SIG empowers European UHT milk mega plant with state-of-the-art aseptic technology

23 Apr 2020 --- SIG is set to supply 15 aseptic filling machines for one of Europe’s largest greenfield projects in the field of UHT milk, spearheaded by Hochwald, one of the largest German dairy cooperatives. The aseptic specialist's flexible filling technology will enable Hochwald to offer a greater variety of aseptic packaging solutions in five different carton formats, with a wide range of volumes, closures and straw solutions. SIG’s innovative carton structures also have proven environmental benefits compared to many packaging alternatives.

As part of the mega project, Hochwald will build a new plant with a capacity of more than 800 million liters of milk per annum. Milk will be processed and sold as UHT milk, cream, condensed milk and flavored milk for the European market and export to China, the Middle East and Africa from 2022.

Pasteurized dairy products have to be stored and transported chilled, meaning they can be restrictive to effective distribution. Against this background, UHT milk in aseptic carton packs can offer manufacturers advantages, such as significantly longer shelf life of up to 12 months without preservatives. The aseptic process ensures the safe retention of vitamins, flavor and overall high product quality without the need for refrigeration.

SIG has been selected as the preferred partner for the new project and will supply 15 aseptic filling machines for the new plant, which will be based in Mechernich, Germany – just one hour’s drive from SIG’s plant and European HQ in Linnich.Hochwald's new plant will have a capacity of more than 800 million liters of UHT milk per annum.

The biggest challenges for SIG’s customers in the UHT milk space, according to Robert Kummer, Head of Market Area Germany, is to quickly bring trend products to market that are precisely tailored to the needs and demands of consumers – in the most suitable packaging.

Filled with high productivity
SIG filling machine technology provides flexibility and enables customers to produce up to 16 product variants on one machine. “We believe our filling machines are state-of-the-art in terms of speed, reliability, efficiency and aseptic safety, assisting customers in achieving consistently high productivity levels,” Kummer tells PackagingInsights.

“Our sleeve-fed systems allow for a range of packaging formats, volumes and opening solutions, providing our customers with more than 270 different packaging options. Sealing each carton individually allows customers to rapidly adjust filling volumes and formats and to use our system with a wide range of products.”

Further, SIG’s system has superior capabilities to fill a wide range of liquids with different viscosity levels and particulates. This flexibility and the supplier's sleeve-based system allow customers to maximize their asset utilization by addressing a broad range of different product categories, ranging from soups and sauces to drinks, all with varying levels of viscosity or with particulates, Kummer explains.

The format, volume, product and decor flexibility of SIG's filling machines enable F&B manufacturers to keep production extremely flexible and cost-effective.“In a market environment which is getting more competitive every day, efficiency and flexibility in our production are as crucial as ever,” says Thorsten Oberschmidt, COO at Hochwald.

“Our new state-of-the-art plant will enable us to build a competitive and futureproof manufacturing facility and our close cooperation with SIG will make a significant contribution to our major European greenfield UHT project, with products assured of the best flexible and innovative packaging solutions of their kind,” Oberschmidt adds.

Environmental and economic gains
SIG filling machines come with a very low waste rate – below a reported 0.5 percent – and have “the highest level of flexibility” in terms of carton formats, volumes, decors and even the type of products customers can put in them. This speed, efficiency and flexibility have a direct effect on the customer’s bottom line, Kummer notes.

“We have our eye firmly on our ecological footprint. In all-new designs, we aim to substantially reduce energy and water consumption, and the use of hydrogen peroxide.”

An example of this is the CFA 124 and CFA 724 high-speed filling machines. These machines can fill 24,000 packages per hour. Compared to the preceding models, for the corresponding formats, these machines require 30 percent less energy, 25 percent less water, 54 percent less compressed air and 18 percent less hydrogen peroxide per unit produced.

SIG recently published its Corporate Responsibility Performance Update for 2019, highlighting several key environmental sustainability achievements. Notably, the supplier introduced the world’s first Aluminium Stewardship Initiative labeled packs and the first aseptic carton packs with all materials from certified sources – paperboard, plant-based polymers and aluminum foil. Pivotal progress has been made but 2020 presents further challenges for SIG as it works to secure its Way Beyond Good social and environmental targets before the year’s end.

By Joshua Poole