energy usage in dairy production systems...water usage january/may 2015 milk lines 48% milk tanks...
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Energy Usage in Dairy Production Systems
Brad Heins West Central Research and Outreach Center Morris, MN
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© 2012 Regents of the University of Minnesota. All rights reserved.
WCROC Dairy Herds • Organic herd
• 126 cows
• 36 lbs milk, 4.1% fat, 3.1% protein, 288 SCC
• Milk price: $35.62 /cwt.
• Conventional herd
• 140 cows
• 57 lbs milk, 3.7% fat, 3.2% protein, 286 SCC
• Milk price: $17.65/cwt.
• Dairy breeds • Holstein, Jersey, Montbéliarde, Viking Red, Normande, 1964 Holstein
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Dairy research and outreach at WCROC
• Grain supplementation strategies
• Summer annuals for grazing
• Pasture forage quality
• Out wintering
• Fodder production systems
• Group rearing of dairy calves
• Crossbreeding of dairy cattle
• Renewable energy for dairy farms
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Major energy use on a Dairy Farm
• Milk Harvest*
• Milk Cooling*
• Lighting*
• Air Circulation* and Ventilation
• Washing and Water Heating*
• Feed Handling
• Manure Handling
• Water Pumping
• Compressed Air
*Indicates significant use
energy savings is possible
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© 2012 Regents of the University of Minnesota. All rights reserved.
Dairy farm energy generation
Source: Innovation Center for U.S. Dairy
Irrigation, grain drying, waterers, laundry
Milk harvest
Milk cooling
Lighting
Hot water Air heating Ventilation
Motors
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© 2012 Regents of the University of Minnesota. All rights reserved.
Electricity use on dairy farms
Manure handling
5%
Feeding equipment
3%
Lighting
17%
Ventilation
24%
Electric water heating
5%
Miscellaneous
2%
Milk cooling
26%
Milking
18%
Source: NATC, Ithaca, NY
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Freestall vs. Tie Stall operations
• Freestall operations • Tie stall operations
Manure
Handling
4%Feeding
Equipment
1%
Ventilation
22%
Lighting
26%
Misc.
1%
Vacuum Pumps
17%
Milk Cooling
27%
Electrical Water
Heating
2%
Milk Cooling
23%
Electrical Water
Heating
10%Lighting
17%
Ventilation
21%
Misc.
1%
Vacuum
Pumps
18%
Feeding
Equipment
7%
Manure
Handling
3%
Source: NATC, Ithaca, NY
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© 2012 Regents of the University of Minnesota. All rights reserved.
Dairy hot water needs
• Rule of thumb: 2 – 2.5 gal hot water/cow/day
• “Hot” water means temperatures from 160 to 170°
• High temperatures are required for proper sanitation and equipment wash
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© 2012 Regents of the University of Minnesota. All rights reserved.
Pre-cooling milk
• Can reduce the milk temperature by as much as 20°
• Can reduce cooling costs by as much as 30%
• Adding a variable speed drive to the milk pump will enhance pre-cooler savings
• Pre-cooling can improve milk quality
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© 2012 Regents of the University of Minnesota. All rights reserved.
Energy flow for small dairy farm
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• Conduct baseline energy audits of dairy and swine facilities
• Develop and evaluate energy- optimized system for conventional and alternative production systems • Conduct life cycle assessment in dairy and swine production systems
Dairy/Swine project objectives
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© 2012 Regents of the University of Minnesota. All rights reserved.
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© 2012 Regents of the University of Minnesota. All rights reserved.
Scroll vs. Reciprocating compressor
Scroll compressor bulk tank Reciprocating compressor bulk tank
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Scroll vs. Reciprocating compressor
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VFD vacuum pump
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Daily dairy hot water usage
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Monthly dairy water usage
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Yearly dairy water usage
0
200
400
600
800
1000
1200
1400
1600
Gal
lon
s/D
ay
All Water
Total Hot Water
Press. Washer
Sink H
Tank Wash H
Washer H
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© 2012 Regents of the University of Minnesota. All rights reserved.
Yearly dairy electricity usage
0
50
100
150
200
250
300
350
400
kWh
's/D
ay
Total Electricity
Comp. Recip Conv
Comp. Scroll Org
Vac. Pump
Press. Washer
Dryer
Ventilation
Heaters
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Yearly dairy electricity usage
0
10
20
30
40
50
60
70
80
90
100
kWh
's/D
ay Comp. Recip Conv
Comp. Scroll Org
Vac. Pump
Press. Washer
Dryer
Ventilation
Heaters
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© 2012 Regents of the University of Minnesota. All rights reserved.
November 2014 dairy electricity usage
0
50
100
150
200
250
300
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
kWh
's/D
ay
Day
Total Meas.
Furnace
Conv. Comp.
Org. Comp.
Vac. Pump
Press. Washer
Dryer
Utility Fan
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WCROC dairy milk production
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
Mil
k (
Lb
s/D
ay)
Conv. Milk
Org. Milk
Total Milk
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WCROC dairy cows
0
50
100
150
200
250
300
Co
ws
Conv. Cows
Org. Cows
Total Cows
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Electricity usage January/May 2015
1.44 kwh/cow .58 kwh/lb fat and protein (Org) .42 kwh/lb fat and protein (Conv)
1.05 kwh/cow .52 kwh/lb fat and protein (Org) .35 kwh/lb fat and protein (Conv)
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Water usage January/May 2015
Milk Lines 48%
Milk Tanks 18%
Washing Machine
17%
Bathroom 5%
Parlor 12%
2015 January Hot Water Usage (349 gal/day Total)
Milk Lines 44%
Milk Tanks 20%
Washing Machine
17%
Bathroom 6%
Parlor 13%
2015 May Hot Water Usage (362 gal/day Total)
1.62 gal/cow 1.05 gal/cow
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Conclusions
• Greatest energy usage for cooling milk
• Milk house heaters use an immense amount of energy
• Greatest water usage is for cleaning milking system
• More education needed for producers about renewable and energy saving technologies