The dairy agribusiness in a sustainable perspective
Juliano Zaffalon Gerber - [email protected]
Universidade Estadual de Santa Cruz
Colegiado de Engenharia de Produção
Rodovia Jorge Amado, Km 16
Ilhéus, Bahia – Brazil
Francisco Gaudêncio Mendonça Freires - [email protected]
Universidade Federal da Bahia
Escola Politécnica – Departamento de Engenharia Mecânica
Rua Aristides Novis, 02
Salvador, Bahia – Brazil
Martin Tanco - [email protected]
Universidad de Montevideo
Facultad de Ingenería – Departamiento de Organización de la Producción
Avenida Luis P. Ponce 1307
Montevideo – Uruguay
Luane Alcântara Nunes ([email protected])
Universidade Estadual de Santa Cruz
Colegiado de Engenharia de Produção
Rodovia Jorge Amado, Km 16
Ilhéus, Bahia – Brazil
Abstract
The purpose of this article is to conduct a study about the disposal of dairy production with
emphasis on whey, suggesting that the treatment of these wastes agribusinesses are
performed through reverse logistics.
Keywords: Whey, dairy supply chain, Reverse Logistics.
The residue Whey and Environment
Concerns about the environment have become the reality of organizations, be they public or
private. Issues such as environmental protection of fauna and flora, maintaining biodiversity,
aesthetic and sanitary conditions of the medium as well as the health of populations are
closely related to the form of resource use by humans. As Braga et al. (2009), the quality of
life on earth is associated with the balance of three points: resources, population and
pollution, and the greater the population size, the greater the utilization of resources and
consequently the greater the amount of resulting materials these activities, depending on the
way they are disposed , are formed as pollutants to the environment.
The National Solid Waste Policy - PNRS (Brazil, 2010) classifies waste as any
material resulting from human activities in society, which can come in solid, liquid or
gaseous state and require an environmentally correct disposal. Waste may also be
characterized as something that was part of a production process and possibly not being
tapped, although still present some use, in the same process or as a source of raw materials
for other processes. The unconscious residue of small and medium agribusinesses disposal is
1
still an issue of concern these days (Ecogreens, 2010). Industries have sought alternatives,
innovative and feasible for treatment and recovery of waste and agro-industrial development
of new products, thus the production of alternative materials, is presented as a viable
alternative to reduce costs in the disposal of tailings (Leo, 2011).
In the environment of agribusiness, there are the dairy companies, which during its
production of cheese and derivatives, we obtain the serum, liquid waste, opaque, with rich
nutritional composition and high organic load, aspects which makes it a high- agent polluter
when dropped into water courses without treatment, due to its high Biological Oxygen
Demand (BOD) (Frigon et al.2009; Marwaha and Kennedy, 1988). According to Oliveira
(2010), BOD of whey, or the amount of oxygen required to oxidize the organic matter present
in it, equals 30,000 to 40,000 mg per liter of oxygen, an amount 100 times greater than
necessary to oxidize the same amount of sewage. The alarming is that the production of 1 kg
of cheese requires 10 L of milk and results in 9 L of serum (Prazeres, 2012). Due to the rich
nutritional composition of the whey residue formed by proteins, minerals, vitamins, lactose,
among others, research has been demonstrated by its use in the production of alternative
materials such as sweeteners, animal protein concentrates, feed, biofuel/ethanol, foaming
agent and emulsifier (Barbosa, Florentino and Florencio, 2010). Alternate materials whey,
when they come on the market in production or business cycle, can be recycled product
called whey, since undergone a process in which there was a reuse of the serum and from
then on, became whether new products, since recycling is a process of transformation of solid
waste involving the alteration of their physical, physico-chemical and biological properties,
aiming for processing into new products or inputs (Brazil, 2010).
In Brazil is produced on average 450 000 tonnes of cheese per year, and therefore are
obtained around 4 million tonnes of whey. On the world stage, the generation of these
organic residues corresponds to approximately 130 million tons per year, with only 15 % of
which are from high- scale industries (Guimarães Teixeira and Domingues, 2010), with the
remainder being medium, small and micro enterprises, which produce small amounts of
serum and often located in rural or difficult to access areas, hindering the flow of the effluent
and facilitating their improper disposal into the environment (Toni, Dorta and Imamura,
2012).
Law No. 12.305/10, establishing the National Solid Waste (PNRS) sets a priority
order for the environmentally sound management of wastes: (1) non-generation, (2)
reduction, (3) re-use, (4) recycling (5), treatment of solid waste and (6) environmentally
sound disposal of waste, also proposing the shared responsibility of everyone: manufacturers,
importers, distributors, traders, consumers and holders of public cleaning services at the life
cycle of products (Brazil, 2010). However, for lack of supervision and outsourced
alternatives for small and medium producers of whey, there is a lack of management for their
waste, resulting in product storage tanks for future decision-making in environmentally costly
treatments for disposal correct or even prohibited disposal in the middle, without proper
treatment (Toni, Dorta and Imamura, 2012).
In this context, this paper analyzes the disposal of waste from the dairy
agribusinesses, with emphasis on whey, proposing that your treatment is done through
planning of reverse logistics, which is in a method, which enables action the reverse channel
recycling and understanding of the supply chain for recycled products, understanding how
recycled product, the alternative material generated by manipulation and reuse of whey.
Supply Chain and Reverse Logistics and Production Cycle
It is known that different types of waste, resulting in a productive or human activity, may
serve as a source for raw materials and trigger a new production cycle, depending on the
management that you receive during your treatment. A production cycle is associated with
2
the sight of a supply chain, according to Ballou (2010) is equivalent to the integrated
management of supply logistics, production logistics and distribution logistics, thus
answering in the movement of raw materials and equipment from the point of origin, through
production and processing to the final consumer. The Reverse Logistics is related to the
activities involved in managing reduction, handling and disposal of products and packaging
(Razzolini, 2009).
According to Leite (2009) is the area of logistics business that plans, operates and
controls the flow and the corresponding logistical information, the return of goods after-sales
and post-consumer productive cycle through the channels of distributions reverse: recycling,
reuse and chop, adding values: economic, ecological, cool, logistics, the corporate image,
among others. The Reverse Logistics can be associated with a term used to refer to logistics
in recycling, disposal and management of waste contaminants aiming to recapture the
intended value or proper disposal, handling the impact of related to this process (Pereira
2011) costs. Figure 1 shows the supply chain/production cycle, major decisions regarding
your process and performance of the Reverse Logistics.
Figure 1 - Supply Chain / Production Cycle and the performance of the Reverse Logistics.
As illustrated in Figure 1, suppliers or responsible for the extraction and delivery of a
raw material or supplies, match source Supply Chain / Production Cycle and end consumers
to the same end point. The Reverse Logistics enters its activities, collaborating with: waste
treatment, the ultimate disposition of these environmentally appropriate, recycling and/or
reuse. The performance of the Reverse Logistics is refers to waste generated in the
manufacture of products, responsible for Production Logistics, or waste generated by the final
consumer, in order to return them to the top Supply Chain/Cycle Productive Way of the
prolong the life of them, thus increasing the time of use of a resource and helping to maintain
the quality of life on the planet. Regarding the logistics of supplies, this is the main function,
create conditions for the purchase of supplies (raw materials, equipment, labor, information),
3
manage your inventory and prepare effective conditions for storage and transport (Severo
2006). Have the logistics of production, begins with the Planning, Programming and
Production Control (PPCP) (Severo, 2006).
The PPCP is a system of plans and methods, divided into strategic, tactical and
operational levels, with various integrated activities, and are responsible to assist in decision
making, involving a range of issues, in order to define what, how much and when to produce,
buy and deliver, in addition to who and/or where and/or how to produce, intervening in the
strategic management of business operations (Fernandes and Godinho, 2010; Tubino, 2000
and 2009; Corrêa and Corrêa, 2012). The logistics of distribution, in turn, is responsible for
planning the distribution of finished products to local warehouses, wholesalers, retailers,
dealers, stores or consumers. From the applications, it defines the transport modes and routes,
and also responsible for the dispatch of the withdrawal of stocks until delivery to the final
customer (Ballou 2010).
Method of Reverse Logistics planning for Whey
With the understanding of Supply Chain / Production Cycle , as well as the performance of
the Reverse Logistics in it, it is possible to develop a method for managing waste in this case
whey. Therefore, an appropriate proposal for the management of waste whey milk in dairy
agribusinesses, would be the implementation of reverse logistics planning through a reverse
channel recycling. About a scaling or projection of the supply chain or production cycle of a
recycled product whey is possible to understand the application of Reverse Logistics and
manage it.
The proposed Reverse Logistics whey develops in 5 subsequent steps, namely: the
producers, the market, the supply logistics, the logistics of production and distribution
logistics. The setting, the actions and the theoretical basis of each step are presented below.
1) The Producers - consists of seeking information on location and quantity of the
waste producers whey and seeks to define: the relative area of the region of interest,
the location and number of sampling points of matéria-prima/soro milk; the amount of
production of whey milk residue at each collection point selected, and then at full
capacity within the sample collection (Corrêa and Corrêa 2012).
2) The Market - establishes the choice of recycled product whey would benefit the
region and obtain good demand, so that offset the costs and the process through
market research. Consists of performing: market research and choose a product or
alternative material; estimating the target audience or consumers of recycled product;
beyond adequate to forecast demand (Fernandes and Godinho 2010) calculations.
3) Logistics Supply - consists in planning the logistics of supply of recycled product
chosen , aiming planning conditions of purchase of supplies, inventory and effective
conditions for storage and transport. Becomes necessary to define: the politics of
collection management between suppliers and the system storage, transport and
packaging of raw materials, the routing of waste transportation to the point of storage
( Ballou 2010).
4) Logistics Production - involves planning the production of recycled product in
order to define what, how much and when to produce, buy and deliver, in addition to
who and / or where and / or how to produce. In this step you will need to develop: a
production plan at a strategic level for the recycled product of the serum, and the
production plan should address structural decisions, such as production capacity,
facilities, technology, vertical integration, among others. As infrastructural decisions:
human resources, quality, planning and control of production / materials, performance
measures, organization, among others (Tubino 2009).
4
5) Distribution Logistics - involves planning the logistics of distribution, in order to
define the modes of transport and routes by which the recycled product would be
delivered. Should determine: the management policy distribution to customers, the
system storage, transport and packaging of finished recycled product, the routing and
transport to distribution of recycled product (Ballou 2010). Table 1 presents the
compiled method to implement the Reverse Logistics whey, their steps and their
actions.
Table 1 – Method of Reverse Logistics for implementation of whey, their steps and their actions.
STEPS
ACTIONS
THEORETICAL BASES
1 - PRODUCERS
Define the area
of the region of
interest.
Define
localization and
amount of
producers.
Calculate the amount of
production of whey milk
residue in the region.
Corrêa e Corrêa, 2012
2 - MARKET
Conduct market
research.
Choose the
recycled product.
Estimate the audience
through a demand forecast.
Fernandes e Godinho,
2010
3 – SUPPLY
Set policy for
collection
management
between
suppliers.
Stablish a system
of storage,
transport and
packing of rawmaterials.
Estimate the routing of
waste transportation to the
point of storage.
Ballou, 2010
4 – PRODUCTION
Develop a
Strategic Plan
Production
Level.
Develop
structural
decisions.
Develop infrastructure
decisions.
Tubino, 2009
5 - DISTRIBUTION
Define the
management
policy
distribution to
customers.
Determine the
system of
storage, transport
and packing of
the recycled
product.
Estimate the routing and
transport to distribution of
the recycled product.
Ballou, 2010
5
Conclusions
With the completion of these steps, believed to be possible to get a proper planning of reverse
logistics whey through a recycling process that would lead to a new product: animal feed,
sweeteners, dietary supplements, nutritional feed additives, biofuels, etc. emulsifiers or
foaming agents, in order to enable his return to Supply Chain/production stages, bringing
benefits to society in terms of socio-economic development as well as collaborating with a
sustainable approach to the preservation of the environment and for the extension the useful
life of milk.
References
ABENUTRI, 2013 Associação Brasileira das Empresas de Produtos Nutricionais. Mercado de
suplementação nutricional. Disponível em: ,http://www.abenutri.org>. Acesso em 25 agos.
2013.
BRAGA, et al. 2009. Introdução a engenharia ambiental. 2º Edição, Prentice-Hall , São Paulo.
BRASIL, 2010. Lei 12.305, de 02 de agosto de 2010. Institui a Política Nacional de Resíduos
Sólidos; altera a Lei no 9.605, de 12 de fevereiro de 1998; e dá outras providências. - Data
da legislação: 02/08/2010 – Publicado no Diário Oficial da União - DOU de 03/08/2010.
BALLOU, R. H. , 2010. Logística Empresarial. 1º. Edição, 23º impressão, São Paulo.
BARBOSA, A. S.; FLORENTINO, E. R.; FLORÊNCIO, I. M. 2010. Utilização do soro como
substrato para a produção de aguardente: estudo cinético para a produção de etanol,
Minas Gerais.
BERTAGLIA, P. R., 2009 Logística e gerenciamento da cadeia de abastecimento, 2º ed, Editora:
Saraiva, São Paulo.
CORRÊA, C. A.; CORRÊA, H. L., 2012. Administração de produção e operações: Manufatura e
Serviços – Uma Abordagem Estratégica. 3ª edição, São Paulo.
ECOGREENS,
2013
Composteiras
e
Minhocários.
Disponivel
em:
http://www.ecogreens.com.br/v2/composteiras-e-minhocarios. (Acessed in december 03,
2013).
FERNANDES, F.C.F.; GODINHO F°, M., 2010 Planejamento e Controle da Produção: Dos
Fundamentos ao Essencial. São Paulo.
FLORENTINO, E. R. 2005. Caracterização do soro de queijo visando processo de aproveitamento.
Higiene Alimentar, v. 19, n. 130, p. 30-32,. Rio de Janeiro.
FRIGON, J. C.; BRETON, J.; BRUNEAU, T.; MOLETTA, R.; GUIOT, S. R. , 2009. The treatment
of cheese whey wastewater by sequential anaerobic and aerobic steps in a single digester at
pilot scala. Bioresource Technology. v. 199, p. 4156-4163.
GUIMARÃES, P. M. R.; TEIXEIRA, J. A.; DOMINGUES, L., 2010. Fermentation of lactose to
bioethanol by yeasts as part of integrated solutions for the valorization of cheese whey.
Biotechnology Advances, v. 28, p. 375-388.
LEÃO, A. L., CHERIAN, B. M., SOUZA, S. F., THOMAS, S. 2011. Resíduos agroindustriais –
Caracterização e utilização, UNESP - FCA, Revista Citricultura Atual, nº 80,. Botucatu, SP
6
MARWAHA, S. S., KENNEDY, J. F. 1988. Review: whey pollution problem and potential
utilization. International Journal of food Science and Technology. v. 23. n. 4, p. 323-336.
OLIVEIRA, D.F.; BRAVO, C. E. C.; TONIAL, I. B. 2012. Soro de leite: um subproduto valioso.
Revista do Instituto de Laticínios Cândido Tostes. v. 67, n. 385. Minas Gerais.
PEREIRA, André Luiz, et al., 2011. Logística Reversa e Sustentabilidade. Cengage Learning, São
Paulo.
PRAZERES, A. R.; CARVALHO, F.; RIVAS, J. 2012. Cheese whey management: A review. Journal
of Environmental Management. v. 110, p. 48-68, Australasian.
SEVERO F. J., 2006. Administração de logística integrada materiais, pcp e marketing. E-papers, Rio
de Janeiro.
SGARBIERI, V. C. 2004 Propriedades fisiológicas-funcionais das proteínas do soro de leite. Revista
de Nutrição de Campinas, São Paulo, v. 17, n. 4, p. 397-409, out./dez.. In: OLIVEIRA, C.
MARIA, SILVA, O. FREITAS. 2008. Utilização do soro de leite bovino como revestimento
protetor em morangos, B.CEPPA, Curitiba.
TONI, J. C. V.; IMAMURA, K. B.; DORTA, C., 2012. Reaproveitamento do soro de leite bovino
para produção de biomassa por Kluyveromyces Marxianus 229. Revista Alimentus. p. 3657, 2ª Ed., São Paulo.
TUBINO, D. F., 2009. Planejamento e Controle da Produção: Teoria e Prática. 2.ed. Atlas, São
Paulo.
7