SUL4R-PLUS Sustainability: The Carbon Footprint of Commonly Used Fertilizers

Travis Banet, PhD (Integrated Plant and Soil Sciences)
SUL4R-PLUS Manager of Research and Development

In 2025, SUL4R-PLUS partnered with Tunley Environmental to measure SUL4R-PLUS carbon footprint.

What is a carbon footprint?

Greenhouse gas emissions are commonly created when fuel and energy are used to power things. For example, burning fossil fuels such as coal, natural gas, or gasoline to create heat, electricity, and fuel vehicles leads to greenhouse gas emissions. A carbon footprint describes the amount of greenhouse gases that are created when things are manufactured. A carbon footprint can generally be broken into three stages:

  • Raw Material Extraction: this includes all the greenhouse gases created to harvest ingredients from their sources.
  • Raw Material Acquisition: this includes all the greenhouse gases created during the transport of ingredients from their sources to the point of production.
  • Manufacturing: this includes all the greenhouse gases that are created during production.

What is SUL4R-PLUS carbon footprint and how does it compare to other fertilizers?

Compared to a dozen other commonly used fertilizers, SUL4R-PLUS has the third lowest carbon footprint (Figure 1). Of these, SUL4R-PLUS carbon footprint is 34% – 81% less than the ten fertilizers that have a greater carbon footprint.

Figure 1: This figure demonstrates the cradle-to-gate carbon footprint of commonly used fertilizers as reported in published literature. Reported units were all converted to pounds of CO2 equivalents per pound of fertilizer produced. In cases where multiple sources reported the same fertilizer, values from the most recently published source were used. References to the data used in this figure are cited below in Table 1.

It’s also important to recognize that each fertilizer’s carbon footprint is unique because they each require different ingredients and processes to create the final product. For SUL4R-PLUS, more than 60% of its carbon footprint comes from creating its main ingredient: flue gas desulfurization gypsum.

Flue gas desulfurization gypsum, or FGD gypsum, is a waste product created when coal-fired power plants scrub sulfur-based gases from smokestacks. Per federal regulations, these sulfur-based gases must be scrubbed out of smokestack exhaust to prevent harmful environmental effects like acid rain. Even if SUL4R-PLUS was not on the market, the FGD gypsum would still be produced and would keep creating greenhouse gas emissions to keep the smokestacks free of sulfur oxide gases.

SUL4R-PLUS makes use of this waste product and turns it into a valuable plant-available nutrient source that can enhance crop growth and productivity. Learn more about our Research and the impact that SUL4R-PLUS can have on a variety of crop yields.

Table 1: Citations to the data referenced in Figure 1.

FertilizerCitationReference in Text
SUL4R-PLUSTunley Environmental, 2025Table 2, page 9
Ammonium Sulfate
Ammonium NitrateFertilizers Europe, 2018Table 6, page 13
Calcium Ammonium NitrateTable 8, page 15
UreaTable 10, page 17
UAN 30Table 12, page 19
Ammonium NitrosulfateBretrup and Hoxha, 2016Table 3, page 5
Calcium Nitrate
Diammonium Phosphate
NPK (15-15-15)
Triple Super Phosphate
Muriate of Potash
Anhydrous AmmoniaLiu et al., 2020Figure 4, page 7

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SUL4R-PLUS® Sustainability: Carbon Footprint and Life Cycle Analysis

Travis Banet, PhD (Integrated Plant and Soil Sciences)
SUL4R-PLUS Manager of Research and Development

In 2025, SUL4R-PLUS partnered with Tunley Environmental to answer two questions:

  1. What is the carbon footprint of SUL4R-PLUS?
  2. What overall effect does using SUL4R-PLUS in the field have on greenhouse gas emissions?

What is a carbon footprint?

Every process requires some kind of energy source. Gas-powered vehicles get their energy from burning gasoline. Electric vehicles (most likely) get their energy from burning coal at a power plant, which transforms the combusted coal into electricity that is stored in the vehicle’s battery. Processes that consume energy commonly create greenhouse gases as a byproduct of the chemical reactions that power each process.

A carbon footprint describes the amount of greenhouse gases that are created when fuel and energy are used to power a process.

What makes up the carbon footprint of SUL4R-PLUS?

The SUL4R-PLUS carbon footprint can be divided into three phases:

What is the SUL4R-PLUS carbon footprint?

About 63% of the SUL4R-PLUS carbon footprint comes from raw material extraction. Raw material extraction for SUL4R-PLUS can be broken down into three items:

Creating Flue Gas Desulfurization (FGD) gypsum, a main ingredient in SUL4R-PLUS, is energy intensive and accounts for more than half of the SUL4R-PLUS carbon footprint. 

However, even if SUL4R-PLUS was not on the market, FGD gypsum would still be produced and contribute to CO2 emissions. FGD gypsum is a waste product created as coal-fired power plants scrub sulfur-based gases from smokestacks. Per federal regulations, these sulfur-based gases must be scrubbed out of smokestack exhausts to prevent harmful acid rain.

SUL4R-PLUS repurposes the FGD gypsum waste into a valuable product that can enhance plant growth and performance. Check out our research from the field to learn more about the impact that SUL4R-PLUS has on crop yields.

The SUL4R-PLUS carbon footprint is also 68% less than ammonium sulfate, a commodity fertilizer also used to supply plant-available sulfur.

What is the complete life cycle of SUL4R-PLUS?

After production, SUL4R-PLUS is transported to retailers and growers, applied in the field, and then taken up by plants. 

Unlike previous steps in the product’s life cycle, using SUL4R-PLUS results in negative emissions. Negative emissions indicate that CO2 is being removed from the atmosphere rather than added to the atmosphere.

Net CO2 emissions = -82.6 lbs Co2e over one acre treated with 100 lbs of SUL4R-PLUS

Our Mill Creek Production Facility makes about 60,000 tons of SUL4R-PLUS each year.  At 100 lbs SUL4R-PLUS per acre, that’s enough to treat 1.2 million acres of cropland, and remove approximately 50,000 tons more CO2 than untreated croplands.   

For comparison, removing 50,000 tons of CO2 is approximately equal to removing the greenhouse gases created by:

  • Driving 11,000 powered passenger vehicles for one year
  • Consuming 5.4 million gallons of gasoline
  • Burning 53 million pounds of coal
  • Powering 6,400 homes for one year

To remove 50,000 tons of CO2, it would take:

  • 795,000 tree seedlings 10 years
  • 48,000 acres of U.S. forests one year

How does SUL4R-PLUS enhance CO2 removal?

Field trial data from 2016 to present has shown that SUL4R-PLUS can increase crop growth compared to untreated fields. More crop biomass in the field means that more photosynthesis is happening and drawing down increased levels of CO2 from the atmosphere to grow crop stems higher, larger leaves, and produce more grain, seed and fruits (figure for animation concept below).

For more details on the Carbon Footprint and Life Cycle analysis from Tunley Environmental, please see the full report.

Note: CO2e stands for “CO2 equivalents.” Not all greenhouse gases are equal, and some retain more heat than CO2. These gases have been accounted for and are standardized as CO2 equivalents, or CO2e. Units in this blog post have been converted into lbs of CO2e per lb of SUL4R-PLUS, whereas the full report displays the results in kg of CO2e per lb of SUL4R-PLUS. Approximations of CO2 emissions created by burning fossil fuels, powering homes, removed by tress, etc., were calculated using the U.S. EPA Greenhouse Gas Equivalencies Calculator.

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Calcium Clarified: Soybeans

As the quest for higher-yielding soybeans advances, balanced fertility will be required to push yields higher. Proper crop nutrition goes beyond the macronutrients of nitrogen (N), phosphorus (P) and potassium (K). Soybeans also need secondary nutrients, like calcium to grow and thrive. In fact, calcium plays an essential role in numerous physiological processes throughout the soybean plant.     

Generally, calcium supports the plant in the following areas:  

Cell Division & Elongation:
Calcium acts as a secondary messenger to regulate the cell cycle and promote proper cell expansion. Calcium ions help activate enzymes that facilitate cell division and elongation, contributing to the overall growth and development of the plant.

Cell Wall Elongation & Strength:
Calcium is important for the formation of pectin, a component of the cell wall matrix. Adequate calcium levels contribute to strong and well-developed cell walls, providing rigidity to the plant stem, branch, and leaf structure.

Nitrogen Uptake & Metabolism:
Calcium influences the activity of transport proteins for the uptake of nitrate from the soil. Calcium also modulates enzymes involved in nitrate assimilation within the plant, ensuring proper nitrogen utilization for various physiological processes.

Abiotic Stress Management:
Calcium helps maintain cell membrane stability and integrity during periods of environmental stress, such as drought or extreme temperatures. Calcium is vital for preventing cellular damage and ensuring the plant’s resilience to adverse conditions.

Disease Resistance & Defense Mechanisms:
Calcium contributes to the activation of defense responses in the plant, including the synthesis of antimicrobial compounds and reinforcement of cell walls. Adequate calcium levels enhance the plant’s ability to resist infections and protect plants from common diseases because the surface of the plant tissues are more resilient with stronger cell walls.

Soil Structure Health & Biological Activity:
Calcium is vital for maintaining soil structure health and promoting biological activity in the rhizosphere, the region of soil engaged by the plant’s roots. Calcium also facilitates nutrient availability and microbial activity to foster a healthy environment for plant growth.

Calcium Availability

Today’s high-yielding crops require more calcium than ever before. Even when soil tests indicate high calcium levels, it does not guarantee optimal plant availability for the critical nutrient. Generally, less than 5% of measured calcium shown on traditional soil test results  is plant-available.  

The availability of calcium for plants to uptake in soils can be influenced by interactions with soil colloids, the presence of other nutrient ions and soil pH. Therefore, regular soil and plant tissue testing and consideration of the soil chemistry dynamics are essential for tailoring calcium management strategies and optimizing plant nutrition.  

Supplemental Calcium 

Supplemental calcium nutrient sources vary in plant availability. Therefore, in many cases, it is critical to apply calcium products that are more plant-available and can address plant uptake needs during critical growth and development periods. By choosing calcium sources that are readily absorbed by plants, growers can help maximize uptake and deliver elevated returns on their fertilizer investment. With 100% plant-available nutrition, SUL4R-PLUS® calcium-sulfate is an excellent option for helping crops meet their calcium needs (and it helps improve the soil too).   

Overall, calcium is important for supporting plant growth and development and ensuring robust yields across most crops. Stay tuned for future blog posts in our Calcium Clarified series where we will break down the role of calcium in specific crops including alfalfa, corn, potatoes, soybeans and wheat.  

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    Calcium Clarified: Corn

    Calcium is an important nutrient for proper corn plant nutrition. Even though it is a secondary nutrient, calcium is critical for optimizing plant strength, ear and kernel development and plays a key role in numerous physiological processes throughout the plant.   

    More specifically, calcium supports corn plants in the following ways:

    Cell Division & Elongation:
    Calcium acts as a secondary messenger to regulate the cell cycle and promote proper cell expansion in corn plants. Calcium ions also help to activate enzymes that facilitate cell division and elongation, contributing to the overall growth and development of corn plants.

    Cell Wall Development & Strength:
    Calcium plays a pivotal role in forming pectin, an integral component of the cell wall matrix. Adequate calcium levels contribute to strong and well-developed cell walls, providing rigidity to the corn plant structure. This strength is especially important during the reproductive stages when the developing kernels require structural support.  

    Nitrogen Uptake & Metabolism:
    Calcium helps to regulate nitrate uptake and metabolism in corn plants. It influences the activity of transport proteins responsible for the uptake of nitrate from the soil. Calcium also modulates enzymes involved in nitrate assimilation within the plant, ensuring proper nitrogen utilization for various physiological processes, including ear kernel development.  

    Abiotic Stress Reduction:
    Calcium helps maintain cell membrane stability and integrity to mitigate abiotic stressors in corn plants. This is vital for preventing cellular damage and ensuring the plant’s resilience to adverse conditions, such as drought or extreme temperatures. 

    Disease Resistance & Defense Mechanisms:
    Calcium contributes to the activation of defense responses, including the synthesis of antimicrobial compounds and reinforcement of cell walls. Ample calcium levels enhance corn plants’ ability to resist infections, adding a layer of protection from common diseases that can impact kernel development.  

    Soil Structure & Biological Activity:
    Calcium is vital for maintaining soil structure health and promoting biological activity in the rhizosphere, the sheath of soil immediately surrounding the corn roots. Calcium also facilitates nutrient availability and microbial activity to foster a healthy environment for plant growth.  

    Overall, calcium is integral to the overall health and productivity of corn crops. Understanding the multifaceted role calcium plays in corn production is essential for enabling optimal growth and development. With soil-stable, readily available sulfur and calcium, SUL4R-PLUS® calcium-sulfate is an excellent option for helping corn plants meet their calcium and sulfur requirements for optimal crop growth and robust yields.  

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    More specifically, calcium supports alfalfa plants in the following ways:

    Crown Establishment & Early Growth:
    In the early stage of crown establishment, calcium ions support cell cycle-regulating enzymes, ensuring precision control of the plant’s cell division process. This regulation is crucial for the formation of growth tissues in the crown, which serve as reservoirs for growth cells waiting for further division and elongation. 

    Cell Wall Development & Strength:
    Calcium is an essential component of cell walls within all stem and leaf tissue. It is also an essential ingredient for the formation and maintenance of strong and rigid cell walls. This helps protect plants from stress and pest damage and allows them to support their own weight under rigorous growth between cuttings.  

    Nitrogen Uptake & Metabolism:
    Calcium influences the transport proteins which influence the uptake of nitrate from the soil. Calcium also modulates enzymes involved in nitrate assimilation within the plant, ensuring proper nitrogen utilization for various physiological development and growth processes 

    Abiotic Stress Reduction:
    Calcium helps maintain cell membrane stability and integrity during periods of environmental stress, such as drought or extreme temperature fluctuations. Calcium is vital for preventing cellular damage during these events and ensures the plant’s growth and resilience during and after adverse stress conditions.  

    Disease Resistance & Defense Mechanisms:
    Calcium contributes to the activation of defense responses in alfalfa plants. Adequate calcium levels enhance the plant’s ability to resist infections and protect plants from common diseases because the surface of the plant tissues is more resilient with stronger cell walls.

    Overall, understanding and managing calcium levels is crucial to enabling the optimal growth, development and resilience of alfalfa. With 100% plant-available nutrition, SUL4R-PLUS® calcium-sulfate is an excellent option for helping alfalfa plants meet their calcium and sulfur requirements for optimal crop growth and yield.   

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    Generally, calcium supports the plant in the following areas:  

    Cell Division & Elongation:
    Calcium acts as a secondary messenger to regulate the cell cycle and promote proper cell expansion. Calcium ions help activate enzymes that facilitate cell division and elongation, contributing to the overall growth and development of the plant.

    Cell Wall Elongation & Strength:
    Calcium is important for the formation of pectin, a component of the cell wall matrix. Adequate calcium levels contribute to strong and well-developed cell walls, providing rigidity to the plant stem, branch, and leaf structure.

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    Calcium influences the activity of transport proteins for the uptake of nitrate from the soil. Calcium also modulates enzymes involved in nitrate assimilation within the plant, ensuring proper nitrogen utilization for various physiological processes.

    Abiotic Stress Management:
    Calcium helps maintain cell membrane stability and integrity during periods of environmental stress, such as drought or extreme temperatures. Calcium is vital for preventing cellular damage and ensuring the plant’s resilience to adverse conditions.

    Disease Resistance & Defense Mechanisms:
    Calcium contributes to the activation of defense responses in the plant, including the synthesis of antimicrobial compounds and reinforcement of cell walls. Adequate calcium levels enhance the plant’s ability to resist infections and protect plants from common diseases because the surface of the plant tissues are more resilient with stronger cell walls.

    Soil Structure Health & Biological Activity:
    Calcium is vital for maintaining soil structure health and promoting biological activity in the rhizosphere, the region of soil engaged by the plant’s roots. Calcium also facilitates nutrient availability and microbial activity to foster a healthy environment for plant growth.

    Calcium Availability

    Today’s high-yielding crops require more calcium than ever before. Even when soil tests indicate high calcium levels, it does not guarantee optimal plant availability for the critical nutrient. Generally, less than 5% of measured calcium shown on traditional soil test results  is plant-available.  

    The availability of calcium for plants to uptake in soils can be influenced by interactions with soil colloids, the presence of other nutrient ions and soil pH. Therefore, regular soil and plant tissue testing and consideration of the soil chemistry dynamics are essential for tailoring calcium management strategies and optimizing plant nutrition.  

    Supplemental Calcium 

    Supplemental calcium nutrient sources vary in plant availability. Therefore, in many cases, it is critical to apply calcium products that are more plant-available and can address plant uptake needs during critical growth and development periods. By choosing calcium sources that are readily absorbed by plants, growers can help maximize uptake and deliver elevated returns on their fertilizer investment. With 100% plant-available nutrition, SUL4R-PLUS® calcium-sulfate is an excellent option for helping crops meet their calcium needs (and it helps improve the soil too).   

    Overall, calcium is important for supporting plant growth and development and ensuring robust yields across most crops. Stay tuned for future blog posts in our Calcium Clarified series where we will break down the role of calcium in specific crops including alfalfa, corn, potatoes, soybeans and wheat.  

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    SUL4R-PLUS vs. AMS Fertilizer

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    SUL4R-PLUSAMS
    Nitrogen021
    Sulfur1724
    Calcium210
    Sulfate ReleaseContinuousUp front
    Pellet Strength82
    Pellet Size (SGN)265235
    Lignosulfonate6-8%0%
    Soil AcidificationNoneSignificant
    Options to Include MicronutrientsYesNo
    Low Salt IndexYesNo

    SUL4R-PLUS does not acidify the soil like ammonium sulfate does. AMS creates a need for 5.4 pounds of lime to match each pound of nitrogen, but SUL4R-PLUS doesn’t require it. This makes it an easier, cost-effective and more environmentally-friendly option for producers.

    In a 2021 soybean trial in Nebraska, SUL4R-PLUS fertilizer showed an average yield advantage of 3.65 bu/acre above AMS and 5.12 bu/acre over Grower Standard. SUL4R-PLUS cost is a lot less volatile than that of AMS and typically more affordable per acre.

    SUL4R-PLUS granules are uniform and size and density—optimized for even spreading.  The SUL4R-PLUS granules are dust free because the binder we use makes the granules strong, preventing them from fracturing during handling, while also providing some fulvic acid to feed the soil and improve plant health.

     Plus, their water solubility ensures that the crops receive the nutrients they need to stay healthy by providing plant available calcium and sulfate almost immediately and then throughout the growing season.

    Overall, SUL4R-PLUS fertilizer is a reliable and effective option for producers looking to improve crop yield and health. Its homogeneous granule, superior spread, fulvic acid, low salt and truly dust-free handling from the warehouse through application make it the preferred choice of calcium and sulfate nutrition for suppliers and producers of all kinds.

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    Improve Soil Health & Crop Yields With Low Salt Fertilizer: See the Field Trial Results

    Fertilizer is an essential component of modern agriculture, providing the essential nutrients for plants to grow and thrive. However, not all fertilizers are created equal, and some can have negative impacts on soil and crop health. One factor that is often overlooked when selecting a fertilizer is its salt index, or the potential any fertilizer has to harm a crop. Excessive salt levels can lead to soil compaction, reduced water penetration, decreased plant growth, increase susceptibility to insects and disease, and reduced yields.

    This is one of the reasons why we developed SUL4R-PLUS. Sul4rPlus is a unique, gradual-release, 100% plant-available calcium sulfate product with a low salt index of 5 as compared to AMS, a traditional dry commodity fertilizer with a salt index above 80. This is a significant benefit for growers, as it allows them to reduce the potential for crop injury while improving soil health and increasing productivity.

    To demonstrate, we ran multiple trials comparing top dress application vs. in-furrow application of SUL4R-PLUS and the results were telling.

    Using SUL4R-PLUS positively impacts crop yields and quality. Because the product is specifically designed to provide plants with essential secondary-nutrients in a form that is readily available, it can lead to improved plant health and higher yields. Additionally, the low salt index of SUL4R-PLUS eliminates the risk of salt injury, which can damage plant root systems.

    When comparing the impact of SUL4R-PLUS to traditional dry commodity fertilizers, the benefits of the former are clear. Dry commodity fertilizers may have high salt indexes, which can lead to negative impacts on soil health and plant growth. Additionally, dry commodity fertilizers are often less efficient in terms of nutrient uptake, meaning that they may require higher application rates to achieve the same results as SUL4R-PLUS.

     Overall, the impact of salt index on fertilizer selection should not be overlooked. Choosing a low salt index product like SUL4R-PLUS can lead to improved soil health, higher crop yields, and better quality crops. Making the switch to SUL4R-PLUS, growers can ensure that they are providing their crops with one of the best possible nutrition products, while also protecting the long-term health of their soil.

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    Through this test, we saw strong results to demonstrate the effectiveness of SUL4R- PLUS. On a 30-acre trial, we used our continuous release fertilizer and confirmed that less nitrogen was needed to result in the same or improved  crop yield. In this trial we reduced the nitrogen application by 10% and reached a positive revenue difference of $188.21/acre vs their grower standard nitrogen application rate.

    To estimate margin improvement per acre associated with varying the nitrogen application rate, we carefully split the 30-acres into three 10-acre plots and tested a 10% ammonia (NH3) reduction on plot 1, 20% NH3 reduction on plot 2, and finally a typical “grower standard” NH3 application on plot 3.  All other nutrient application rates (P-K-Ca-S) were the same. We saw the largest margin per acre increase on plot 1 with plot 2 also showing positive results.

    REVENUE/ACRE TOTAL REVENUE NH3 COST REVENUE/ACRE DIFFERENCE FROM NORMAL NH3 APPLICATION
    PLOT 1 – 10% NH3 REDUCTION $1,816.65 $1,682.04 $188.21
    PLOT 2 – 20% NH3 REDUCTION $1,681.88 $1,562.23 $68.40
    PLOT 3 – NORMAL NH3 APP $1,643.40 $1,493.83 $0.00

    These results aren’t standalone either. See our previous corn field trials conducted in Western Kentucky to learn more about our results and the consistent savings you could find with SUL4R-PLUS. Want to increase your yields and fight inflation? Talk to our sales team today.

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    Trials Continue to Show Improved Yields by Adding SUL4R-PLUS

    The results are in from our 2022 corn field trials conducted in Western Kentucky! These trials demonstrated that SUL4R-PLUS can improve corn yields while also increasing nitrogen uptake efficiency and utilization by the crop. Let’s dig into the details.

    The graph below illustrates the improvements we saw when compared to the farmer’s standard N-P-K application program. It demonstrated that when SUL4R-PLUS is used in your fertility program, you can not only get increased yields, but increased nitrogen utilization efficiency to further enhance grower margin per acre.

    Using this combination of SUL4R-PLUS and up to 23.3% less nitrogen translated to a higher gross margin per acre in this instance. The best gross margin we found during this trial was a 15% reduction in nitrogen applied versus the grower standard and it resulted in $74.13 higher gross margin.

    If you’re ready for higher yields and higher margins per acre for your growers, it’s time to consider SUL4R-PLUS. Connect with our sales team today.

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