Tetra Pak research shows modernizing dairy lines can cut emissions by up to 49%

A new study by Tetra Pak indicates that modernizing existing dairy processing equipment can reduce greenhouse gas emissions by 40% to 49%, depending on the type of line. The research also shows that improving existing equipment lines can lead to significant reductions in operating costs. The results highlight that the reduction does not necessarily require a complete overhaul of the lines and can be achieved with solutions already available on the market. 

The new Dairy Processing Impact Assessment, independently reviewed by Carbon Trust, uses a methodology aligned with leading international benchmarks for emissions to be avoided. This analysis quantifies the potential gains from upgrading existing liquid dairy processing lines. The study compares best-practice lines from 2019 with potential emission savings based on a global implementation model for modernized lines in 2025. 

“For many dairy producers, improving efficiency while managing costs is a daily challenge. Our study shows that practical improvements to existing lines can reduce energy and water consumption and product losses, helping customers improve their performance and reduce the total cost of ownership without major disruptions,” explains Rodrigo Godoi, Vice President of Processing Portfolio Management at Tetra Pak. 

The global dairy sector plays a critical role in world food systems through the food and beverages it provides and the livelihoods it sustains around the world. At the same time, it is a major consumer of water and energy and was responsible for 2.7% of global greenhouse gas (GHG) emissions in 2023 1 . 

Despite this, the context opens up a significant opportunity: by optimizing existing processing lines with solutions already available on the market, producers can increase efficiency, reduce costs, and improve environmental performance without having to wait for new technologies or carry out complete line replacements. These proven improvements offer a practical and immediate path to more resilient and resource-efficient dairy operations. 

Tetra Pak's study shows that modernizing existing equipment generates substantial efficiency gains, with average reductions of 47% in greenhouse gas emissions, 45% in water use, and 57% in product losses. If these modernizations were implemented across global dairy production, this could result in global carbon savings of up to 12.7 MtCO₂e, the equivalent of taking three million cars off the road. Implementing water-saving and recovery solutions – for example, advanced membrane filtration systems and Clean in Place – could reduce water use in dairy production lines by up to 455 million m³ per year globally. 

“Improvements, aided by favorable regulatory frameworks and access to targeted financial incentives, can be further expanded, helping producers overcome initial investment barriers and accelerating progress across the dairy sector,” adds Rodrigo Godoi. 

The evaluation results highlight the contribution that improvements to existing processing lines can make to more stable and resilient food systems. These reductions can be supported by Tetra Pak through a range of upgrades already available on the market for existing lines, such as: 

• Electric heat pumps replace or reduce the use of fossil fuels in boilers and chillers , with the aim of decreasing fuel consumption and reducing heat-related emissions. 

• Integrated process efficiency, enabled by OneStep technology for UHT milk and yogurt, which combines multiple process steps into a single, more efficient concept, generating savings in electricity and steam. 

• Membrane filtration and recovery solutions , which include membrane filtration, recovery in CIP systems, and water filtration stations that recover product and water losses from process and cleaning streams. 

“Our food systems offer significant decarbonization opportunities. Assessing emissions that can be avoided is an important way to understand the carbon savings that these solutions can provide,” comments Veronika Thieme, Associate Director for Europe at the Carbon Trust. “By quantifying the emissions avoided by new solutions that can help decarbonize the agricultural industry, we create the necessary evidence base to scale them up.”