How South African dairy producers can cut emissions by nearly half

Dairy producers can reduce greenhouse gas emissions by between 40% and 49% simply by upgrading their existing processing lines. That is the central finding of the Dairy Processing Impact Assessment, a new study by Tetra Pak, independently reviewed by the Carbon Trust.

The study covers four major processing line types: chilled pasteurisation, chilled fermented, ambient UHT indirect and ambient UHT direct. Across all four, average reductions of 47% in greenhouse gas emissions, 45% in water use and 57% in product losses are achievable. These figures are conservative. The assessment excludes additional savings from reduced water consumption and product loss, meaning the true environmental benefit is higher.

For South Africa’s dairy sector, the findings are timely. Rising input costs, the persistent threat of foot and mouth disease, unreliable energy supply and water scarcity are pressing on producers simultaneously. The study points to relief that does not require a full capital overhaul. The technology is available now, working on equipment already in place.

Three categories of upgrade are driving the results. Electrically powered heat pumps replace or reduce fossil fuel-based boilers and chillers, cutting fuel consumption and heat-related emissions. Integrated process efficiency solutions, including OneStep Technology for UHT milk and yoghurt, combine multiple production steps, reducing electricity and steam use. Filtration and recovery solutions, including cleaning-in-place recovery systems and water filtering stations, cut product loss and water consumption across the line.

South Africa’s solar resource gives one upgrade particular local relevance. Solar thermal collectors generate industrial process heat, replacing fossil fuel-based heating. In a country with some of the world’s highest solar irradiation levels, where energy costs and supply reliability remain daily concerns, this is a practical option.

Globally, rolling out these upgrades could deliver carbon savings of up to 12.7 million tonnes of CO₂ equivalent per year, equivalent to removing three million cars from the road. Water saving solutions could reduce dairy production line water use by up to 455 million cubic metres annually worldwide.

Most processing lines currently in operation are older than the 2019 baseline used in the assessment. Real plants are likely consuming more energy than the baseline reflects, meaning actual savings from upgrading could exceed the headline numbers.

Roberto Franchitti, executive vice-president for Processing Solutions and Equipment at Tetra Pak, says: “For many dairy producers, improving efficiency while managing costs is a daily challenge. Our study shows that practical improvements to existing lines can reduce energy, water, chemicals and product loss, helping customers strengthen performance and lower total cost of ownership without major disruption.”

Maintaining those gains requires consistent technical support. In South Africa, processing equipment routinely operates under loadshedding conditions and technical capacity on the ground is often stretched. An upgrade not properly maintained loses its gains.

For producers investing in efficiency improvements, the quality of ongoing support matters as much as the upgrade itself.

Image credit: Freepik/usertrmk