Energy intensity and global warming potential of corn grain ethanol production in Wisconsin (USA)

Increasing demand for renewable alternative fuels, such as ethanol, is driven by decreasing availability of fossil resources and increasing attention to climate change. Life cycle assessment (LCA) is the tool used to evaluate environmental impacts, such as energy intensity (EI) and global warming potential (GWP), from ethanol production, but the application of this tool varies greatly. The goals of this study were to enumerate the life cycle EI, net energy value (NEV), and GWP of corn grain ethanol production in Wisconsin, to explore ethanol production scenarios which differ at the treatment of the whole stillage (WS) coproduct, and to evaluate the various solutions to the multifunctionality problem which arises in LCA. In Scenario 1, all suggested solutions to the multifunctionality problem are considered by transforming WS into the animal feed dried distillers grains with solubles (DDGS). Scenario 2 avoids allocation using an integrated system which recycles the WS with an anaerobic biodigester and a combined heat and power (CHP) plant to provide electricity and steam to the ethanol refinery and returns the residue to the land as fertilizer. Based on the Scenario 1 analysis, we recommend the use of the subdivision (SD) solution to the multifunctionality problem because it enables clear comparisons between different ethanol production systems, it distinguishes between the environmental impacts from ethanol production and coproduct processing and it reduces the number of assumptions in the LCA calculations. From the comparison of both scenarios, we find that recycling the WS into electricity, heat, and fertilizer is the most environmentally beneficial coproduct use because it results in a 54% lower EI and a 67% lower GWP than the processing of WS into DDGS

Effect of teatcup removal settings on milking efficiency and milk quality in a pasture-based automatic milking system

peer-reviewedIn automatic milking systems (AMS), it is important to maximize the amount of milk harvested per day to increase profitability. One strategy to achieve this goal is to reduce the time it takes to milk each cow. Several studies in conventional milking systems have shown that milking time can be reduced by increasing the milk flow rate at which the teatcup is removed. One study analyzed the effect of increasing the milk flow switch point on milking time in a confinement AMS. No research has been conducted on teatcup removal settings in pasture-based automatic milking systems. Furthermore, not all AMS remove the teatcups based on absolute milk flow rate (kg/min); hence, it is important to study alternative strategies. The aim of this experiment was to measure the effect of 3 novel teatcup removal strategies on box time (time in the AMS), milking time, somatic cell count (SCC), and milk production rate of cows milked in a pasture-based automatic milking system. Each teatcup removal strategy in this study was applied for a period of 1 wk to 1 of 3 groups of cows and then switched to the following group until cows had transitioned through all treatments. The teatcup removal strategies consisted of removing the teatcup when the quarter flow rate fell below 20% of the quarter rolling average milk flow rate (TRS20), when quarter milk flow rate was below 30% of the rolling average milk flow rate (TRS30), and when quarter milk flow rate dropped below 50% of the rolling average milk flow rate (TRS50). A limit prevented teatcup removal if the calculated milk flow rate for teatcup removal was above 0.5 kg/min. This limit was in place for all treatments; however, it only affected the TRS50 treatment. The TRS30 strategy had 9-s shorter milking time and 11-s shorter box time than the TRS20 removal strategy. The TRS50 strategy had 8-s shorter milking time and 9-s shorter box time than the TRS20 teatcup removal strategy. There was no significant difference in milking time or box time between the TRS30 and TRS50 teatcup removal strategies, probably due to the large variability in milk flow rate at teatcup removal. The TRS20 and TRS30 strategies did not differ in SCC or milk production rate. The 0.5 kg/min limit, which affected roughly 25% of milkings in the TRS50 treatment, may have distorted the effect that this setting had on milk time, box time, milk production rate, or SCC. The difference in box time for the TRS30 and TRS50 strategies could allow for more than 3 extra milkings per da

Short communication: Increasing the teatcup removal settings of the last milking quarter did not reduce box time in a pasture-based automatic milking system

peer-reviewedThis research followed our previous experimental and simulation work on the effect of different teatcup removal settings based on the rolling average milk flowrate and on milking duration at the quarter and udder levels. The aims of this experiment were to (1) quantify the differences in quarter milking duration in a pasture-based automatic milking system and (2) test the effect of increasing the milk flowrate at which teatcups are removed on the last milking quarter on udder milking duration, box time, milk production rate, and somatic cell count (SCC). Milking duration is an important component of efficiency and profitability in conventional and automatic milking systems. Additionally, quarters within an udder have significantly different milk yields and milking durations. This study used data from April to May 2018 of a pasture-based automatic milking system to evaluate quarter milking duration differences between quarters of an udder. Subsequently, we experimentally evaluated the use of 2 percentage-based teatcup removal settings applied to the last milking quarter (i.e., the last quarter with a teatcup still attached) on milking duration, box time, milk production rate, and SCC. The teatcup removal settings were at 30 or 50% of the last quarter's rolling average milk flowrate, while the other quarters remained at the 30% level. The selection of the quarter that would receive the more aggressive teatcup removal setting was determined by identifying the last quarter with a teatcup attached in every milking. Sixty-nine cows were divided into 2 groups that each received 1 of the 2 treatments for a 1-wk period and then switched to the other treatment for a second week. For the months of April and May 2018, quarter milking duration was significantly different between the quarter with the longest and the second longest milking duration within an udder. The quarter with the longest milking duration was milked on average 49 s longer than the quarter with second longest milking duration. However, in 36% of the milkings, the quarter with the longest milking duration was different from that of the previous milking. In the experimental part of this study, we saw no differences in milking duration, box time, milk production rate, or SCC between the 30 and 50% teatcup removal setting applied to the last milking quarter. Further research on using a variation of this percentage-based setting to target the quarter with the average longest milking duration or using an absolute milk flowrate switch-point or a maximum milking duration setting on the last quarter for reducing cow milking duration and box time is warranted

Effect of pulsation rest phase duration on teat end congestion

peer-reviewedThe objective of this study was to quantify the effect of d-phase (rest phase) duration of pulsation on the teat canal cross-sectional area during the period of peak milk flow from bovine teats. A secondary objective was to test if the effect of d-phase duration on teat canal cross-sectional area was influenced by milking system vacuum level, milking phase (b-phase) duration, and liner overpressure. During the d-phase of the pulsation cycle, liner compression facilitates venous flow and removal of fluids accumulated in teat-end tissues. It was hypothesized that a short-duration d-phase would result in congestion of teat-end tissue and a corresponding reduction in the cross-sectional area of the teat canal. A quarter milking device, designed and built at the Milking Research and Instruction Laboratory at the University of Wisconsin–Madison, was used to implement an experiment to test this hypothesis. Pulsator rate and ratios were adjusted to achieve 7 levels of d-phase duration: 50, 100, 150, 175, 200, 250, and 300ms. These 7 d-phase durations were applied during one milking session and were repeated for 2 vacuum levels (40 and 50kPa), 2 milking phase durations (575 and 775ms), and 2 levels of liner overpressure (9.8 and 18kPa). We observed a significant reduction in the estimated cross-sectional area of the teat canal with d-phase durations of 50 and 100ms when compared with d-phase durations of 150, 175, 225, 250, and 300ms. No significant difference was found in the estimated cross-sectional area of the teat canal for d-phase durations from 150 to 300ms. No significant interaction was observed between the effect of d-phase and b-phase durations, vacuum level, or liner overpressure

A method for assessing teatcup liner performance during the peak milk flow period

peer-reviewedThe objective of this study was to develop a method to quantify the milking conditions under which circulatory impairment of teat tissues occurs during the peak flow period of milking. A secondary objective was to quantify the effect of the same milking conditions on milk flow rate during the peak flow rate period of milking. Additionally, the observed milk flow rate was a necessary input to the calculation of canal area, our quantitative measure of circulatory impairment. A central composite experimental design was used with 5 levels of each of 2 explanatory variables (system vacuum and pulsator ratio), creating 9 treatments including the center point. Ten liners, representing a wide range of liner compression (as indicated by overpressure), were assessed, with treatments applied using a novel quarter-milking device. Eight cows (32 cow-quarters) were used across 10 separate evening milkings, with quarter being the experimental unit. The 9 treatments, with the exception of a repeated center point, were randomly applied to all quarters within each individual milking. Analysis was confined to the peak milk flow period. Milk flow rate (MFR) and teat canal cross sectional area (CA) were normalized by dividing individual MFR, or CA, values by their within-quarter average value across all treatments. A multiple explanatory variable regression model was developed for normalized MFR and normalized CA. The methods presented in this paper provided sufficient precision to estimate the effects of vacuum (both at teat-end and in the liner mouthpiece), pulsation, and liner compression on CA, as an indicator of teat-end congestion, during the peak flow period of milking. Liner compression (as indicated by overpressure), teat-end vacuum, vacuum in the liner mouthpiece, milk-phase time, and their interactions are all important predictors of MFR and teat-end congestion during the peak milk flow period of milking. Increasing teat-end vacuum and milk-phase time increases MFR and reduces CA (indicative of increased teat-end congestion). Increasing vacuum in the liner mouthpiece also acts to reduce CA and MFR. Increasing liner compression reduces the effects of teat-end congestion, resulting in increased MFR and increased CA at high levels of teat-end vacuum and milk-phase time. These results provide a better understanding of the balance between milking speed and milking gentleness

Assessing liner performance using on-farm milk meters

peer-reviewedThe primary objective of this study was to quantify and compare the interactive effects of liner compression, milking vacuum level, and pulsation settings on average milk flow rates for liners representing the range of liner compression of commercial liners. A secondary objective was to evaluate a methodology for assessing liner performance that can be applied on commercial dairy farms. Eight different liner types were assessed using 9 different combinations of milking system vacuum and pulsation settings applied to a herd of 80 cows with vacuum and pulsation conditions changed daily for 36d using a central composite experimental design. Liner response surfaces were created for explanatory variables milking system vacuum (Vsystem) and pulsator ratio (PR) and response variable average milk flow rate (AMF=total yield/total cups-on time) expressed as a fraction of the within-cow average flow rate for all treatments (average milk flow rate fraction, AMFf). Response surfaces were also created for between-liner comparisons for standardized conditions of claw vacuum and milk ratio (fraction of pulsation cycle during which milk is flowing). The highest AMFf was observed at the highest levels of Vsystem, PR, and overpressure. All liners showed an increase in AMF as milking conditions were changed from low to high standardized conditions of claw vacuum and milk ratio. Differences in AMF between liners were smallest at the most gentle milking conditions (low Vsystem and low milk ratio), and these between-liner differences in AMF increased as liner overpressure increased. Differences were noted with vacuum drop between Vsystem and claw vacuum depending on the liner venting system, with short milk tube vented liners having the greater vacuum drop than mouthpiece chamber vented liners. The accuracy of liner performance assessment in commercial parlors fitted with milk meters can be improved by using a central composite experimental design with a repeated center point treatment, rotating different clusters to different stalls (milk meters), and adjusting performance estimates for similar claw vacuum and pulsation conditions

Estimating teat canal cross-sectional area to determine the effects of teat-end and mouthpiece chamber vacuum on teat congestion

peer-reviewedThe primary objective of this experiment was to assess the effect of mouthpiece chamber vacuum on teat-end congestion. The secondary objective was to assess the interactive effects of mouthpiece chamber vacuum with teat-end vacuum and pulsation setting on teat-end congestion. The influence of system vacuum, pulsation settings, mouthpiece chamber vacuum, and teat-end vacuum on teat-end congestion were tested in a 2 × 2 factorial design. The low-risk conditions for teat-end congestion (TEL) were 40 kPa system vacuum (Vs) and 400-ms pulsation b-phase. The high-risk conditions for teat-end congestion (TEH) were 49 kPa Vs and 700-ms b-phase. The low-risk condition for teat-barrel congestion (TBL) was created by venting the liner mouthpiece chamber to atmosphere. In the high-risk condition for teat-barrel congestion (TBH) the mouthpiece chamber was connected to short milk tube vacuum. Eight cows (32 quarters) were used in the experiment conducted during 0400 h milkings. All cows received all treatments over the entire experimental period. Teatcups were removed after 150 s for all treatments to standardize the exposure period. Calculated teat canal cross-sectional area (CA) was used to assess congestion of teat tissue. The main effect of the teat-end treatment was a reduction in CA of 9.9% between TEL and TEH conditions, for both levels of teat-barrel congestion risk. The main effect of the teat-barrel treatment was remarkably similar, with a decrease of 9.7% in CA between TBL and TBH conditions for both levels of teat-end congestion risk. No interaction between treatments was detected, hence the main effects are additive. The most aggressive of the 4 treatment combinations (TEH plus TBH) had a CA estimate 20% smaller than for the most gentle treatment combination (TEL plus TBL). The conditions designed to impair circulation in the teat barrel also had a deleterious effect on circulation at the teat end. This experiment highlights the importance of elevated mouthpiece chamber vacuum on teat-end congestion and resultant decreases in CA.Avon Dairy Solution

Effect of teatcup removal settings on milking efficiency and milk quality in a pasture-based automatic milking system

peer-reviewedIn automatic milking systems (AMS), it is important to maximize the amount of milk harvested per day to increase profitability. One strategy to achieve this goal is to reduce the time it takes to milk each cow. Several studies in conventional milking systems have shown that milking time can be reduced by increasing the milk flow rate at which the teatcup is removed. One study analyzed the effect of increasing the milk flow switch point on milking time in a confinement AMS. No research has been conducted on teatcup removal settings in pasture-based automatic milking systems. Furthermore, not all AMS remove the teatcups based on absolute milk flow rate (kg/min); hence, it is important to study alternative strategies. The aim of this experiment was to measure the effect of 3 novel teatcup removal strategies on box time (time in the AMS), milking time, somatic cell count (SCC), and milk production rate of cows milked in a pasture-based automatic milking system. Each teatcup removal strategy in this study was applied for a period of 1 wk to 1 of 3 groups of cows and then switched to the following group until cows had transitioned through all treatments. The teatcup removal strategies consisted of removing the teatcup when the quarter flow rate fell below 20% of the quarter rolling average milk flow rate (TRS20), when quarter milk flow rate was below 30% of the rolling average milk flow rate (TRS30), and when quarter milk flow rate dropped below 50% of the rolling average milk flow rate (TRS50). A limit prevented teatcup removal if the calculated milk flow rate for teatcup removal was above 0.5 kg/min. This limit was in place for all treatments; however, it only affected the TRS50 treatment. The TRS30 strategy had 9-s shorter milking time and 11-s shorter box time than the TRS20 removal strategy. The TRS50 strategy had 8-s shorter milking time and 9-s shorter box time than the TRS20 teatcup removal strategy. There was no significant difference in milking time or box time between the TRS30 and TRS50 teatcup removal strategies, probably due to the large variability in milk flow rate at teatcup removal. The TRS20 and TRS30 strategies did not differ in SCC or milk production rate. The 0.5 kg/min limit, which affected roughly 25% of milkings in the TRS50 treatment, may have distorted the effect that this setting had on milk time, box time, milk production rate, or SCC. The difference in box time for the TRS30 and TRS50 strategies could allow for more than 3 extra milkings per day

Methods of estimating liner compression

The aim of this study was to compare 2 methods of measuring overpressure (OP) using a new test device designed to make OP measurements more quickly and accurately. Overpressure was measured with no pulsation (OPnp) and with limited pulsation (OPlp) repeatedly on the same cow during a single milking. Each of the 6 liners (3 round liners and 3 triangular liners) used in this study were tested on the same 6 experimental cows. Both OPnp and OPlp were measured on all 4 teats of each experimental cow twice for each liner. The order of OPnp and OPlp alternated sequentially for each cow test. The OP results for the 6 liners were also compared with liner compression estimated on the same liners with a novel artificial teat sensor (ATS). The OPlp method showed small but significantly higher values than the OPnp method (13.9 vs. 13.4kPa). The OPlp method is recommended as the preferred method as it more closely approximates normal milking condition. Overpressure values decreased significantly between the first and the following measurements, (from 15.0 to 12.4kPa). We recommend performing the OP test at a consistent time, 1min after attaching the teatcup to a well-stimulated teat, to reduce the variability produced by OP changing during the peak flow period. The new test device had several advantages over previously published methods of measuring OP. A high correlation between OP and liner compression estimated by the ATS was found, but difficulties were noted when using the ATS with triangular liners