UNXT LCA Chocolate Production Wei3materials

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 Medelln Facultad de Minas
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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
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
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 .
Figure 1 Overview of the complete Model
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
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 doubleclicking 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.
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.
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.
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.
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
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.
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.
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
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
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.
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.
DST/1000
Figure 19 Specification Transport
There is no normal output. However, the generic material Cargo is defined in the
tab Generic Materials.
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:
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.
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.
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.
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
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
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.
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
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 consumers 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.
Drag the materials waste aluminum and waste paper, sorted to the output
side.
Figure 35 Specification Package Disposal
Figure 36 Overview of the Processes Grinding to Package Disposal
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
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.
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:
Figure 41 Specification Mixing
Material name
Function
Cocoa Butter
TOT*CBUT/100
Milk
TOT*MIL/100
Cocoa Liquor
TOT*CLIQ/100
Sugar
TOT*SUG/100
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.
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.
Storage in Refrigeration
The bought chocolate is likely to stay in the consumers 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
Refrigerators 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
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.
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
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.
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.
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.
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
organic, for
modified,
ecoinvent 3
cocoa seed,
setting [GLO]
based
on
(v3.01)
electricity,
medium
voltage
MJ
market for electricity,

medium voltage [RoW]
m3
market
[RoW]
chlorothalonil 2
kg
market for chlorothalonil

[GLO]
pesticide,
unspecified
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]
tkm
market
for
transport,
freight, lorry >32 metric
ton, EURO3 [GLO]
tkm
market
for
transport,
freight, lorry >32 metric
ton, EURO3 [GLO]
Wh
market for electricity, low

voltage [RoW]
irrigation
Cocoa
Seedlings
0,317
15
0,25
transport,
Transport of freight, lorry
Cocoa Beans
> 32 metric
ton, EURO3
DT/100
Transport
transport,
freight, lorry
> 32 metric
ton, EURO3
DST/100
for
irrigation
Industrial
Cleaning
electricity,
low voltage
Heat
Production
petrol,
unleaded
0,008
kg
market
for
unleaded [RoW]
Winnowing
electricity,
low voltage
0,12
Wh

voltage [RoW]
Wh

voltage [RoW]
Grinding
Pressing
Milling
Mixing
1,7
petrol,
electricity,
low voltage
0,12
Biowaste
User defined
functions
g
market
[RoW]
electricity,
low voltage
0,038
Wh

voltage [RoW]
MJ

voltage [RoW]
electricity,
low voltage
0,003
sugar, from User defined

sugarcane
functions
g
for
biowaste
market for sugar, from

sugarcane [GLO]
electricity,
low voltage
Milk
User defined
functions
MJ

voltage [RoW]
User defined
functions
g
market for milking [GLO]

modified,
based
on
ecoinvent 3 (v3.01)
Conching
Tempering
& electricity,
low voltage
0,1
Wh

voltage [RoW]
Moulding
Packaging
& electricity,
low voltage
20
Wg

voltage [RoW]
market
for
paper,
woodfree, coated [RoW]
Cooling
in electricity,
Supermarket
low voltage
User defined
functions
g

voltage [RoW]
Storage
in electricity,
Refrigerator
low voltage
User defined
functions
g

voltage [RoW]
Package
Disposal
market
for
aluminium [GLO]
market for waste paper,

sorted [GLO]
kg
market for aluminium,

primary, ingot [GLO]
kg
sheet rolling, aluminium

[RoW]
paper,
woodfree,
coated
waste
aluminium
waste paper,
sorted
3
Subnet:
Aluminium
Production
aluminium,
priamry,
ingot
sheet rolling,
aluminium
1
waste
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 chocolates 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 chocolates packages.
Name the subnet process Aluminium production and put the following on the input
side:
Material
Coefficient
Unit
Sheet rolling, aluminum
kg
Aluminum, primary, ingot
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.
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
Figure 56 Overview of the chocolate production
Figure 57 Overview of the distribution, consumer use and disposal phase
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
Figure 59 Result Sankey View
VIII. List of all applied materials

Table 2 List of all applied materials
Process
Material
Cocoa Seeds
Crop
Establishme
nt
Cocoa
Seedlings
Source
User Defined
Type
Good
Coefficie
nt/
Unit
4,5
Unit
kg
Input
/
Outpu
t
Activity for
Expansion
Input
market for
cocoa seed,
organic, for
setting
[GLO]
modified,
based on
ecoinvent 3
(v3.01)
Input
market for
electricity,
medium
voltage
[RoW]
market for
irrigation
[RoW]
electricity,
medium
voltage
ecoinvent 3
(v3.01)
irrigation
ecoinvent 3
(v3.01)
Good
15
m3
Input
Cocoa
Plantation
User Defined
Good
ha
Output
Carbon
dioxide, nonfossil[air/unsp
ecified]
ecoinvent 3
(v3.01)
Bad
4,00E-05
kg
Output
Cocoa
Plantation
User Defined
Good
ha
Input
chlorothalonil
ecoinvent 3
(v3.01)
pesticide,
unspecified
phosphate
fertiliser, as
P205
ecoinvent 3
(v3.01)
ecoinvent 3
(v3.01)
Good
Good
Good
Good
0,317
0,25
18
MJ
kg
kg
kg
Input
market for
chlorothaloni
l [GLO]
Input
market for
pesticide,
unspecified
[GLO]
Input
market for
phosphate
fertiliser, as
P2O5 [GLO]
market for
potassium
fertiliser, as
K2O [GLO]
potassium
fertiliser, as
K20
ecoinvent 3
(v3.01)
Good
14
kg
Input
Cocoa Pods
User Defined
Good
4032
kg
Output
Cocoa Pods
User Defined
Good
4032
kg
Input
Harvesting &
Extraction
Transport of
Cocoa Beans
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,
freight, lorry
> 32 metric
ton, EURO3
ecoinvent 3
(v3.01)
Good
Generic
Material:
Cargo
Fermentatio
n & Sun
Drying
Transport
Input
Mass[kg
]
Both
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,
freight, lorry
> 32 metric
ton, EURO3
Raw, dried
cocoa beans
Heat
Production
tkm
Unfermented
Cocoa Beans
ecoinvent 3
(v3.01)
Good
Generic
Material:
Cargo
Industrial
Cleaning
DT/100
User Defined
Good
DST/100
tkm
Input
Mass[kg
]
Both
150
Input
electricity, low
voltage
ecoinvent 3
(v3.01)
Good
1,7
Wh
Input
Cleaned cocoa
beans
User Defined
Good
125
Output
Cocoa beans
waste
User Defined
Good
25
Output
Cocoa beans
waste
User Defined
Good
0,025
kg
Input
petrol,
unleaded
ecoinvent 3
(v3.01)
Good
0,008
kg
Input
heat energy
ecoinvent 3
(v3.01)
Bad
3,00E-06
kg
Output
market for
transport,
freight, lorry
>32 metric
ton, EURO3
[GLO]
market for
transport,
freight, lorry
>32 metric
ton, EURO3
[GLO]
market for
electricity,
low voltage
[RoW]
market for
petrol,
unleaded
[RoW]
Roasting
Winnowing
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
Cleaned cocoa
beans
User Defined
Good
125
Input
Heat energy
User Defined
Good
0,2
kWh
Input
Roasted cocoa
beans
User Defined
Good
125
Output
Roasted cocoa
beans
User Defined
Good
Input
electricity, low
voltage
ecoinvent 3
(v3.01)
Good
0,12
Wh
Input
Cocoa nibs
User Defined
Good
0,8
Output
Shells
User Defined
Good
0,2
Output
Good
User
defined
functions
Input
Good
User
defined
functions
Wh
Input
Good
User
defined
functions
Output
Output
Input
Cocoa Nibs
Grinding
Pressing
User Defined
electricity, low
voltage
ecoinvent 3
(v3.01)
Cocoa Liquor
ecoinvent 3
(v3.01)
Biowaste
User Defined
Bad
User
defined
functions
Cocoa Liquor
User Defined
Good
65
electricity, low
voltage
ecoinvent 3
(v3.01)
Good
0,038
Wh
Input
Cocoa Butter
User Defined
Good
25
Output
market for
electricity,
low voltage
[RoW]
market for
electricity,
low voltage
[RoW]
market for
biowaste
[RoW]
market for
electricity,
low voltage
[RoW]
Milling
Cocoa Cake
User Defined
Good
40
Output
Cocoa Cake
User Defined
Good
40
Input
electricity, low
voltage
ecoinvent 3
(v3.01)
Good
0,003
MJ
Input
Cocoa Powder
User Defined
Good
40
Output
Good
User
defined
functions
Good
User
defined
functions
sugar, from
sugarcane
electricity, low
voltage
ecoinvent 3
(v3.01)
ecoinvent 3
(v3.01)
Mixing
Milk
Cocoa Liquor
Cocoa Butter
Semi-liquid
Mix
Conching &
Tempering
User Defined
User Defined
User Defined
User Defined
MJ
Input
market for
sugar, from
sugarcane
[GLO]
Input
market for
electricity,
low voltage
[RoW]
market for
milking
[GLO]
modified,
based on
ecoinvent 3
(v3.01)
Good
User
defined
functions
Input
Good
User
defined
functions
Input
Good
User
defined
functions
Input
Good
User
defined
functions
Output
electricity, low
voltage
ecoinvent 3
(v3.01)
Good
0,1
Wh
Input
Semi-liquid
Mix
User Defined
Good
100
Input
Solid
Chocolate Mix
User Defined
Good
80
Output
Steam
User Defined
Bad
20
Output
aluminium,
foil
User Defined
Good
Input
Moulding &
Packaging
electricity, low
voltage
ecoinvent 3
(v3.01)
Good
20
Wg
market for
electricity,
low voltage
[RoW]
Input
market for
electricity,
low voltage
[RoW]
market for
electricity,
low voltage
[RoW]
Refrigerated
Transport
paper,
woodfree,
coated
ecoinvent 3
(v3.01)
Good
Input
Solid
Chocolate Mix
User Defined
Good
100
Input
Chocolate
User Defined
Good
106
Output
transport,
freight, lorry
> 32 metric
ton, EURO3
ecoinvent 3
(v3.01)
Good
DST/100
tkm
Input
Good
Mass[kg
]
Both
Good
User
defined
functions
kWh
Input
Good
User
defined
functions
Input
Good
User
defined
functions
Output
Good
User
defined
functions
Input
Good
User
defined
functions
kWh
Input
Output
Generic
Material:
Cargo
Chocolate
Cooling in
Supermarket
electricity, low
voltage
Chocolate
Chocolate
Storage in
Refrigerator
Eating
eletricity, low
voltage
ecoinvent 3
(v3.01)
User Defined
User Defined
User Defined
ecoinvent 3
(v3.01)
Chocolate
User Defined
Good
User
defined
functions
Chocolate
User Defined
Good
106
Input
Eating
Chocolate
User Defined
Good
unit
Output
Package
Waste
User Defined
Bad
Output
Package
Waste
User Defined
Bad
Input
Package
Disposal
waste
aluminium
ecoinvent 3
(v3.01)
Bad
Output
market for
paper,
woodfree,
coated
[RoW]
market for
electricity,
low voltage
[RoW]
market for
electricity,
low voltage
[RoW]
market for
waste
aluminium
[GLO]
waste paper,
sorted
Subnet:
Aluminium
Production
ecoinvent 3
(v3.01)
Bad
Output
market for
waste paper,
sorted [GLO]
Input
market for
aluminium,
primary,
ingot [GLO]
sheet rolling,
aluminium
[RoW]
aluminium,
priamry, ingot
ecoinvent 3
(v3.01)
sheet rolling,
aluminium
ecoinvent 3
(v3.01)
Good
kg
Input
aluminium,
foil
User Defined
Good
kg
Output
Good
kg

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Umberto NXT LCA

ifu Hamburg GmbH

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Umberto is a registered trademark of ifu Hamburg GmbH

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Getting Started ............................................................................... 7

Welcome to Umberto NXT LCA................................................................... 7

Crop Establishment ................................................................................ 14

User Defined Specifications .......................................................... 29

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Using the Expand Function ........................................................... 36

Creating a Subnet for the Aluminum Production........................... 43

VII. Evaluation .................................................................................... 46

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Figure 1 Overview of the complete Model

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Welcome to Umberto NXT LCA

Figure 2 Overview of the workspace

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Step 1- Creating a first process module

Figure 3 Crop Establishment, the first project

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Another way to create elements is to use the 'Draw' menu and to

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Step 2 - Defining Materials

Figure 5: Project Explorer

Press the 'New Material' button

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Figure 6: Property Editor

Material groups and sub groups can be created by selecting a

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Step 3 - Specifying the Process

Materials can also be added to a process by using the

Figure 7: Process specification Industrial Cleaning

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Figure 8: Process Crop Establishment

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Figure 9 Overview of the cocoa bean production

Phosphate fertilizer, as P2O5

Potassium fertilizer, as K20

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Figure 10 Specification Cocoa Seedlings

Harvesting & Extraction

Figure 11 Specification Harvesting & Extraction

Transport of Cocoa Beans

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Figure 12 Specification Transport of Cocoa Beans

Figure 13 Parameter Transport of Cocoa Beans

Figure 14 Generic Materials Transport of Cocoa Beans

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Fermentation & Sun Drying

Figure 15 Parameters Fermentation & Sun-Drying

Figure 16 Specifications Fermentation & Sun-Drying

Below, find a first rough overview of the processes entered so far.

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

Figure 18 Parameter Transport

The coefficient of `transport, lorry >32t, EURO3 [RER] is described as a

Figure 19 Specification Transport

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Figure 20 Generic materials for transport services

Figure 21 Specification Industrial Cleaning

Universidad Nacional de Colombia Sede Medelln Facultad de Minas

The coefficient of `unleaded petrol is described as a formula.