and Arla Foods have worked together on many large projects around the world so there is a history of successful projects which has helped build up a relationship of trust. We have an effective framework for working together which helps create a productive partnership,” explained Mike Corrigan, Commercial Director of Tetra Pak Processing UK.

A joint project team was set up to evaluate the existing equipment in the old dairies. To reduce the installation time in the new building Tetra Pak Processing created a temporary workshop where much of this existing equipment was overhauled and rebuilt. New milk and cream pasteurizing modules along with valve manifolds were preassembled and prepared for quick installation in the new facility. In parallel with the work in the old dairies the teams of engineers from Tetra Pak and Arla Foods worked closely together on the new installation over a period of around 10 months.

Both old and new equipment is controlled by the modular plant automation system, Tetra PlantMaster, which is customised for each client. The milk pasteurization system includes standardisation, separation and bactofugation equipment. A new, more efficient, high capacity (25000 l/h) Tetra Plex C10 SR heat exchanger was installed along with a new Tetra Alex 25 homogenizer. These were linked to the original Tetra BBRPX 618 HGV bactofuge and Tetra MRPX 614 HGV separator. The Tetra Alfast Plus standardisation system was used for milk and cream.

Despite shared access to the new building with all contractors, installation was finished early. This allowed Tetra Pak Processing to complete a thorough commissioning of the plant. As a result, Arla Foods was able to begin commercial production to the agreed plant performance standards (KPI’s) ahead of schedule.

Mike Corrigan said:
“The excellent teamwork from all involved certainly contributed to the success of the project. It is a good example of how a close working partnership can achieve excellent results and make best use of all resources, including existing equipment.”