Manufacturing companies from organic startups to established food corporations are looking for the right production concepts to stay ahead of the curve in the dynamically growing market. Hygienic valves from the modular GEA VARIVENT® valve system provide essential tools for this, based on functional and safety concepts that have been setting standards in the dairy and food industries for decades. State-of-the-art valve technology is the key to ensuring fast system implementation, flexible process design and hygienically safe beverage products.

Contemporary drinks made from traditional plants

Plant-based drinks with milk-like properties look back on old traditions, especially in Asia, and industrially produced variants have also been around for decades. But since the turn of the millennium, both the variety and sales of these products have been growing faster and faster, as young, fitness-minded and environmentally conscious consumer groups have embraced the vegan milk alternative in coffee bars and supermarkets. Soy drinks are market leaders in East Asia, as are almond drinks in the USA, while oat drinks have emerged as top sellers in Europe. Other popular source crops are rice, millet, coconut or walnut, and some new milk alternatives are made from different pulses, such as peas.

When it comes to consumer preferences, regional factors play a role, but also the different properties of the raw materials: Soy drinks are comparable in protein content to cow’s milk, which helps with a wholesome vegan diet. Oats, on the other hand, can be grown in particularly eco-friendly ways. All plant drinks are naturally lactose- and cholesterol-free and rich in fiber. Special “Barista” variants offer coffee drinkers a perfect cappuccino foam. Most plant-based beverages are made for storage and sale at ambient temperature, like UHT milk, but yogurt and cheese-like preparations can be found on refrigerated shelves. Cooking cream and even chocolates made from plant extracts are also no longer uncommon.

Valve technology for complex challenges

All modern plant drinks are based on well-known crops, but the respective processing methods can differ greatly. With newer product variants, such as oat beverages, the standard process is not even fully established yet. Dairy corporations entering this market are facing a learning curve, in particular regarding the first process stages, in which the liquid basic product first has to be obtained by extraction and is not delivered like raw milk. The various grains, pulses and other source ingredients all have highly specific properties and requirements that must be taken into account. Smaller specialist plant drink producers at the other end of the manufacturer spectrum, often with an organic or vegan background, generally know their chosen crops well, but may need support in scaling up to industrial processes. Only the soy drink process is mature, and most soy drink manufacturers have industrial experience. The challenge for them, especially in the dynamic Asian core markets, is to be able to adapt their production quickly and flexibly to ongoing developments in demand and competition.

The global technology provider GEA has been supporting the food and beverage industry for years in the effort to develop and improve plant-based beverage production processes. The recognized health, environmental and climate benefits of plant foods have been key drivers in this endeavor. A global network of GEA specialist consultants and test centers is available to manufacturers and system planners, providing expertise and supplying all necessary system components – from technically advanced decanter centrifuges, UHT stations, hygienic valves, pumps, tank cleaners and piping systems to complete process systems.

Automated process control

The more advanced the beverage produced and the associated system, the more likely industrial manufacturers will rely on digital control and monitoring technology to ensure the pre-programmed flow of all production and cleaning operations. GEA VARIVENT® valve units are equipped with modern control digitally connected to the plant’s central control unit. This setup streamlines processing of the liquid base into beverage products from different recipes: The various mixing ratios and process schedules are simply programmed into the central control unit and can be called up with just a few clicks. The valve status is permanently digitally monitored but can also be visually checked at any time via a 360° LED signal. For greatest ease of use, the state-of-the-art control tops enable fully automatic commissioning of the valve, which greatly reduces the time and staff expenditure.

Phase 3: Dosing and filling

Towards the end of the process, most current plant-based beverages pass through a UHT station so that they can be sold at ambient temperature. In other cases, the product is pasteurized, then cooled, stored and transported in a cold chain.

UHT-treated product must be treated aseptically during the dosing and filling phase in order to avoid possible recontamination. Here too, hygienic GEA VARIVENT® valves can be applied to carry out selected functions. Special GEA Aseptomag® and D-tec® valves are available for critical applications in the Aseptic and UltraClean hygiene classes. Both these valve families are serviced by the same maintenance network as the other GEA valves.