On-site Planning
Installation & Commissioning
Automated & Energy Efficient
Client Name: N****D
Country: New Zealand
Region: Canterbury Plains – A core high-quality dairy source region in the Southern Hemisphere, exemplifying natural pasture and sustainable dairy farming
Core Products: High-activity whole milk freeze-dried powder, infant formula milk base powder, instant skim freeze-dried milk powder, lactoferrin-fortified freeze-dried powder
Equipment Configuration: Hadof custom continuous vacuum freeze-drying production line (industrial dual-chamber system + multi-stage temperature control curve module + in-place CIP cleaning system)
Commissioning Date: Q3 2020
As a leading country in global dairy trade, New Zealand's Canterbury Plains, with ample rainfall and a mild climate, have become a prime region for grass-fed dairy farming. N****D Company has over thirty years of history in dairy deep processing in this region. Its partner farms produce over 200 million liters of high-quality fresh milk annually, known for high milk protein content and low somatic cell counts. When expanding into the international markets for high-end infant formula and functional milk powder, traditional spray drying technology faced three major bottlenecks:
Loss of Heat-Sensitive Nutrients: Traditional high-temperature spray drying caused denaturation of whey protein, with retention rates of immunoglobulins (IgG) and lactoferrin activity below 50%, failing to meet the stringent requirements of the European, American, and Chinese markets for "high-activity" formula powders.
Instant Solubility and Flavor Shortcomings: Spray-dried milk powder particles have a hydrophobic surface, leading to clumping during reconstitution. Additionally, the high-temperature process imparts a slight cooked flavor, making it difficult to pass sensory tests for premium organic infant formula brands.
Hygienic Design and International Certification Challenges: Exporting to the EU, US, and Southeast Asian markets required compliance with FSSC 22000, GMP, and low-allergen control standards. The old production lines had shortcomings in terms of airtightness and cleaning validation, resulting in the loss of several long-term international orders.
N****D Company clearly needed an industrial freeze-drying line capable of maximizing the preservation of fresh milk's native nutrition, achieving excellent instant solubility, and meeting strict export compliance standards. After evaluating multiple proposals from Europe and North America, the client ultimately chose Hadof's fully customized continuous freeze-drying system. We deeply optimized the system for the physical properties of milk and whey protein concentrate:
Solution: Three Core Designs Tailored to Dairy Product Characteristics
1. "Precise Eutectic Point Control + Low-Temperature Sublimation" Custom Freeze-Drying Curve
Milk concentrate is rich in lactose, whey protein, and milk fat, with a complex eutectic point and high temperature sensitivity. Hadof's R&D team measured the eutectic point of the concentrate using differential scanning calorimetry and established a three-stage gentle drying process:
- Pre-freezing Stage: Rapid crystallization at -40°C forms uniform, fine ice crystals, preventing large ice crystals from damaging the protein colloidal structure;
- Primary Drying Stage: Dynamic matching of vacuum (30Pa～60Pa) and shelf temperature ensures uniform sublimation of moisture, increasing drying efficiency by approximately 26%;
- Secondary Drying Stage: Gentle temperature control not exceeding 42°C, achieving final moisture content ≤2.0%, preventing Maillard reactions and browning, preserving the natural milky white color and light, fresh aroma.
This process achieved a Whey Protein Nitrogen Index (NSI) of over 96% and increased IgG retention by 52% compared to traditional spray drying. The reconstituted powder showed no wall adhesion or clumping and passed sensory blind tests conducted by international authorities.
2. All-Stainless Steel Hygienic Design and CIP Automatic Cleaning System
To meet the high hygiene standards for infant formula powder and EU exports, the entire production line is constructed with SUS316L stainless steel. The internal surfaces are electropolished to Ra≤0.4μm to prevent bacterial biofilm formation. An automatic rotary high-pressure CIP system supports phased programs for acid washing, alkali washing, and hot rinsing, with cleaning validation compliant with EHEDG guidelines. Aseptic isolation valves are used between the freeze-drying chamber and the condenser, ensuring zero cross-contamination between batches. The production line successfully passed on-site audits for FSSC 22000 and China's overseas manufacturing registration for infant formula.
3. Heat Pump Energy-Saving System and Low-Carbon Manufacturing
Considering New Zealand's stringent environmental regulations and carbon emission targets, the system integrates an industrial-grade high-temperature heat pump. Waste heat from the refrigeration system is recovered for the secondary drying stage, and defrost water from the condenser is heat-exchanged to preheat raw materials. Overall energy consumption is reduced by approximately 32% compared to traditional freeze-drying equipment, earning financial support from the New Zealand government's "Sustainable Manufacturing Innovation Project" and achieving a product carbon footprint 22% lower than the industry benchmark.
Client Testimonial: From Bulk Milk Powder Supplier to International Premium Functional Milk Powder Brand
After four years of stable operation, N****D Company successfully transitioned from a "raw milk powder exporter" to a "high-value-added freeze-dried milk powder own-brand manufacturer."
Market & Certification Breakthrough
- Achieved overseas manufacturing registration for infant formula in China, EU Organic certification, and US FDA GRAS certification;
- Became a core supplier of freeze-dried milk base powder for three European premium infant formula brands, with export order value growing at an average annual rate of 62%.
Significant Economic Benefits
- Material Loss Control: Traditional spray drying resulted in approximately 6%–9% material loss due to wall adhesion and thermal degradation; the freeze-drying line reduced total loss to under 1.2%;
- Product Premium: The final selling price of high-activity freeze-dried milk powder is 2.8 times that of conventional spray-dried milk powder. The client achieved full investment payback by the third year of operation and entered a phase of rapid profit growth.
Sustainable Development
- Through the heat pump and waste heat recovery system, annual CO? emissions are reduced by approximately 410 tons, securing support from New Zealand's "Green Industry Financing Scheme";
- Collaborates with partner farms to utilize biogas from anaerobic digestion of cow manure to supplement factory energy needs, further reducing reliance on fossil fuels and creating a low-carbon dairy supply chain.
"From pasture to freeze-drying chamber, our pursuit is not just about extending shelf life, but about completely delivering the pure nutrition of the Canterbury Plains to families worldwide. Hadof's industrial freeze-drying system proves that 'activity' and 'instant solubility' need not be conflicting indicators. Our milk powder reconstitutes in a cup to a state remarkably close to fresh milk. This is the ideal path for premium dairy manufacturing."
—— N****D, Technical Operations Director
