Dairy and cheese production: energy savings at the heart of competitiveness
Dairy and cheese production: energy savings at the heart of competitiveness
Far from sparing the cheese industry, energy challenges are now determining its level of performance. Industry players are striving to maintain their production capacity and reduce their energy expenses by optimizing their energy mix and committing to a gradual decarbonization process. It is important to remember that even a 10% drop in gas supply could hinder the operation of these industries.
Caught between escalating production costs and inadequate price increases, industrialists are even advocating for an energy shield, which would involve imposing a temporary cap on gas prices. They are also seeking new tariff negotiations, considering that the price of milk paid to producers is one of the lowest in Europe[1]. However, these measures alone will not be sufficient.
Although the challenges faced by industrialists are complex, they can regain control over their energy future through decisive choices regarding equipment, engineering, and management. These choices will be instrumental in determining the path they take in managing their energy resources.
Issues and trends
The cheese industry is not only highly territorialized, with production sites located near dairy farms, but it is also known for its high energy consumption. Based on our calculations using field data and information from ADEME[2], the energy used in cheese production accounts for 6% to 10% of the cheese's carbon footprint throughout its entire lifecycle, from cow to store shelf. The amount of greenhouse gases (GHGs) emitted during the manufacturing process varies depending on the type of cheese, with soft cheeses emitting around 140g of CO2eq per 1kg of cheese produced, and hard cheeses emitting around 250g of CO2eq per 1kg.
However, energy costs are skyrocketing, with the Lactalis group alone spending 1 billion euros and Sill Entreprises experiencing an 800% increase in energy expenses between 2021 and 2023, as explained by Mr. Huard, president of CNIL, in September of last year[3]. For cheese factories, energy now accounts for almost half of their expenses[4]. This situation raises concerns about potential failures in the coming months.
These rising costs are a serious issue for manufacturers who aim to optimize their production costs and minimize their environmental impact while staying close to their consumers. Carbon management has become a common practice in the industry, as seen in the Bel group's Bel Low Carbon program. Furthermore, customers, particularly younger ones, are increasingly concerned and will choose energy-efficient brands and products.
In this context, the cheese industry is compelled to optimize its energy mix. Fortunately, there is significant potential for energy savings in the industry. This can be achieved through proper sizing and optimization of equipment such as boilers and refrigeration units, heat recovery in the production process, and the implementation of renewable energy solutions for self-consumption (biomass & solar).
Numerous initiatives and achievements have already been implemented in this direction:
- Bel has installed biomass boilers[5] and achieved 100% sustainable energy usage in its plants in France[6].
- La Compagnie des Fromages et RichesMonts has installed a new generation heat pump at its Vire site, resulting in a 30% reduction in gas consumption.
- La Fromagerie Bongrain Gérard d'Illoud fuels its wood biomass boiler with wood chips from forestry residues [7].
- La Fromagerie Henri Hutin, winner of the "Decarbonation of Industry" call for projects, has replaced a major gas-consuming evaporator with a process combining nanofiltration, reverse osmosis, and diafiltration, leading to a reduction of 1,584 t CO2/year (-26.4%) at its Dieuse sur Meuse site[8].
- La Fromagerie Réo has improved its Lessay site by implementing various measures, including replacing a heavy fuel oil boiler with a natural gas one, installing new generation cooling units, using insulating mattresses, recovering energy lost from cooling units to produce hot water at 60°C, and implementing an energy supervision system (BEX)[9].
- Finally, Savencia has launched significant investment programs to upgrade the energy infrastructure at 13 of its sites, and currently generates 35% of the electricity for its "Cheese & Dairy" plants from hydraulic sources[10].
Energy optimization opportunities
They primarily focus on regulating thermal energy for the maturation and pasteurization cycles.
In practice, the milk used to make cheese arrives at a temperature of 5°C, and the cheese also leaves at this temperature, despite the milk being pasteurized at 72°C and undergoing maturation at 40°C in the meantime. This process consumes a significant amount of energy, as heating is typically achieved using steam at 180°C generated by gas boilers. This was not a problem when gas prices were low. However, the Ukrainian crisis has changed the situation, making it urgent to reduce gas expenses.
Fortunately, cheese manufacturers are resourceful. They have found ways to synergize heat sources from one process to fulfill the heat requirements of another. They can recover heat from refrigeration units, which also produce heat, or even from the "whey," which is at 35°C and can potentially be wasted but is recoverable as an additional heat source. This approach works because hot water at 80°C can achieve similar results to steam at 180°C, which was difficult to control.
Nevertheless, there is no compromise when it comes to pasteurization. It is crucial for ensuring the quality of the cheese, and it serves as the starting point for optimizing the heating process and reaching the critical temperature as efficiently as possible. Currently, avoiding the pasteurization process or producing cheese at lower temperatures is out of the question.
Additionally, it is worth mentioning that some manufacturers, such as Bel, are innovating by offering plant-based formulas. For example, a "plant-based" mini-Babybel has been introduced in the United Kingdom, and a 100% plant-based edition of Vache qui rit was launched last year to celebrate the brand's 100th anniversary. These products require specific processes, which can also be optimized for maximum efficiency.
Solutions
Industrialists, if you are not short of options, our catalog will help you to play your cards right:
- Develop a concrete strategy to reduce your energy consumption through process performance;
- Gain energy autonomy, notably by rebalancing in favor of renewable energies;
- Search for grants and financing for the upgrade or acquisition of new facilities;
- Finally, monitor and promote your energy performance.
Learn more and discover all our solutions
We work alongside cheese manufacturers to find and implement decisive and sustainable solutions.
Sources
[1] Selon François-Xavier Huart, président de la CNIL dans http://www.oise-agricole.fr/actualites/l-industrie-laitiere-prise-en-etau:EG22X5I6.html
[5] https://www.ria.fr/actualites/bel-accelere-sa-decarbonation/
[6] https://www.usinenouvelle.com/article/comment-le-groupe-bel-s-engage-pour-la-decarbonation.N1783727
[8] http://www.industrie-mag.com/article22728.html
[9] http://www.industrie-mag.com/article22728.html
[10] https://www.savencia.com/reduire-notre-empreinte-environnementale