Spray drying is one of the most energy-intensive processes in dairy production – and a big contributor to CO₂ emissions. At Arla’s milk powder factory AKAFA in Svenstrup, Denmark, the challenge was clear: decarbonize without disrupting production or profits. To solve the challenge, a collaborative partnership between Arla and GEA was formed.
Together, the partners have achieved a world first: the integration of GEA’s AddCool® high-temperature heat pump system into an operational spray dryer. The result is a 59% reduction in natural gas use for the dryer in question, cutting 1,500 tons of CO₂ emissions in the first year of operations.
As a longstanding GEA customer, it was straightforward to organize a joint investigation into possible options for decarbonizing the plant with the Arla team. This was carried out by means of a holistic energy audit, which was conducted in 2018. The challenge of reducing CO₂ emissions by means of profitable investment was evident from the subsequent analysis, however the findings also presented less obvious opportunities to the partnership that would prove to be impactful.
Line Brandt Pedersen
Director, Supply Chain Sustainability, Arla Foods
Having identified energy consumption as an area of significant importance, a highly focused team of GEA and Arla experts worked closely to design a tailor-made solution which could achieve outstanding reductions of natural gas consumption and therefore CO₂ emissions. Through a combined heating and cooling process delivered by a high-temperature heat pump system, the GEA AddCool® solution at Arla’s Svenstrup site became the first installation of its kind in a dairy production plant globally.
As GEA designed both the heat pump and the integrated heating and cooling concept, Arla received stringent performance guarantees over six years. An independent energy advisor, selected by Arla, validated the design and guarantees ahead of installation and after commissioning the system passed its site performance test on the first attempt.
Its performance is being continuously monitored through the GEA InsightPartner® solution and is on track to deliver the promised savings within the forecasted payback time.
Jens Løkke Ganderup
Project Manager, Arla Foods
The GEA AddCool® system provided several benefits to Arla:
Line Brandt Pedersen
Director, Supply Chain Sustainability, Arla Foods
At Arla’s Svenstrup site, the AddCool® integration shows that meaningful reduction of CO₂ and dependable operations can advance together when expertise and partnership align. Building on this result, both Arla and GEA are exploring a phased rollout of additional spray-drying plants at the AKAFA site, where the business case and emissions impact are strongest – reflecting GEA’s commitment to engineering for a better world.