In a world where environmental issues take center stage, Tetra Pak is stepping up to meet the challenge of driving sustainability and efficiency within the manufacturing process. Since its establishment in 1951, Tetra Pak has been at the forefront of packaging innovation, renowned for their paper-based cartons that safeguard liquids such as milk, juice, and soups without the need for refrigeration.

Beyond Packaging: A Pivotal Role in Food Production

Beyond just packaging, the Swedish-based company plays a crucial role in food production. It offers processing and service solutions aimed at enhancing efficiency and reducing waste. Tetra Pak's operations encompass the entire food value chain, from the processing of raw materials to the final packaged product.Blair Jordan, Tetra Pak's processing director for Oceania, explained how the company is taking measures to reduce food waste, enhance sustainability, and integrate smart technologies into the food production landscape.

Processing Expertise: A Dual Focus

While Tetra Pak is widely recognized for its packaging solutions, its expertise extends far beyond that. The company provides essential processing equipment to assist food producers in manufacturing products more efficiently and sustainably. "We offer a wide 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 distinct advantage. By handling both aspects, Tetra Pak can offer more insights into production processes, ensuring that products not only meet market demands but also align with the sustainability goals of producers and consumers.

Addressing Food Waste: A Global Concern

Food waste is a significant global issue. In Australia alone, approximately 7.6 million tonnes of food is wasted each year, with a value of around $36 billion. At the same time, nearly 2 million Australian households still face food insecurity."These statistics are alarming, especially when considering the ongoing challenges of feeding a growing global population," said Jordan. "Food waste also contributes significantly 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 tackle food waste directly. It has developed technologies that reduce spoilage and extend shelf life."One of our key solutions is our aseptic processing and packaging technology," said Jordan. "Products like UHT (ultra-high temperature) beverages and ESL (extended shelf life) products can stay fresh for much longer without the need for preservatives. This significantly reduces the amount of food discarded due to expiration."For instance, UHT milk can have a shelf life of up to a year, compared to the typical 10-15 days for fresh milk. ESL products, although still requiring refrigeration, last significantly longer than fresh counterparts, which is beneficial for longer transport routes and enables more efficient, centralized production.These innovations help reduce food waste throughout the supply chain, from production and transportation to retail and consumption. Additionally, they contribute to lower energy consumption as ambient products, which don't require refrigeration, reduce the need for energy-intensive cooling during distribution.Other innovative solutions focus on reprocessing and upcycling production by-products and waste streams into valuable consumer products and ingredients. "For example, turning Brewers Spent Grain (BSG), a by-product of brewing rich in fibre and protein but low in sugar and often considered waste, into a nutritious ingredient for plant-based beverages," said Jordan.

Commitment to Sustainability: Beyond Food Waste

Reducing food waste is just one part of Tetra Pak's sustainability commitment. The company is dedicated to a range of initiatives aimed at reducing the environmental impact of food production.From energy-efficient heat pumps to water recovery technologies, Tetra Pak 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. We're also integrating more energy-efficient systems with heat recovery and regeneration," said Jordan.These technologies, along with advancements in reverse osmosis and ultra and nano filtration for water and chemical recovery, allow customers to minimize resource use and reduce costs while helping them 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 their environmental footprint."

Smart Factory Solutions: Shaping the Future

Another area where Tetra Pak is making significant progress is in smart manufacturing. As automation and digital technologies continue to reshape the future of food production, Tetra Pak is integrating these innovations into its operations to help customers enhance efficiency and sustainability.Smart factory solutions, including 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, reducing waste due to quality issues," said Jordan. "By automating processes, we can lower labour costs and improve sustainability by optimizing energy and resource usage."While investment in highly automated plants is prominent in countries like China, the director notes that interest in smart manufacturing is growing globally, with an increasing number of companies seeking to modernize their 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 well-suited for these products as well, helping to extend shelf life and reduce waste," said Jordan.The versatility of Tetra Pak's processing equipment allows it to adapt to a wide 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 constantly innovating to meet the growing demand for diverse food products," Jordan added. "Whether it's converting 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 remains at the forefront of innovation. These centres focus on helping Tetra Pak's customers develop and test new technologies and products that can be tailored to local markets, ensuring that Tetra Pak remains agile and responsive to the ever-changing needs of the food industry."Our mission is straightforward yet 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 dedicated 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 combination of cutting-edge technologies, innovative sustainability solutions, and a commitment to reducing food waste, the company is making significant progress towards a more sustainable future for all. Tetra Pak's approach, from reducing food waste to pioneering energy-efficient technologies, demonstrates that innovation, sustainability, and food production can work together to create lasting value for both businesses and the planet.