Life Cycle Assessment for Cheese Plants FX Milani UW-Madison Wisconsin Dairy Products Association...
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![Page 1: Life Cycle Assessment for Cheese Plants FX Milani UW-Madison Wisconsin Dairy Products Association September 28, 2010.](https://reader035.fdocuments.net/reader035/viewer/2022062803/56649efb5503460f94c0d7ac/html5/thumbnails/1.jpg)
Life Cycle Assessment for Life Cycle Assessment for Cheese PlantsCheese PlantsFX MilaniUW-MadisonWisconsin Dairy Products AssociationSeptember 28, 2010
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FIL/IDF, UN-FAO dairy FIL/IDF, UN-FAO dairy reportreport
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Nat’l Project Cheese & Nat’l Project Cheese & Whey LCAWhey LCA
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Wisconsin cheese and Wisconsin cheese and wheywhey
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
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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
Wisconsin cheese and Wisconsin cheese and wheywhey
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The projects: 3 this yearThe 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
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Specific information to Specific information to collectcollectEnergy use: gas, electric, wood,
LP, etcTransportation useRefrigerant useRaw material, chemical usePackaging useWater use, wastewater generatedPounds and types of cheese
produced
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Milk compositionMilk composition
Water 87.8%
Fat (emulsion) 3.7
Protein 3.1
(colloidal suspension) Casein (2.5)
(true solution) Lactoglobulin (0.3)
“ Lactalbumin (0.07)
“ Others (0.22)
Lactose 4.7
Minerals (ash) 0.7
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Cheese Yield 10%, ~50% Cheese Yield 10%, ~50% solids loss to wheysolids loss to whey
Percent milk constituents
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Milk is high in phosphorousMilk is high in phosphorous
Food item mg of P / Liter
Milk 930
Cream 710
Eggs 1800
USDA Handbook 8
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Cheese P loss to whey (50-Cheese P loss to whey (50-90%)90%)
Cheese Type mg of P / LiterCheddar 546
Colby 526
Jack 575
Mozzarella 519
Swiss 447
Brick 465
(Wendorff & Matzke, 1993)
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The 4 F’s of wheyThe 4 F’s of whey
FOODFeedFuel
Fertilizer
HighValue
LowValue
$
$
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Options for wheyOptions for wheySell to aggregate processorLand spreadConcentrate and sell (wet or dry)UF concentrate, sell wet protein
◦Permeate: sell wet or land spreadUF 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
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Average Wisconsin cheese Average Wisconsin cheese plantplant
44.7 M pound cheddar cheese annually28.8 M pounds sweet whey equivalent447 M pounds milk (1.2 M pounds per
day)116 k gal per day water use, high vary230 k gal per day wastewater flow,
med vary14,355 kWhr per day electric6568 therms per day natural gas459,801 pounds of caustic annual useCitations listed at end of presentation
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http://www.foodsci.wisc.edu
http://www.cdr.wisc.edu
Wastewater and Carbon Wastewater and Carbon Footprint Short Courses, Footprint Short Courses, November 9-11November 9-11
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Citations for average cheese Citations for average cheese plantplant
Cheese production: http:www.nass.usda.gov/Statistics_by_State/Wisconsin/Publications/Annual_Statistical_Bulletin/annbull_2008.pdf
Whey conversion: USDA Handbook 8Milk Input: Van Slyke equation for cheddar cheeseWater use: Fietz et al. Int. J. LCA 12(2) 109-17, 2007Wastewater output: Danalewich, et al. Wat. Res. 32(12)
3555-68, 1998Electric and natural gas use: C. Ling et al. USDA report,
2004Sodium Hydroxide use: Fernadez, et al. J. Food Eng 97,
319-28, 2010
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How much energy is in How much energy is in permeate?permeate?
Yield of pure carbohydrate is 0.38 cubic meter methane per kg lactose
1 kg lactose is 13,300 BTU, or 0.133 therm1 therm is $0.4751 kg lactose is $0.063, or $0.029 per
poundCurrent 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
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Carbon credits with Carbon credits with lactoselactose
1 kg lactose produces 0.38 cubic meters methane, and 0.74 kg CO2
2685 kg of lactose produces mton CO2Assume EU trading at $15 per mton,
get additional $0.0055 per kg lactose ($0.0025 per pound)
$50,287 per year new revenueConsumer 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
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Whey processing stepsWhey processing steps
Clarified whey
Separator Whey Cream
Pasteurization
RO Evaporator
CondensedWhey
To Processor
Drained Whey
Fines Saver Cheese Fines
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Whey Processing stepsWhey Processing steps
Crystallizer
Spray Dryer
Condensed Whey
Dry Sweet Whey
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Whey Protein ConcentrateWhey Protein Concentrate
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Permeate processingPermeate processing
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Important nutrients in Important nutrients in wheywhey
Nutrient Whole whey Whey permeateN 12.2 2.0P 4.0 3.8K 14.6 8.2Ca 2.9 2.7Mg 0.55 0.59Na 4.2 3.4
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Benefits to landspreadingBenefits to landspreading
Nutrient recycling Residual fertility Soil physical properties Cost effectiveness Pollution reduction
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Land spreading, Chloride, Land spreading, Chloride, WIWI
Ave. Cl (mg/L) Gal/A/yr.
Whey/permeate 1183 16,000
Salty whey 56,900 500
Used brines 187,000 89
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Issues with landspreadingIssues with landspreadingNitrogen contentSalt concentrationSoil oxygen levelsOdorsSoil limitationsSeasonal limitations (injection)