In the evolving landscape of dairy, value-added segments like cheese, paneer (cottage cheese), yogurt and whey are driving demand for advanced processing solutions. We spoke with Mr. T. K. Radhakrishnan, Vice President – Food Systems Business Unit at HRS Process Systems Ltd., to understand the technological advancements, sustainability imperatives and innovations shaping the industry.
Q1. What are the biggest technological advancements in thermal processing specifically shaping the future of cheese and yogurt production?
Thermal processing has evolved far beyond conventional pasteurisation. Today, we see advancements such as high-temperature short-time (HTST) systems, thermisation for microbial control while retaining nutritional properties. Precision temperature profiling is another key development, enabling processors to fine-tune texture, viscosity and culture activity in cheese and yogurt. These improvements not only ensure consistent quality but also allow manufacturers to innovate with specialty and probiotic-rich products.
Q2. How are dairy processors balancing product quality and food safety with the need for energy efficiency and sustainability?
The balance comes from process integration and smarter energy recovery. Heat recovery systems allow reuse of thermal energy, significantly reducing fuel and utility costs. Low-temperature long-time (LTLT) alternatives are also making a comeback, particularly for specialty and artisanal products, without compromising safety. The core challenge is achieving microbial safety and extended shelf life while using fewer resources, and that is exactly where engineering design makes the difference.
Q3. Can you describe how your turnkey process lines are designed to ensure regulatory compliance while improving operational efficiency?
At HRS, compliance with EHEDG, 3-A Sanitary, FDA, ATEX, TPED and HAZOP study is embedded in the design of our turnkey solutions. Hygienic equipment design is critical — smooth finishes, minimal dead legs and fully automated CIP (clean-in-place) systems ensure food safety while reducing downtime. Traceability is enabled through advanced control systems, giving processors real-time monitoring and documentation. By integrating these features, our cheese, paneer (cottage chest), yogurt and whey process lines deliver not just compliance but also improved operational efficiency, reducing waste and enhancing throughput.
Q4. With growing consumer demand for value-added dairy products, what processing challenges are most common — and how is the industry addressing them?
In cheese and yogurt, culture management, viscosity control, whey fractionation and yield optimisation are the most frequent challenges. For instance, ensuring probiotic viability in yogurt or managing curd firmness in cheese requires precise process control. The industry is addressing these with advanced membranes, centrifugal separation, enzymatic aids, and digital formulation control systems. The emphasis is on delivering consistent quality while enabling product differentiation, such as probiotic yogurts, specialty cheeses, and whey-protein enriched beverages.
Q5. What role does equipment customisation and modularity play in helping dairy companies pivot rapidly for new SKUs?
Flexibility is crucial in today’s dairy sector. Modular and customisable equipment allows processors to scale up from pilot to commercial production seamlessly. For example, a yogurt line can be adapted for probiotic or flavoured variants with minimal changeover time. Similarly, flexible automation recipes and sanitary fittings support faster line adjustments and reduce downtime. This adaptability is vital for companies introducing new SKUs to meet changing consumer demands in cheese, paneer (cottage cheese), yogurt and whey-based products.
Q6. Looking ahead, what types of innovation will most help dairy companies remain competitive in both domestic and export markets?
I see three areas of innovation driving competitiveness. First, processing technologies — from advanced thermal systems will shape efficiency and product quality. Second, digital process control will give manufacturers real-time insights for yield optimisation, energy reduction and traceability. Finally, waste-to-value solutions, particularly for whey, will be transformative. Instead of being treated as a by-product, whey can be valorised into high-value protein powders, beverages and nutraceutical ingredients. Together, these innovations will enable dairy companies to expand their product portfolios, reduce costs, and compete more effectively in global markets
To know more about our range of products and technology in dairy process engineering, Let’s connect with our team of experts.
HRS Process Systems Limited
3rd Floor, Kalpataru Infinia, F. P. No 21, Old Mumbai-Pune Highway, Wakdewadi, Shivajinagar, Pune 411005, Maharashtra, India
website: www.hrsasia.co.in, Email us: info@hrsasia.co.in, Call us: +91 20 25663581 / 82
