In conversation with Mr. TK Radhakrishnan, Vice President – Food Systems Business Unit at HRS Process Systems Ltd., he delves into the nuances of HRS heat exchangers, how they function in the dairy sector, and the future of dairy processing
Question- How have your heat exchangers been specifically adapted or optimized for dairy applications like yogurt and cheese production, where temperature control is critical?
In dairy processing, temperature precision determines product quality. Our corrugated tube heat exchangers (CTHEs) are engineered to deliver highly stable thermal performance with fast response times, making them ideal for yogurt, cultured milk and cheese applications. The corrugation pattern enhances turbulence even at low velocities, ensuring uniform heat transfer and minimising the risk of burn-on or thermal stress to sensitive dairy proteins.
For yogurt and fermented products, we optimise exchanger geometry to allow gentle handling and controlled heating profiles, which are essential for maintaining culture viability and consistent coagulation. In cheese processing, our systems deliver precise temperature control during milk standardisation, enzyme addition and curd formation, enabling consistent yields and improved textural stability.
Question- Maintaining consistent texture and flavor in dairy products is key. How do your systems help processors maintain uniform product quality during pasteurization, fermentation, and cooling?
Dairy processors rely on repeatability, and this is where our thermal systems excel. Our CTHE-based pasteurizers provide accurate temperature hold, minimal thermal gradients and smooth product pathways that preserve fat globule structure and protein integrity. The result is a more stable body, texture and mouthfeel.
During fermentation, our process modules ensure a controlled heating and cooling ramp, supporting predictable culture activity and acidification curves. For final chilling, the corrugated design enhances heat transfer even with viscous or partially fermented products, ensuring rapid and uniform cooling that locks in flavour and prevents syneresis. This integrated approach ensures processors achieve consistent quality across batches and across product categories.
Question- Energy costs are a major concern for dairy processors. Could you share how your heat recovery or regenerative systems contribute to lowering energy consumption and operational costs?
Energy optimisation is integral to HRS design philosophy. Our regenerative systems use counter-current corrugated tube exchangers that achieve very high thermal efficiency, enabling processors to save energy during pasteurisation and cooling cycles. In a typical dairy pasteurizer regeneration efficiencies can reach 93% or more, which directly translates into substantial energy savings.
This recovered energy reduces boiler load, cuts refrigeration requirements and significantly decreases steam and electrical consumption. For dairy plants running multiple skids—milk heating, yogurt incubation, whey concentration—we integrate these modules to maximise heat reuse across the line. Many of our clients have seen measurable reductions in utility consumption and operational costs, directly strengthening their bottom line.
Question- Hygiene is paramount in dairy. What design innovations in HRS equipment ensure effective cleaning, minimal contamination risk, and reduced downtime between production batches?
Our systems design adherence to EHEDG design principles and 3A sanitary standards, incorporating polished internal surfaces, minimal dead zones and hygienic welds. The natural turbulence created by corrugated tubes reduces fouling, making cleaning easier and faster.
For high-viscosity dairy products such as yogurt, processed cheese or paneer slurries, we use our UNICUS® scraped surface heat exchanger. Its unique reciprocating scrapers prevent product build-up while maintaining gentle handling. This not only improves heat transfer but also reduces the frequency and duration of CIP cycles.
Our CIP-ready designs, automated valve manifolds and real-time monitoring of flow, temperature and pressure ensure consistent cleaning, reduced product carryover risks and lower downtime between batches.
Question- How are HRS solutions integrating with modern automation and digital monitoring systems to ensure process precision and traceability in dairy processing lines?
Automation has become a necessity for dairy processors, not a luxury. Our systems come equipped with SCADA-enabled controls, PLC automation, recipe management and batch tracking capabilities. This ensures that pasteurisation temperature, fermentation time, cooling curves and CIP cycles are monitored and logged in real time.
We also support integration with DCS, IOT and other related systems, enabling processors to achieve full traceability from raw milk to finished yogurt or cheese. Predictive maintenance sensors on critical components help avoid unexpected downtime, ensuring more stable production and leaner operations.
Question- Dairy processors range from small artisanal producers to large industrial plants. How does HRS tailor its technology for different production scales, especially for products like Greek yogurt or processed cheese?
Flexibility is one of our strongest advantages. For small and medium producers, we offer modular, skid-mounted units that are easy to install, operate and scale. These are ideal for artisanal yogurt, regional specialty dairy products or niche cheese varieties.
For large industrial plants, we design fully integrated processing lines with high-capacity corrugated tube modules, UNICUS® scraped surface systems and energy-efficient heat recovery networks. Whether the requirement is yogurt, high-protein formulations, flavored dairy drinks or processed cheese, we tailor exchanger geometry, scraper speed, automation level and CIP configuration to match production volumes, rheology and process goals.
Question- What major trends do you foresee shaping the future of dairy processing, such as plant-based alternatives, energy-efficient systems, or circular economy principles—and how is HRS preparing to meet those demands?
The dairy industry is moving in multiple strategic directions. First, the demand for value-added dairy, yogurt, probiotic drinks, whey-based beverages and cheese variants—is increasing rapidly. Second, energy-efficient and sustainable processing is becoming central to capital investment decisions. Third, plant-based and hybrid dairy alternatives are expanding the category, requiring equipment that can handle diverse viscosities and ingredient systems.
HRS is responding to these trends with next-generation corrugated tube technology, enhanced regenerative modules, low-waste CIP designs and automation-ready dairy skids. We are also developing solutions suitable for plant-based formulations, where thermal sensitivity and texture preservation are key. Our goal is to provide processors with future-ready systems that maximise efficiency, support sustainability targets and enable innovation across both traditional and emerging dairy categories.
