(140f) Evaluation of Innovative Pathways for Waste Valorization of Ice-Cream Byproducts Towards a Sustainable Food System

For decades, the solid byproduct of ice cream production was re-incorporated into food products within the dairy industry. However, due to allergen concerns, the 2004 enactment of the Food Allergen Labeling and Consumer Protection Act (FALCPA) in the US. prohibited its use for human consumption. As a result of this regulatory change, the dairy industry and ice cream manufacturers have since been generating large volumes of solid ice cream waste (ICW), incurring significant disposal costs. On the other hand, solid ICW contains a rich composition of valuable organic matter, such as sugars, fats, and proteins. Despite this, effective and sustainable management strategies for this ice cream waste remain underdeveloped. Currently, one of the main methods considered or employed by the industry is repurposing the waste as animal feed, predominantly for pigs. Utilizing it as animal feed necessitates costly refrigeration, specialized storage to prevent spoilage, and energy-intensive transportation. As such, there’s an urgent need for innovative and environmentally responsible management solutions for this unique waste stream, which can also lead to new opportunities to turn waste into value-added products and create new economic avenues.

Through this work, we evaluate multiple pathways for ice cream waste valorization: (1) co-anaerobic digestion using mixed dairy wastes for the production of biogas and electricity, (2) fermentation process for bioethanol generation, and (3) conversion of fat-, protein-, and carbohydrate-rich components into biofuels and bioproducts using biocatalytic processes. A comprehensive systems analysis framework is employed, combining techno-economic analysis (TEA) and life cycle assessment (LCA) methodologies, to explore the economic and environmental feasibility of valorizing ice cream waste through a range of bioconversion pathways. Process modeling is conducted using a hybrid approach in Aspen Plus, the process and inventory inputs integrate First-principles material and energy balances with regression-based models informed by experimental data. To further enhance system efficiency, supply chain optimization will be carried out through mathematical modeling of transportation and logistics, ensuring both technical and environmental feasibility.

Altogether, this study integrates experimental data, process modeling, and sustainability analysis to explore the economic and environmental feasibility of ice cream waste valorization through multiple bioconversion pathways, providing insights to support near-term deployment in industry.