Case story Alfa Laval

Smarter Fruit Processing at Dolomiti

In Italy, fruit juices, pulps and purées made from organically grown apples and pears are a staple in every household. However, competition is fierce and producers need to balance quality with efficiency. Dolomiti Fruits, a Northern Italian fruit processor, successfully did both by upgrading to Alfa Laval’s WideGap plate heat exchangers, boosting productivity and cutting energy costs.

Challenging the Tubular Norm

Back in 2018, Dolomiti relied on a tubular heat exchanger for the enzymatic deactivation process. Over time, operators noticed caramelised sugars sticking to the tube walls, significantly reducing thermal efficiency and making cleaning time-consuming. With pressure drops reaching 16 bar, their pumps were under strain, leading to excessive energy use and higher operational costs.

From Problem to Plate Heat Exchangers
Seeking a more efficient solution, Dolomiti turned to Alfa Laval. Their goals were clear: reduce pressure loss, minimise energy use, and improve cleanability. Alfa Laval recommended testing Alfa Laval’s plate heat exchanger with wider channels, designed to handle fibrous, viscous media like fruit pulp.

The Results: Efficiency in Action
This change brought instant improvements. Heat recovery increased, allowing steam consumption to drop by 45%. In parallel, pressure loss decreased significantly, reducing electricity usage by 10 to 15%. Still, Dolomiti’s production team wasn’t fully satisfied. Cleaning remained a concern.

Innovation through Collaboration
Recognising the importance of hygiene and cleanability, Dolomiti collaborated directly with Alfa Laval’s channel manager, Jakob Worsoe. Their feedback kickstarted a joint development project aimed at improving the plate design. According to Clemens Wictor, Industrialisation Project Manager at Alfa Laval: “By listening closely to the customer’s challenges, we developed something better,not just for them, but for the market as a whole.”

The Launch of Hygienic WideGap HL8-WG Plates
Following successful trials, Alfa Laval introduced an improved version of the WideGap plates: the HL8-WG. These new hygienic plates provided enhanced cleanability, while maintaining performance and durability, marking a major step forward in fruit processing hygiene.

New Plant, Clear Choice
When Dolomiti built a new facility two years later, the choice was easy. Instead of reverting to traditional tubular technology, they fully embraced the WideGap solution. “The energy savings alone paid for the investment within a year,” says Dolomiti. “And now, three years in, performance is still outstanding.”

A Sustainable Future with Proven Results
Today, Dolomiti operates four production lines equipped entirely with Alfa Laval WideGap plate heat exchangers. The factory processes up to 250 tonnes of high-quality fruit per day, totalling over 80,000 tonnes to date. Benefits include:

Pressure drops reduced from 16 to 9 bar
A more compact footprint, saving valuable floorspace
Improved product quality and hygiene
Energy savings estimated at €400,000 annually, thanks to 10–15% lower electricity usage and 45–55% reduced steam consumption

Energy savings

45% lower energy consumption

Technology shift

Replaced old-style technology with new solution

Energy cost savings

Energy cost savings of €400,000 per year

Emissions savings

Savings of 500 tonnes of CO2

At SKS, we empower companies like Dolomiti to achieve smarter and more sustainable production using Alfa Laval’s advanced technology.
Our focus is on long-term value through cleaner processes and greater energy efficiency.