Alfa Laval’s new electrical system slashes dairy pasteurization cleaning time and water use
Alfa Laval has introduced a new technology that significantly reduces biofilm formation in dairy pasteurization equipment, enabling processors to extend cleaning intervals while reducing water, chemical and energy consumption. The Extend system, which can be retrofitted to existing heat exchangers, uses low-voltage electrical current to inhibit bacterial growth on equipment surfaces.
Technical innovation in biofilm prevention
The system works by transmitting a weak electrical current through the heat exchanger, achieving a 90-99% reduction in biofilm formation. This technological advancement allows dairy processors to safely extend the time between cleaning in place (CIP) operations from the industry standard of eight hours to 12 hours or more, whilst maintaining food safety standards.
Field-proven performance data
In a year-long implementation at a major Scandinavian dairy facility operating two 70,000-litre-per-hour pasteurization lines, the Extend™ system demonstrated significant operational benefits.
The installation achieved:
• 50% increase in operational uptime
• 30% reduction in cleaning intervals
• 7,000 m³ reduction in water consumption
• 100,000 kWh energy savings
• 35-tonne reduction in cleaning chemical usage
System specifications and compatibility
The compact device, measuring 15×6 cm and weighing 350g, is designed for seamless integration into existing dairy processing systems.
Key technical features include:
• Operating temperature range: -40°C to 105°C
• Chemical resistance to standard CIP solutions
• CE, RoHS, and Reach compliance
• Universal compatibility with heat exchangers regardless of manufacturer
Installation and implementation
The system’s plug-and-play design allows for installation without production downtime, offering flexibility through three size options to accommodate various heat exchanger configurations. This adaptability makes it particularly suitable for dairy processors looking to upgrade existing pasteurization equipment.
Environmental impact
As the dairy industry faces increasing pressure to reduce its environmental footprint, the technology addresses several key sustainability challenges. The significant reductions in water, energy, and chemical usage align with industry efforts to meet stricter environmental regulations while maintaining operational efficiency.
Quality assurance and monitoring
According to Anna Andrys, Strategic Project Manager at Alfa Laval, the implementation process includes comprehensive monitoring: “We closely monitored every aspect of the installation together and eagerly awaited the real-life results. It’s undoubtedly been a shared success.”
Industry context
The development comes at a crucial time for the dairy industry, which is actively seeking solutions to reduce its environmental impact while maintaining production efficiency. The technology represents a practical approach to achieving sustainability goals without compromising processing capabilities or food safety standards.
For more information, visit: www.alfalaval.com
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