In a time where environmental concerns are front and centre, Tetra Pak is rising to the challenge of driving sustainability and efficiency in the manufacturing process.
Since its founding in 1951, Tetra Pak has been a pioneer in packaging innovation, most known for their paper-based cartons that protect liquids like milk, juice, and soups without refrigeration.
Beyond packaging, the Swedish-based company also plays a pivotal role in food production, offering processing and service solutions designed to enhance efficiency and reduce waste.
Tetra Pak’s operations span the entire food value chain, from the processing of raw materials to the final packaged product.
Blair Jordan, Tetra Pak’s processing director, Oceania, explained how the company is taking steps to reduce food waste, enhance sustainability, and integrate smart technologies into the food production landscape.
A dual focus
While Tetra Pak is perhaps most known for its packaging solutions, the company’s expertise goes far beyond that. Tetra Pak provides essential processing equipment to help food producers manufacture products more efficiently and sustainably.
“We offer a broad range of technologies including pasteurisation, sterilisation, separation, mixing, evaporation, spray drying, and powder handling,” said Jordan.
“These diverse technologies form the backbone of our processing portfolio for end-to-end solutions, which is a core part of our business.”
This integration of processing and packaging gives Tetra Pak a unique advantage.
By handling both sides of the equation, Tetra Pak can offer more insights into production processes, making sure that products not only meet market demands but also align with both producer and consumer sustainability goals.
Food waste
Food waste is a global concern. In Australia, approximately 7.6 million tonnes of food is wasted every year, valued at around $36 billion. At the same time, nearly 2 million Australian households continue to face food insecurity.
“These statistics are concerning, especially when you consider the ongoing challenges of feeding a growing global population,” said Jordan.
“Food waste is also a major contributor to climate change, accounting for about 10 per cent of Australia’s annual greenhouse gas emissions.”
Given the scale of the problem, Tetra Pak has made it a priority to address food waste head-on, developing technologies that reduce spoilage and extend shelf life.
“One of the key solutions we offer is our aseptic processing and packaging technology,” said Jordan.
“Products like UHT (ultra-high temperature) beverages and ESL (extended shelf life) products are able to stay fresh for much longer, without adding preservatives, which significantly reduces the volume of food thrown out due to expiration.”
For example, UHT milk can have a shelf life of up to a year, compared to the typical 10-15 days for fresh milk, while ESL products, though still requiring refrigeration, last significantly longer than fresh counterparts – beneficial for longer transport routes and enabling more efficient, centralised production.
These innovations help reduce food waste across the supply chain, from production and transportation to retail and consumption.
Additionally, they contribute to lower energy usage, as ambient products, those that don’t need refrigeration, reduce the need for energy-intensive cooling during distribution.
Other innovative solutions focus on reprocessing and upcycling of production by-products and waste streams into valuable consumer products and ingredients.
“For example, turning Brewers Spent Grain (BSG), a by product of brewing that is rich in fibre and protein but very low in sugar and generally considered waste, into a nutritious ingredient for plant-based beverages,” said Jordan.
Reducing food waste is just one piece of the puzzle. Tetra Pak’s commitment to sustainability extends across a range of initiatives designed to reduce the environmental impact of food production.
From energy-efficient heat pumps to water recovery technologies, the company is developing innovations that make food manufacturing more sustainable.
“In recent years, we’ve seen a growing interest in renewable energy solutions like industrial heat pumps, solar power, and shifting from coal or gas generated steam to electric heat generation, and we’re also integrating more energy-efficient systems with heat recovery and regeneration,” said Jordan.
These technologies, along with advances in reverse osmosis and ultra and nano filtration for water and chemical recovery, allow customers to minimise resource use and reduce costs while helping meet their sustainability targets.
“We’re particularly focused on sustainable solutions in the Oceania region, where we see strong opportunities to introduce these applications,” Jordan added.
“Companies in markets like New Zealand, where sustainability is highly valued, are increasingly eager to invest in technologies that reduce the environmental foot-print.”
Smart factory solutions
Another area where Tetra Pak is making waves is in smart manufacturing.
As automation and digital technologies continue to shape the future of food production, Tetra Pak is integrating these innovations into its operations, helping customers boost efficiency and sustainability.
Smart factory solutions, which include traceability systems, enterprise resource planning (ERP), and order management, are already transforming the industry.
“We’re investing in technologies that not only improve production efficiency but also ensure product consistency cutting out waste due to quality issues,” said Jordan.
“By automating processes, we can reduce labour costs and improve sustainability by optimising energy and resource usage.”
While investment in highly automated plants is evident in countries like China, the director notes that interest in smart manufacturing is growing globally, with an in-creasing number of companies seeking to modernise operations.
Innovating across food categories
Tetra Pak’s commitment to sustainability is not limited to traditional food products. The company is increasingly focusing on plant-based alternatives, including soy, oat, and pea protein products.
“Our sterilisation and packaging technologies are ideal for these products as well, helping extend shelf life and reduce waste,” said Jordan.
The versatility of Tetra Pak’s processing equipment allows it to adapt to a range of food categories, providing sustainable solutions for both conventional dairy and beverage products as well as emerging plant-based and new food alternatives..
“We’re continuously innovating to meet the growing demand for diverse food products,” Jordan added.
“Whether it’s turning milk into milk powder or developing new ways to process plant-based foods, we’re committed to finding ways to reduce waste and improve sustainability across the entire food value chain.”
Tetra Pak’s global network of product development centres ensures that the company stays at the forefront of innovation.
These centres focus on helping Tetra Paks customers develop and test new technologies and products that can be adapted to local markets, ensuring that Tetra Pak remains agile and responsive to the ever-changing needs of the food industry.
“Our mission is simple but powerful: to protect food, people, and the planet,” said Jordan. “Our company was founded on the principle that a package should save more than it costs.”
“By investing in sustainable technologies and working closely with our customers, we’re helping to address the challenges of food waste, energy efficiency, and environmental sustainability.
“It’s a journey we’re committed to, and we’re excited to continue leading the way in transforming the food production industry.”
As the world grapples with climate change, resource scarcity, and a growing population, Tetra Pak’s solutions offer hope.
Through its blend of cutting-edge technologies, innovative sustainability solutions, and a commitment to reducing food waste, the company is making inroads toward a more sustainable future for all.
Tetra Pak’s approach, from reducing food waste to pioneering energy-efficient technologies, shows that innovation, sustainability, and food production can go hand in hand, creating lasting value for both businesses and the planet.
