Enhancing Environmental Sustainability in the Coffee Processing Industry via Energy Recovery and Optimization: A Life Cycle Assessment Case Study

Tryfon Kekes (), Sokratis Emmanouil Koskinakis, Christos Boukouvalas and Magdalini Krokida
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Tryfon Kekes: Laboratory of Process Analysis and Design, School of Chemical Engineering, National Technical University of Athens, Iroon Polytechneiou 9, 15780 Athens, Greece
Sokratis Emmanouil Koskinakis: Laboratory of Process Analysis and Design, School of Chemical Engineering, National Technical University of Athens, Iroon Polytechneiou 9, 15780 Athens, Greece
Christos Boukouvalas: Laboratory of Process Analysis and Design, School of Chemical Engineering, National Technical University of Athens, Iroon Polytechneiou 9, 15780 Athens, Greece
Magdalini Krokida: Laboratory of Process Analysis and Design, School of Chemical Engineering, National Technical University of Athens, Iroon Polytechneiou 9, 15780 Athens, Greece

Sustainability, 2025, vol. 17, issue 3, 1-21

Abstract: The coffee processing industry is amongst the most energy-intensive industrial sectors, with the roasting process requiring substantial quantities of energy. To enhance sustainability, various energy optimization and recovery methods have been proposed. This study evaluates the environmental benefits of integrating energy recovery techniques in a typical coffee processing industry using a Life Cycle Assessment (LCA) approach. Specifically, two alternative scenarios were compared to a baseline processing line; (i) Scenario A, which involves recycling hot air streams to reduce natural gas consumption, and (ii) Scenario B, which utilizes an Organic Rankine Cycle (ORC) to convert waste heat to electricity. The LCA analysis indicated that Scenario A achieved a 25% reduction in greenhouse gas emissions and an 18% decrease in fossil fuel use. Scenario B demonstrated even greater environmental benefits, with a 40% reduction in greenhouse gas emissions and a 36% decrease in fossil fuel depletion. These findings underline the potential of integrating energy recovery technologies to enhance the sustainability of coffee production, offering valuable insights for industry stakeholders and researchers focused on sustainable manufacturing practices.

Keywords: coffee industry; sustainability; life cycle assessment; organic Rankine cycle; energy recovery; energy efficiency (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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