Towards Real-Time Sustainable Post-Harvest Operations: Gate-to-Gate Life Cycle Assessment of Sensor-Informed Sweet Cherry Sorting and Packing in Greece

This study presents a gate-to-gate life cycle assessment (LCA) of an industrial sweet cherry sorting and packing facility in Greece, directly addressing environmental sustainability in agri-food supply chains through data-driven impact quantification and improvement pathways in post-harvest operations. The assessment focuses on a gate-to-gate system boundary encompassing all processes inside the cherry sorting and packing facility, while upstream cherry production and downstream waste management are modeled and reported separately to provide system-level context. Core-stage hotspots are then analyzed in detail in the Results section, highlighting the dominant role of electricity use compared with packaging materials. The functional unit is defined as 1 kg of packed, market-ready cherries at the factory gate. Primary data are obtained from high-resolution, batch-level measurements of mass flows, energy use, water consumption, packaging materials and waste streams over a full processing season, structured as virtual sensor outputs. These sensor-informed operational data are combined with secondary life cycle inventory information from established databases to quantify climate change impacts and identify environmental hotspots across materials, energy, water, and waste, thereby delivering a quantified picture of environmental performance in the post-harvest stage. The results show that corrugated cardboard and associated packaging components are among the main contributors within the facility-level, gate-to-gate system, while the Core stage accounts for 28.43% of total GWP100. Upstream cherry production dominates the overall Upstream–Core–Downstream climate footprint with 70.61% of total impacts. Moreover, practical mitigation scenarios are modeled, including packaging optimization, partial substitution of grid electricity with photovoltaic generation, and increased water recirculation. Ιn the combined mitigation scenario, where packaging optimization, low-carbon electricity and improved water management are implemented simultaneously, total GWP100 decreases from 114,207.32 to 92,500.27 kg CO2-eq (−19.0%) relative to the baseline, providing actionable sustainability improvements for industry stakeholders and supporting Sustainable Development Goals (SDGs) related to climate action and resource efficiency. In addition, the proposed virtual sensor architecture and data workflow support continuous monitoring, eco-efficiency management and near-real-time LCA implementation in post-harvest agri-food systems, enabling operational sustainability.