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Reducing energy consumption in milk pasteurizers through insulation of holding tube : A case study

Year: 2025

Type: article

Abstract: The dairy industry is a major energy consumer, with pasteurization processes accounting for a significant portion of this demand. While the general concept of thermal insulation is well established, this study provides a context-specific contribution by quantitatively assessing the impact of insulating holding tubes in High-Temperature Short-Time (HTST) pasteurizers—a component often overlooked in published literature, particularly within the Indian dairy sector. Four commercial pasteurizing units (two at 10,000 LPH and two at 20,000 LPH) were analyzed for holding time compliance, heat loss, and economic impact before and after the application of polyethylene foam insulation. Theoretical and practical calculations confirmed that holding times (18–28 seconds) exceeded regulatory standards, ensuring product safety. Without insulation, heat losses in 10KL units were 0.85 and 1.06 kW, and in 20KL units, 1.80 and 1.60 kW; with insulation, these losses dropped to 0.66 and 0.61 kW (10KL) and 0.43 kW (20KL). The resulting annual revenue savings ranged from ₹4,611 to ₹33,264 per unit, demonstrating rapid payback and significant cost-effectiveness. This case study advances the field by providing actionable engineering data on insulation material selection, thickness optimization, and practical implementation for holding tubes, which are prevalent in dairy plants. Furthermore, it links energy savings to environmental benefits, such as reduced greenhouse gas emissions, supporting the adoption of sustainable practices in dairy processing. By bridging the gap between theoretical principles and real-world application, this study offers a holistic, evidence-based framework for dairy engineers and plant managers seeking to enhance energy efficiency, economic performance, and sustainability in milk pasteurization operations.

Source: Environment Conservation Journal

DOI: 10.36953/ecj.31883040

Authors: Spoorthy G. S., Venkata Surya Avinash Rebba, Manjunatha B. M.

Institutions: Sri Venkateswara University, Sri Venkateswara Veterinary University, University of Reading

Language: English

Topic: Energy Efficiency and Management

Subfield: Renewable Energy, Sustainability and the Environment

Field: Energy

Domain: Physical Sciences

SDGs: Industry, innovation and infrastructure, Affordable and clean energy, Responsible consumption and production, Zero hunger, Climate action

Open Access status: gold

Estimated APC paid: $225