Determinants of Energy Consumption in the Dairy Industry: A Case Study in Poland
Data publikacji: 31 gru 2023
Zakres stron: 69 - 91
DOI: https://doi.org/10.2478/oszn-2023-0017
Słowa kluczowe
© 2023 Janusz Wojdalski et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.
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Figure 6.

Figure 7a.

Figure 7b.

Figure 8a.

Figure 8b.

Figure 9.

Technological factors influencing energy demand in selected dairy plants
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Ae = 488731.7 kWh/month | S/W | Ae = 38530 + 21.93Zm | 0.917 | |
We = 104.9 kWh/1000L | We = 178.6 - 0.019Zm | −0.982 | |||
P = 5400 kW |
Ae = 1842461 kWh/month | S/W | Ae = 80.184 - 74908Zm | 0.63 |
Zm: 21749 – 25541 Mg/month Z15: 2184 – 3023 Mg/month |
Ae = 155.75·Z11+84.68·Z12 - 573.45·Z13–11.36·Z14+232.33·Z15 + 139383.53 | 0.72 | ||||
We = 77.0 kWh/1000 L | We = 0.0002 Zm + 72.558 | Weak correlation | |||
We = 3∙10−3 Z11 + 7∙10−3·Z12 - 0.017·Z13 - 0.025·Z14 + 3∙10−3·Z16 + 36.5 | 0.31 | ||||
Ac = 17060.39 GJ/month | Ac = 0.0946Zm + 14799 | Weak correlation | |||
Ac= −1.49·Z11 - 1.33·Z12 + 3.46·Z13 + 5.84·Z14 + 3.93·Z15 + 16572.40 | 0.65 | ||||
Wc = 0.71 GJ/1000 L | Wc= −3E-05Zm + 1.3441 | 0.47 | |||
Wc = −1∙105·Z11 - 3∙105·Z12 + 2∙104·Z13 + 7∙10−6 ·Z14 + 1∙10−5 ·Z15 + 0.99 | 0.83 | ||||
P = 420 kW Z = 132,765 L/24h |
Ae = 101,516 kWh/month | S/W | 0.741 |
Z20: 3,962 – 35,914 kg/month Z22: 37,806 –187,223 kg/month Z23: 281 – 3079 kg/month |
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Ae = 0.17·Z16 + 3.38·Z17 + 0.32·Z18 - 0.70·Z19 + 1.62·Z20 + 0.48·Z21 + 0.08·Z22 - 0.84·Z23 - 15048.70 | 0.984 | ||||
We = 25.94 kWh/1000 L | 0.526 | ||||
0.905 | |||||
P = 300 kW Z4d = 181,300 L/96 h |
Ae = 10,681 kWh/4d | S/W | Ae = 84.71Z4d - 4676.82 | 0.675 | Z4d: 173,430 – 192,500 L/4d |
We = 58.87 kWh/m3 | We = 0.1479Z4d + 31.75 | 0.285 | |||
Ac = 56.93 GJ/4d | Ac = 0.6966Z4d - 69.36 | 0.719 | |||
Wc = 313.56 MJ/m3 | Wc = 2.00 Z4d - 48.81 | 0.482 |
Influence of the daily production profile and the installed capacity of electrical devices on energy consumption in T4 dairy plants (producing only milk, dairy beverages, tvorog, and, in some cases, also butter)
S | 50.0 – 2,385.0 (34) | 2,374.1 | 59.305 | 32.13 | 1.0882 | Ae = 559.42 + 29.374Z1 | 0.834 | Z1: 2.5 – 80.6 |
Ae =345.63 + 4.420P1 + 18.787P2 | 0.950 |
P1: 0.0 –1785.0 P2: 7.5 –170.0 |
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Ac = 18.658 + 0.460 Z1 + 1.766Z2 | 0.849 |
Z1: 2.5 – 80.6 Z2: 3.1 – 39.6 |
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W | 63.0 – 646.0 (24) | 1,081.4 | 52.366 | 30.70 | 1.7502 | Ae = 358.08 + 35.352Z1 | 0.672 | Z1: 1.0 – 59.1 |
Ae = 463.75 + 6.235P3 | 0.429 | P3: 6.0 – 250.0 | ||||||
Ac = −0.121 + 0.531P1 − 1.899P7 | 0.811 |
P1: 17.4 – 273.7 P7: 0.0 – 41.2 |
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Ac = 30.777 + 1.054Z1 | 0.441 | Z1: 1.0 – 59.1 |
Types of examined dairy plants
Milk, dairy beverages, cream, tvorog, cheese, butter, casein, milk powder | |
Identical to |
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Identical to |
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Milk, dairy beverages, cream, and tvorog only |
Literature on energy consumption and environmental performance of dairy plants
Energy consumption (direct) and energy conservation | |
Heat recovery | |
Energy consumption in wastewater treatment | |
Renewable energy | |
Cleaner production standards | |
Best available techniques | |
Environmental performance | |
Energy efficiency and optimization of selected production processes | Alves et al. [2014], |
Financial and environmental implications of energy management | |
Process integration | |
Pulsed electric field processing | |
Solar energy | |
Electric power substitution/electrification | |
Life cycle assessment ( |
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Cleaner production and the environmental impact of dairy production | |
Cleaning of production equipment |
General characteristics of the analysed types of dairy plants in summer and winter
0.59 – 3.10 | 0.36 – 5.66 | 0.54 – 3.10 | 0.62 – 2.42 | 0.32 – 2.90 | 0.22 – 2.99 | 0.25 – 2.90 | 0.40 – 1.16 | |
0.35 – 1.33 | 0.23 – 3.54 | 0.30 – 2.13 | 0.14 – 0.82 | 0.19 – 1.18 | 0.13 – 2.46 | 0.13 – 1.35 | 0.18 – 0.90 | |
3.52 – 17.74 | 3.93 – 40.46 | 5.30 – 31.67 | 1.13 – 21.40 | 4.13 – 17.74 | 1.16 – 39.55 | 1.17 – 17.74 | 2.26 – 13.53 | |
2.43 – 12.91 | 1.26 – 23.75 | 3.06 – 23.75 | 0.49 – 8.93 | 0.70 – 13.16 | 1.02 – 32.41 | 1.08 – 11.92 | 1.31 – 8.77 | |
3.74 – 13.69 | 2.63 – 28.79 | 4.02 – 28.79 | 0.99 – 24.66 | 1.76 – 24.66 | 1.99 – 34.33 | 1.99 – 32.26 | 3.38 – 24.64 |
Influence of the daily production profile and the installed capacity of electrical devices on energy consumption in T3 dairy plants (not producing milk, dairy beverages or tvorog)
S | 83.0 – 1,923.0 (22) | 3,079.5 | 148.151 | 37.83 | 1.5542 | Ae = 953.19 + 29.707Z4 + 430.898Z6 | 0.932 |
Z4: 10.0 – 335.8 Z6: 0 – 22.5 |
We = 42.633 - 0.481Z5 | 0.346 | Z5: 0 – 80.3 | ||||||
Ac = −36.781 + 0.607P1 - 0.523P3 + 1.037P4 + 0.968P6 + 5.555P10 | 0.990 |
P1: 30.3 – 574.0 P3: 0.0 – 320.0 P4: 0.0 – 592.0 P6: 0.0 – 58.6 P10: 0.0 – 101.0 |
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Wc = 1.476 + 0.001P4 - 0.012P6+0.013P10 | 0.662 | |||||||
Ac = 41.899 - 0.964Z3 + 2.204Z4 + 15.219Z6 | 0.971 |
Z3: 0 – 164.2 Z4: 10.0 – 335.8 Z5: 0– 80.3 Z6: 0 – 22.5 |
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Wc = 1.6316-0.006Z3 + 0.003Z4 - 0.013Z5 | 0.608 | |||||||
W | 30.3 – 1,938.0 (20) | 3,548.8 | 230.243 | 42.82 | 2.9086 |
Ae = 2133.00 - 85.291Z4 We = 32.375 + 5.757Z6 |
0.660 0.770 |
Z4: 0 – 53.0 Z6: 0 – 7.9 |
Ac = 1.145 + 0.444P1 + 0.936P4 + 1.275P7 | 0.985 |
P1: 30.3 – 470.0 P4: 0.0 – 592.0 P7: 0.0 – 87.0 |
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Wc = 2.2652 + 0.028P7 | 0.627 | |||||||
Ac = 117.423 + 62.187Z6 | 0.399 | Z6: 0 – 7.9 | ||||||
Wc = 2,3795 + 0.291Z6 | 0.563 |
Factors that influence energy consumption in dairy production
Basic operating parameters and process automation | ||
Production profile |
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Technical equipment |
Influence of the daily production profile and the installed capacity of electrical devices on energy consumption in T1 dairy plants (producing milk powder)
S | 454.0 – 2,421.7 (21) | 7,682.1 | 432.650 | 41.73 | 2.3207 | Ae = 3944.70 + 37.110 Z4 | 0.568 | Z4:19.0 – 335.8 |
Ac = 134.293 + 0.546P2 + 0.760P4 | 0.789 |
P2: 31.0 – 777.0 P4: 100.0 – 964.0 |
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Ac = 140.56 + 2.433Z4 + 1.977Z5 + 0.815 Z8 | 0.834 |
Z4: 19.0 – 335.8 Z5: 0 – 81.8 Z8: 0 – 335.8 |
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W | 318.0–2,548.0 (19) | 6,246.0 | 396.632 | 52.70 | 3.4125 | Ae = 4289.00 + 41.401Z4 for Wc R2 < 0.20 | 0.502 | Z4: 10.4 –282.7 |
Ac = 83.369 + 0.530P2 + 0.644P4 + 0.857P10 for Wc R2 < 0.34 | 0.846 |
P2: 31.0 – 777.0 P4: 100.0 – 964.0 P10: 0.0 – 358.3 |
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Ac = 246.86 + 3.168 Z4 | 0.546 | Z4: 10.4 – 282.7 |
Selected indicators and factors for analysing the energy performance of dairy plants
Electric energy consumption | kWh/m3 of raw milk | Total production | WZ | 90 | 10 – 680 | |
kWh/m3 of milk | Milk powder, cheese, butter, yogurt, dairy desserts | 27 | - | |||
Cheese, tvorog, yogurt, dairy desserts | 32 | - | ||||
Cheese, butter, yogurt, dairy desserts | - | 34 – 52 | ||||
Butter, milk powder, yogurt, dairy desserts | - | 53 – 57 | ||||
Cheese, milk powder, butter | 64 | |||||
Cheese, butter | 65 | |||||
Yogurt, dairy desserts, tvorog, butter | 66 | |||||
kWh/m3 of milk | Cheese | WT | - | 2.9 – 6.6 | ||
kWh/Mg of butter | Butter (continuous method) | - | 12.9 – 17.0 | |||
kWh/Mg of milk | Milk processing output (based a study of three dairy plants) | WZ | - | 30 – 80 | ||
kWh/Mg of end product | Milk powder | WZ | 429.9 | 377.0 – 482.9 | ||
Heat consumption | GJ/m3 of raw milk | Total production | WZ | 2.01 | 0.12 – 14 | |
MJ/m3 of processed milk | Milk powder, cheese, butter, yogurt, dairy desserts | 1348 | - | |||
Cheese, tvorog, yogurt, dairy desserts | 1439 | - | ||||
Cheese, butter, yogurt, dairy desserts | - | 1583 – 2380 | ||||
Butter, milk powder, yogurt, dairy desserts | - | 2733 – 3171 | ||||
Cheese, milk powder, butter | 2882 | - | ||||
Cheese, butter | 1884 | - | ||||
Yogurt, dairy desserts, tvorog, butter | 2698 | - | ||||
GJ/Mg of evaporated water | Spray-drying | WA | 4.87 | 3 – 20 | ||
GJ/Mg of processed milk | Modern dairy plants with heat recovery systems | WZ | 0.34 | - | Bosworth et al. [2001] | |
Modern plants where hot water is used as an energy carrier | 0.50 | - | ||||
Older plants where steam is used as an energy carrier | 2.00 | - | ||||
Total energy consumption | MWh/Mg of milk powder | Milk powder (mechanical vapor recompression, MVR) | WP | 3.08 | - | |
GJ/Mg of product | Milk powder | WZ | 29.95 | 26.41–33.49 | ||
MWh/Mg of dry product | Spray-drying of cheese whey | WA | 2.049 | - | ||
Fuel gas | kWh/Mg of milk | Total production (based on a study of three production plants) | WZ | - | 100 – 220 | |
Total energy consumption | GJ/m3 of processed milk |
Milk, tvorog (based on a study of a selected dairy plant) | - | 3.04 | 1.93 – 2.47 Summer | |
3.63 – 4.19 Winter | ||||||
GJ/m3 of processed milk |
WZ | 2.46 | 1.40 –1.96 Summer | |||
3.04 – 3.55 Winter | ||||||
Total energy consumption | kWh/kg of evaporated water | Three-phase evaporator | WA | 0.14 | - | |
Five-phase evaporator | 0.085 | - | ||||
Total energy consumption expressed in fuel equivalents | kg of fuel equivalent/m3 of processed milk |
Milk, tvorog (based on a study of a selected dairy plant) | WZ | 104 | 66 – 84 Summer | |
124 –143 Winter | ||||||
kg of fuel equivalent/m3 of processed milk |
84 | 48 – 67 Summer | ||||
103–121 Winter | ||||||
Energy consumption in wastewater treatment | kWh/kg BOD5 | Total production | WT | - | 0.89 – 3.22 | |
kWh/m3 of wastewater | - | 1.94 – 6.32 | ||||
SO2 emissions | kg/m3 of raw milk | Total production | WZ | 1.65 | 0.05 – 22.4 | |
kg/m3 of processed milk | - | 0.83 | - | |||
NOx emissions | kg/m3 of raw milk | Total production | WZ | 0.49 | 0.03 – 6.4 | |
kg/m3 of processed milk | - | 0.60 | - | |||
CO2 emissions | kg/m3 of raw milk | Total production | WZ | 1.97 | 0.01 – 9.23 | |
kg/m3 of processed milk | 1.25 | - | ||||
Carbon footprint of end products | kg CO2eq/kg of butter | Butter | WZ | 8.1 | - | |
kg CO2eq/kg of milk powder | Milk powder | 7.4 | - | |||
kg CO2eq/kg of cheese | Cheese | 6.5 | - | |||
kg CO2eq/kg of dairy beverage | Dairy beverages | 1.2 | - | |||
Particulate-matter emissions | kg/m3 of raw milk | Total production | 1.3 | 0.01 –14.4 | ||
kg/m3 of processed milk | Total production | WZ | 1.15 | - | ||
Black carbon emissions | kg/m3 of raw milk | Total production | WZ | 19 | 0.01 – 193 | |
kg/m3 of processed milk | Total production | - | 0.04 | - |
Structure of energy consumption in the analysed dairy plant
End product storage | - | - | 41,868 | - | 41,868 | 9.46 |
Packing | - | 3,489 | - | - | 3,489 | 0.71 |
Storage before packing | - | - | 20,934 | - | 20,934 | 4.73 |
Deodorissation | 5,815 | - | - | - | 5,815 | 1.32 |
Cooling | - | - | 19,771 | - | 19,771 | 4.47 |
Homogenisation | - | - | - | 2,326 | 2,326 | 0.53 |
Pasteurisation | 213,992 | - | - | - | 213,992 | 48.30 |
Separation | - | - | - | 41,868 | 41,868 | 9.46 |
Clarification/Standardisation | - | - | - | 20,934 | 20,934 | 4.73 |
Reception and Storage | - | 30,238 | 41,868 | - | 72,106 | 16.29 |
Total | 219,807 | 33,727 | 124,441 | 65,128 | 443,103 | 100 |
Influence of the daily production profile and the installed capacity of electrical devices on energy consumption in T2 dairy plants (not producing milk powder)
S | 83.0 – 2,935.0 (37) | 3,289.9 | 118.909 | 39.52 | 1.3607 | Ae= 748.34 + 60.1453Z1 + 39.4929Z3 + 22.079Z5 + 75.286Z8 for We R2 < 0.32 | 0.442 |
Z1: 0 – 211 Z3: 0 – 164 Z5: 0 – 141 Z8: 0 – 157.5 |
Ac= 1.152 + 0.310P1 + 1.266P2 + 1.082P6 for Wc R2 < 0.37 | 0.860 |
P1: 24.4 – 1155.1 P2: 0.0 – 434.0 P6: 250.0 – 956.0 |
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Ac= 18.295 + 1.501Z1 + 1.748Z2 + 0.990Z3 +1.006 Z5 −5.385 Z7 + 5.265 Z8 | 0.830 |
Z1: 0 – 211 Z2: 0 – 73 Z3: 0 – 164 Z5: 0 – 141 Z7: 0 – 44.4 Z8: 0 – 157.5 |
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W | 30.3 – 1,938.0 (24) | 2129.3 | 120.581 | 39.92 | 2.4672 | Ae = 864.92 + 94.4138Z2 + 104.032Z8 for We R2 < 0.20 | 0.603 |
Z2: 0 – 63.6 Z8: 0 – 75.6 |
Ac = −4.109+0.364P1 +0.989P2+ 1.080P7 + 0.191P10 for Wc R2 < 0.33 | 0.896 |
P1: 30.3 – 708.0 P2: 0.0– 312.0 P7: 0.0 – 68.0 P10: 0.0 – 377.0 |
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Ac = 26.259+2.981Z1 +2.492Z3 + 15.157Z7 + 6.733Z8 | 0.693 |
Z1: 0 – 111.6 Z3: 0 – 64.2 Z7: 0 – 9.9 Z8: 0 – 75.6 |