LCA STUDY, CARBON FOOTPRINT AND GOOD PRACTICES IMPLEMENTED
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LCA STUDY, CARBON FOOTPRINT AND GOOD PRACTICES IMPLEMENTED
INDEX: 1. Background 1.1. LCA 1.2. Carbon Footprint 2. Impact updating 2.1. CO2 emissions balance 2.2. Economic balance 3. Action plan to reduce emissions in a technical – economic way 3.1. Actions in cultivation processes 3.2. In the production processes of olive polyphenols 3.3. In grinding and use of by-product processes 4. Conclusions and calculations 4.1. Recalculation of CO2 emissions after improvements. 4.2. Conclusions and indicators monitoring
1. Background
Allotarra Association of Ecological Agriculture and Livestock,
entity linked to Biosasun, is made up of various farmers from
Tierra Estella (Navarra)
Its main activities are the practice and promotion of
agricultural, livestock, commercial and professional activities.
After cultivating organic olive trees for more than 30 years
and its objective is to make organic farming and its
sustainable processes available to all, always respecting the
environment and its resources.
https://ekodenda.allotarra.eu
1. Background
BIOSASUN
BIOSASUN S.A. It is located in Álava and Navarra. Founded in 2001 by the
interest of various professionals in the production of organic products.
www.biosasun.eu
Marketing, distribution and Engineering, design and
elaboration of ecological and advice on sustainable R&D projects
functional products. solutions
1. Background
BUSSINES ESTRATEGY
Biotechnology for Based on strains purchased from third parties. We try to
PROBIOTIC complement them with native strains, provided by technology
production centers and universities in the nearby environment. (CNTA,
UNAV, UPV/EHU etc).
PREBIOTIC Based on polyphenol extract from own organic olive trees and,
production in the future, from other plants.
technologies
COLLABORATIO
N CHALLENGES
LOOKING FOR
Nanotechnology Lipid nanoparticles and nano-oxides
for plant
(Provided by CT L´Urederra)
compounds
encapsulation
HEALTHY AND
ECOLOGICAL SOLUTIONS
WIDE EXPERIENCE
CHALLENGES CONSUMER
WASTE RECOVER LINKAGE
1. Background
Process map “cradle to grave”
1. Background
MANUFACTURING
PROCESS
1. Background: 1.1. ACV
Start - end date: January 2008 - December 2010 (RECYWASTEOLHIVA PROJECT)
Objective: carry out the calculation of the ECOLOGICAL, ECONOMIC AND SOCIAL impacts of
the classic production of extra virgin olive oil, in order to have an impact matrix to improve
processes and make them more sustainable.
Datos generales
Matriz de valoración
Residuos
generados
Tratamiento de
Etapa 1 del Ciclo de vida
Componentes de la Herramienta ACV
Ecológica los residuos
Producción Agrícola
Consumos de
Hoja de datos materias primas
Etapa 2 del Ciclo de vida
Generación de
Transporte y
Ecológica (KWh/TP) aguas residuales
almacenamiento de MP
Ecosocial (ht/TP)
Económica (€/TP) Uso de
Etapa 3 del Ciclo de vida agroquimicos
Transformación y
elaboración
Etapa 4 del Ciclo de vida
Almacenamiento y Contaminación de
distribución suelos
Ecológica Contaminación de
Etapa 5 del Ciclo de vida Hoja de aire
Consumo resultados
Contaminación de
agua
Ecológica (KWh/TP)
Etapa 6 del Ciclo de vida Ecosocial (ht/TP) Consumo de
Post consumo Económica (€/TP) recursos naturales
Resumen ACV
1. Background: 1.1. ACV
Start date - end date: January 2008 - December 2010 (RECYWASTEOLHIVA PROJECT)
Producción de olivas y Fabricación de Aceites
Fases
Transporte y Transformación,
Producción Almacenamiento y Post-
Impactos Almacenamiento elaboración, Consumo
Agrícola Distribución consumo
MP envasado,..
Principales
1. Incineración de
podas
1. Consumo de 1. Consumo de
1. Vertido o tratamiento
2. Uso de fertilizantes combustibles combustibles fósiles Bajo nivel Tecnologías
Ecológicos de Alperujos recogida de reciclaje
nitrogenados en fósiles por Transporte
selectiva inadecuadas
dosis superiores a las 3. Pérdida de suelo
absorbidas por las
plantas
1. Consumo energético
Laboreo para Precios alto
Coste del
Económicos eliminación de malas productos
2. Consumo de envases Transporte
hierbas y embalajes
ecológicos
Eco- Accidentes en Accidentes de Accidentes de Afecciones
sociales maquinaria agrícola tráfico tráfico para la salud
1. Background: 1.2. Carbon Footprint
CARBON FOOTPRINT OF CLASSIC PROCESSES FOR OBTAINING OLIVE OIL
GHG emissions by stages of the product life cycle and
and their contribution in percentage to the total Carbon
Footprint.
gr CO2 eq/ l aceite
ETAPAS
Botella Vidrio 500 ml PET 2L PET 5 L
AGRICOLA
7.766,00 7.766,00 7.766,00
EXTRACCIÓN
3.813,51 3.813,51 3.813,51
ENVASADO
5.969,14 426,50 320,47
DISTRIBUCION
20,56 7,90 3,27
FIN DE VIDA
9,84 1,73 0,92
TOTAL 17.579 12.016 11.904
Glass bottle format contributes significantly to the final Carbon Footprint, reprsenting about 34% GHG
emissions. This is due to the high energy consumption of glass bottles production. PET bottles should be
considered as an essential alternative from a Carbon Footprint point of view.2. Impact update: IMPROVEMENTS ALREADY MADE Continuous improvement of the practices of the olive grove in organic farming: Plant cover maintenance on farms. Chopped grass and choping pruning incorporation as organic amendment in the farms themselves Keeping pruning in the ground for a while for protection of the olive tree itself agains plagues. Maintenance of wild vegetation areas (borders, banks, ...) Concentrate phytosanitary treatments so as to minimize atmosphere emissions and fuel consumption during application. Use of Potassium Oleate manufactured with own oil residues Plant alfalfa and similar forage plants on farms with slopes to prevent erosion and fix nitrogen Controlled use of Milling and / or Alperujo Waters to control weeds in young olive groves
2. Impact update: IMPROVEMENTS ALREADY MADE
Design and construction of sustainable facilities: Cleaner processes:
Installation of our plant in an olive grove in the center and closest
Adjustment of the different machinery to the productive
point to the rest of the olive groves to minimize journeys. capacities
Construction with recycled materials: marine containers and Adaptation of the olive groves to be collected with a
construction houses vibrating umbrella, avoiding displacement for collection and
Use of recyclable metal and wood materials collecting leaves for the use of polyphenols
Minimization of the use of concrete in the Urbanization-facilities
Zero waste water discharges: sanitary and cleaning waters
Supporting containers and booths on the perimeter on recycled
are collected in a septic tank, using these waters in the
tires filled with concrete
Collection of rainwater from the roofs for irrigation of the olive irrigation of compost and the olive grove, avoiding their
grove discharge into a public channel
Adjustment of the dimensions of the different enclosures to what Composting the organic waste generated in the different
is necessarily essential for the proper functioning of the processesprocesses to incorporate it as an organic amendment in the
olive grove
Savings and Energy Efficiency: Orientation to the local and nearby market, avoiding the
Installation of solar panels for self-consumption of energy, impacts caused by transport
without network connection Label, back label and cardboard box weight adjustments
Adaptation of a diesel electricity generator to work with propane. Elimination of the use of pasquinades in each of the
installation of an automation system so that the generator starts containers
operating when the batteries that accumulate solar energy are Change from a black bottle to a lower impact green bottle
empty and the demand of the processes requires energy. Development of R&D projects to obtain clean processes
Take advantage of the heat of the fumes generated by the energy and high added value products related to the world of
generators for the drying of olive leaves and the pomace needed health, taking advantage of waste2. Impact update: 2.1. CO2 Emissions balance
ACTIVITIES INITIAL PRODUCTION METHODS DESCRIPTION INDICATORS/Kg olive - h TOTAL
ENERGY Organic olive tree cultivation Kwh/year 86.435
CONSUMPTION Tranformation and manufacturing processes Kwh/year 144.819
TOTAL Kwh/year 231.254
Total CO2 initial agricultural production
methods Kg CO2/Kg olive - leave 1,46
Total CO2 to obtain aqueous concentrates of
Kg CO2/Kg leaves 3,69
olive polyphenols 5g / l
PRODUCTION
Grinding and whipped Kg CO2/Kg olive - leave 0,293
COSTS
(€) Oil and water extraction in centrifugal decanter Kg CO2/Kg olive - leave 0,289
Decantation, storage and coupages in tanks Kg CO2/Kg olive- leave 0,128
Pomace pellets and use Kg CO2/Kg olive - leave 0,383
Product packaging - distribution - end of life Kg CO2/Kg olive - leave 0,29
TOTAL CO2 EMISSIONS Kg CO2/Kg olive - leaves 6,527
ECONOMIC CO2 ABSORTIONS Kg CO2/Kg olive - leaves 85,5
BALANCE (€/Kg CO2 NET BALANCE Kg CO2/kg olive – leaves -78,97
olive) CO2 TOTAL BALANCE (24,2ha – 2 t Olive- T CO2/year -3822
leave/ha)2. Impact update: 2.2. Economic balance
ACTIVITIES INITIAL PRODUCTION METHODS
INDICATORS/Kg olive - h TOTAL
DESCRIPTION
Total CO2 initial agricultural production
€/Kg olive - leave 0,81
methods
Total CO2 to obtain aqueous concentrates of
olive polyphenols 5g / l €/Kg olive - leave 6,56
PRODUCTION Grinding and whipped €/Kg olive - leave 0,08
COSTS Oil and water extraction in centrifugal
€/Kg olive - leave 0,08
(€) decanter
Decantation, storage and coupages in tanks €/Kg olive- leave 0,04
Pomace pellets and use €/Kg olive - leave 0,09
Product packaging - distribution - end of life €/Kg olive - leave 0,11
TOTAL PRODUCTION COSTS €/Kg olive - leave 7,77
Oil sales income €/Kg olive – leave equiv. 1,05
ECONOMIC Pellet sale income €/Kg olive – leave equiv. 0,25
BALANCE (€/Kg Income sale of aqueous olive polyphenols 16
€/Kg olive – leave equiv.
olive) concentrates 5 g / l
Total income € / kg olive-leaves 17,05
Net margins € / kg olive-leaves 9,273. Action plan for the reduction of emissions in a
technical-economic way : 3.1. In cultivation processes
2019 2020 2021
ACCIONES A REALIZAR OBJETIVOS
2do Trim. 3er Trim. 4to Trim. 1er Trim. 2do Trim. 3er Trim. 4to Trim. 1er Trim. 2do Trim.
PROCESOS DE CULTIVO
Modificaciónes a Introducir en la Operación de Poda de Invierno:
Corte de Ramas más grandes cada dos años mediante motosierra y tijeras eléctricas Reducir tiempos y mejorar follaje
Dejar ramas en el centro de la calle y troncos gruesos bajo la sombra del olivo Recoger, triturar y producir pellets
Alimentación de cabras y ovejas:
Recogida con narria de ramas y transporte a ganadero Directo-Pienso
Recogida manual de ramas y transporte a Biosasun Extracción de Polifenoles
Trituración de Ramas no recogidas con picadora Fertilización y eliminación parasitos
Nuevas Actividades para el Control de Malas Hierbas
Aplicación de Aguas de molturación cada 4 años Reducir hierbas y reciclar aguas
Sustituir la Labor ligera de cultivador por otra con narria 2 veces/año Reducir el consumo Energético
Cosecha mezcladas con ramón y
Años de no poda siembra de cereales/leguminosas/… alimentación de ovejas-fertilización
Mejora de la Fertilización
Aplicación manual debajo árboles de 4T/Ha de compost cada 4 años Reducir costes actuales3. Action plan for the reduction of emissions
in a technical-economic way : 3.2. In the production
processes of olive polyphenols
2019 2020 2021
ACCIONES A REALIZAR OBJETIVOS
2do Trim. 3er Trim. 4to Trim. 1er Trim. 2do Trim. 3er Trim. 4to Trim. 1er Trim. 2do Trim.
PROCESOS DE PRODUCCIÓN DE POLIFENOLES DE OLIVO
Preparación de las Instalaciones y Equipamientos
Sistema de limpieza de frutos, hojas, alperujos para extracción de polifenoles Aprovechar Hojas
Equipos periféricos sinfín elevador orujo, tolva alperujo, sinfín tubo alimentación alperujo yProcesar
depósitos
también
de recogida
alperujo
de líquidos.
Sistema de separación mecánica de los restos de aguas y aceites Aprovechar Aguas de Molturación
Automatización arranque automático y mejora sistema actual de cargador fotovoltaico Aprovecha mejor Energía Solar
Separar aceites Aguas conpolifenoles
Sistema de separación y recuperación de frutos, hojas, alperujos y residuos y producción orujo
Depósitos con control de atmósfera Evitar oxidaciones
Generador recuperación calor humos secado Reducir consumo-emisiones
Control masa, caudal y temperatura Mejorar la calidad de los productos
Recepción, selección y Lavado de la oliva y Hojas y ramitas
Pulverizado de agua “duchas” en la recepción, si fuera necesario lavar Redudir consumo de agua al 50%
Trituración de hojas secas para Proceso de Molienda Recoger mejor y más barato
Utilización de hojas de recolección de olivas para secado directo Eliminar recogida manual de hojas
Preparación de hojas para la extración
Uso directo de Hojas en saco filtrante para concentraciones no muy altas Reducir tiempos operación
Molienda de Hojas y extracción en centrífuga de polifenoles Lograr alta concentración Polifenol
Extracción Pasterización
Introducción de hojas en un recipiente con agua de molturación (AM) Aprovechar AM con polifenoles
Calentamiento a 105ºC durante un mínimo de 20 minutos en Recipiente a Presión Pasterizaión directa
Proceso de evaporación en 4 horas Reducir tiempo-consumo-emisión
Separación de las hojas sacando el Saco filtrante Liempieza y menor tiempo
Sustituir proceso de Liofilización por Destilación a vacío
Reducir a menos de la mitad
Ejecución del proceso de Destilación: Calentamiento-Vacio-Evaporación consumos y emisiones
Evitar la pasterización por terceros Reducir costes y emisiones3. Action plan for the reduction of emissions
in a technical-economic way : 3.3. In grinding and use of
by-product processes
2019 2020 2021
ACCIONES A REALIZAR OBJETIVOS
2do Trim. 3er Trim. 4to Trim. 1er Trim. 2do Trim. 3er Trim. 4to Trim. 1er Trim. 2do Trim.
PROCESOS DE MOLIENDA Y DE APROVECHAMIENTO DE SUBPRODUCTOS
Preparación de las Instalaciones y Equipamientos
Instalacion de Pelletizadora, ensacadora y apiladora. Pelletizar orujo, serrín y piensos
Construcción de Secadero adicional: Pérgola para secado, elaboración y almacenaje Secar el Orujo y pellets
Sistema de separación y recuperación de frutos, hojas, alperujos y residuos Separar aceites-polifenoles y orujo
Generador recuperación calor humos secado Reducir consumo, emisiones
Molienda y Batido
Reducir consumo, emisiones
Recirculación de Aguas de Molturación de Tanque Decanter a Batidora sobre el 50%
Concentrar Polifenoles en las Aguas
Introducción Alternativa de Hoja-Orujo+Aguas de Molturación (AM) finales a valorizar
Extracción del aceite y aguas en “Decanter Centrifugo”
Introdución de Aguas de Molturación en el Decanter Concentrar Polifenoles en las AM
Envío de Aguas de Molturación preconcetrada a Depósitos 1º ó 2º Concentrar Polifenoles en las AM
Salida de Orujo a zona de Pellets Valorizar el orujo como Pellets
Decantación, almacenamiento y coupages en depósitos
Decantación de Aceites en Depósitos Primarios Reducir consumo, emisiones
Coupages de aceites de oliva directos con otros aceites Concentrar polifenoles en Aceites
Concentración y Pasterización de Aguas de Molturación 2º Depósito en Deposito Final Reducir consumo, emisiones y
con hojas, mediante calor residual concentrar Polifenoles
Mezclado de Orujo con Aguas de Molturación en Batidora Recuperar aceites y polifenoles
Envío de Aguas de Molturación a Control de Malas Hierbas Adaptar producción-mercado
Orujos pelletizado y aprovechamiento
Secado de Orujo con calores residuales en Secadero Solar Reducir consumo y emisiones
Mezclado de orujo con serrines o Ramón con Avena/Cebada Producir Pellets o Piensos
Pelletizado de Orujo-Serrín ó Ramón-Avena/cebada Producir Pellets o Piensos
Ensacado de Pellet o Pienso en sacos de 15 Kg Valorizar el orujo como Pellets
Alternetiva Reprocesado de Orujo Adaptar producción-mercado
Alternativa Uso del Orujo Para Compots-Fertilización A1 Adaptar producción-mercado
Envasado de los productos
Sustituir botellas de vidrio por otros envases de menor HC Reducir emisiones4. Conclusions and calculations: 4.1. Recalculation of CO2
emissions after improvements.
NEW EKO-PRODUCTION METHODS DESCRIPTION INDICATORS/Kg olive - h TOTAL
Total CO2 initial agricultural production methods Kg de CO2/Kg olive - leaves 0,38
Total CO2 to obtain aqueous concentrates of olive Kg de CO2/Kg leaves 1,44
polyphenols 5g / l
Grinding and whipped Kg de CO2/Kg olive - leaves 0,231
Oil and water extraction in centrifugal decanter Kg de CO2/Kg olive - leaves 0,205
Decantation, storage and coupages in tanks Kg de CO2/Kg olive – leaves 0,080
Pomace pellets and use Kg de CO2/Kg olive – leaves 0,265
Product packaging - distribution - end of life Kg de CO2/Kg olive – leaves 0,29
CO2 total emissions Kg de CO2/Kg olive – leaves 2,894
CO2 absorption Kg de CO2/Kg olive – leaves 85,5
CO2 net balance Kg de CO2/Kg olive - leaves -82,61
CO2 total balance (40 Ha – 2 t olive – leave/Ha) t CO2/year -6608
CO2 emissions reduction: CO2 emissions balance improvement:
29% 56%4. Conclusions and calculations: 4.2. Conclusions
Regarding CO2 emissions of the different Regarding production costs of the processes in olive
processes: circular economy:
Emissions from the manufacture of glass containers are High profitability of the production of olive polyphenol
relatively high, compared to the set of olive production concentrates must be transferred to boost this organic
operations, so it is highly recommended to replace this production sector, influencing these aspects:
type of bottle with PET containers or others with less Promote entry into the Cosmetic and Food Ingredients
impact. markets, achieving a gradual and logical growth, since
Emission reduction in the whole olive growing processes otherwise, the use of the remains of pruning, milling, ...,
is due to the integration of the processes and the recovery would hardly allow maintaining a reduced profitability of
of all by-products under the concept of circular economy. the set of activities: Agricultural and industrial of
This can represent a significant reduction in emissions of transformation.
more than 50% globally.
Taking into account the absorption of CO2 by olive trees Maintain prices similar to those we have outlined, that
themselves (570 Kg CO2 per centennial olive tree and year) do not plummet, when this type of application becomes
lead us to persist in the objective of protecting and
widespread.
promoting ecological cultivation of Arroniz variety in our
Limited profitability of the production and sale of Extra Virgin
environment. It manages a net absorption of more than 80
Olive Oils. Organic market prices, maintains the activity thanks
Kg of CO2 per Kg of product put on the market.
to the CAP.
Viability of promoting both activities, which are essential to
be carried out together to reduce emissions and costs to levels
that allow high profitability, greater than 30. This should allow
for the expansion of this type of crops and the maintenance of
their ecosystems in Navarra.
EFSA: “the polyphenols in olive oil contribute
to the protection of blood lipids against
oxidative damage”4. Conclusions and calculations: 4.2. Indicators monitoring
Indicators comparison
Indicators Absolut impact
Objectives 31-12-2019 31-12-2021
6,5 Kg CO2/Kg olive-leaves 2,9 Kg CO2/Kg olive-leaves
GHG emissions CO2 -78 Kg CO2/ Kg olive-leaves -82 Kg CO2/Kg olive-leaves
Max 3.476 TCO2/year Max 6.036 TCO2/year
Improving
Hazardous
environmental substances
284,85 Kg/Ha - year 15,35 Kg/Ha - year
Toxic
Reduction /
performance Substitution
10.262,94 Kg/ year 594,81 Kg/year
Waste reuse Made: 120 Kg 3.150 Kg/Ha - year
Waste management
Substances recover Potential: 29 T 122.062 Kg/year
Raw materials for
Better use of cosmetics
20 Kg 2,2 T/year
natural Resources replaced Raw materials for
100 kg 8,7 T/year
by By-products organic food
resources Raw materials for
65,3 T/year
fertilizers
Water consumption
Water 2.636 m3/year 2.087 m3/year
reduction
4,8 Kw-h/Kg olive-leaves 2,7 Kw-h/Kg olive-leaves
Energy
Energy consumption
Max 231 Mw-h/year Max 217 Mw-h/year
reduction4. Conclusions and calculations: 4.2. Indicators monitoring
Indicators comparison
Indicators Absolut Impact
Objectives 31-12-2019 31-12-2021
Market replication Initial replication 24,2 Has 40-50 Has
Economic Market size 0,21 M€ 1,59 M€
Performance/
Potential market
Market Market size
2.000 consumers 91.120 consumers
(Final clients)
Replication
New transnational markets entry Europe Europe America
Food, self – fertilization, cosmetic –
New sectors entry Food, Self - fertilization
pharmaceutical, energy
Aqueous concentrate 5g/l PT 58 %
Others Cost reduction per unit or process Dried powder 150 g/Kg PT 66%
Leaf powder 130 g/Kg PT 6%
Invented capital / net
Payback Time 20 years 5 years
income
Europe 2 Industrial secrets 1 patent + 3 secrets
Patents
Out of the UE 3 patentsTHANK YOU VERY MUCH MERCI BEAUCOUP MUCHAS GRACIAS ESKERRIK ASKO
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