Reducing energy consumption and carbon footprint in traditional sheep cheese production: A Portuguese case study

The present study presents a comprehensive evaluation of an optimized integrated solution for reducing energy consumption and reduce environmental impact of a traditional sheep cheese production facility. A detailed analysis of the production process and associated energy flows revealed significant inefficiencies, particularly in the original refrigeration system composed of independent, low-efficiency units. An optimized and centralized CO2 (R744) refrigeration system including electronic control, combined with modular evaporators and LED lighting, result in a substantial reduction in electricity consumption. Also, complementary measures, such as heat recovery, solar thermal system, and biomass boiler, achieved reduced thermal energy demand by approximately 93%, enabling near self-sufficiency in the process. The installation of a photovoltaic system further decreased grid electricity consumption, resulting in an overall 61% reduction in electrical energy use and a 68% decrease in specific energy consumption (SEC). The optimized system achieved reductions of 87% in CO2 emissions, 66% in SO2 emissions, and a marked decrease in the TEWI index, highlighting the lower global warming potential. Economic analysis demonstrated a payback period of just over four years, confirming both the technical and financial viability of the proposed measures. Results demonstrate that the combined application of efficient refrigeration, renewable energy integration, and heat recovery can significantly improve energy efficiency, reduce environmental impact, and provide an optimized integrated solution for sustainable solutions for the agro-food sector.