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Umberto® NXT LCA (v2.0)
Tutorial
Chocolate Production
ifu Hamburg GmbH Max-Brauer-Allee 50
22765 Hamburg / Germany www.ifu.com
DocVersion: 2.0
Datum: May 2014 Publisher: ifu Hamburg GmbH
http://www.umberto.de
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
Umberto® is a registered trademark of ifu Hamburg GmbH Microsoft and MS are registered trademarks. Windows and Excel are trademarks of Microsoft Corp. Other brand and product names are trademarks or registered trademarks of their respective holders.
Information in this manual is subject to change without notice. No liability for the correctness of the information in this manual. All figures are for demonstration purposes only and contain fictitious data. Reproduction or translation of any part of this manual in any form (electronic or mechanic) without prior written permission of the copyright owner is unlawful. Requests for permission should be addressed to ifu Hamburg GmbH, Hamburg, Germany.
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
Content Overview
I. Background .................................................................................... 5
II. Getting Started ............................................................................... 7
Welcome to Umberto NXT LCA................................................................... 7
Step 1- Creating a first process module ...................................................... 8
Step 2 - Defining Materials ..................................................................... 10
Step 3 - Specifying the Process ............................................................... 12
III. Processes ..................................................................................... 14
Crop Establishment ................................................................................ 14
Cocoa Seedlings .................................................................................... 14
Harvesting & Extraction .......................................................................... 15
Transport of Cocoa Beans ....................................................................... 15
Fermentation & Sun Drying ..................................................................... 17
Transport .............................................................................................. 18
Industrial Cleaning................................................................................. 19
Heat Production ..................................................................................... 19
Roasting ............................................................................................... 20
Winnowing ............................................................................................ 21
Grinding ............................................................................................... 21
Pressing ............................................................................................... 22
Milling .................................................................................................. 22
Mixing .................................................................................................. 22
Conching and Tempering ........................................................................ 23
Moulding & Packaging ............................................................................ 24
Refrigerated Transportation ..................................................................... 25
Cooling in Supermarket .......................................................................... 26
Storage in Refrigerator ........................................................................... 26
Eating .................................................................................................. 26
Package Disposal ................................................................................... 26
IV. User Defined Specifications .......................................................... 29
Mixing .................................................................................................. 30
Cooling in Supermarket .......................................................................... 32
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
Storage in Refrigeration .......................................................................... 34
V. Using the Expand Function ........................................................... 36
VI. Creating a Subnet for the Aluminum Production........................... 43
VII. Evaluation .................................................................................... 46
VIII. List of all applied materials .......................................................... 48
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
I. Background
Based on a real life cycle assessment study about the cocoa production and
processing in Ghana (Environmental impacts of cocoa production and processing
in Ghana: life cycle assessment approach, Ntiamoah 2008) and the process
description for the production of cocoa powder in the UK (Scenario building to test
and inform the development of a BSI method for assessing greenhouse gas
emissions from food, Defra 2009) the procedure for creating a full life cycle
assessment of the Chocolate Production using Umberto NXT LCA will be explained.
Therefore, the following documentation will guide through different steps that have
to be performed. The overall model can be seen in Figure 1 Overview of the
complete Model .
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
Figure 1 Overview of the complete Model
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
II. Getting Started
Welcome to Umberto NXT LCA
The first thing that appears after opening Umberto NXT is the start page. This page offers some information about the software and provides links to commands for creating a new Umberto project file.
In Umberto NXT, the topmost data structure is a project file. A project file is a
database where the models and materials are stored in. Several models can be created in one project file. A model typically contains one network for calculation. Every material defined in a project can be used for every model within the same
project.
All changes made while working on a project are instantly written in the project database. Therefore, it is not necessary to actively save the working progress.
Before a model can be created, a new Umberto project file needs to be opened. There are three ways to do so. Either, follow the link 'New Umberto Project File' on
the start page, or navigate to 'File' in the menu bar and choose the entry 'New'. The third possibility is to click on the 'New Project File' button in the main toolbar
at the top ( ).
A file save dialog will be shown asking whether to save the project file on the hard disk. Please find an adequate name for the Umberto project file. Now that a new
project file has been opened, the graphical user interface of Umberto NXT shows the workspace: There are four windows on the screen (see below).
Figure 2 Overview of the workspace
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The largest window is called ‘Net Editor’. The net editor allows for creating a
graphical model.
The window pane on the top left is the so called ‘Project Explorer’. It shows all models and materials that are contained in the respective Umberto project file.
At the bottom left there is the ‘Property Editor’ window pane. The first information on the top of this window shows the type and name of the selected
element. Further properties of this element are also displayed and can be edited here.
Below the net editor the ‘Specification Editor’ is located. It allows for specifying the elements of the model. This pane is also used to show the calculation results.
Since no network has been created yet, the specification editor is empty.
Step 1- Creating a first process module
After having created a new project and a new model, you can start to build the
first network model by creating a first process. In this example, the first process
step ‘Crop Establishment’ will be developed.
Start by clicking on the process symbol in the toolbar of the net editor. The
cursor changes to a cross, indicating that the design mode is active. Next, click in
the middle of the net editor to draw the first process.
To draw several elements in a row without exiting the editing mode,
double-click on the desired element in the toolbar. After double-
clicking on an element a small pin is shown in the button icon
indicating that multiple elements can be created → . To exit the
multi-draw mode, use the right mouse button or click on the arrow
button again.
Name the process by clicking the the text label located right below the process.
Navigate to the property editor and enter the name ‘Crop Establishment’ in the
field ‘Text’. It is also possible to change a text label by clicking on its text while it
is selected. Apply the change by hitting the tab key or by clicking elsewhere in the
net editor.
Figure 3 Crop Establishment, the first project
The process will need an input place and an output place. Choose the input place
(symbol with a green line and a vertical trace on the left) and place it left of the
process by clicking there. Then, select the output place from the toolbar (symbol
with a red line and a vertical trace on the right) and place it on the right side of
the process.
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
Another way to create elements is to use the 'Draw' menu and to
select the desired element. Alternatively, choose 'Draw' from the
context menu, which pops up by right clicking on the area of the
model editor.
The next step is to connect the three elements with arrows, on which the materials
or substances flow into the process and out of the process. As a general rule,
places always connect to a process, and processes always connect to a place.
Never does an arrow connect a place directly to another place, or a process directly
to another process.
To connect the input place to the process with an arrow, click the arrow button
in the toolbar. Place the cursor over the input place. When a grey filling appears,
drag the cursor onto the process symbol (keeping the left mouse button pressed).
Watch the arrow emerging from the element. When the cursor comes close to a
connectable target element, the arrow snaps to this element automatically as the
mouse button is released: the two elements are now connected with an arrow
leading from the input place to the process.
In the same way, draw an arrow from the process to the output place. The first
very simple network model should now look like the figure below. The process
shows a small red warning sign. This means, that the process is unspecified.
Figure 4: A process with inputs and outputs, the start of a process chain
The function 'Snap to Grid' in the net editor's toolbar can be used
to easily align elements. By default, this feature is enabled, which
is indicated by a blue square around the symbol. To disable this
feature, click on the symbol and the blue square will disappear. The
grid to which the elements are aligned can also be enabled and
disabled by using the 'Show Grid' button.
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
Step 2 - Defining Materials
Before you can start to specify the process, it is necessary to add materials to your
project.
In this example, it is demonstrated how to create new materials. Materials are
categorized into material groups. Material groups are shown as folders in the
Project Explorer.
The material group 'Project Materials' contains all materials used within a project.
Figure 5: Project Explorer
Press the 'New Material' button in the Project Explorer's toolbar or use the
context menu to create a new material.
The properties of the material are managed in the properties editor (situated below
the project explorer). Rename the material to ‘Cocoa Seeds’. At this stage of the
tutorial there is no need to change other material properties. The unit type should
be ‘Mass [kg]’, the display unit ‘kg’ and the material type ‘Good’.
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
Figure 6: Property Editor
Material groups and sub groups can be created by selecting a
directory for the group within the Project Explorer and pressing the
'New Material Group' symbol on the Project Explorer's toolbar.
Another option is using the context menu to create a new material
group by pressing the right mouse button. Material groups are
useful for large projects with a variety of materials.
A material group can be named and renamed by selecting it and
editing the name field within the Property Editor.
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
Step 3 - Specifying the Process
To specify the process ‘Crop Establishment’ with input and output material
entries, click the process in the net editor. When the process is selected, the
specification pane below the net editor shows two sections: the left section for the
inputs of the process and the right section for its outputs.
Materials from the materials list can easily be added to the input or output side
using drag and drop. Drag and drop the material ‘Cocoa Seeds’ to the input side
of the process specification window. In the Project Explorer, you can also search
for those materials provided through the databases used in Umberto NXT. Search
for ‘irrigation’ and ‘electricity, medium voltage’ and add those to the input side
too. These materials are already existing in the datasets of Umberto NXT. The list
at the very end of the tutorial names all materials applied including data source.
Create the new material ‘Cocoa Plantation’ with material type ‘Good’, unit type
‘Area’ and unit ‘ha’. Then, add this material as well as the already existing material
‘Carbon dioxide, non-fossil [air/unspecified]’ to the output place.
Materials can also be added to a process by using the button
at the bottom of the Specification editor below the table. This button
prompts a dialogue, which allows searching for materials by group,
name, display unit and source.
As there is still a warning marker on the process element, the process is still not
fully specified. It is necessary to determine the ratio between the input and output
materials. This can be done by adding coefficients to the materials in the
specification pane for this process.
In this first process ‘Crop Establishment’, the growth of cocoa plants requires
electricity for the irrigation. Enter a new input place above the process and connect
it to the process. Name the new input place ‘Energy’. To avoid the arrow crossing
through the name label of the input place simply drag the label to another position,
e.g. above the place.
The material ‘electricity, medium voltage’ should have a coefficient of 0,317
kWh and ‘Cocoa Seeds’ requires a coefficient of 4,5 kg. Also enter a coefficient
of 15m3 for ‘irrigation’.
Enter the ‘Cocoa Plantation’ and ‘Carbon dioxide, non-fossil
[air/unspecified]’ with coefficients of 25 g and 125 g to the output side. The
process specification should look similar to Figure .
Figure 7: Process specification ‘Industrial Cleaning’
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A comma (',') is used as the decimal point. Type '1,7' not '1.7' for
the coefficients in the process specification window. Otherwise a
message will be prompted to confirm the right value.
After entering the coefficients, the process is specified and the warning sign
disappears.
Figure 8: Process ‘Crop Establishment’
Note that adding the material on the output side results in a change of the
respective font to bold and of the 'Material Type' to 'Reference Flow'. This is
because the product is connected to a system output place and therefore leaves
the system. Any product that leaves the system is considered a reference flow and
is assumed to be (one of) the functional unit(s) of the network.
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
III. Processes
The following processes use materials that need to be created as well as materials
existing in the ecoinvent dataset provided in Umberto NXT. Chapter VIII at the end
of this tutorial provides a list of all applied materials, sorted by processes.
Information on the unit, material type and data source is given.
The following figure shows an overview of the first processes until the ‘Cocoa
Beans’.
Figure 9 Overview of the cocoa bean production
Crop Establishment
As this process has already been established above in chapter ‘II.Getting
Started’, precede with the next process ‘Cocoa Seedlings’.
Cocoa Seedlings
Growing seedlings requires a cocoa plantation, fertilizer and pesticide. Put the
following materials on the input side:
Material Coefficient
chlorothalonil 2 kg
Cocoa Plantation 1 ha
Pesticide, unspecified 0,25 kg
Phosphate fertilizer, as P2O5 18
Potassium fertilizer, as K20 14
Create the material ‘Cocoa Pods’ with the material type ‘Good’ and the type
‘Mass’ and enter it on the output side, with a coefficient of 4 032 kg.
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Figure 10 Specification ‘Cocoa Seedlings’
Harvesting & Extraction
To the input side of the process ‘Harvesting & Extraction’, enter ‘Cocoa Pods’
with the coefficient 4 032 kg. Create new materials named ‘Prunings’ and ‘Cocoa
Husks’, both with the unit type ‘Mass’ and the material type ‘Bad’. Drag ‘Prunings’
to the output side and enter a coefficient of 2 232 kg. Then, drag ‘Cocoa Husks’
to the output side and enter a coefficient of 1 500 kg. Create a new material
called ‘Unfermented Cocoa Beans’ with the material type ‘Good’ and the unit
type ‘Mass’ and include it to the output side, with a coefficient of 300 kg.
Figure 11 Specification ‘Harvesting & Extraction’
Transport of Cocoa Beans
The unfermented cocoa beans need to be transported for further processing. Add
the material ‘transport, freight, lorry > 32 metric ton, EURO3’ to the input
side of the transport process.
The coefficient of `transport, lorry >32t, EURO3 [RER]’ is described as a
formula in the ‘Function’ column. DST is a parameter, described in the ‘Parameters’
tab that resembles the distance. As the transport unit takes into account the weight
in tons, the distance in km needs to be divided by 1000.
transport, lorry >32t, EURO3 [RER] DST/1000
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Figure 12 Specification ‘Transport of Cocoa Beans’
‘DST’ is a parameter that you need to add in the ‘Parameters’ tap. Working with
parameters has the benefit that, in case of changes, the numbers can quickly be
adjusted and the process adapts it. Name the parameter ‘Distance’ and enter a
quantity of 100 km.
Figure 13 Parameter ‘Transport of Cocoa Beans’
In this process, generic materials are very useful. As the input and output of the
process are the same, namely ‘Cocoa Beans’, this should not be calculated twice
regarding the environmental impacts. Create the generic material ‘Cargo’ with
each 1 unit on the input and output side of this process.
Figure 14 Generic Materials ‘Transport of Cocoa Beans’
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Fermentation & Sun Drying
Around 3 % of the incoming unfermented cocoa beans are damaged and cannot
be used for further processing. This material connects to an output place.
Therefore, create an output place and called ‘Waste’.
Now, enter the parameter ‘PCD’ named ‘Percentage Damaged Cocoa Beans’
and enter a quantity of 3 %. Add the parameter ‘PDCB’, Percentage Dried
Cocoa Beans, with the quantity 97 %. The parameter ‘UCB’ named
‘Unfermented Cocoa Beans’ with the quantity 300 kg needs to be added to
show the overall volume of unfermented beans.
Figure 15 Parameters ‘Fermentation & Sun-Drying’
Now, create the materials ‘Damaged Beans’ with the material type ‘Good’ and
unit type ‘Mass’ and drag it to the output side of the process. Instead of entering
the coefficient, insert the function ‘UCB*PDB/100’. Create the material ‘Raw,
Dried Cocoa Beans’ with the material type ‘Good’ and the unit type ‘Mass’. Drag
it to the output side of the fermentation and drying process and enter the function
‘UCB*PDCB/100’.
Figure 16 Specifications ‘Fermentation & Sun-Drying’
Below, find a first rough overview of the processes entered so far.
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Figure 17 Overview of the chocolate production from ‘Raw Dried Cocoa Beans’ to ‘Chocolate’
Transport
Before the actual chocolate production can start, the cocoa beans are transported
200 km to the production facility. This distance is changeable by using the
parameter `DST’ defined in the Parameters tab as described in the previous
transportation process.
Figure 18 Parameter ‘Transport’
The coefficient of `transport, lorry >32t, EURO3 [RER]’ is described as a
formula.
transport, lorry >32t, EURO3 [RER] DST/1000
Figure 19 Specification ‘Transport’
There is no normal output. However, the generic material ‘Cargo’ is defined in the
tab ‘Generic Materials’.
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Figure 20 Generic materials for transport services
The following figure shows a rough overview of the processes in the production
phase of chocolate that will be created next.
Industrial Cleaning
Cleaning the cocoa beans requires electricity. Therefore, enter the material
‘electricity, low voltage’ with a coefficient of 1,7 Wh to the input side of the
process. In addition, add ‘Raw, Dried Cocoa Beans’ with a coefficient of 150 g.
Create the output materials ‘Cocoa Beans Waste’ and ‘Cleaned Cocoa Beans’
with the unit type ‘Mass’ and the material type ‘Good’ and add them with
coefficients of 25g and 125 g.
Figure 21 Specification ‘Industrial Cleaning’
Heat Production
The cocoa bean waste from the cleaning process is being burned to produce heat
that is required for the roasting. Add 0,025 kg of the material ‘Cocoa Beans
Waste’ to the input side. Fuel is required for burning the waste. Therefore, enter
‘petrol, unleaded’ to the input side. A function is needed to define the amount of
petrol needed.
In this process, parameters are useful. Create the parameters ‘HVB’, heating
value biomass, with a quantity of 4,5 kWh/kg and ‘HVP’, heating value
petrol, with the 11,5 kWh/kg. Now, add the material ‘petrol, unleaded’ to the
input side and insert the function:
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The coefficient of `unleaded petrol’ is described as a formula.
Unleaded petrol (0.2-(0.025*HVB))/HVP
Now, edit the output side of the heat production process. Create the material ‘Heat
Energy’ and drag it to the output side. Enter the coefficient 0,2 kWh. The
following materials leave the process as direct emissions and need to be included
into the output side:
Material Coefficient Unit
Methane, fossil [air/unspecified] 3,000E-06 kg
Dinitrogen monoxide [air/unspecified] 6,800E-07 Kg
Carbon dioxide, from soil or biomass stock [air/unspecified] 1,200E-04 Kg
Carbon dioxide, fossil [air/unspecified] 0,024 kg
Figure 22 Specification ‘Heat Production’
Roasting
The cleaned cocoa beans can now be roasted. Add the material ‘Cleaned Cocoa
Beans’ to the input side of the process and enter the coefficient 125g. Create a
new material ‘Heat Energy’ with the material type ‘Good’ and the unit type
‘Energy’. Drag it to the input side and enter a coefficient of 0,2 kWh.
For the output side, create the material ‘Roasted Cocoa Beans’ with the material
type ‘Good’ and the unit type ‘Mass’. Enter it with the coefficient 125g.
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Figure 23 Specification ‘Roasting’
Winnowing
The cocoa nibs are valuable for the chocolate production but the shells must be
sorted out via the winnowing process, which requires electricity.
Enter the material ‘electricity, low voltage’ to the input side of the process with
the coefficient 0,12 Wh. Enter ‘Roasted Cocoa Beans’ with the coefficient 1g to
the input side, as well.
Create new materials ‘Cocoa Nibs’ and ‘Shells’, both with the unit type ‘Mass’ and
material type ‘Good’. Insert both to the output side, shells with a coefficient of 0,2
g and the cocoa nibs with 0,8 g. The shells can be used as mulch and connect to
an output place named ‘Cocoa Shell Mulch’.
Figure 24 Specification ‘Winnowing’
Grinding
The roasted nibs are broken into pieces. This process not only produces cocoa
liquor but also little pieces of roasted nibs that are treated as bio waste.
The process is specified with user defined functions. Therefore, it is explained in
section ‘III. User Defined Specifications’.
Grinding is followed by two parallel process strings, one starting with ‘Pressing’
and one beginning with ‘Mixing’.
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Pressing
During the pressing process, cocoa butter and the remaining cakes are extracted
from the cocoa paste. The cocoa liquor leads to two new materials: ‘Cocoa Butter’
and ‘Cocoa Cake’. Create both materials with the material type ‘Good’ and unit
type ‘Mass’ and enter them with the coefficients 25g and 40 g.
Drag the ‘Cocoa Liquor’ to the input side and enter a coefficient of 65 g and put
the material ‘electricity, low voltage’ with a coefficient of 0,0384 Wh to the
input side of the pressing process.
Figure 25 Specification ‘Pressing’
Milling
The pressing is followed by milling, where the remaining cocoa cakes are ground
to powder.
40 g of ‘Cocoa Cake’ produce 40 g of ‘Cocoa Powder’. Name the output place
connected to the milling process ‘Cocoa Powder’ as well.
Figure 26 Specification ‘Milling’
Mixing
The next step includes adding new materials to the process in order to get the
chocolate mix as a final product. As this process is specified with user defined
functions, it is explained in chapter ‘III. User Defined Specifications’.
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Conching and Tempering
During the conching, the residual moisture is removed, while tempering transforms
the semi-liquid mix into a solid product using heat treatment. A new material
named ‘Solid Chocolate Mix’ must be created, and added with a coefficient of 80
g.
Drag the materials ‘electricity, low voltage’ with a coefficient of 0,1 Wh and
‘Semi-liquid Mix’ with a coefficient of 100 g to the input side. In addition to
‘Solid Chocolate Mix’, a new material ‘Steam’ needs to be created with the the
material type ‘Bad’ and the unit type ‘Mass’. Add it with a coefficient of 20g to the
output side. Steam will be connected to a new output place.
Electricity can connect to the same output place as the other materials ‘electricity,
low voltage’ used before. Just connecting it to the exact same place would result
in arrows crossing each other. Therefore, right-click on the ‘Energy’ connection and
choose ‘Duplicate’. A new connection will be created, which is similar but can be
located separately. Drag it to ‘Mixing’ and set is as the place for the corresponding
input in the Specifications window. When you click it, the original place as well as
its duplicate are highlighted in green, showing that they are the same. This is
presented in the following figure.
Figure 27 The input place ‘Energy’ and its duplicate
Figure 28 Specification ‘Conching & Tempering’
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Moulding & Packaging
In the last step, the chocolate is poured into moulds of different shapes and then
packaged for the market.
The main output in this process is the new material ‘Chocolate’, with the material
type ‘Good’ and a coefficient of 106 g, as packaging materials are used.
Thus, the new material ‘aluminium foil’ with a coefficient of 3 g and ‘paper,
woodfree, coated, at regional storage [RER]’ with a coefficient of 3 g, both
from the ecoinvent database, have to be added to the input side. In addition, add
‘electricity, low voltage’ with a coefficient of 20 Wh and ‘Solid Chocolate Mix’
with a coefficient of 100 g to the input side.
Figure 29 Specification ‘Moulding & Packaging’
The following figure gives a rough overview of the processes in the distribution,
consumer use and disposal phase that will be modelled next.
Figure 30 Overview of the processes involved in the distribution, consumer use and disposal phase
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Refrigerated Transportation
When delivering the chocolate to the supermarkets, the temperature must be kept
low to prevent melting. Consequently, it is delivered by refrigerated transportation.
This distance is changeable by using the parameter `DST’ defined in the
‘Parameters’ tab. See below. The chocolate is transported 200 km by lorry.
Figure 31 Parameter ‘Refrigerated Transportation’
The coefficient of the input material ‘transport, lorry >32t, EURO3 [RER]’ is
described as a formula.
transport, lorry >32t, EURO3 [RER] DST/1000
Figure 32 Specification ‘Refrigerated Transportation’
There is no normal output. However, generic materials are defined in the generic
materials tab similar to the transportation processes presented before.
Figure 33 Generic Materials ‘Refrigerated Transportation’
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Cooling in Supermarket
Most supermarkets have air conditioning in order to keep the chocolate at low
temperature. The electricity consumption should therefore be taken into account.
As the process is specified with user defined functions, it is explained in section
‘III. User Defined Specifications’.
Storage in Refrigerator
The bought chocolate is likely to stay in the consumer´s refrigerator for a couple
of days.
As the process is specified with user defined functions, it is explained in section
‘III. User Defined Specifications’.
Eating
After all, the consumer will eat the chocolate and leave the packaging behind for
disposal. A new material ‘Eating Chocolate’ needs to be created and added to
the output side. It has the unit type ’Amount’ and the material type ‘Good’ as well
as the coefficient 1 unit.
Create the material ‘Package waste’ with the material type ‘Bad’ and the unit
type ‘Mass’ and put it to the output side of the process. The coefficient is 6 g.
Figure 34 ‘Specification Eating’
Package Disposal
The package waste is disposed. The package for one unit of chocolate consists of
3 g ‘paper’ and 3 g ‘aluminum’.
The input side consists of the ‘Package waste’ with a coefficient of 6 g.
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Drag the materials ‘waste aluminum’ and ‘waste paper, sorted’ to the output
side.
Figure 35 Specification ‘Package Disposal’
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Figure 36 Overview of the Processes ‘Grinding’ to ‘Package Disposal’
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IV. User Defined Specifications
Some processes got specified with user defined functions (UDFs). For the
processes ‘Grinding’, ‘Mixing’, ‘Cooling in Supermarket’ and ‘Storage in
Refrigerator’ the changes are shown below.
Grinding
The roasted nibs are broken into pieces. This process not only produces cocoa
liquor but also little pieces of roasted nibs that are treated as bio waste. The mass
of this bio waste is calculated with the parameter ‘WR’.
Figure 37 Parameter ‘Grinding’
The electricity consumption is calculated, assuming that 0,1536 Wh of electricity
are consumed for grinding 1 g of cocoa nibs.
This value was calculated with real data taken from a small chocolate factory in
Grenada. A grinder consumes 7 680 Wh of electricity per day, based on the
assumption that 50 000 kg of chocolate are produced.
Overview of the used formulas:
Material name Function
Cocoa Liquor Cocoa Nibs*(1-WR/100)
Biowaste Cocoa Nibs*WR/100
Electricity, low
voltage
0.15360*Cocoa Nibs
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Figure 38 User Defined Function ‘Grinding’
Figure 39 Specification ‘Grinding’
Mixing
A typical milk chocolate recipe is formed by 45% of sugar, 10% of cocoa liquor,
20% milk and 25% cocoa butter (ADM Cocoa, 2009, p. 83).
For this process, two new materials must be added: The material ‘sugar, from
sugarcane, at sugar refinery [BR]’, from the ecoinvent dataset and the new
material ‘Milk’ with the material type ‘Good’ and unit type ‘Mass’ (Mogensen,
Hermansen, Halberg, & Dalgaard, 2009, p. 124). In addition, it is necessary to
create a new material named ‘Semi-liquid Mix’, which is the main output after
finishing the mixing process. It has the unit type ‘Mass’ and material type ‘Good’
Further information is needed for the calculation of the coefficient of each
ingredient. This information will be stored in parameters to keep them easily
changeable. The parameters and their values needed for the calculation are shown
in the following figure.
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Figure 40 Parameter ‘Mixing’
According to this ratio, the mass of the materials is calculated as shown below.
The electricity consumption is calculated assuming that 0.00015 MJ are used for
100 g of semi-liquid mix.
Overview of the used formulas:
Material name Function
Cocoa Butter TOT*CBUT/100
Milk TOT*MIL/100
Cocoa Liquor TOT*CLIQ/100
Sugar TOT*SUG/100
Figure 41 Specification ‘Mixing’
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Figure 42 User Defined Function ‘Mixing’
Cooling in Supermarket
Most supermarkets have air conditioning in order to keep the chocolate at low
temperature. The electricity consumption should therefore be taken into account.
Five parameters are defined in the ‘Parameters’ Tab (see below).
‘EC’ is the total electricity consumption for air conditioning over the period of one
year.
‘RP’ is a retention period of chocolate. It takes into consideration how long the
chocolate will stay in the supermarket before being sold.
Figure 43 Parameter ‘Cooling in Supermarket’
First, the overall electricity consumption caused by the retention period is
calculated by dividing the electricity consumption for 1 year by 365 and multiplying
by the retention period, which is defined as a parameter. This results in the EPRP,
which is the electricity consumption for the whole supermarket.
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Then, the electricity consumption for the retention period is allocated to the
chocolate sales area by multiplying the EPRP with the share of the chocolate rack
area (CRS) of the the supermarket area (RC).
Finally, the electricity consumption of the chocolate sales area is allocated to the
chocolate bars, which are stocked in the chocolate rack area, by using chocolate
per rack. We are assuming that 1 chocolate rack takes up 1 m2 space.
Chocolate per gram=Electricity consumption of chocolate sales area/CPR
Figure 44 User Defined Function ‘Cooling in Supermarket’
See the process specifications below.
Figure 45 Specification ‘Cooling in Supermarket’
Expand ‘Electricity, low voltage’ to ‘market for electricity, low voltage
[RoW]’. This activity should stand alone and not be connected to the connection
‘Energy’ as it was used before. ‘Cooling in Supermarket’ is part of the distribution
phase. Processes in different phases should not be linked to the same activities as
this causes problems regarding calculations.
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Storage in Refrigeration
The bought chocolate is likely to stay in the consumer´s refrigerator for a couple
of days.
3 parameters are defined in the ‘Parameters’ tab to calculate the energy
consumption of a refrigerator.
Var Name Quantity Unit
RC Refrigerator’s capacity 100 Kg
RP Retention Period 3.00 Day
EC Electricity Consumption 295 kWh
The electricity consumption is calculated in a stepwise approach. First, the overall
electricity consumption for the retention period is calculated in the same way as it
was done previously. Divide the annual electricity consumption by 365 and multiply
it with the retention period (RP). EPRP is the overall electricity consumption for the
refrigerator.
In a second step, the overall electricity consumption for the retention period is
allocated to the volume of the chocolates. The electricity consumption of chocolate
per gram can be calculated by dividing EPRP by the product of multiplying the
retention period by 1000.
Figure 46 User Defined Function ‘Storage in Refrigerator’
Figure 47 Specification ‘Storage in Refrigerator’
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‘Storage in Refrigerator’ is part of the consumer use phase. As described above
regarding ‘Cooling in Supermarket’, it should be expanded to its own ‘market for
electricity, low voltage [RoW]’ and not linked to an activity from another life
cycle phase.
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V. Using the Expand Function
In this step, some activities that deliver the specified flows or intermediate
exchanges to the model need to be added as the LCA methodology requires taking
into account the pre-chains of intermediate flows. In the table at the end of this
chapter, the affected processes as well as the material names and their
corresponding activities are listed.
If it is already known, which process delivers a certain product or service, the
corresponding activity can be added manually. You can search for it in the project
explorer and drag and drop it into the grid in order to connect it to the process.
The input ‘pesticide, unspecified’ in the process ‘Cocoa Seedlings’ shall be
expanded to ‘market for pesticide, unspecified [GLO]’. Make sure to select the
‘Result’ activity with the system model ‘Allocation Default’. The following figure
shows, how this activity was selected from the project explorer and dropped into
the grid in order to be connected to the corresponding process next.
Figure 48 Manually expanding through the project explorer
In some cases, it is not known which process delivers a certain product. The user
may want to research the different activities that can deliver an input or output.
Therefore, use the automatic 'Expand' feature. This will be explained by expanding
the same material as done manually above - ‘pesticide, unspecified’ from the
process ‘Cocoa Seedlings’. First, mark the input ‘pesticide, unspecified’ and
then press the button. Umberto NXT will search for activities that deliver
this intermediate material. Pick the corresponding ‘market for pesticide
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unspecified [GLO]’ activity. Be sure to always select activities of the type
‘Result’, which are marked with the system model ‘Allocation, default’.
Figure 49 Select activity window for expanding processes
After clicking 'OK', the complete activity will automatically be added to the
network. The process stub will appear in the grid.
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Figure 50 Model stub of the selected activity
Next, it will be explained how to expand materials of several processes to the same activity. For example, the following chocolate production processes require the
input ‘electricity, low voltage’: Industrial Cleaning, Roasting, Winnowing, Grinding, Pressing, Milling, Mixing, Conching & Tempering, and Moulding & Packaging. They
can all connect to the same connection point and activity to keep the model simple. Start with ‘Industrial Cleaning’. Mark ‘electricity, low voltage’ in the process’
input side and press the button. Choose the ‘Result’ activity ‘market for
electricity, low voltage [RoW]’ with the system model ‘Allocation, default’. Name the connection point between ‘Industrial Cleaning’ and the activity ‘Energy’. Now, merge that connection place with the already existing place ‘Energy’. In order
to do so, turn the input place into a connection. Click on the input place and tick the ‘Connection’ box in the properties editor. Now you can simply move the two
places onto each other to merge them.
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Figure 51 Properties Editor of ‘Energy’
Instead of using the expand function in every process that requires electricity,
simply link the connection place to those processes mentioned and choose this place for the input materials ‘electricity, low voltage’.
The processes ‘Mixing’ and ‘Conching and Tempering’ cannot be connected to ‘Energy’, without arrows crossing. Therefore, the connection ’Energy’ was
duplicated before (see Mixing). This duplicate will connect the processes to the same activity as the original place ‘Energy’.
Note that it is important to keep the model as clearly structured and simple as
possible. Ecoinvent activities that are needed by several other processes in one
phase can be connected to them without having to create several identical
processes of the same type. They must, however, not be connected to different
phases. Each phase must have an own process to enable accurate calculations. For
example, ‘market for electricity, low voltage [RoW]’ can be connected to different
processes that use low voltage electricity but it must be given separate markets
for each phase that requires this activity. For example, the processes in the
production phase can use one activity, but processes from the distribution phase
have to use a separate activity.
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Figure 52 Overview of the processes from ‘Transport’ to ‘Moulding & Packaging’
Use the same approach described in this chapter to expand the model. All affected
processes including the corresponding materials are listed in Table 1. Always select
the result activity with the correct system model - ‘Allocation, default’ – and the
correct geography as referred to in the table.
As no dataset for ‘milk’ exists in ecoinvent 3, a similar process will be adapted.
Searching the database, you will find ‘market for milking [GLO] modified,
based on ecoinvent 3 (v3.01)’. Drag it into the net. In order to modify the
market, click the lock button ( ) to unlock the activity. Now, rename it into
‘market for milk [GLO]’, delete the output ‘milking’ and replace it with the
already used material ‘milk’ and a quantity of 1 kg. The activity will now appear
as ‘market for milk [GLO] modified based on ecoinvent 3(v3.01)’. Connect
it to the corresponding process and make sure to select the right place of the input
‘milk’ in the process ‘Mixing’.
Similar to ‘milk’, no dataset for ‘cocoa seeds’ exists in ecoinvent 3. Searching the
database you will find ‘market for potato seed, organic, for setting [GLO]’.
Unlock the activity, rename it into ‘market for cocoa seeds, organic, for setting
[GLO]’ and replace the output ‘potato seed, for setting’ with ‘cocoa seeds’.
Enter a coefficient of 1 kg. The activity will now appear as ‘market for cocoa
seeds, organic, for setting [GLO] modified based on ecoinvent 3(v3.01)’.
Table 1 Overview of the required expansions
Process Material
Coefficient/
Function Unit Activity for Expansion
Crop
Establishment
Cocoa Seeds 4,5 kg
market for cocoa seed,
organic, for setting [GLO]
modified, based on
ecoinvent 3 (v3.01)
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electricity,
medium
voltage 0,317 MJ
market for electricity,
medium voltage [RoW]
irrigation 15 m3
market for irrigation
[RoW]
Cocoa
Seedlings chlorothalonil 2 kg
market for chlorothalonil
[GLO]
pesticide,
unspecified 0,25 kg
market for pesticide,
unspecified [GLO]
phosphate
fertiliser, as
P205 18 kg
market for phosphate
fertiliser, as P2O5 [GLO]
potassium
fertiliser, as
K20 14 kg
market for potassium
fertiliser, as K2O [GLO]
Transport of
Cocoa Beans
transport,
freight, lorry
> 32 metric
ton, EURO3 DT/100 tkm
market for transport,
freight, lorry >32 metric
ton, EURO3 [GLO]
Transport
transport,
freight, lorry
> 32 metric
ton, EURO3 DST/100 tkm
market for transport,
freight, lorry >32 metric
ton, EURO3 [GLO]
Industrial
Cleaning
electricity,
low voltage 1,7 Wh
market for electricity, low
voltage [RoW]
Heat
Production
petrol,
unleaded 0,008 kg
market for petrol,
unleaded [RoW]
Winnowing electricity,
low voltage 0,12 Wh
market for electricity, low
voltage [RoW]
Grinding electricity,
low voltage 0,12 Wh
market for electricity, low
voltage [RoW]
Biowaste
User defined
functions g
market for biowaste
[RoW]
Pressing electricity,
low voltage 0,038 Wh
market for electricity, low
voltage [RoW]
Milling electricity,
low voltage 0,003 MJ
market for electricity, low
voltage [RoW]
Mixing sugar, from
sugarcane
User defined
functions g
market for sugar, from
sugarcane [GLO]
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electricity,
low voltage
User defined
functions MJ
market for electricity, low
voltage [RoW]
Milk
User defined
functions g
market for milking [GLO]
modified, based on
ecoinvent 3 (v3.01)
Conching &
Tempering
electricity,
low voltage 0,1 Wh
market for electricity, low
voltage [RoW]
Moulding &
Packaging
electricity,
low voltage 20 Wg
market for electricity, low
voltage [RoW]
paper,
woodfree,
coated 3 g
market for paper,
woodfree, coated [RoW]
Cooling in
Supermarket
electricity,
low voltage
User defined
functions g
market for electricity, low
voltage [RoW]
Storage in
Refrigerator
electricity,
low voltage
User defined
functions g
market for electricity, low
voltage [RoW]
Package
Disposal
waste
aluminium 3 g
market for waste
aluminium [GLO]
waste paper,
sorted 3 g
market for waste paper,
sorted [GLO]
Subnet:
Aluminium
Production
aluminium,
priamry,
ingot 1 kg
market for aluminium,
primary, ingot [GLO]
sheet rolling,
aluminium 1 kg
sheet rolling, aluminium
[RoW]
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VI. Creating a Subnet for the Aluminum Production
In some cases, a refinement of the model is needed, while keeping the initial
graphical layout intact. In other cases, the analysis of results of one part of the
model shall be separated from the overall results. In either case, the use of subnets
is indicated.
Use the context menu of the process ‘aluminum production’ to convert the
process into a subnet. The subnet will automatically open in a new sub net.
For the chocolate’s packaging, thin aluminum foil is needed. The production of that
foil will be modeled in more detail in its own Subnet. This subnet is composed of 3
processes: the primary aluminum, the sheet rolling, and the actual aluminum foil
production. This is presented below. Following, the specification of the process will
be explained.
Figure 53 Subnet ‘Aluminum Production’
During this process, aluminum ingots are rolled and processed into aluminum foils,
which are used as chocolate´s packages.
Name the subnet process ‘Aluminium production’ and put the following on the input
side:
Material Coefficient Unit
Sheet rolling, aluminum 1 kg
Aluminum, primary, ingot 1 Kg
Create a new material ‘aluminum, foil’ with the material type ‘Good’ and the unit
type ‘Mass’. Drag it to the output side with the coefficient 1 kg.
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Figure 54 Specification ‘Aluminum Production’
Expand the input side to the ‘Result’ activities ‘market for aluminium, primary,
and ingot [GLO]’ and ‘sheet rolling, aluminium [RoW]’.
Now, the model is prepared and can almost be calculated. The following figures
show the complete model, separated into three parts. First, the raw materials
phase is presented, followed by the chocolate production and finally the
distribution, consumer use and disposal phases are shown.
Figure 55 Overview of the processes up to ‘Fermentation & Sundrying’
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Figure 56 Overview of the chocolate production
Figure 57 Overview of the distribution, consumer use and disposal phase
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VII. Evaluation
Two important things still need to take place before calculating. First, the reference
flow must be set. The main product, chocolate, leaves the process ‘Eating’ to an
output place. To create a reference flow here, drag the product ’Eating Chocolate’
onto the arrow between the process and the output place and enter the quantity
1 unit. The arrow will turn purple, indicating a reference flow.
Next, the different life cycle phases need to be drawn so the impacts of each phase
can be distinguished. The phases can be either included in the very beginning,
when starting to create the model, but in this tutorial it makes more sense to
create the phases last. Now that you know the different processes. Click ‘Draw –
Life Cycle Phases’ on top left corner in the screen. As the whole life cycle will be
considered choose the ‘Cradle-to-Grave’ approach. Now, the phases are drawn in
different colours. On top of each phase, next to the caption (e.g. Raw Materials),
you can click and drag the shape in order to distinguish the right phases. The
phases of this example are listed below. The model now includes the five life cycle
phases represented through different colours.
Phase Starting Process
Raw Materials Crop Establishment
Production Industrial Cleaning
Distribution Refrigerated Transportation
Consumer User Storage in Refrigerator
Disposal Package Disposal
The life cycle model is now ready to be calculated. Calculate by clicking on the
button with the calculator icon in the toolbar. If the model is fully specified and no
problems occur, all arrows will turn their colour from light grey to black.
After the calculation has finished, two new tabs will appear in the specification
window at the bottom, displaying the calculation results.
Figure 58 LCA Results Chocolate Production
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Figure 59 Result Sankey View
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VIII. List of all applied materials
Table 2 List of all applied materials
Process Material Source Type
Coefficie
nt/
Unit Unit
Input
/
Outpu
t
Activity for
Expansion
Crop
Establishme
nt
Cocoa Seeds User Defined Good 4,5 kg Input
market for
cocoa seed,
organic, for
setting
[GLO]
modified,
based on
ecoinvent 3
(v3.01)
electricity,
medium
voltage
ecoinvent 3
(v3.01) Good 0,317 MJ Input
market for
electricity,
medium
voltage
[RoW]
irrigation
ecoinvent 3
(v3.01) Good 15 m3 Input
market for
irrigation
[RoW]
Cocoa
Plantation User Defined Good 1 ha Output
Carbon
dioxide, non-
fossil[air/unsp
ecified]
ecoinvent 3
(v3.01) Bad 4,00E-05 kg Output
Cocoa
Seedlings
Cocoa
Plantation User Defined Good 1 ha Input
chlorothalonil
ecoinvent 3
(v3.01) Good 2 kg Input
market for
chlorothaloni
l [GLO]
pesticide,
unspecified
ecoinvent 3
(v3.01) Good 0,25 kg Input
market for
pesticide,
unspecified
[GLO]
phosphate
fertiliser, as
P205
ecoinvent 3
(v3.01) Good 18 kg Input
market for
phosphate
fertiliser, as
P2O5 [GLO]
potassium
fertiliser, as
K20
ecoinvent 3
(v3.01) Good 14 kg Input
market for
potassium
fertiliser, as
K2O [GLO]
Cocoa Pods User Defined Good 4032 kg Output
Cocoa Pods User Defined Good 4032 kg Input
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Harvesting &
Extraction
Unfermented
Cocoa Beans User Defined Good 300 kg Output
Cocoa Husks User Defined Bad 1500 kg Output
Prunings User Defined Bad 2232 kg Output
Transport of
Cocoa Beans
transport,
freight, lorry
> 32 metric
ton, EURO3
ecoinvent 3
(v3.01) Good DT/100 tkm Input
market for
transport,
freight, lorry
>32 metric
ton, EURO3
[GLO]
Generic
Material:
Cargo 1
Mass[kg
] Both
Fermentatio
n & Sun
Drying
Unfermented
Cocoa Beans User Defined Good 300 kg Input
Raw, dried
cocoa beans User Defined Good
UCB*PDC
B/100 kg Output
Damaged
Beans User Defined Bad
UCB*PDB
/100 kg Output
Transport
transport,
freight, lorry
> 32 metric
ton, EURO3
ecoinvent 3
(v3.01) Good DST/100 tkm Input
market for
transport,
freight, lorry
>32 metric
ton, EURO3
[GLO]
Generic
Material:
Cargo 1
Mass[kg
] Both
Industrial
Cleaning
Raw, dried
cocoa beans User Defined Good 150 g Input
electricity, low
voltage
ecoinvent 3
(v3.01) Good 1,7 Wh Input
market for
electricity,
low voltage
[RoW]
Cleaned cocoa
beans User Defined Good 125 g Output
Cocoa beans
waste User Defined Good 25 g Output
Heat
Production
Cocoa beans
waste User Defined Good 0,025 kg Input
petrol,
unleaded
ecoinvent 3
(v3.01) Good 0,008 kg Input
market for
petrol,
unleaded
[RoW]
heat energy
ecoinvent 3
(v3.01) Bad 3,00E-06 kg Output
Universidad Nacional de Colombia – Sede Medellín – Facultad de Minas
Carbon
monoxide
[air/unspecifie
d]
ecoinvent 3
(v3.01) Bad 6,80E-07 kg Output
Carbon
dioxide, from
soil or
biomass stock
[air/unspecifie
d]
ecoinvent 3
(v3.01) Bad 1,20E-04 kg Output
Carbon
dioxide,
fossil[air/unsp
ecified]
ecoinvent 3
(v3.01) Bad 2,40E-02 kg Output
heat energy User Defined Good 2,00E-01 kWh Output
Roasting
Cleaned cocoa
beans User Defined Good 125 g Input
Heat energy User Defined Good 0,2 kWh Input
Roasted cocoa
beans User Defined Good 125 g Output
Winnowing
Roasted cocoa
beans User Defined Good 1 g Input
electricity, low
voltage
ecoinvent 3
(v3.01) Good 0,12 Wh Input
market for
electricity,
low voltage
[RoW]
Cocoa nibs User Defined Good 0,8 g Output
Shells User Defined Good 0,2 g Output
Grinding
Cocoa Nibs User Defined Good
User
defined
functions g Input
electricity, low
voltage
ecoinvent 3
(v3.01) Good
User
defined
functions Wh Input
market for
electricity,
low voltage
[RoW]
Cocoa Liquor
ecoinvent 3
(v3.01) Good
User
defined
functions g Output
Biowaste User Defined Bad
User
defined
functions g Output
market for
biowaste
[RoW]
Pressing
Cocoa Liquor User Defined Good 65 g Input
electricity, low
voltage
ecoinvent 3
(v3.01) Good 0,038 Wh Input
market for
electricity,
low voltage
[RoW]
Cocoa Butter User Defined Good 25 g Output
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Cocoa Cake User Defined Good 40 g Output
Milling
Cocoa Cake User Defined Good 40 g Input
electricity, low
voltage
ecoinvent 3
(v3.01) Good 0,003 MJ Input
market for
electricity,
low voltage
[RoW]
Cocoa Powder User Defined Good 40 g Output
Mixing
sugar, from
sugarcane
ecoinvent 3
(v3.01) Good
User
defined
functions g Input
market for
sugar, from
sugarcane
[GLO]
electricity, low
voltage
ecoinvent 3
(v3.01) Good
User
defined
functions MJ Input
market for
electricity,
low voltage
[RoW]
Milk User Defined Good
User
defined
functions g Input
market for
milking
[GLO]
modified,
based on
ecoinvent 3
(v3.01)
Cocoa Liquor User Defined Good
User
defined
functions g Input
Cocoa Butter User Defined Good
User
defined
functions g Input
Semi-liquid
Mix User Defined Good
User
defined
functions g Output
Conching &
Tempering
electricity, low
voltage
ecoinvent 3
(v3.01) Good 0,1 Wh Input
market for
electricity,
low voltage
[RoW]
Semi-liquid
Mix User Defined Good 100 g Input
Solid
Chocolate Mix User Defined Good 80 g Output
Steam User Defined Bad 20 g Output
Moulding &
Packaging
aluminium,
foil User Defined Good 3 g Input
electricity, low
voltage
ecoinvent 3
(v3.01) Good 20 Wg Input
market for
electricity,
low voltage
[RoW]
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paper,
woodfree,
coated
ecoinvent 3
(v3.01) Good 3 g Input
market for
paper,
woodfree,
coated
[RoW]
Solid
Chocolate Mix User Defined Good 100 g Input
Chocolate User Defined Good 106 g Output
Refrigerated
Transport
transport,
freight, lorry
> 32 metric
ton, EURO3
ecoinvent 3
(v3.01) Good DST/100 tkm Input
Generic
Material:
Cargo Good 1
Mass[kg
] Both
Cooling in
Supermarket
Chocolate
ecoinvent 3
(v3.01) Good
User
defined
functions kWh Input
electricity, low
voltage User Defined Good
User
defined
functions g Input
market for
electricity,
low voltage
[RoW]
Chocolate User Defined Good
User
defined
functions g Output
Storage in
Refrigerator
Chocolate User Defined Good
User
defined
functions g Input
eletricity, low
voltage
ecoinvent 3
(v3.01) Good
User
defined
functions kWh Input
market for
electricity,
low voltage
[RoW]
Chocolate User Defined Good
User
defined
functions g Output
Eating
Chocolate User Defined Good 106 g Input
Eating
Chocolate User Defined Good 1 unit Output
Package
Waste User Defined Bad 6 g Output
Package
Disposal
Package
Waste User Defined Bad 6 g Input
waste
aluminium
ecoinvent 3
(v3.01) Bad 3 g Output
market for
waste
aluminium
[GLO]
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waste paper,
sorted
ecoinvent 3
(v3.01) Bad 3 g Output
market for
waste paper,
sorted [GLO]
Subnet:
Aluminium
Production
aluminium,
priamry, ingot
ecoinvent 3
(v3.01) Good 1 kg Input
market for
aluminium,
primary,
ingot [GLO]
sheet rolling,
aluminium
ecoinvent 3
(v3.01) Good 1 kg Input
sheet rolling,
aluminium
[RoW]
aluminium,
foil User Defined Good 1 kg Output