STORIES IN THE MAKING
Efficient use of heat has become one of the most important conversations in modern dairy processing. Around the world, dairy producers face rising utility costs, stricter sustainability commitments and the ongoing need to maintain high product quality. Because heating, cooling and evaporation account for a large share of total energy consumption, heat recovery systems now represent one of the fastest and most measurable ways to improve plant performance and reduce environmental impact.
Heat recovery is not simply a technical upgrade. It’s a strategic approach that helps producers reduce operating costs, stabilize production and support long-term decarbonization goals while meeting customer and regulatory expectations across global markets.
Why Heat Recovery Matters in Today’s Dairy Plants
Thermal processes such as pasteurization, UHT treatment, evaporation and CIP drive both energy demand and operational cost. In many dairy operations, up to 70 percent of total energy use is tied to heat. That makes thermal efficiency a powerful lever for improving sustainability and lowering emissions.
As global markets tighten sustainability standards, implementing heat recovery solutions helps plants remain competitive while reducing overall energy intensity.
Plate Heat Exchangers: The Foundation of Efficient Heat Transfer
High-efficiency plate heat exchangers (PHEs) are a core component of thermal optimization. By recovering heat that would otherwise be lost, they reduce demand on both boilers and cooling systems.
Why PHEs Drive Measurable Energy Savings
- Improve heat transfer and reclaim thermal energy
- Reduce total heating and cooling requirements
- Deliver consistent temperatures for process stability
- Support sustainability goals and energy compliance
Modern PHEs offer fast payback periods and remain one of the most effective ways for dairy processors to improve efficiency plant-wide.
Electrification and SteamRecycle™: A Breakthrough for Closed-Loop Heat Recovery
Dairy processors are increasingly turning to electrification to reduce reliance on fossil-fuel boilers. SPX FLOW’s APV® Infusion UHT featuring SteamRecycle shows how electrification can transform thermal efficiency.
How SteamRecycle Works
SteamRecycle captures and recirculates 100 percent of process vapor in a closed loop. After startup, the system requires no new steam, dramatically reducing energy consumption.
Key Energy and Sustainability Benefits
- Coefficient of Performance (COP) near 4, delivering nearly four times more heat energy than electrical energy consumed
- Reduction of CO₂ emissions by more than 1,000 tons annually for a typical 12,000 L/h UHT line
- Up to 33 m³/h reduction in cooling water demand
- Lower utility requirements across global production environments
SteamRecycle represents one of the most significant leaps forward in sustainable UHT operations available today.
Learn More in Our Webinar
Join our webinar Unlocking Energy Efficiency in UHT Processing with SteamRecycle. In this session, SPX FLOW experts walk through real-world performance data, CO₂ reduction potential and how closed-loop steam recovery supports long-term decarbonization strategies in dairy and plant-based processing.
Integrated Hot and Cold Water Loops: A Holistic Approach to Heat Recovery
A complete heat recovery strategy looks beyond individual equipment to plant-wide energy flow. Integrated hot and cold water loops help ensure heat is captured, reused and distributed where needed.
Benefits of Integrated Thermal Loops
- Reuse warm water to preheat incoming product
- Reduce load on refrigeration and heating systems
- Improve plant-wide energy balance and stability
This holistic design helps dairy processors reduce total energy waste and improve thermal consistency across operations.
Recuperators for Spray Dryers: Improving Efficiency in Powder Production
Spray drying is one of the highest energy consumers in dairy processing. Recuperators recover heat from exhaust air and reuse it to preheat incoming air, significantly lowering the energy needed for evaporation.
Operational Impact
- Reduced energy intensity in powder production
- Lower utility costs
- Improved alignment with sustainability strategies
For large-scale milk and whey powder plants, recuperation can deliver substantial savings and operational resilience.
Regeneration Technologies: Smart Heat Management for Every Dairy Line
Regeneration systems transfer heat from hot product streams to colder ones, reducing the need for additional heating. This method is widely used across dairy facilities.
Where Regeneration Delivers the Biggest Wins
Regeneration is one of the most proven ways to reduce energy demand without compromising product quality.
A Holistic Heat Recovery Strategy Strengthens Dairy Competitiveness
Dairy processors that adopt a comprehensive heat recovery approach benefit from:
- Lower Operating Costs: Reduced steam generation, improved heat transfer and optimized thermal loops help lower total utility costs.
- More Stable Operations: Consistent temperature control improves reliability across production environments.
- Enhanced ESG Performance. Measurable reductions in CO₂ emissions support sustainability reporting and global compliance.
- A Future-Ready Production Model. Electrification and advanced heat recovery systems prepare plants for evolving energy standards.
A Clear Path to a More Efficient Dairy Industry
Heat recovery technologies, from PHEs to recuperators to SteamRecycle™, offer dairy producers a practical and achievable way to increase efficiency and reduce emissions. With thoughtful design and integrated thermal management, plants can unlock significant savings while supporting global sustainability commitments.
To see how these technologies come together in a seamless, plant-wide strategy, explore SPX FLOW End-to-End Turnkey Solutions.
Dairy processors that prioritize efficient heat use today will be the ones best positioned to succeed in a rapidly changing energy landscape.