In an increasingly diverse and competitive dairy market, the industry has invested in technology to increase efficiency without sacrificing quality. In the case of cream cheese, a staple in the daily lives of Brazilians, the challenge for manufacturers is to find a way to accelerate the pace of production without increasing operating costs or losing the expected quality standard for the product. To support the sector, Tetra Pak, a world leader in food and beverage processing and packaging solutions, offers solutions that contribute to greater agility and flexibility for factories.

Faced with such varied consumer demands, the multinational highlights three fundamental pillars for optimizing this operation: efficiency, flexibility, and product quality.

“In addition to increasing production capacity, manufacturers need to assess where the opportunities for gains lie during the process. Our role is to combine state-of-the-art equipment with processes that can make a difference both in the utilization of ingredients and in processing time and product quality,” comments Ana Paula Forti, Director of the Processing area at Tetra Pak Brazil.

1. Produce more in less time with efficiency.

To keep up with market demands, the industry needs to find ways to increase productivity without raising operating costs. Simplifying the flow of ingredients, reducing steps, and making better use of resources are some of the ways to make production faster and more economical.

Among the technologies that can contribute to this goal is the Tetra Pak® High Shear Mixer. This equipment centralizes the entire process, and crushing, melting, homogenization, and deaeration are performed in a single step. By concentrating the operation, the manufacturer can work with larger batch capacities in less time, simplifying the production flow and increasing line capacity. “The high mechanical performance of this equipment allows achieving the desired texture using up to 20% less texture-modifying ingredients, such as gums,” reports the Processing Director of Tetra Pak Brazil.

2. Greater flexibility to meet different demands.

The ability to adapt production is another important factor for the ricotta cheese industry. Flexible production lines allow working with different types of products, helping manufacturers develop new products and lead innovation in such a competitive market, reducing the need for new investments in complementary technologies.

In this context, Tetra Pak offers solutions that allow adjusting different process parameters according to the formulation and desired product characteristics. The technology embedded in the Tetra Pak® High Shear Mixer features an automatic recipe program that allows fine process adjustments to meet the characteristics of each product type. This feature enables the production of traditional cream cheese, culinary cream cheese, creamy and processed cheeses using the same technology, while also guaranteeing texture, creaminess, consistency, and improved yield.

3. Standardization and consistency in each batch.

To maintain the quality of the requeijão cheese batch after batch, rigorous control over the different stages of the process is essential. Factors such as humidity, pH, and the type of curd coagulation can directly influence the texture, flavor, and appearance. Reducing the number of batches results in less product variability, ensuring better standardization throughout the entire process until it reaches the final consumer.

The Tetra Pak® High Shear Mixer features a turbo unit that can operate with low or high shear, a patented technology that brings flexibility and versatility to product development. The upward shear mesh allows for greater mixing intensity and turbulence for better ingredient dispersion; conversely, the downward shear mesh allows for finer, smoother, and more uniform homogenization. This control contributes to a more stable product and standardized cream cheese.

“More than just increasing production capacity, it’s important to look at the process as a whole and understand where technology can generate gains. When efficiency, flexibility, and quality control are considered together, the manufacturer can better utilize the available infrastructure and respond to market demands more consistently, in addition to having optimized workforce management, since employee turnover is increasingly high within industries,” concludes Ana Paula Forti.