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Life Cycle Assessment for Cheese Plants

Life Cycle Assessment for Cheese Plants. FX Milani UW-Madison Wisconsin Dairy Products Association September 28, 2010. FIL/IDF, UN-FAO dairy report. World dairy contributes 4% of all manmade green house gases. Nat’l Project Cheese & Whey LCA. Wisconsin cheese and whey.

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Life Cycle Assessment for Cheese Plants

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  1. Life Cycle Assessment for Cheese Plants FX Milani UW-Madison Wisconsin Dairy Products Association September 28, 2010

  2. FIL/IDF, UN-FAO dairy report World dairy contributes 4% of all manmade green house gases

  3. Nat’l Project Cheese & Whey LCA

  4. Wisconsin cheese and whey • Who: Rural development is VERY interested in the contribution of cheese/dairy manufacturing • What: Concern about sustainability issues, want to find “hot spots” and new potential returns

  5. Wisconsin cheese and whey • Where: Wisconsin based manufacturing • When: This year and next spring, beyond? • Why: Ultimately, dairy manufacturing is vital • How: Survey work to get baseline concerns and data, model potential ideas, investigate best ideas

  6. The projects: 3 this year • Sustain Metrics: • UW Food Science, CDR,UW Biological Systems Engineering • F. Milani, D. Reinemann, D. Sommer, students • Modeling, Survey audits, Outreach program, Reports • Whey Disposal: • UW Food Science, CDR, Industrial Partners • F. Milani, M. Molitor, D. Sommer, Contractors • Survey audits, Whey/permeate data, Waste water data, Reports/potential • Sustainability Outreach: • UW Food Science, Biological Systems Engineering • F. Milani, A. Newenhouse • Short course, Involvement with 2011 WCMA LaCrosse, Outreach materials, Bus trips

  7. Specific information to collect • Energy use: gas, electric, wood, LP, etc • Transportation use • Refrigerant use • Raw material, chemical use • Packaging use • Water use, wastewater generated • Pounds and types of cheese produced

  8. Milk composition

  9. Cheese Yield 10%, ~50% solids loss to whey Percent milk constituents

  10. Milk is high in phosphorous USDA Handbook 8

  11. Cheese P loss to whey (50-90%) (Wendorff & Matzke, 1993)

  12. The 4 F’s of whey High Value $ FOOD Feed Fuel $ Fertilizer Low Value

  13. Options for whey • Sell to aggregate processor • Land spread • Concentrate and sell (wet or dry) • UF concentrate, sell wet protein • Permeate: sell wet or land spread • UF concentrate, sell dry protein • Permeate: sell dry lactose, dry/landspd wet DLP • (note: lactose market is very volatile) • UF concentrate, sell wet protein • Permeate: biogas, dump minerals

  14. Average Wisconsin cheese plant • 44.7 M pound cheddar cheese annually • 28.8 M pounds sweet whey equivalent • 447 M pounds milk (1.2 M pounds per day) • 116 k gal per day water use, high vary • 230 k gal per day wastewater flow, med vary • 14,355 kWhr per day electric • 6568 therms per day natural gas • 459,801 pounds of caustic annual use Citations listed at end of presentation

  15. Wastewater and Carbon Footprint Short Courses, November 9-11 http://www.foodsci.wisc.edu http://www.cdr.wisc.edu

  16. Citations for average cheese plant • Cheese production: http:www.nass.usda.gov/Statistics_by_State/Wisconsin/Publications/Annual_Statistical_Bulletin/annbull_2008.pdf • Whey conversion: USDA Handbook 8 • Milk Input: Van Slyke equation for cheddar cheese • Water use: Fietz et al. Int. J. LCA 12(2) 109-17, 2007 • Wastewater output: Danalewich, et al. Wat. Res. 32(12) 3555-68, 1998 • Electric and natural gas use: C. Ling et al. USDA report, 2004 • Sodium Hydroxide use: Fernadez, et al. J. Food Eng 97, 319-28, 2010

  17. How much energy is in permeate? • Yield of pure carbohydrate is 0.38 cubic meter methane per kg lactose • 1 kg lactose is 13,300 BTU, or 0.133 therm • 1 therm is $0.475 • 1 kg lactose is $0.063, or $0.029 per pound • Current market lactose is $0.29-0.35, less drying cost at about $0.19, plus operational 3-12 cents, profitable now, but… • Wet permeate is 4.5% lactose

  18. Carbon credits with lactose • 1 kg lactose produces 0.38 cubic meters methane, and 0.74 kg CO2 • 2685 kg of lactose produces mton CO2 • Assume EU trading at $15 per mton, get additional $0.0055 per kg lactose ($0.0025 per pound) • $50,287 per year new revenue • Consumer milk is burdened with1.2 CO2 per kg milk. Milk contains 45 g lactose, potential 0.033 kg CO2 / kg milk carbon credit from lactose

  19. Whey processing steps Drained Whey Fines Saver Cheese Fines Separator Whey Cream Clarified whey Pasteurization RO Evaporator Condensed Whey To Processor

  20. Whey Processing steps Condensed Whey Crystallizer Spray Dryer Dry Sweet Whey

  21. Whey Protein Concentrate

  22. Permeate processing

  23. Important nutrients in whey

  24. Benefits to landspreading • Nutrient recycling • Residual fertility • Soil physical properties • Cost effectiveness • Pollution reduction

  25. Land spreading, Chloride, WI

  26. Issues with landspreading • Nitrogen content • Salt concentration • Soil oxygen levels • Odors • Soil limitations • Seasonal limitations (injection)

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