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Advancing Paneer production: New technology delivers on efficiency

Andreas Charalambous

Andreas Charalambous is technical manager at Cyprus-based Agathangelou, where he oversees project management, R&D, technical sales and after sales support. He also supervises the engineering, installation, commissioning and electrical teams. He contributes this column exclusively for Cheese Market News®.

The global dairy industry is undergoing rapid transformation, driven by increasing demand for high-quality, protein-rich products. Among them, Paneer has gained immense popularity not only in South Asia but also in international markets, where consumers seek authentic, consistent and scalable production solutions.

However, traditional Paneer production methods often struggle to keep up with these rising demands due to labor-intensive processes, quality inconsistencies and production bottlenecks.

Companies like Agathangelou can provide the technology to bridge the gap between tradition and innovation by providing cutting-edge solutions that help dairy manufacturers optimize their processes while preserving the authenticity of Paneer. One recent success story featuring a semi-automated Paneer production line for a leading U.S.-based dairy manufacturer demonstrates the transformative impact of new technology in increasing efficiency, maximizing yield and maintaining superior product quality.

• A case study: Transforming production efficiency, profitability

A major U.S. Paneer producer previously relied on a fully manual production system. While effective for small-scale operations, this method presented multiple challenges, including high labor costs that limited profitability, inconsistent texture and moisture levels that led to variable product quality, and limited scalability that made it difficult to meet increasing market demands. Hygiene and compliance concerns also posed obstacles, particularly in highly regulated markets.

To address these inefficiencies, the company sought a robust solution that could streamline operations without compromising the traditional characteristics of Paneer. After in-depth consultation, a semi-automated Paneer production line was identified as the ideal solution. By integrating intelligent automation into key production stages, the system successfully reduced labor costs by 60%-65%, allowing the company to reinvest in expansion and product innovation.

• Beyond efficiency: Maximizing yield, quality and sustainability

One of the most significant advantages of this advanced Paneer production system is the substantial increase in yield. Through optimized process control and precision engineering, the company reported a 1%-4% improvement in yield, an essential factor in improving profitability and resource utilization. Every percentage point increase in yield translates into tangible cost savings in raw materials while ensuring higher production output.

Additionally, the system is designed to enhance product quality by incorporating automated curd coagulation for precise texture and moisture retention, precision pressing technology that ensures optimal firmness without compromising softness, high-efficiency cutting mechanisms that deliver uniform Paneer blocks with minimal waste and real-time quality control sensors that maintain consistency across batches. Unlike traditional manual methods, where quality variations are inevitable, this semi-automated system ensures a consistently high standard of Paneer that meets both consumer expectations and industry compliance standards.

Client experience: Improving efficiency, yield with semi-automation

The operations manager of this major U.S.-based Paneer producer shared their experience with the transition to semi-automated production:

“Switching to a semi-automated Paneer production line has been a game-changer for our facility. We have not only cut labor costs significantly but also have seen a measurable improvement in product yield, consistency and overall efficiency. This investment has streamlined our production, allowing us to scale our operations while maintaining the authentic Paneer characteristics our customers love.”

• Innovation meets tradition

Automation must be carefully integrated to preserve the artisanal qualities of traditional Paneer, and semi-automated lines are engineered to balance efficiency with authenticity, ensuring that manufacturers can scale operations without sacrificing product integrity. The modular design allows businesses to start small and expand as demand grows, while optimized power and water usage reduce operational costs and environmental impact. These systems also are designed to meet international dairy regulations across U.S., European Union and Asian markets, with customization options to match different milk compositions, production capacities and facility layouts.

• The future of Paneer production

As dairy manufacturers look for ways to improve efficiency, consistency and scalability, semi-automated and fully automated solutions are becoming an essential part of modern Paneer production. Leaders in this space continue to work with the industry to refine and advance production technology, ensuring that manufacturers can meet growing market demands without compromising on product quality.

CMN

The views expressed by CMN’s guest columnists are their own opinions and do not necessarily reflect those of Cheese Market News®.

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