Economic simulation modeling of reprocessing alternatives for corn masa byproducts

K. A. Rosentrater, T. L. Richard, C. J. Bern, R. A. Flores

Research output: Contribution to journalArticle

11 Citations (Scopus)

Abstract

Increasing production of corn masa for tortillas, chips, and related snack foods is resulting in large quantities of organic residuals requiring environmentally sound management. These byproduct streams appear suitable for use as livestock feed material, thus eliminating landfilling costs. Possibilities for developing livestock feed include direct shipping to livestock feeding facilities, blending prior to shipping, extrusion processing, pellet mill processing, and dehydration. To assess the viability of these options for reprocessing masa byproducts as livestock feed materials, an economic model was developed and applied to each of these alternatives. Through a series of simulation runs with this model, it was determined that direct shipping was by far the most inexpensive means of recycling masa processing residuals (10-57 $/Mg). Other alternatives examined in increasing order of costs included blending prior to shipping, extrusion, pellet mill processing (3-15, 5-18, and 4-18 times greater than direct shipping, respectively), while dehydration was clearly cost-prohibitive (33-81 times greater). Bagged feed was slightly more expensive to produce than bulk feed (1.1 times greater), and reprocessing costs increased as delivery distance increased, due to increased labor, equipment, and fuel costs, but decreased as byproduct generation rate increased, due to the development of the economies of scale. Alternately, based on a tipping fee of 50 $/Mg, the total estimated cost to landfill ranged from 65 to 112 $/Mg. Based on this cost analysis, direct shipping and feeding to livestock is the recycling option of choice for masa processing byproducts. Although specific details of process configurations and associated costs will vary, similar results are likely for other high moisture food processing residuals destined for utilization as livestock feed or components thereof. Crown

Original languageEnglish (US)
Pages (from-to)341-367
Number of pages27
JournalResources, Conservation and Recycling
Volume39
Issue number4
DOIs
StatePublished - Nov 1 2003

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shipping
maize
livestock
economics
cost
modeling
simulation
extrusion
dehydration
mill
recycling
food processing
economy of scale
cost analysis
reprocessing
Costs
By-products
Economics
Corn
Simulation modeling

All Science Journal Classification (ASJC) codes

  • Waste Management and Disposal
  • Economics and Econometrics

Cite this

Rosentrater, K. A. ; Richard, T. L. ; Bern, C. J. ; Flores, R. A. / Economic simulation modeling of reprocessing alternatives for corn masa byproducts. In: Resources, Conservation and Recycling. 2003 ; Vol. 39, No. 4. pp. 341-367.
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Economic simulation modeling of reprocessing alternatives for corn masa byproducts. / Rosentrater, K. A.; Richard, T. L.; Bern, C. J.; Flores, R. A.

In: Resources, Conservation and Recycling, Vol. 39, No. 4, 01.11.2003, p. 341-367.

Research output: Contribution to journalArticle

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