Lausanne, Switzerland: Modernising existing dairy processing equipment can reduce greenhouse gas emissions by 40–49%, depending on the type of production line, according to a new study by Tetra Pak. The findings highlight that such reductions can be achieved without a complete overhaul of processing lines, using solutions already available in the market. The study also noted that upgrading existing systems can significantly cut emissions, product losses, and operating costs.
The Dairy Processing Impact Assessment, independently reviewed by the Carbon Trust, follows internationally recognised avoided emissions frameworks. It evaluates the benefits of upgrading liquid dairy processing lines by comparing 2019 best-practice systems with projected improvements from a global rollout of upgraded lines by 2025.
The global dairy sector plays a vital role in food systems and livelihoods, but it is also resource-intensive, accounting for 2.7% of global greenhouse gas emissions in 2023. The study highlights that optimising existing infrastructure offers a practical opportunity to improve efficiency, reduce environmental impact, and lower costs without waiting for new technologies or undertaking large-scale replacements.
According to the assessment, modernising current equipment can deliver average reductions of 47% in greenhouse gas emissions, 45% in water usage, and 57% in product losses. If implemented globally, these improvements could result in carbon savings of up to 12.7 million tonnes of CO2 equivalent—comparable to removing around three million cars from the road. Additionally, advanced water-saving technologies such as filtration and cleaning-in-place (CIP) systems could reduce water use in dairy processing by up to 455 million cubic metres annually.
Rodrigo Godoi, vice president, processing portfolio management at Tetra Pak, said that improving efficiency while managing costs remains a key challenge for dairy producers. He noted that practical upgrades to existing lines can lower energy and water use, reduce product losses, and decrease overall costs without major operational disruptions, especially when supported by favourable policies and financial incentives.
The findings also emphasise the role of accessible technologies such as electrically powered heat pumps to reduce reliance on fossil fuels, integrated processing solutions like OneStep Technology for UHT milk and yoghurt, and advanced filtration and recovery systems that minimise waste and conserve water.
Veronika Thieme, associate director Europe at the Carbon Trust, stated that assessing avoided emissions is key to understanding the potential of such solutions. She added that building a strong evidence base can help scale these innovations and accelerate decarbonisation across the global dairy sector.