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Variable Frequency Drives: Milk Vacuum Pump

alternative practice names:

Vacuum Pump Variable Speed Drive (VSD); Vacuum Pump VFD; Vacuum Pump Speed Controller

Milk vacuum pump variable frequency drives (VFDs) are a type of electronic controller that can drastically reduce the amount of energy required to harvest milk from the herd. On the average dairy farm, milk harvesting consumes around 20-25% of the total electricity used. Milk harvesting typically uses milking units and a vacuum pump with an accompanying motor to pump milk from the cows to the bulk tank. During this process, the amount of vacuum pressure needed from the pump varies greatly, and a significant amount of energy is wasted without a way to modulate the speed of the vacuum pump motor.  


By installing a milk vacuum pump VFD and a pressure sensor on the milk line, the VFD can vary the speed of the motor in real-time based on the vacuum demand. The VFD can typically reduce the electricity usage of the vacuum pump system by 50-60% and generally has a fast payback period even without financial incentives.

When used, in what regions in the U.S. is the practice found: 

Northwest, West, Upper Midwest, Southwest, Northeast, Southeast

FARM SIZE 

When used, typically found on farms of the following sizes:

All Sizes

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Practice Benefits 

Improved profitability: The main benefit of installing a vacuum pump VFD is improved profitability by reducing the amount of electricity used to harvest milk. Furthermore, a vacuum pump VFD will extend the life of the vacuum pump and motor by reducing their average speed, typically to less than half the speed they would be operating at without a VFD.


Noise reduction: Vacuum pump VFDs also greatly reduce noise in the milk room.

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Implementation Insights

Site-specific or Farm-specific requirements 

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In most cases, there are no specific site or farm requirements.

Required Capital Expenditures (CapEx)

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  • Vacuum pump VFD: The primary expense is the vacuum pump VFD itself, along with the labor required to install it. Additional up-front costs may be necessary if the vacuum pump and/or vacuum pump motor are incompatible with the VFD, or if a phase converter is required in the case of a dairy farm with single-phase power. If a new pump and/or motor are needed, it is worth considering installing high-efficiency models to reduce the amount of electricity usage over the life of the equipment. The sizing and installation of a vacuum pump VFD should be completed by an experienced equipment vendor.

Required Operational Expenditures (OpEx)

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  • Maintenance: Ongoing maintenance costs for vacuum pump VFDs are generally low, and maintenance can be performed in-house without skilled labor. Maintenance costs can often be reduced for the milk harvesting system by using a VFD because they result in less wear and tear on the vacuum pump and vacuum pump motor. Additionally, any maintenance costs will be greatly outweighed by the annual energy cost savings provided by the VFD. Maintenance of a vacuum pump VFD mainly involves keeping it dust-free and dry as well as ensuring that the vacuum pressure sensor remains functional. It is also important to perform checks and maintenance on the vacuum pump, motor, and milk pulsators according to manufacturer recommendations. The lifespan of a vacuum pump VFD is typically at least 10 to 20 years.

Implementation Considerations

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  • Selection and installation: Vacuum pump VFDs are generally straightforward to install with the design and installation assistance of an experienced equipment vendor. It is important to select a high-quality VFD equipped with radiofrequency filters to avoid electrical interference with other equipment on the farm.

  • Compatibility: Milk vacuum pump VFDs are not compatible with all types of motors and pumps, so it is important to discuss with an experienced equipment dealer. They are most commonly installed on rotary lobe pumps as well as some sliding vane pumps. They are not recommended for use with turbine and water ring-style pumps. Additionally, vacuum pump VFDs function best with 3-phase power but can be used with single-phase using a phase converter. If the existing pump and/or motor are incompatible with a VFD, they will need to be replaced. 

Financial Considerations and Revenue Streams

FEDERAL COST-SHARE AND CONSERVATION FUNDING

Funding is available for this practice through USDA's Natural Resources Conservation Service (NRCS) Environmental Quality Incentives Program (EQIP) On-Farm Energy Initiative.

Notes:

  • An Agricultural Energy Management Plan (AgEMP), or other qualifying energy audit, needs to be completed before applying for EQIP assistance.

  • Check with the local NRCS office on payment rates and practice requirements relevant to your location.


The USDA Rural Development Rural Energy for America Program (REAP) also offers competitive grants and loan guarantees for installing energy efficiency projects.


OTHER CONSERVATION FUNDING

Vacuum pump VFD rebates are sometimes available through the farm’s electric utility company.  

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Environmental Impacts

REDUCES FARM GREENHOUSE GAS FOOTPRINT

Improving energy use efficiency reduces a farm's greenhouse gas (GHG) footprint. Since energy production typically involves processes that emit greenhouse gases like carbon dioxide and methane, cutting energy use directly lowers the GHG footprint of the farm.

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Alignment with FARM Program

FARM Environmental Stewardship (ES) V2-V3 Alignment

FARM ES captures a farm's energy usage and calculates the associated GHG emissions based on regional energy production and transmission averages. Any practice that reduces farm energy consumption will directly lower the farm's GHG footprint. The reduction in GHG emissions is particularly pronounced in regions where a larger proportion of energy is derived from coal, natural gas, or other fossil fuel sources, as these energy types have higher carbon footprints compared to renewable energy sources.

Contents

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We're always eager to update the website with the latest research, implementation insights, financial case studies, and emerging practices. Use the link above to share your insights. 

We're always eager to update the website with the latest research, implementation insights, financial case studies, and emerging practices. Use the link above to share your insights. 

Contents

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Practice Overview

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Practical Insights.png
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Research Results.png
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Milk vacuum pump variable frequency drives (VFDs) are a type of electronic controller that can drastically reduce the amount of energy required to harvest milk from the herd. On the average dairy farm, milk harvesting consumes around 20-25% of the total electricity used. Milk harvesting typically uses milking units and a vacuum pump with an accompanying motor to pump milk from the cows to the bulk tank. During this process, the amount of vacuum pressure needed from the pump varies greatly, and a significant amount of energy is wasted without a way to modulate the speed of the vacuum pump motor.  


By installing a milk vacuum pump VFD and a pressure sensor on the milk line, the VFD can vary the speed of the motor in real-time based on the vacuum demand. The VFD can typically reduce the electricity usage of the vacuum pump system by 50-60% and generally has a fast payback period even without financial incentives.

Practices and technologies

Variable Frequency Drives: Milk Vacuum Pump

alternative practice name:

Vacuum Pump Variable Speed Drive (VSD); Vacuum Pump VFD; Vacuum Pump Speed Controller