Parakh Agro, Elecster deepen UHT pouch ecosystem

Finland-based Elecster is strengthening its India presence through a long-standing collaboration with Parakh Agro Industries, combining UHT processing technology with locally manufactured high-barrier films and service support.

The partnership, active in India since 2010, has evolved beyond equipment supply to include a dedicated spare parts and service vertical. This enables local stocking and faster turnaround for Elecster’s installed base, reducing dependence on imports from Europe.

“We now have a separate team handling spare parts and service for register lines, ensuring local availability and support,” said Ronald Dsouza, UHT Technical Specialist (Sales and Service), Elecster.

Elecster specialises in UHT (ultra-high temperature) processing systems, operating across India, Africa and South America. In India alone, the company has installed 36 sterilisers and over 100 filling heads, servicing major dairy brands including Karnataka Milk Federation (Nandini).

A key innovation lies in its flexible pouch solution, positioned as a cost-effective alternative to carton-based systems such as Tetra Pak. The system uses five-layer co-extruded films incorporating EVOH for high oxygen barrier properties, enabling ambient shelf life of up to 90 days without refrigeration.

“Compared to rigid cartons, flexible pouches are easier to transport, store and significantly more economical,” said Prasad Upasani, head - technical sales and prepress Parakh Agro. “For consumers, this translates into meaningful savings, while maintaining product safety and shelf life.”

The films are engineered specifically for Elecster’s filling lines, with recipes transferred to Parag Agro for local production. Early challenges included print distortion and film instability under India’s varied climatic conditions, which were resolved through joint R&D efforts.

From a processing standpoint, the system relies on continuous-flow UHT sterilisation at around 135–140°C, ensuring microbial safety while preserving product quality. Unlike conventional pasteurised milk, which typically lasts a few days under refrigeration, UHT-treated milk in these pouches remains stable at room temperature.

Sustainability remains a focus area. While multi-layer films pose recycling challenges, the companies are exploring mechanical recycling and internal reuse streams, including converting production scrap into polymer-based stationery products.

 

Converter’s Box: Substrates, Inks, Structures

Film structure

• Type: Co-extruded, high-barrier flexible pouch
• Layers: 5-layer structure
• Typical configuration: PE / Tie / EVOH / Tie / PE
• Core barrier: EVOH (ethylene vinyl alcohol) for oxygen barrier
• Seal layer: LDPE/LLDPE blend for heat seal integrity and burst strength
• Thickness range: Typically 80–120 microns (application dependent)

Substrates & materials

• Primary polymer: Polyethylene (PE-based structure)
• Barrier material: EVOH for extended shelf life (up to ~90 days ambient)
• Additives: Anti-block, slip agents, and process stabilisers for machinability
• Recyclability: Multi-layer structure; recyclable via mechanical recycling with compatibilisers (non-food applications currently)

Printing & inks

• Process: CI flexo printing (inline or offline)
• Ink systems: Solvent-based inks (preferred for adhesion and resistance in high-temperature filling environments)
• Challenges addressed:
  • Ink adhesion under high heat (UHT conditions ~135–140°C)
  • Print distortion/stretch under climatic variation
• Solutions: Ink reformulation and film surface optimisation through joint R&D

Processing compatibility

• Filling system: UHT aseptic pouch filling (Elecster lines)
• Temperature resistance: Designed to withstand sterilisation temperatures up to ~140°C
• Seal performance: High hot-tack strength for vertical form-fill-seal operations
• Throughput: Compatible with high-speed lines (~6,000+ litres/hour)

Conversion considerations

• Tight control on gauge variation critical for sealing and barrier consistency
• Registration stability essential due to multi-head filling systems
• Scrap segregation (printed vs unprinted, barrier vs non-barrier) required for effective recycling streams