Process technology for in-house plant-based dairy production

In the dairy and food processing industry, traditional manufacturers are increasingly investing in process technology to establish their own plant-based value chains and produce dairy alternatives in-house.

Activity and operational challenges
The private dairy Bauer, located in Wasserburg am Inn, Germany, manufactures a range of dairy products, including plant-based yogurt alternatives. Previously, the company sourced the soy base required for these products from external suppliers. The operational challenge involved integrating this upstream production step into their own facilities to build up in-house industrial expertise and gain control over the raw material processing line.

Improvement objectives
The primary goal was to bring the production of plant-based concentrates in-house to reduce reliance on external suppliers. The company sought to implement a complete, end-to-end process technology solution that would encompass all steps from raw material intake to the final concentrate. Additionally, management aimed for an ambitious project timeline, requiring a streamlined integration process with minimal interfaces to ensure the facility was operational by August 2026.

Selected technical solution
Bauer selected GEA as the single-source provider for the complete process technology. The implemented solution covers the entire upstream production, including raw soybean receiving and storage in silos, mixing and grinding, solids separation via decanters, and thermal inactivation using heating technology. The system also integrates tank storage, water treatment, and associated Clean-in-Place (CIP) cleaning systems. GEA was chosen because of its ability to act as a general contractor, consolidating process design, engineering, and testing under one project lead.

Deployment and support
The collaboration began with feasibility tests and building planning. The technology provider utilized its process test centers in Ahaus and Oelde to develop and validate initial concepts and performance data. The contract was awarded in May 2025, and installation commenced in January 2026. By minimizing the number of interfaces and coordinating various expert teams from Munich and the testing facilities, the solution provider enabled a rapid deployment, scheduling the first production batch just months after installation began.




Quantifiable results
The integration of the new facility allows Bauer to independently produce the plant-based concentrate used for its yogurt alternatives. Consolidating testing, engineering, and implementation with a single point of contact eliminated operational bottlenecks and accelerated the project timeline. "We had a single point of contact for the entire process chain – that saved us time in every phase of the project without having to compromise on quality," explains Sebastian Bodmeier, Technical Project Manager at Bauer. Prior to the start of regular production, the process validation phase successfully facilitated the development of a market-ready plant-based kefir drink, demonstrating the effectiveness of the implemented technology.

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.gea.com