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Techno-economic and Environmental Evaluation of Cheesemaking Waste Valorization Through Process Simulation Using SuperPro Designer

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Abstract

Purpose

The objective of this work was to perform a techno-economic and environmental assessment of several technological alternatives for production of whey syrups and protein concentrate (WPC) via process simulation under two scenarios: Stand-alone process and process attached to a cheese production plant.

Methods

Information related to different industrial dairy processes (parameters, variables and diagrams) was consulted and gathered. A base case and three alternative technological configurations for production of whey syrups and WPC were designed. SuperPro Designer was employed as the process simulation tool and for the techno-economic assessment of the technological configurations, and WARGUI software was used for their environmental evaluation. A combined techno-economic and environmental indicator was calculated to identify the best alternative.

Results

The alternative involving the production of WPC, glucose syrup, and glucose and fructose syrup had the best economic indicators (net present value of $3,381,000 and $16,354,000 for the stand-alone and attached processes, respectively). This alternative had a Potential Environmental Impact of 14,510 PEI/kg products for both scenarios. Water recovery from different waste streams was simulated, managing to reuse 322,338,477 kg water/year.

Conclusions

The implementation of a process for producing whey syrups and WPC attached to a cheese production facility has the potential to generate a significant profitability for the dairy industries in a middle-income country like Colombia. Simulation techniques employed are a powerful supporting tool when making decisions in investment projects for valorization of waste from the food industry in order to find the most appropriate process configuration.

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Adapted from Chen et al. [45]

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Acknowledgements

The authors thank the Vice-rectorate of Research and Post-graduate Programs at Universidad de Caldas for its administrative and logistic assistance. This work was supported by the Administrative Department of Science, Technology and Innovation of Colombia (Colciencias) through the research project “Design of a Biorefinery for the Use of the Lignocellulosic and Starchy Waste of the Plantain Agribusiness” (Call 757 for Funding of National Doctorates) [Grant Number 1640318]; and the Universidad de Caldas through the research project “Basic Process Development for the Use of Agro-industrial and Urban Waste Under the Concept of Biorefineries” [Grant Number 0240518].

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  1. Research Group on Food and Agro-Industry, Department of Engineering, Oficina de Posgrados, Universidad de Caldas, Edificio del Parque, Piso 3, Calle 65 No. 26-10, 170004, Manizales, Colombia

    James A. Gómez, Óscar J. Sánchez & Leonardo F. Correa

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  1. James A. Gómez
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Correspondence to Óscar J. Sánchez.

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Appendix

Appendix

See Figs. 8, 9, 10 and Table 14 .

Fig. 8
figure 8

Process flowsheet of Alternative 1 for production of glucose syrup and WPC. FI: Raw material (whey). F4, F5, F9: Drinking water input. F3, F7: Air input. F6: Washing solution (NaOH). F10: Ferric sulfate. F11: Polymer. W: Wastewater stream. P1: WPC. P2: Glucose syrup

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Fig. 9
figure 9

Process flowsheet of Alternative 2 for production of glucose syrup, glucose and fructose syrup, and WPC. FI: Raw material (whey). F4, F5, F9, F12: Drinking water input. F3, F7: Air input. F6: Washing solution (NaOH). F10: Ferric sulfate. F11: Polymer. W: Wastewater stream. P1: WPC. P2: Glucose syrup. RW: Water recovered

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Fig. 10
figure 10

Process flowsheet of Alternative 3 for production of powdered glucose syrup and WPC. FI: Raw material (whey). F4, F5, F9: Drinking water input. F3, F7: Air input. F6: Washing solution (NaOH). F10: Ferric sulfate. F11: Polymer. W: Wastewater stream. P1: WPC. P2: glucose syrup. RW: Water recovered

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Table 14 Cost of equipment used in the simulation of the processes for production of WPC and sweetener syrups
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Gómez, J.A., Sánchez, Ó.J. & Correa, L.F. Techno-economic and Environmental Evaluation of Cheesemaking Waste Valorization Through Process Simulation Using SuperPro Designer. Waste Biomass Valor 11, 6025–6045 (2020). https://doi.org/10.1007/s12649-019-00833-4

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