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Licensing Unit I

Office of Licensing and Guidance 1 lnitiais ---e--- Environmental Protection Agency Headquarters

PO Box 3000

Johnstown Castle Estate

County Wexford

Envi ron men ta I Contaminated Land

Environmental Consultancy

Geographic Information Systems

Health H Safety

Hydrogeology

Management Systems

Waste Management

31 st October 2006

RE: IPPC Licence Review Application

To Whom It May Concern,

Please find enclosed 1 No. original and 2 No. copies of the IPPC Licence Review Application for

Premier Proteins (2000) Ltd located at Poolboy, Ballinasloe, Co. Galway. In addition, please find

enclosed 2 copies of the application on CD-ROM in searchable Pdf format.

If you have any questions please do not hesitate to contact us here at the office.

Yours sincerely,

On Behalf of White Young Green Environmental (Ireland) Ltd.,

Charlotte GreeneV

I

Apex Business Centre, Blackthorn Road, Sandyford, Dublin 18

QTel. +353 1 293 1200 U Fax. +353 1 293 1250 CJ Email: enviro [email protected] I I

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~1 White Young Green Environmental (Ireland) Limited Registered in Republic of Ireland Number 387 419 Registered Office Eastgate House, Lock Quay, Limerick

A list of directors may be inspected at the above address I I

Belfast - Cork - Derty - Dublin - Limerick - Offices the UK &nd overseas I

beyond construction

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mailto:[email protected]

Premier Proteins (2000) Ltd.

IPPC LICENCE REVIEW APPLICATION –

For:

Meat Rendering Facility at Poolboy,

Ballinasloe, Co. Galway

Prepared by:

White Young Green Environmental Ltd Apex Building Centre

Blackthorn Road Sandyford Industrial Estate

Dublin 18

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Premier Proteins (2000) Ltd White Young Green

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Table of Contents Section 1 IPPC Licence Review Application Form

Section 2 Attachment A.1 Non Technical Summary

Section 3 IPPC Licence Review Attachments

Attachment B.1 Certified Copy of Certificate of Incorporation Company’s Number in Company’s Registration Office and Particulars of Registered Office of the Company Attachment B.2 Site Location Maps Attachment B.5 Register of Planning Permissions Copy of Newspaper notice Attachment C.1

Technical Amendment for new Oxidiser P00045-03 EPA Letters giving permission to process additional materials

Attachment C.2 Proposed new Material streams to be processed at the facility Attachment D.6 Details of Environmental Considerations and BAT Attachment E.1

Information requested regarding application for IPC Licence review to accommodate Installation of Regenerative Thermal Oxidizer Drawing No: AK7001-103

Attachment G Premier Proteins (2000) Ltd. - Energy Audit 2005

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Attachment I Pg 1.0 Statutory Requirements 1 1.1 Of Section 83(5)(a)(i) to (iv) of the EPA Acts 1992 and 2003 1 1.2 In accordance with Chapter 1 of S.I. No. 94 of 1997,

or in accordance with Article 5 of the EU Habitats Directive (92/43/EEC) 8 1.3 In accordance with S.I. No. 258 of 1998 (Local Government 8

(Water Pollution) Act, 1977 (Water Quality Standards for Phosphorus) Regulations, 1998) 1.4 Emission of substances in the Schedule of the EPA (Licensing)

(Amendment) Regulations, 2004 (S.I. No. 394 of 2004) which are likely to have an adverse effect on the environment 9

1.5 State whether the activity is an establishment to which the EC (Control of Major Accident Hazards involving Dangerous Substances) Regulations, 2000 (S.I. No. 476 of 2000) apply. 9

2.0 Fit and Proper Person requirements 10 3.0 Obligations as set out in the IPPC Directive (96/61/EC) 11 Supplement I.1 Premier Proteins Financial Statement 2005 Supplement I.2 Premier Proteins Safety Statement September 2006 Supplement I.3 Hazard Identification and Risk Assessment Sheets

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SECTION 1

IPPC REVIEW LICENCE APPLICATION

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IPPC Review application

Integrated Pollution Prevention and

Control Licensing

IPPC Licence Review Application Form

This document does not purport to be and should not be considered a legal interpretation of the provisions and

requirements of the EPA Acts 1992 and 2003.

Environmental Protection Agency P.O. Box 3000, Johnstown Castle Estate, Co. Wexford

Telephone : 053-9160 600 Fax : 053-9160 699

EPA Reg. No: (Office use only)

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IPPC Licence Review Application Form

Contents

Environmental Protection Agency

Application for a Review of an Integrated Pollution Prevention and Control Licence

Environmental Protection Agency Acts, 1992 and 2003.

CONTENTS

INTRODUCTION 3

SECTION A NON-TECHNICAL SUMMARY 4

SECTION B GENERAL 5

SECTION C APPROVED ADJUSTMENTS 12

SECTION D EMISSIONS AND ENVIRONMENTAL IMPACT 13

SECTION E CONTROL AND MONITORING 19

SECTION F ACCIDENT PREVENTION & EMERGENCY RESPONSE 20

SECTION G ENERGY EFFICIENCY 23

SECTION H REMEDIATION, DECOMMISSIONING, RESTORATION & AFTERCARE 24

SECTION I STATUTORY REQUIREMENTS 25

SECTION J DECLARATION 27

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INTRODUCTION

The Protection of the Environment Act 2003 (POE Act) has transposed the Integrated Pollution Prevention and Control (IPPC) Directive (96/61/EC) into national legislation. This IPPC licence review application form enables the applicant to show compliance with the statutory requirements as set out in the IPPC Directive and the POE Act and any regulations made thereunder. Article 3 of the IPPC Directive (96/61/EC) specifies that the Agency shall ensure that installations are operated in accordance with basic obligations. This application form requires applicants to describe measures in place to ensure compliance with these basic obligations including use of best available techniques (BAT), energy efficiency and waste minimisation as set out in Article 6 of the IPPC Directive. Furthermore the applicant is required to submit information to show compliance with the requirement of the Fit and Proper Person provisions in accordance with Section 84(4) of the EPA Act as amended. Each page of the application form must be numbered, e.g. page 5 of 45, etc. The basic information should for the most part be supplied in the spaces given in application form and any supporting documentation should be supplied as attachments, as specified. While all sections in the application form may not be relevant to the activity concerned, the applicant should look carefully through all aspects of the form and provide the required information, in the greatest possible detail. All maps/drawings/plans must be no larger than A3 size and scaled appropriately such that they are clearly legible. In exceptional circumstances, where A3 is considered inadequate, a larger size may be requested by the Agency. Information supplied in this application, including supporting documentation will be put on public display and open to inspection and copying by any person at Agency headquarters and on its website. Should the applicant consider certain information to be confidential, this information should be submitted in a separate enclosure bearing the legend, “ In the event that this information is deemed not to be held as confidential, it must be returned to ........”. When submitting such information you should outline clearly the nature of information. The reasons why the information is considered confidential (with reference to the “Access to Information on the Environment” Regulations of 1993) should be stated in the Application Form, where relevant.

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SECTION A NON-TECHNICAL SUMMARY

Non-Technical Summary of IPPC Licence Application A non-technical summary of the application is to be included here. The summary should identify all environmental impacts of significance associated with the carrying on of the activity/activities, and describe mitigation measures proposed or existing to address these impacts. This description should also indicate the normal operating hours and days per week of the activity. The following information should be included in the non-technical summary: A description of: − the installation and its activities, − the raw and auxiliary materials, other substances and the energy used in or generated by the

installation, − the sources of emissions from the installation, − the conditions of the site of the installation, − the nature and quantities of foreseeable emissions from the installation into each medium as

well as identification of significant effects of the emissions on the environment, − the proposed technology and other techniques for preventing or, where this not possible,

reducing emissions from the installation, − where necessary, measures for the prevention and recovery of waste generated by the

installation, − further measures planned to comply with the general principles of the basic obligations of

the operator, i.e.,

(a) all the appropriate preventive measures are taken against pollution, in particular through the application of best available techniques (BAT);

(b) no significant pollution is caused; (c) waste production is avoided in accordance with Council Directive 75/442/EEC of 15

July 1975 on waste; where waste is produced, it is recovered or, where that is technically and economically impracticable, it is disposed of while avoiding or reducing any impact on the environment;

(d) energy is used efficiently; (e) the necessary measures are taken to prevent accidents and limit their consequences; (f) the necessary measures are taken upon definitive cessation of activities to avoid any

pollution risk and return the site of operation to a satisfactory state. − Measures planned to monitor emissions into the environment. See Attachment No A.1

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SECTION B GENERAL

B.1. Owner/Operator

* Review Applicants Name: Premier Proteins (2000) Ltd

Address: Poolboy Balinasloe Co. Galway Telephone No: 090 9642305 Fax No: 090 9642738 E-mail: [email protected] / [email protected] This should be the name of the review applicant on the date the Review Application is lodged with the Agency. This should be the name of the legal entity (which can be a limited company or a sole trader). A trading/business name is not acceptable. Address for correspondence : As Above (if different from above) Address of Body Corporate : As Above (if applicable) Contact e-mail address: [email protected] / [email protected]

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Confirm whether the information submitted in relation to the legal entity of the company has changed from that detailed in the original application or in the most recent review application.

Has information in relation to legal entity of the company changed?

Yes No

If yes, supply the following information: (a) Certified Copy of Certificate of Incorporation (b) Company’s Number in Company’s Registration Office and (c) Particulars of Registered Office of the Company. Supporting information is provided in Attachment No B.1. Name and address of the proprietor(s) of the Land on which the Activity is situated (if different from review applicant named above) Proprietor’s Name: As Above Address: As Above Name and address of the owner(s) of the building and ancillary plant in which the activity is situated (if different from review applicant named above). Name: As Above Address: As Above

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B.2. Location of Activity Company Name: Premier Proteins Full Address: Poolboy Ballinasloe Co. Galway Telephone No: 090 9642305 Fax No: 090 9642738 Contact Name(s): Noel Ryan Position(s): General Manager Contact e-mail: [email protected] Irish National Grid Reference (12 digit-6E, 6N) * 186300E 229870N * The Grid Reference should be supplied using GPS in Irish National Grid. Location maps (no larger than A3) with site boundary outlined in colour, a specified drawing number and grid references are provided in Attachment No B.2.

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B.3. Class of Activity

1. Identify the relevant activity / activities in the First Schedule of the EPA Acts, 1992 and 2003 to which the activity relates:

Schedule No Class No. Description Note 1

1 7.7.2 The rendering of animal by-products

1 11.1

The recovery or disposal of waste in a facility, within the meaning of the Act of 1996, which facility is connected or associated with another activity specified in this Schedule in respect of which a licence or revised licence under Part IV is in force or in respect of which a licence under the said Part is or will be required.

Note 1: In order to give a precise identification select only those words from the description of the class or classes that best describes the nature of the activity for which the licence is being applied for.

B.4. Employees

Give the number of employees and other persons working or engaged in connection with the activity on the date of submission of this application for a review and the number required during normal levels of operation.

Number of Employees (at the present): 33 Number of Employees (normally) : 33

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B.5. Relevant Planning Authority Give the name of the planning authority in whose functional area the activity is carried out. Name: Ballinasloe Town Council Address: Bridge Street, Ballinasloe Co. Galway Telephone No: (090) 96 42263 Planning Permission for this project:-

Obtained Applied for � Not applied for � Local Authority Planning File Reference No: PD2657 Attachment No B.5 contains a schedule of all planning permissions in force at the time of this submission. Evidence should also be included in the attachment of a notification having been given to the relevant Planning Authority in accordance with the requirements of Section 87(1)(a) of the EPA Acts 1992 and 2003, as well as a copy of notice published in a newspaper (circulating in the district) of intention to apply for a review of licence.

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B.6. Relevant Sanitary Authority In the case of a discharge of any trade effluent or other matter to a piped sewer of a sanitary authority, give the name of the sanitary authority in which the sewer is vested or by which it is controlled. Name:

Address: Telephone No: In the case of a discharge of any trade effluent or other matter to a sewer not owned by or vested in a sanitary authority, the applicant must supply as Attachment No B.6 the names, addresses and telephone contact information for the owners or those responsible for:

a. The sewer or drain into which the trade effluent is discharged; b. The waste water treatment facility into which the sewer discharges; and c. The quality of the resultant treated effluent prior to discharge to waters.

ATTACHMENT NO B.6 Trade Effluent is collected and discharged to the Company’s own Wastewater Treatment Plant (WWTP) located at the site. The WWTP treats the effluent and discharges the treated effluent to the river Suck under licence. The quantity and quality of the treated effluent meets and exceeds the requirements of the licence.

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B.7. Relevant Health Service Executive Region The applicant should indicate the Health Service Executive Region where the activity is located. Name: HSE, West ( Western Health Board) Address: Merlin Park regional Hospital Galway Ireland Telephone No: 091 751131

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SECTION C APPROVED ADJUSTMENTS In the case where the Office of Environmental Enforcement (OEE) of the Agency has agreed any variations or adjustments to the conditions of the existing licence, the applicant must supply a schedule detailing these agreed variations and adjustments to the existing licence conditions. An updated, scaled drawing of the site layout (no larger than A3) providing visual information on such adjustments or variations where appropriate should be included. Attachment No C.1 shall include the schedule of variations and/or adjustments together with the updated drawing. Attachment No C.1 contains: EPA letter giving permission to process water arising from ABPs EPA letter giving permission to process sludge from fish industries in Killybegs EPA letter giving permission to process blood Attachment No C.2 Attachment C2 provides details on proposed new material streams to be processed at the facility.

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SECTION D EMISSIONS AND ENVIRONMENTAL IMPACT D.1. Emissions to Atmosphere Specify whether there has been a change in the quantity or nature of emission to atmosphere from that detailed in the original application or earlier review application(s) and/or specified in your existing licence:

Yes No If yes, provide further information as detailed below. D.1.A Point-source emissions to atmosphere Outline significant adjustments to the operations on site, if any, which has led to a change in the quantity or nature of emissions to atmosphere. A summary list of any revised emission points, together with maps/drawings (no larger than A3) and supporting documentation should be included as Attachment No D.1.A The applicant should address in particular any emission point where those substances listed in the Schedule to the Environmental Protection Agency (Licensing) (Amendment) Regulations, 2004 (S.I. No. 394 of 2004) are emitted. For emissions outside the BAT guidance level, a full evaluation of the existing abatement/treatment system must be provided. A planned programme of improvement towards meeting upgraded standards in advance of 30th September 2007 is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required bringing the emissions within the emission levels as set out in the BAT guidance note(s). D.1.B Fugitive and Potential Emissions State whether the Council Directive 1999/13/EC on the limitation of emissions of volatile organic compounds due to the use of organic solvents in certain activities and installations apply to the operation:

Council Directive applies Yes No If yes, Attachment No D.1.B should include details of relevant category of activity in the Schedule and how the requirements in relation to fugitive emissions will be met. D.1. C Assessment of atmospheric emissions If relevant, give summary details and an assessment of the impacts of any emissions (as detailed above) on the environment, including environmental media other than those into which the emissions are being made. The assessment should include details of relevant ambient air quality standards. Details of the assessment and any other supporting information should form Attachment No D.1.C.

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D.2. Emissions to Surface Waters Specify whether there has been a change in the quantity or nature of emissions to surface waters from that detailed in the original application or earlier review application(s) and/or specified in your existing licence:

Yes No If yes, provide further information as detailed below. NOT APPLICABLE D.2.A Emissions to Surface Water Outline significant adjustments to the operations on site, if any, which has led to a change in the quantity or nature of emissions to surface waters. A summary list of any revised emission points, together with maps/drawings (no larger than A3) and supporting documentation should be included as Attachment No D.2.A. The applicant should address in particular any emission point where those substances listed in the Schedule to the Environmental Protection Agency (Licensing) (Amendment) Regulations, 2004 (S.I. No. 394 of 2004) are emitted. State whether Water Quality (Dangerous Substances) Regulations, 2001 (S.I. No. 12 of 2001) apply to the operations on site:

Water Quality (Dangerous Substances) Regulations apply

Yes No

If yes, include in Attachment No D.2.A whether the operations on site comply with the prescribed standards set out in the S.I. No. 12 of 2001. For emissions outside the BAT guidance level, a full evaluation of the existing abatement/treatment system must be provided. A planned programme of improvement towards meeting upgraded standards in advance of 30th September 2007 is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required to bring the emissions within the emission levels as set out in the BAT guidance note(s). D.2.B Assessment of Impact on Receiving Surface Water If relevant, give summary details and an assessment of the impacts of any emissions (as detailed above) on the environment, including environmental media other than those into which the emissions are to be made. The assessment should include details of relevant environmental quality standards or other legislative standards. Details of the assessment and any other supporting information should form Attachment No D.2.B.

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D.3 Emissions to Sewer Specify whether there has been a change in the quantity or nature of emissions to sewer from that detailed in the original application or earlier review application(s) and/or specified in your existing licence:

Yes No If yes, provide further information as detailed below. NOT APPLICABLE D.3.A Emissions to Sewer Outline significant adjustments to the operations on site, if any, which has led to a change in the quantity or nature of emissions to sewer. A summary list of any revised emission points, together with maps/drawings (no larger than A3) and supporting documentation should be included as Attachment No D.3.A. For emissions outside the BAT guidance level, a full evaluation of the existing abatement/treatment system must be provided. A planned programme of improvement towards meeting upgraded standards in advance of 30th September 2007 is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required to bring the emissions within the emission levels as set out in the BAT guidance note(s). D.3.B Assessment of Impact of Sewage Discharge. If relevant, give summary details and an assessment of the impacts of any emissions (as detailed above) on the environment, including environmental media other than those into which the emissions are to be made. The assessment should include details of relevant environmental quality standards or other legislative standards. Details of the assessment and any other supporting information should form Attachment No D.3.B. D.4 Emissions to Ground Specify whether there has been a change in the quantity or nature of emissions to ground from that detailed in the original application or earlier review application(s) and/or specified in your existing licence:

Yes No If yes, provide further information as detailed below. NOT APPLICABLE D.4.A Emissions to Ground Outline significant adjustments to the operations on site, if any, which has led to a change in the quantity or nature of emissions to ground.

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For emissions outside the BAT guidance level, a full evaluation of the existing abatement/treatment system must be provided. A planned programme of improvement towards meeting upgraded standards in advance of 30th September 2007 is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required to bring the emissions within the emission levels as set out in the BAT guidance note(s).

Any supporting information should form Attachment No D.4.A. D.4.B Assessment of impact of ground/groundwater emissions If relevant, give summary details and an assessment of the impacts of any emissions (as detailed above) on the ground (aquifers, soils, sub-soils and rock environment), including any impact on environmental media other than those into which the emissions are to be made. This includes landspreading, land injection etc. Details of the assessment and any other supporting information should be included in Attachment No D.4.B. D.5. Noise Emissions Specify whether there has been a change in the quantity or nature of noise emissions from that detailed in the original application or earlier review application(s) and/or specified in your existing licence:

Yes No If yes, provide further information as detailed below. D.5.A Noise Emissions Outline significant adjustments to the operations on site, if any, which has led to a change in source, location, nature, level and the time period or periods during which the noise emissions are made or are to be made. For emissions which lead to an impact in excess of the limits set out in the EPA Guidance Note for Noise for Scheduled Activities, a full evaluation of the existing abatement/treatment systems must be provided. A planned programme of improvement towards meeting upgraded standards in advance of 30th September 2007 is required. This should highlight specific goals and a time scale, together with options for modification, upgrading or replacement as required to bring the emissions within the required limits as set out in the Guidance Note for Noise for Scheduled Activities (1995).1 Any supporting information should form Attachment No D.5.A. D.5.B Noise Impact. If relevant, give summary details and an assessment of the impacts of any emissions (as detailed above) on the environment, including environmental media other than those into which the emissions are to be made.1

1 Where noise evaluation / assessment reports have been prepared for the purposes of compliance with an existing licence, such reports may be submitted in fulfilment of the requirements of this part of the application.

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Details of the assessment and any other supporting information should be included in Attachment No D.5.B.

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D.6 Environmental Consideration and BAT Describe any environmental considerations which have been made with respect to the use of cleaner technologies, waste minimisation and raw material substitution since the grant of the existing licence. Describe the measures proposed or in place to ensure that the Best Available Technique (BAT) will be used to prevent or eliminate or, where that is not practicable, generally reduce an emission from the activity. Supporting information is included in Attachment No D.6.

The company have recently been granted permission from the EPA to install a Regenerative

thermal oxidiser in to the facility to filter and purify the odorous gases that have been generated

throughout the process. See Attachment E.1 for structural details. In addition a copy of the Premier

Proteins submission document describing the new system is included in Attachment No. E.1

The use of Fuel Oil by Premier Proteins is now totally discontinued, with the fuel oil being

replaced by the more sustainable Tallow Oil. This practice is beneficial to the environment in

relation to Sulphur Dioxide (SO2) emissions, as the sulphur content of Tallow is generally

insignificant whereas the Sulphur content of Medium or Light fuel oil is now controlled by

EEC Directive at 1% or less. Approximately 3.85 million litres of Tallow Oil is used as a fuel

in the Steam boilers for the production of process steam and now accounts for 100% of usage

(See Premier Proteins Energy Audit 2005). There is also reduced pollution associated with

transport as the tallow is burned on the same site as it is produced. A tallow separator has also

been installed at the facility.

The Company proposes to accept used cooking oils (UCO) for purification and blending into

tallow produced on site. The oils either will be transported in road tankers or closed containers.

All transfers will take place within the factory building or will use back venting in the case of

road tankers. The oils pass through centrifugal decanters and a separator to remove impurities.

They will then be blended with normal production tallow before going to storage. No additional

storage or process modifications will be required to accept UCOs for processing.

Supporting information is provided in Attachment No D.6.

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SECTION E CONTROL AND MONITORING Describe any adjustment (not detailed in Section C) made to technology and other techniques for preventing or, where this is not practicable, reducing emissions from the installation. E.1: Treatment, Abatement and Control Systems Details of revised treatment/abatement systems (air and effluent emissions) should be included, together with schematics as appropriate. Attachment No E.1 contains the relevant supporting information. E.2: Emissions Monitoring and Sampling Points Identify any revised monitoring and sampling points and outline any revised or updated proposals for the monitoring of emissions. Attachment No E.2 should contain an updated drawing (no larger than A3) detailing all proposed monitoring points including National Grid References (12 digit 6E, 6N). Not Applicable. There is no revision to monitoring frequency or sampling locations

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SECTION F ACCIDENT PREVENTION & EMERGENCY RESPONSE Describe the existing or proposed accident prevention measures and procedures. Provide details of emergency procedures to minimise the impact on the environment of an accidental emission or spillage. Also outline what provisions have been made for response to emergency situations outside of normal working hours, i.e., during night-time, weekends and holiday periods. Describe the arrangements for abnormal operating conditions including start-up, leaks, malfunctions or short-term stoppages. Supporting information should form Attachment No F.

Environmental Emergency Response

The purpose of this document is to outline the steps to be taken should any emergency

arise at the plant. These emergencies are:

* Fire

* Chemical spillage

* Tallow spillage

* Fuel Oil spillage

* Spill or Release of untreated Effluent form the site

* Accidental Emission of other material

* Any emission which does not comply with the requirements of the IPPC license

* Any accident with possible impacts on the Environment

Procedure

In case of fire

raise the alarm ,

initiate evacuation,

Inform the Site manager

Check that all surface waters are diverted to the Waste Water Treatment Plant via Non

Condensate line(under normal circumstances the surface water will be already diverted).

Inform the Environmental Protection Agency, the fisheries board and the local authority

of the incident as soon as possible

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In the case of minor spillage of any kind (fuel oil, tallow, lubricant oil or chemical)

Shut down the source as soon and as effectively as possible

Inform the site manager

Use absorbent Booms, mats and powder to prevent spillage from entering drains,

Clean up spillage using specialist absorbent materials

Have oils and chemical spills disposed of at appropriate facilities

Recycle tallow spillage

Inform the EPA, fisheries board and local authority as soon as practiceable

In the case of a significant spill or release of untreated effluent from the site

Take immediate action to stop the spill or release as soon as it is noticed.

Inform the site manager Take immediate action to prevent the untreated effluent from entering surface waters

Recover the untreated effluent and return it to the waste water treatment plant for

treatment

Notify the Environmental Protection agency as soon as possible

If the untreated effluent enters the waters, notify the local authorities and Shannon

Regional fisheries Board by telephone or facsimile as soon as practicable after the

occurrence of the accidental emission to waters.

In the case of an accidental emission of other materials

Take immediate action to stop the emission as soon as it is noticed

Inform the site manager Take immediate action to prevent further emission of the material, and prevent the

material from entering waters

Recover the materials for reprocessing, treatment or disposal as appropriate

Notify the EPA as soon as possible

If the materials enters the waters, notify the local authorities and Shannon Regional

fisheries Board by telephone or facsimile as soon as practicable after the occurrence of

the accidental emission to waters

In the case of major spillage (fuel oil, tallow, lubricant oil or chemical)

Divert all waters to the Waste Water Treatment Plant via Non Condensate line and switch

off forward feed pumps ( P0201 and P0202)

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Initiate clean up and examine contents of the buffer tank for the potential impact of the

spill on the Waste Water Treatment Plant

Inform the Environmental Protection Agency of the incident as soon as possible

In the Case of the odour abatement failure (and cannot be repaired promptly)

Divert all incoming raw material, process material already received and then

Shut down the cooker

Inform the Environmental Protection Agency of the incident as soon as possible

For all of the above the Environmental Officer must be informed of the incident and must give

instruction as to the clean up operations. In the event of any serious environmental incident on

the site notify the Environmental Protection Agency, the Local Authority and Shannon

Regional Fisheries Board of the incident as soon as practicable

Authority Phone Number Fax. Number

E.P.A. 053 60600 053 60699

Shannon Regional Fisheries Board 061 455171 061 326533

Galway County Council 091 563151 091 509033

Ballinasloe U.D.C. 0905 42274 0905 42928

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SECTION G RESOURCE USE & ENERGY EFFICIENCY Provide a description of resources used, energy used or energy generated by the activity. Provide summary information on the details and results of any previously conducted audit of the energy efficiency of the site. (See note 1 below in relation any proposal to carry out an audit.) Outline the measures taken to ensure that resources and energy are used efficiently in the operation. The information on resource use and energy efficiency is attached in Attachment No G. Contents- 2005 Energy Audit Note 1: Any proposed audit which is to be conducted after the submission of this application shall be carried

out in accordance with the guidance published by the Agency “Guidance Note on Energy Efficiency Auditing”. The audit shall identify all opportunities for energy use reduction and efficiency.

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SECTION H REMEDIATION, DECOMMISSIONING, RESTORATION & AFTERCARE

Describe the existing or proposed measures to minimise the impact on the environment after the activity or any part of the activity ceases operation, including provision for post-closure care of any potentially polluting residuals. Supporting information should be included as Attachment No. H.

It is not envisaged that Premier Proteins Ltd. will cease activity at the Ballinasloe site in the

near or even the long term. Should circumstances arise whereby it becomes necessary to close

the facility the, Premier Proteins will ensure any negative environmental impact is avoided and

minimised. The corporate commitment to provide such resources is consistent with the

company principles for safety and environmental protection

Operations at the facility will be ongoing with an open-ended lifespan and to date a closure

plan has not been developed. In the event of a decision to close the facility for reasons of

financial difficulties or other reasons a closure plan will be developed. This plan will allow for

removal of all materials and wastes from the site and cleaning of all surfaces where

materials/wastes have been handled or stored. All plant and equipment will be decommissioned

and sold off where possible. Any other plant/equipment will be dismantled and recycled. A

comprehensive monitoring programme will be carried out on environmental media including

air and water to ensure that all emissions from the facility have ceased.

It is assumed that upon closure of the site, the premises will be suitable for industrial use and

will have a re-sale value, which will cover the costs of the closure plan including the removal

of materials/waste, site cleaning and monitoring.

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SECTION I STATUTORY REQUIREMENTS

1. The applicant should provide the following information:

(i) Indicate how the requirements of Section 83(5)(a)(i) to (iv) of the EPA Acts 1992 and 2003 shall be met, having regard, where appropriate, to any relevant specification issued by the Agency under section 5 (3) of the Act and the reasons for the selection of the arrangements proposed.

(ii) Indicate whether or not the activity is carried out on, or may be carried out on, or is

located such that it is liable to have an adverse effect on:-

(a) a site placed on a list in accordance with Chapter 1 of S.I. No. 94 of 1997, or (b) a site where consultation has been initiated in accordance with Article 5 of the

EU Habitats Directive (92/43/EEC).

(iii) Indicate whether or not the activity is liable to have an adverse effect on water quality in light of S.I. No. 258 of 1998 (Local Government (Water Pollution) Act, 1977 (Water Quality Standards for Phosphorus) Regulations, 1998).

(iv) Indicate whether any of the substances specified in the Schedule of the EPA

(Licensing)(Amendment) Regulations, 2004 (S.I. No. 394 of 2004) are discharged by the activity to the relevant medium and whether the emission of these substances are likely to have an adverse effect on the environment.

(v) State whether the activity is an establishment to which the EC (Control of Major

Accident Hazards involving Dangerous Substances) Regulations, 2000 (S.I. No. 476 of 2000) apply.

2. Fit and Proper Person:

The EPA Acts, 1992 and 2003 (Section 83(5)(xi)) specifies that the Agency shall not grant a licence unless it is satisfied that the applicant or licensee or transferee as the case may be is a fit and proper person. Section 84(4) of the Act specifies the information required to enable a determination to be made by the Agency. In order for the Agency to make a determination the following is to be provided:

• Indicate whether the applicant or other relevant person has been convicted under the

PoE Act, the Waste Management Act 1996, the Local Government (Water Pollution) Acts 1977 and 1990 or the Air Pollution Act 1987.

• Provide details of the applicant’s technical knowledge and/or qualifications, along

with that of other relevant employees.

• Provide information to show that the person is likely to be in a position to meet any financial commitments or liabilities that may have been or will be entered into or incurred in carrying on the activity to which the application relates or in consequence of ceasing to carry out that activity.

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3. Obligations as set out in the IPPC Directive (96/61/EC)

The Agency shall ensure that installations are operated in accordance with basic obligations as set out in Article 3 of the IPPC Directive (96/61/EC). Article 6 of the IPPC Directive (96/61/EC) specifies that a description of the measures in place to ensure compliance with the general principles of the basic obligations of the operator shall be part of the application. Describe the measures proposed or in place to ensure that:

(a) The best available techniques are or will be used to prevent or eliminate or, where that is not practicable, generally reduce an emission from the activity;

(b) no significant pollution is caused;

(c) waste production is avoided in accordance with Council Directive 75/442/EEC of 15 July 1975 on waste; where waste is produced, it is recovered or, where that is technically and economically impossible, it is disposed of while avoiding or reducing any impact on the environment;

(d) energy is used efficiently;

(e) the necessary measures are taken to prevent accidents and limit their consequences;

(f) the necessary measures are taken upon definitive cessation of activities to avoid any pollution risk and return the site of operation to a satisfactory state.

Supporting information is included as Attachment No I with cross-references to where the relevant information can be found in other parts of this review application.

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SECTION J DECLARATION

Declaration I hereby make application for a revised licence, pursuant to the provisions of the Environmental Protection Agency Acts, 1992 and 2003 and Regulations made thereunder. I certify that the information given in this application is truthful, accurate and complete. I give consent to the EPA to copy this application for its own use and to make it available for inspection and copying by the public, both in the form of paper files available for inspection at EPA headquarters and via the EPA's website. This consent relates to this application itself and to any further information, submission, objection, or submission to an objection whether provided by me as Applicant, any person acting on the Applicant’s behalf, or any other person. Signed by : Date : (on behalf of the organisation)

Print signature name: Position in organisation :

Company stamp or seal:

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SECTION 2

ATTACHMENT A – NON-TECHNICAL SUMMARY

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Attachment A.1

Non Technical Summary

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Non-Technical Summary of IPPC Licence Application Premier (2000) Proteins Ltd (IPC licence P0045-03), located just outside Ballinasloe, Co

Galway, is engaged in the rendering of animal by-products to produce tallow oil, and meat and

bone meal. These products are produced via a series of cooking, milling and separation steps. The

plant occupies approximately one third of the 4.1ha site which is located in a rural area adjacent to

the River Suck. The facility operates 24 hours per day and 7 days per week however most of the

process plant is enclosed in industrial buildings The factory is a modern industrial facility that

employs modern processing equipment to maximise yields and to minimise waste. Where

emissions are unavoidable the Company employs the best available technology (BAT), to

minimise the impact of such emissions on the environment. The plant has its own utility

generation and emission treatment.

The company was originally granted an IPC licence (Reg. No. 45) on the 3 April 1996. A

revised IPC licence was issued to the company on the 10 June 1999 bearing Register No. 372.

The review was necessary at that time in order to facilitate updating of the odour clause, new

air emission point (new biofilter), replacement of existing boilers and upgrade of the process

building. Material arriving at the plant for processing is crushed and conveyed to a continuous

cooker heated with steam. The cooked material is separated into tallow oil and meat & bone

meal (MBM). The company operates a continuous cooking process with a capacity of 480

tonnes per day. At present the Company is operating under IPC licence no. P0045-03 (592).

This IPPC licence review application is submitted to upgrade the facility from an IPC licence to an

IPPC licence at the request of the EPA. In addition the Company proposes to accept additional

materials namely, Used cooking oils, waste sludges, wastewater, catering waste and grease trap

liquid waste, details of which are outlined below.

Premier Proteins (2000) Ltd proposes to accept used cooking oils (UCO) for purification and

blending into tallow produced on site. The oils will be transported in either road tankers or

closed 200L to 1000L containers. All transfers will take place within the factory building or will

use back venting in the case of road tankers. The oils pass through centrifugal decanters and a

separator to remove impurities. They will then be blended with normal production tallow before

going to storage. No additional storage or process modifications will be required to accept

UCOs for processing.

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In addition the Company proposes to accept catering food waste and waste sludge which will

be transported to the site in closed/covered containers. On arrival at the site the sludge and

catering waste will be tipped and processed in accordance with EC Regulation 1774/2002. The

dried material will be incorporated into meat and bone meal produced on site and will be

disposed of by incineration/co-incineration at approved facilities. Tonnages are presently

unknown.

The grease trap liquid will be transported to site by road tanker. On arrival the tanker will be

weighed and directed to an offloading point. The liquid will be offloaded into a sump and

pumped to a pre-screen. Once pre-screened, the liquid will be passed through a dissolved air

flotation (DAF) unit to remove fats and oils. Any solid material recover at the screen will be

returned to the cooker for processing as normal. The pre-screen and DAF unit is situated within

an enclosed building which is extracted to the existing biofilter 2. The liquids will then be

treated in the waste water treatment plant (WWTP) in activated sludge tanks along with normal

effluent streams.

All sludge generated at the WWTP is returned to the intake area for processing, sterilisation

and disposal by incineration at approved facilities. Acceptance of these liquids will not

necessitate any process modification as currently the EPA has given permission to process

water from animal collection facilities. Premier Proteins (2000) Ltd cannot give any indication

at this time of quantities as the market is only just starting to develop.

The plant currently consists of:

� A New Raw Material Intake Building

� Meal Store

� Pet food Raw Materials Store

� Utility Buildings

� Engineering Workshop

� Amenity/Stores Building

� Offices/Administration Building

� Waste Water Treatment Plant

� Regenerative Thermal Oxidiser

� Storage Tanks for both Tallow and Fuel Oil

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The following energy sources are used to operate the facility. Tallow oil is used exclusively on

the two 15,000kg/hr steam boilers. Both boilers are currently serviced at least twice per annum

to ensure efficient combustion. Burners are set up to ensure optimum combustion efficiencies

at all times.

The use of Fuel Oil is now totally discontinued, with the fuel oil being replaced by the more

sustainable Tallow Oil. This practice is beneficial to the environment in relation to Sulphur

Dioxide (SO2) emissions, as the sulphur content of Tallow is generally insignificant whereas

the Sulphur content of Medium or Light fuel oil is now controlled by EEC Directive at 1% or

less. Approximately 3.85 million litres of Tallow Oil is used as a fuel in the Steam boilers for

the production of process steam now accounts for 100% of usage.

There will be no additional sources of emissions arising from the additional processes outlined in

this application. An energy audit was conducted in late 2005. The findings of which are discussed

in Attachment No G

There will be no extra effluent emissions to waters as all vapours from the cooking and

sterilisation is treated by thermal oxidation. Effluent volumes emitted will not exceed the ELV

of 290m3/day as the thermal oxidiser has removed approximately 60% of effluent volume.

Monitoring of emissions into the surrounding environment is as per the conditions of the current

IPC licence P0045-03(592). It is not likely that there will any significant effects of emissions

on the environment as the loading on the plant will be kept within design parameter of 1400kg

BOD/day (2323kgCOD/day).

The company have recently been granted permission from the EPA to install a Regenerative

thermal oxidiser in to the facility to filter and purify the odorous gases that have been generated

throughout the process. See drawing No AK7001 an Attachment A for structural details.

As mentioned above the use of fuel oil is now totally discontinued and replaced by the more

sustainable Tallow Oil. The environmental benefit of using Tallow oil as a replacement for fuel

oil is the discontinued use of a natural resource and a reduction in the emission of Sulphur

Dioxide to the atmosphere by approximately 72 tonnes per annum, based on present tallow

consumption.

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Premier Proteins operates the facility to stringent control measures as stipulated in the existing

IPPC Licence. In addition, the company have Safety management plan and Hazard risk

assessment in operation as well as numerous safety operations manuals.

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SECTION 3

ATTACHMENTS B-I

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Attachment B.1

Certified Copy of Certificate of Incorporation Company’s Number in Company’s Registration Office and

Particulars of Registered Office of the Company.

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Premier Proteins Company Details

Company Registered No: 316676

Company Registered address: 151 Thomas St.,

Dublin 8

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Attachment B.2

Location maps

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Attachment No B.5 Schedule of all planning permissions in force at the time of this submission.

Notification having been given to Ballinasloe Town Council in accordance with the requirements of

Section 87(1)(a) of the EPA Acts 1992 and 2003,

A copy of notice published in a newspaper (circulating in the district) of intention to apply for a review of

licence.

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White Young Green Environmental (Ireland) Ltd., Apex Business Centre, Blackthorn Road, Sandyford Industrial Estate, Dublin 18

Tel: 012931200, Fax: 01 2931250

Ballinasloe Town Council,

River Street.

Ballinasloe.

Co. Galway

17th October 2006

RE: Integrated Pollution Prevention and Control Licence Review Application

To Whom it May Concern,

In accordance with Section 87(1)(a) of the EPA Acts 1992 and 2003, White Young Green (on Behalf of

Premier Proteins (2000) Ltd.), wish to advise that an application will be submitted to the Environmental

Protection Agency (EPA) for an Integrated Pollution Prevention and Control Licence later this month.

Attached is a copy of the notice that will be published in the Irish Independent which contains the

relevant information that is outlined in Article 6 of the Environmental Protection Agency (Licencing)

Regulations, 1994 (S.I. No. 85 of 1994).

We trust that this is in order. However, if you require further information please contact the undersigned.

Yours Faithfully,

Charlotte Greene

Environmental Scientist.

Copy sent to Galway County Council.

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Attachment C.1

Schedule of variations and adjustments to the conditions of the existing licence

Variations and adjustments to the Conditions of the existing Licence

1. Technical Amendment for new Oxidiser P00045-03

2. Permission to process Water arising from ABPs

3. Permission to process sludge from fish industries in Killybegs

4. Permission to process Blood

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Headquarters P.O. Box 3000

Johnstown Castle Estate County Wexford

Ireland

TECHNICAL AMENDMENT (i)

TO INTEGRATED POLLUTION PREVENTION &

CONTROL LICENCE (in pursuance of Section 96(1) of the Environmental Protection Agency

Acts 1992 and 2003)

Licence Register Number: P0045-03

Licensee Premier Proteins (2000) Limited.

Location of Installation: Poolboy,

Ballinasloe,

Co. Galway.

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Reasons for the Decision

The Environmental Protection Agency is satisfied, on the basis of the information available, that subject to compliance with the conditions of licence Reg. No. P0045-03 granted on the 24th March 2001, as well as any amendments noted herein, any emissions from the activity will comply with and not contravene any of the requirements of Section 83(5) of the Environmental Protection Agency Acts, 1992 and 2003.

Clerical or Technical Amendment In pursuance of the powers conferred on it by Section 96(1)(b) of the Environmental Protection Agency Acts, 1992 and 2003, the Agency amends Licence Reg. No. P0045-03, granted to Premier Proteins (2000) Limited, Poolboy, Ballinasloe, Co. Galway. Henceforth, IPPC Licence Register No. P0045-03 (granted 24th March 2001) shall be read in conjunction the amendments set out below. This technical amendment is limited to the following Glossary of Terms/Schedules & Condition(s) of Licence Reg. No. P0045-03:

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Amendments

Glossary of Terms

BAT Best Available Techniques.

To be inserted into the Glossary of the existing licence.

Incident The following shall constitute an incident for the purposes of this licence:

(i) an emergency; (ii) any emission which does not comply with the requirements of this

licence; (iii) any trigger level specified in this licence which is attained or exceeded;

and, (iv) any indication that environmental pollution has, or may have, taken

place.


RTO

Regenerative Thermal Oxidiser.


New Conditions or Amended Conditions

5.12 The fuel used for the on-site thermal oxidiser and boiler(s) shall be either low sulphur fuel oil (<1%), natural gas and/or tallow oil. A record of the fuel being used shall be maintained.

To replace Condition 5.12 of the existing licence.

5.17 The temperature as measured within the combustion zone of the regenerative thermal oxidiser

shall be maintained at not less than 8500 C while thermally treating odorous gases. This temperature shall be continuously monitored and recorded and the results shall be available for inspection by authorised persons of the Agency at all reasonable times.

To replace Condition 5.17 of the existing licence. 5.18 The regenerative thermal oxidiser shall be fitted with audible and visual alarms which shall be

triggered when the temperature within the combustion chamber falls below that specified under Condition 5.17.

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5.19 All non-condensable gases and odorous air shall be directed to the regenerative thermal oxidiser.

Non-condensable gases and odorous air shall only be introduced to the thermal oxidiser when the appropriate operating conditions (which as a minimum shall meet those set out in Schedule 1(i) Emissions to Atmosphere) have been achieved. In particular:

(i) The burners in the combustion chamber are on and operating

satisfactorily; (ii) The temperature required under Condition 5.17 has been reached and

maintained in the combustion chamber; and (iii) The temperature probe in the combustion chamber is operating

satisfactorily and recording continuously. 5.20 All off-gases arising from the on-site cookers shall be directed to the thermal oxidiser for

treatment. Off-gases shall only be directed to alternative treatment options temporarily with the prior agreement of the Agency.

5.21 There shall be no solid or liquid waste material combusted in the thermal oxidiser(s).

All liquid wastes arising from the air washers, humidifiers, biofilters and boiler blowdown shall be directed to the wastewater collection system and treatment plant.

5.22 Test programme for thermal oxidiser:

5.22.1 The licensee shall prepare, to the satisfaction of the Agency, a test programme for the thermal oxidiser. This programme shall be submitted to the Agency for approval, not later than four months from the date of grant of this amendment.

5.23 The test programme shall include as a minimum, the following:

5.23.1 Establish all criteria for operation, control and management of the abatement equipment to ensure compliance with the emission limit values specified in this licence.

5.23.2 Assess the performance of any monitors on the abatement systems and establish a maintenance and calibration programme for each monitor.

A report on the test programme, including test results, shall be submitted to the Agency within one month of completion of the programme.

To be inserted after Condition 5.17 of the existing licence.

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Schedule 1 (i): Emissions to Atmosphere Emission Point Reference No.: A3 (Regenerative Thermal Oxidiser)

Grid Reference 186282, 229836

Volume to be emitted: Maximum in any one day: 732,000 m3

Maximum rate per hour: 30,500 m3

Residence Time: 0.8 seconds minimum Chamber operating temperature: 850oC minimum Minimum discharge height: 15 m above ground Maximum TO capacity: 33,000 kg/hr

Parameter Emission Limit Value 30 minute average (mg/m3)

Gaseous and vapour organic substances (as TOC)

10

Total particulate matter 30

Nitrogen monoxide and nitrogen dioxide (as NOx)

250

Sulphur Dioxide (as SOx) 400

Ammonia 5

Append to Schedule 1(i) of the existing licence. .

⎯⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯⎯

Schedule 1 (iii): Monitoring of Emissions to Atmosphere Emission Point Reference No.: A3

Description of Treatment: Regenerative Thermal Oxidiser (RTO)

Control Parameter Equipment Backup Equipment Combustion temperature Continuous Temperature probe

Oxygen content of the flue gases Continuous Oxygen analyser

Pressure of flue gas Continuous Pressure transmitter

Temperature of flue gas Continuous Temperature probe

Combustion air flow Continuous Air flow meter

Flame flow Continuous Flow meter

Append to Schedule 1(iii) of the existing licence. .

⎯⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯⎯

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Schedule 1 (iv) Monitoring of Emissions to Air Emission Point Reference No.: A3

Description of Treatment: Regenerative Thermal Oxidiser (RTO)

Parameter Monitoring Frequency Analysis Method/Technique

Sulphur dioxide (SOx) Biannually (quarterly for the first year of operation)

Flue gas analyser

Nitrogen monoxide and nitrogen dioxide (as NOx)

Biannually (quarterly for the first year of operation)

Flue gas analyser

Gaseous and vapour organic substances (as TOC)

Biannually (quarterly for the first year of operation)

Flue gas analyser

Total particulate matter Biannually (quarterly for the first year of operation)

Isokinetic/Gravimetric

Ammonia Biannually (quarterly for the first year of operation)

Flue gas analyser

Insert new Schedule 1(iv) to the existing licence.

⎯⎯⎯⎯⎯⎯ ⎯⎯⎯⎯⎯⎯

These amendments should be read in conjunction with licence Reg. No. P0045-03, granted on 24th March 2001.

Sealed by the seal of the Agency on this the 1st day of August 2006.

PRESENT when the seal of the Agency was affixed hereto:

________________________________________ Dr. Padraic Larkin, Director

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Attachment No C.2

Proposed new materials to be processed at the facility

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1.0 Introduction

At present the amount of rendering materials processed by Premier Proteins is decreasing and the

company plan to substitute some of these materials with alternative materials including food wastes,

used cooking oils (UCO) and wastewater treatment plant wastes such as sludges, grease-trap waste and

wastewaters. The processing of these new waste streams at the plant has been discussed with the EPA at

a recent meeting and also by correspondence. The amount of new materials/wastes to be accepted at the

facility is presently difficult to predict, however, it is confirmed that there will be no increase in the

overall tonnage processed at the facility and presently stipulated in their existing licence and indeed it is

likely that the overall tonnages processed at the plant will be less than those currently permitted in the

licence. The proposed materials to be processed are described below.

2.0 Process Materials Replacement

2.1 Food Waste

It is planned that food wastes will be obtained from the food processing/catering industry and can be

treated at the plant along with the existing materials. The food wastes will be transported to the site in

closed/covered containers. There will be no changes to the existing storage, processes or procedures and

no changes to any emissions from the process. The food waste will simply be added to the normal

system and processed alongside the existing materials.

2.2 Used Cooking Oil (UCO)

It is proposed to accept and process used cooking oils at the facility. These will be sourced from the food

and catering industry and will be transported to the site in road tankers or closed 200L to 3000L

containers. All transfers will take place within the factory building or will use back venting in the case of

road tankers. The oils pass through centrifugal decanters and a separator to remove impurities. They will

then be blended with normal production tallow before going to storage. No additional storage or process

modifications will be required to accept UCOs for processing and there will be no change to the

emissions from the facility from the processing of these materials.

2.3 Wastewater Treatment Plant Sludge Wastes

It is proposed to accept and process sludge wastes from municipal and some industrial wastewater

treatment plants. The sludges will not be sourced from any chemical, pharmaceutical or other potentially

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hazardous treatment plants and will be transported to the site in closed containers. The need for lime

stabilisation of the sludges prior to transport will be reviewed on an ongoing basis. As with the food

waste and the sludge from the company’s own wastewater treatment plant the sludges will simply be

added in to the normal processes and treated the same and along with the existing materials. Therefore

there will be no changes to any storage, processes or procedures and no changes to the emissions from

the facility.

2.4 Grease Trap Waste and Wastewater

It is planned to accept grease-trap waste and wastewater from non hazardous industrial wastewater

treatment plants in the Connaught region. These liquids/materials will be treated in the site wastewater

treatment plant. The operation of the thermal oxidiser has led to a significant reduction in the volume of

wastewater treated at the wastewater treatment plant (a reduction in the order of 30,000 m3/annum) and

therefore the plant has ample capacity to treat additional quantities of grease-trap waste and wastewater.

The grease trap liquid will be transported to the site by road tanker. On arrival the tanker will be

weighed and directed to an offloading point. The liquid will be offloaded into a sump and pumped to the

pre-screen. Once pre-screened, the liquid will be passed through the dissolved air flotation (DAF) unit

to remove fats and oils. Any solid material recovery at the screen will be returned to the cooker for

processing as normal. The pre-screen and DAF unit is situated within an enclosed building which is

extracted to the existing biofilter 2. The liquids will then be treated in the waste water treatment plant

(WWTP) in activated sludge tanks along with normal effluent streams. In this way, there will be no

material change to the processes and procedures required to treat the off site wastewaters. The only

difference will entail the unloading of the effluent from road tankers into the sump.

While it is presently difficult to predict the volumes of off-site wastewater to be treated at the site it is

confirmed that the total volume of wastewater treated in the WWTP will be less than the volumes

stipulated in the existing licence (105,850 m3/year or 290 m3/day or 12m3/hr.), the overall loadings on

the plant will be less than the thresholds allowed in the licence and there will be no exceedance of the

emission limit values stipulated in the licence.. Therefore, there will be no significant change to the

emissions from the wastewater treatment plant in terms of volumes or quality and indeed, it is likely that

there will be an overall improvement given the reduced volumes treated and lower loadings applied to

the plant.

It is expected that the vehicles used to import the wastewater materials will not add significantly to the

traffic operating at the site. While the volume of wastewater to be imported is not yet known, it is

estimated that the number of vehicles used will range from less than one per day to no more than six per

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day (based on a maximum wastewater volume of 30000 m3/annum, tankers carrying a minimum volume

of 16000 litres, 52 weeks per year and 6 days per week). This gives approximately one vehicle every 2

hours as an absolute maximum and will in reality be a lot less than this figure. Therefore, it is

considered that any potential impacts from traffic and traffic related noise will not be significant in the

overall context of the existing plant and operation. The effluents will be pumped from the tanker to the

holding sump and it is not expected that this will impact adversely on the site odours in the vicinity of

the WWTP.

3.0 General Considerations

If any loads are deemed to be unacceptable for any reason the waste/effluent will as far as practicable be

reloaded onto the tanker and returned to the source. The producer will be notified that no further loads

will be accepted from that source unless practical guarantees are in place to eliminate a recurrence of the

incident.

There is a truck washing facility for the trucks transporting waste materials/effluents to the site. The

effluent from the truck wash is directed to the wastewater treatment facility.

All trucks collecting and transporting waste materials (food, sludges, UCO, wastewater etc.) will be

required to hold waste collection permits from the relevant waste management regions.

It is considered that the acceptance and processing of these materials will have an overall positive

impact on the global environment and reinforce the sustainability of the processes concerned. Much of

the waste materials in question including the food, oils (UCOs) and grease-trap waste are currently

consigned to landfill. The food waste will now be processed along with the other materials at the plant

and energy recovered from the final product by way of incineration at a waste to energy plant. The

UCOs and oils/greases from the grease-trap waste will be recovered and included in the tallow stream

and can be reused in the site boilers.

The treatment of the wastewater in the site WWTP will provide an outlet for wastewaters which will

entail a high level of treatment including tertiary treatment. This level of treatment may not be available

at other facilities and therefore the wastewaters will likely be treated to a higher degree at this plant

which will improve to some extent at least, the quality of the treated discharge.

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Attachment No D.6 Environmental Considerations and BAT

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Table of Contents:

1.0 Installation of Oxidiser

3

1.1 Process Description 3

2.0 Construction of Intake area with air locks 3

3.0 Effluent Re-use 3

4.0 Raw Material Substitution 3

5.0 Tallow Separator installed 4

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2 of 4

1.0 Installation of Oxidiser

On 1st

August 2006, the EPA granted a technical amendment to Premier Proteins IPPC Licence

Reg No. P0045-03 for the installation of a Regenerative Thermal Oxidiser.

1.1 Process Description

See Section 2.5 of the document contained in Attachment E.1

2.0 Construction of intake area with air locks

See drawing No. AK7001-103 attached in Attachment E.1

Materials enter the facility by truck via the airlock area in the processing building. Once inside

the building the external doors are closed and the internal doors dividing the materials intake

area and the truckwash area are opened. The trucks move into this area and the doors are closed

to seal off the air lock area. These areas are kept at a slight negative pressure to prevent odour

contamination to the surrounding environment whilst ensuring that the air is changed

sufficiently frequently for the health and welfare of personnel. Storage times are also kept to a

minimum.

The areas from which ventilation is provided is treated by the new Regenerative thermal

oxidizer. The environmental benefits achieved are reduced odour and dust emissions and aids

in the prevention of odours beyond the site boundary.

3.0 Effluent Re-use

All sludge generated at the WWTP is returned to the intake area for processing, sterilisation

and disposal by incineration at approved facilities. Processing of these materials will not

necessitate any process modification as currently the EPA has given permission to process

water from animal collection facilities.

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4.0 Raw Material Substitution

As described in Attachment C.2, Premier Proteins (2000) Ltd proposes to accept used cooking

oils (UCO) for purification and blending into tallow produced on site. The oils either will be

transported in road tankers or closed containers. All transfers will take place within the factory

building or will use back venting in the case of road tankers. The oils pass through centrifugal

decanters and a separator to remove impurities. They will then be blended with normal

production tallow before going to storage. No additional storage or process modifications will

be required to accept UCOs for processing.

In addition the Company proposes to accept catering food waste and waste sludge which will

be transported to the site in closed/covered containers. On arrival at the site the sludge and

catering waste will be tipped and processed in accordance with EC Regulation 1774/2002. The

dried material will be incorporated into meat and bone meal produced on site and will be

disposed of by incineration/co-incineration at approved facilities. Tonnages are presently

unknown.

The grease trap liquid will be transported to site by road tanker. On arrival the tanker will be

weighed and directed to an offloading point. The liquid will be offloaded into a sump and

pumped to a pre-screen. Once pre-screened, the liquid will be passed through a dissolved air

flotation (DAF) unit to remove fats and oils. Any solid material recovered at the screen will be

returned to the cooker for processing as normal. The pre-screen and DAF unit is situated within

an enclosed building which is extracted to the existing biofilter 2. The liquids will then be

treated in the waste water treatment plant (WWTP) in activated sludge tanks along with normal

effluent streams.

5.0 Tallow separator installed

Replacement of boiler fuel with Tallow oil

Fuel oil is available in various sulphur grades (< 1 %, < 2 %, < 3 % and > 3 %). Tallow is

essentially sulphur free. Boilers have been converted to burn tallow by replacing the burners.

Tallow oil use has a number of environmental benefits:

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� The need to consume fossil fuel is reduced.

� Tallow is virtually sulphur free, therefore lower SO2 emissions can be achieved

without the need for abatement that, e.g. sulphur-containing fuel oil requires.

� Reduced pollution to the atmosphere due to traffic emissions associated with

transport as conventional fossil fuels are not required and the tallow is burned on

the same site as it is produced.

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Attachment No E.1

Treatment, Abatement and Control Systems

Information Requested Regarding Application for IPPC Licence review to

accommodate Installation of regenerative Thermal Oxidiser

Drawing No: AK7001-103

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ERROR: syntaxerrorOFFENDING COMMAND: --nostringval--

STACK:

/Title ()/Subject (D:27.10.2006 09:29:58)/ModDate ()/Keywords (PDFCreator Version 0.8.1)/Creator (D:27.10.2006 09:29:56)/CreationDate (sean.murray)/Author -mark-

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Attachment No G

Resource Use and Energy Efficiency

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Premier Proteins Ltd Poolboy Ballinasloe Co Galway Energy Use Audit Report by Jim Carew C.Eng; MIE Approved: Thomas A Keenan M.Sc. Date: 13/12/2005 Our Ref: P3/05020001

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national environmental services agency 39 kilderry hall ashbourne co meath t +353 1 835 0197 f +353 1 835 2097 e-mail [email protected] web www.nesa.ie 2

TABLE OF CONTENTS

PAGE NO. 1.0 Introduction 3 2.0 Scope 3 3.0 Electricity 3

3.1 Motive power 4 3.2 Lighting 4 3.3 Power Factor Correction 5

4.0 Fuel Consumption 5

4.1 Fuel Usage 5 4.2 Fuel Oil 5 4.3 Tallow Oil 5 4.4 Diesel Oil 6 4.5 Kerosene 6

5.0 Boiler house

5.1 Plant Description 6 5.2 Combustion Efficiency 6 5.3 Condensate Return 6

6.0 Pipe Insulation 7 7.0 Steam Leaks 7 8.0 Compressed Air 8 9.0 Central Heating Boilers 8 10.0 Energy Index 8 11.0 Summary and Recommendations 9

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1.0 Introduction: This is an energy audit carried out at Premier Proteins (2000) Ltd, Ballinasloe, Co Galway in September 2005. Condition 10.1 of the IPC Licence requires that an energy audit be carried out to determine the energy usage on the site and the efficiency with which it is utilised. This report details the results of the audit. 2.0 Scope: The scope of the audit was to analyse the usage of Electricity, Fuel Oil, Tallow Oil and Diesel Oil on the site. Where areas were identified as suitable for energy conservation and where these were considered to be economically viable, an energy conservation programme will be recommended. An analysis of all energy use on the site has been used to prepare an Energy Index (GJ/Tonne) for the site operations. 3.0 Electricity: An analysis of Electricity Bills for period July 2004 to June 2005 was carried out. The electricity usage is mainly motive power with a small amount of electrical lighting. The analysis show the annual electricity usage for the period is 3.010012*106 kWh (Day) and 1.836612 * 106 (Night) equivalent to 17447.92 Gigajoules. A summary of the electricity usage on the site is presented below in Table 1.

Table 1. Summary of Electricity usage during the period July 2004 to June 2005 at Premier Proteins (2000) Ltd.

Month kWh (Day) kWh (Night) Gigajoules (GJ) July 2004 207445 139456 1248.85 August 2004 -250834* -153051* 1454.00* September 2004 -250834* -153051* 1454.00* October 2004 -250834* -153051* 1454.00* November 2004 277544 159510 1573.40 December 2004 256389 155120 1481.43 January 2005 248054 138883 1392.98 February 2005 215347 137773 1271.23 March 2005 264832 155845 1514.44 April 2005 289210 177660 1680.74 May 2005 266766 168512 1567.00 June 2005 231923 144701 1355.85 TOTAL 3010012 1836612 17447.90

1 Gigajoule = 277.777 kWh * Electricity consumption for August, September and October is not available. The consumption for these months is extrapolated based on consumption for the other nine months. The average cost per kWh is 8.62 cents.

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3.1 Motive Power: The register of electric motors installed in the plant shows that Motive power accounts for about 98% of the total installed electrical load. Lighting requirements is responsible for the remaining 2%. Table 2 below shows the approximate percentage of power used in the various operational areas of the process, based on an annual electrical consumption of 17448 Gigajoules.

Table 2. Approximate percentage of power usage at Premier Proteins (2000) Ltd.

Area

Percentage of Installed Capacity

Usage kWh/annum

GJ/Annum

Cost (€)

Presses 17.40 843,313 3,036 €72,732.37 RMS 12.50 605,828 2,181 €52,250.24 WWTP 11.78 570,932 2,055 €49,240.60 Raw Material 9.48 459,460 1,654€ €39,626.58 Milling 9.22 446,858 1,609 €38,539.71 Cooking 6.73 326,178 1,174 €28,131.54 BF (1 & 2) 6.11 296,128 1,066 €25,539.85 Meal Cooler 5.42 262,687 946 €22,655.70 Boiler House 4.47 216,644 780 €18,684.67 ACCs 3.20 155,092 558 €13,376.06 Decanters 3.03 146,853 528 €12,665.48 Cooling Tower 2.98 144,429 520 €12,456.42 Water Pumping 2.07 100,325 361 €8,652.62 Silo 1.98 95,963 345 €8,276.42 Lighting 1.93 93,540 337 €8,067.45 Sterilizing 1.37 66,398 239 €5,726.56 Compressed Air 0.33 15,994 58 €1,379.42

3.2 Lighting. The lighting load is approximately 35 kW. This load accounts for only 1.93% of the total installed electrical load. The type of light emitting equipment used on the site is Fluorescent Tubes, Halogen and a small quantity of Mercury lamps. There is very little scope for savings in lighting on this site as the equipment currently in use on the site is considered to be the most efficient for the required duty. However, the following programme may help to reduce the lighting load slightly;

a) Review lighting requirements in individual areas of the factory to establish if some lighting can be switched off during daylight periods,

b) Develop and operate a lamping programme, i.e. replace fittings after a defined number of hours rather than waiting for the fitting to blow. Output from light fittings can be reduced to about 50% over time although still consuming the same amount of power, and

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c) Always purchase fittings that have the greatest output in term of Lumens/Watt

3.3 Power Factor Correction: Power factor correction equipment (Capacitor) is fitted to ensure that the amount of wattless units (kVar) of power recorded do not exceed the amount allowable, based on a power factor of not less than 0.95. Wattless units are incurred from the use of oversized heavy-duty induction motors, with a small amount being incurred from fluorescent lighting equipment and electric welders. An analysis of electricity supply bills for period July 2004 to June 2005 shows that some power factor surcharges were incurred during the period. However, capacitors were fitted during the year that has eliminated any further power factor surcharge. Therefore, the capacitor load installed is considered to be adequate to meet the current requirements in controlling power factor. However, regular monitoring of electricity bills should continue to ensure that the current situation is maintained. In addition care should be taken to ensure that any new electric motors to be installed on the site are correctly sized for the tasks they are intended to perform. 4.0 Fuel Consumption: 4.1 Fuel Usage: Tallow oil is used exclusively on the two 15,000kg/hr steam boilers. Both boilers are currently serviced at least twice per annum to ensure efficient combustion. Burners are set up to ensure optimum combustion efficiencies at all times. This programme of regular servicing of the boilers and setting of the burners should be continued to maximise fuel efficiency in the boilers.

4.2 Fuel Oil: The use of Fuel Oil is now totally discontinued, with the fuel oil being replaced by the more sustainable Tallow Oil. This practice will have a beneficial environmental effect in relation to Sulphur Dioxide (SO2) emissions as the sulphur content of Tallow is generally insignificant whereas the Sulphur content of Medium or Light fuel oil is now controlled by EEC Directive at 1% or less. 4.3 Tallow Oil: Approximately 3.85 million litres of Tallow Oil is used as a fuel in the Steam boilers for the production of process steam now accounts for 100% of usage. The use of fuel oil has now been discontinued The environmental benefit of using Tallow oil as a replacement for fuel oil is the discontinued use of a natural resource and a reduction in the emission of Sulphur Dioxide to the atmosphere by approximately 72 tonnes per annum, based on present tallow consumption.

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4.4 Diesel Oil: Approximately 15992 Litres of transport diesel oil is consumed on the site, mainly as a fuel for forklift loaders. This total consumption is equivalent to 605 Gigajoules To ensure that this fuel is used efficiently it is important that forklift and loader engines are subject to regular maintenance.

4.5 Kerosene Approximately 14065 litres of Kerosene is consumed in two central heating boilers to heat the offices.

Annual Fuel Consumption

Fuel Quantity Energy Content (GJ) Tallow 3851870 litres 138667 Diesel 15992 litres 605

Kerosene 14065 Litres 510

5.0 Boilerhouse 5.1 Plant Description Two 15,000kg/hr boilers, operating at a pressure of 10.5 Bar, are used to produce process steam. The fuel used is now 100% Tallow Oil. Maintenance and cleaning of steam boiler internal surfaces is important in ensuring that boilers are operating at optimum combustion efficiency at all times. The twice-yearly service of the boilers is adequate to maintain a high level of efficiency. 5.2 Combustion Efficiency The results of combustion efficiency tests, carried out during November 2004, on the boilers during a period of ‘High Fire’ are presented below in Table 3.

Table 3. Results of Combustion Efficiency Tests, High Fire, - November 2004 Boiler No CO2 % Flue Temperature

0C (Net) Flue Gas Loss %

Overall Efficiency %

1 11.7 215 17 83 (100-17) 2 10.7 220 17 83 (100-17)

It can be seen from the above test results that the two boilers are operating at near optimum efficiency. The normal efficiency target for this type of boiler and the fuel used is generally 84%. Operating at 84% would result in a saving of 38500 litres of Tallow. 5.3 Condensate Return Steam is used in the following process on the site:

a) Cooking, b) Sterilising and c) Heating of Tallow Oil.

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About 75% of steam condensate is returned to the boiler from the cooking and sterilising processes. This is a positive energy efficiency measure. Condensate from the steam used to heat tallow oil in the storage tanks is not returned to the boilers. There is a slight risk that this condensate could become contaminated with tallow that may leak from the tanks and if carried into the boiler water system would cause serious damage to the boiler surfaces on the water side. Therefore this condensate cannot be returned to the boiler feed water system. This condensate is discharged to the Waste Water Treatment System for treatment prior to discharge in accordance with the requirements of the IPC licence. 6.0 Pipe Insulation. Steam and condensate pipes were surveyed to identify any steam pipes that were not insulated and to identify steam pipes where insulation may have been damaged, or deteriorated, or otherwise inadequate. Table 4 below lists the pipes that were identified as being un-insulated. The potential heat loss is also calculated in terms of kilograms of tallow equivalent/Annum for these pipes.

Table 4. List of pipes with no insulation, and heat loss in terms of kg of Tallow Oil.

Pipe Length (Metres)

Diameter (mm)

Temperature. 0C

Heat Loss (kWh)

Tallow OilEquivalent (Kg)

Insulation Thickness (mm)

Loss with Insulation (Tallow Kg)

28 200 180 352,800 32,564 50 2,016 50 50 180 19,386 17,894 38 1,883 12 25 180 30,240 2,791 25 332 50 13 180 90,000 8,307 25 1,100 20 40 180 69,600 6,424 40 620 20 40 160 (6 Bar) 50,400 4,652 40 520 TOTAL 72,632 6,471 The calculations used are based on 50 weeks per year and 120 hours per week of operations. It can be seen from the above table that the heat loss from the un-insulated pipes is equivalent to approximately 72.632 Tonnes of Tallow Oil per annum. An insulation programme would reduce this loss to approximately 6.47 Tonnes Oil, a potential annual saving of 66.16 tonnes of Tallow. Insulation of steam and condensate pipes is always economically viable therefore it should be seriously considered.

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7.0 Steam Leaks. Some steam leaks were observed especially around the Tallow tank storage (S2 and S3) Steam leaks can be very costly in terms of energy loss if they are not repaired. For example, a 3mm steam leak on a pipe, flange or steam trap can be responsible for a loss of 13000 litres of Tallow annually. This is based on a steam pressure of 10 bar and 6000 hours of operation. All is required is timely maintenance in repairing leaks. 8.0 Compressed Air Compressed air is provided by two 11 kW compressors (One on standby) operating at a pressure of 9 Bar. Air intake is at ambient temperature therefore availing of the low winter temperatures to operate at maximum air intake efficiency. Savings in compressed air costs could be achieved if the air pressure could be reduced, e.g. Approximately 12% of electrical costs could be saved if the pressure could be reduced from 9.0 Bar to 7.0 Bar. Always chose the most efficient compressor type. A two stage compressor is about 20% more efficient than a single stage. A compressed air leakage test should be carried out at regular intervals. A 1mm leak at 6.0 Bar for one year would result in a waste of 1800 kWh. This highlights the advantage of repairing air leaks promptly. 9.0 Central Heating Boilers Two small central heating boilers are used to heat the offices on site. These boilers should be subject to combustion efficiency tests and regular maintenance to ensure that they are operating at optimum efficiency, which should be about 82%. 10.0 Energy Index. An energy use index is a useful tool for monitoring energy use on the site and for assessing the effectiveness of conservation measures. When an index of energy use per unit weight of raw material processed or per unit weight of product output is established, it can then be used to regularly monitor the efficiency with which energy is converted throughout the plant All energy used on the site has been converted to a common energy unit called a Gigajoule. Using this information a site Energy Use Index is established. The Energy Use Index based on energy usage from July 2004 to June 2005 is calculated to be 2.30 GJ/ tonne.

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11.0 Summary & Recommendations: The results of this energy audit show that energy use is well managed in almost all areas of operation throughout this facility. A small power factor surcharge was incurred in November 2004. Capacitors were installed to maintain power factor above 0.95, thus ensuring that wattless units recorded do not exceed the number allowed and therefore avoiding a power factor surcharge. The load measured on electric motors shows that the motors are generally reasonably sized for the task they are performing. The use of the efficient variable speed motors should be considered. Lighting accounts for almost 2.0% of total electrical load. The most efficient light fittings are used i.e. fluorescent, Halogen and Mercury, therefore, scope for savings is negligible. There is still a range of steam pipes that require insulation or insulation upgrade. Implementation of a comprehensive insulation programme could result in a saving in fuel usage equivalent to about 66 tonnes of Tallow Oil per year. Steam boilers are operating at 83% efficiency on high fire. This high level of efficiency can be maintained or slightly improved by continuing with the regular boiler cleaning and boiler efficiency programmes. Optimum efficiency for this type of boiler is 84%, which can be achieved by maintaining the flue gas side of the tubes clean, and the use of the minimum amount of excess air. Replacing Fuel Oil with Tallow Oil has a positive effect in terms of cost and environmental emissions. Continued use of Tallow Oil as a replacement for Fuel Oil will reduce Sulphur Dioxide emissions from the site by about 72 Tonnes per year. Sulphur content of Fuel Oil is now controlled at 1% or less by EEC legislation. Compressed Air usage should be investigated to determine if the operating pressure can be reduced to around 7.0 Bar (100 psig) resulting in reduced electricity costs. Air leakage tests should be performed at regular intervals. The two central heating boilers should be subject to operating efficiency tests and regular maintenance. ../end.

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Attachment No I

Statutory Requirements

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Premier Proteins IPPC Licence Application Review

1 Of 12

1.1 Indicate how the requirements of Section 83(5)(a)(i) to (iv) of the EPA Acts 1992 and 2003 shall be met, having regard, where appropriate, to any relevant specification issued by the Agency under section 5 (3) of the Act and the reasons for the selection of the arrangements proposed –

Section 83(5) The Agency shall not grant a licence or revised licence for an activity –

(a) unless it is satisfied that –

(i) Any Emissions from the activity will not result in the contravention of any relevant air quality standard specified under Section 50 of the Air Pollution Act 1987 and will comply with any relevant emission limit value specified under Section 51 of the Air Pollution Act, 1987

Premier Proteins (2000) Limited are currently operating under the existing IPC licence

P0045-03. Under the condition 5 of the licence Premier Proteins must adhere to

stringent emission limits as outlined in Schedule 1(i) of the P0045-03 and its technical

amendment. These are detailed below.

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Section 2.2 of AER 2005 relating to Emission to air

Emissions to Air

There are two main sources of emissions to air from the site, which are as follows:

� The Biofilters

� The Boilers.

Biofilter Emissions to air

Emissions from the Biofilters are monitored for Ammonia, Hydrogen Sulphide,

Mercaptans and Amines in accordance with the IPC Licence and a summary of the

emissions to air from the biofilters No. 1 and No. 2 is shown in Table 2.2.

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Table 1 Summary of emissions to air from the biofilters

Mass Emissions for 2004 (kg) Parameter

Biofilter No. 1 Biofilter No.2

Licensed Mass Emissions (kg) per biofilter

Volume (m3) 472,172,760 547,386,120 626,778,000

Ammonia 34.50 37.46 22,106

Hydrogen Sulphide & Mercaptans*

92.35 95.22 4,431

Amines** 2134 2134 7,686

* Mercaptans as Ethylmercaptan ** Amines as Isopropylamine

Boiler Combustion Efficiency/Emissions to Air

The boilers at Premier Proteins are primary fuelled by tallow oil. The Tallow Oil used is

produced on site. Light Fuel Oil can also be used in the boilers but this is avoided for

economic reasons.

The company monitor the emissions from the boilers as part of the efficiency test

carried out on the boilers and the company also ensure that the boilers are operating at

their maximum efficiency and are serviced and maintained on a regular basis to ensure

that all emissions are minimised.

Boiler Efficiency

A boiler combustion efficiency test was carried out on the boilers as part of the

inspection and servicing of the boilers. Boiler efficiency tests were carried out by

SAACKE Limited in April and October 2005. The results of the boiler efficiency tests

carried out in 2005 are shown in Table 2. The levels of efficiency measured are typical

of the efficiency levels achievable from these types of boilers.

Table 2 Summary of Boiler Efficiencies

Fuel Boiler 1Efficency Boiler 2 Efficiency

Tallow 83.7% 83.8%

Light Fuel Oil N/A N/A

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Boiler Emissions

Emission tests were conducted on the boilers at the same time the combustion

efficiency tests were carried out. The data generated has been used to estimate annual

emissions of NOx and CO. SOx emission were calculated using fuel sulphur analysis. A

summary of boiler emissions is shown on table 2.4.

Table 3 Boiler emission summary 2005

Licenced

Mass

Emission

Tallow Light Fuel oil Total

Air Volume

(m3)

N/A 47,415,450 47,415,450

SOx (Kg) N/A 2,338 0 2338

Nox (Kg) N/A 2,282 0 2,282

CO (Kg) N/A 1043 0 1043

During the year 2005, no environmental incidents occurred on the site of the activity

that resulted in any release to atmosphere from any potential emission point; any

emission which did not comply with the requirements of the licence; any malfunction or

breakdown of control equipment or monitoring equipment which was likely to lead to

loss of control of the abatement system.

See also –

Attachment No E.1 (Information Requested regarding application for IPC Licence

Review to accommodate installation of Regenerative Thermal Oxidiser)

Attachment No C.1 (Technical Amendment (i) to Integrated Pollution Prevention &

Control Licence (in pursuance of Section 96(1) of the Environmental Protection Agency

Acts 1992 and 2003)

(ii) Any emissions from the activity will comply with, or will not result in the contravention of, any relevant quality standard for waters, trade effluents and standards in relation to treatment of such effluents prescribed under Section 26 of the Local Government (Water Pollution) Act 1977

Premier Proteins (2000) Limited are currently operating under the existing IPC licence

P0045-03. Under the condition 6 of the licence Premier Proteins must adhere to

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stringent emission limits as outlined in Schedule 2 (i) of the P0045-03 and its technical

amendment. These are detailed below.

AER 2005

Emissions to Waters A summary of the emissions to waters that arise from the wastewater treatment plant is

presented in Table 2.1. All parameters were in compliance with the emission limit

values specified in the IPC Licence for the year 2005.

Table 4: Summary of emissions to water.

Parameter Mass Emissions (kg)

2005 Licensed Mass Emissions (kg)

Volume (m3) 54,287.42 105,850

BOD 299 2,646

Suspended Solids 498 3,705

Total Nitrogen (as N) 1074 4,234

Total Ammonia (as N) 465 2,646

Total Phosphorus (as P) 14.66 212

Oils, Fats, Grease 538 1,587

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(iii) Any Emissions from the activity or any premises, plant, methods, processes, operating procedures or other factors which affect such emissions will comply with, or will not result in the contravention of, any relevant standard including any standard for an environmental medium prescribed under regulations made under the European Communities Act 1972, or under any other enactment,

Within the context of compliance with current draft BATNEEC Guidance Levels, no

non-compliance with EU Regulation into Irish Law under the 1972 European

Communities Act is foreseen. EU Regulations, which are current, such as waste

Management and Safety Regulations, are addressed within Premier Proteins

management systems.

(iv) Any Noise from the activity will comply with, or will not result in the contravention of, any regulations under section 106

Under Condition 9.3 of the IPC Licence P0045-03, Premier Proteins are required to

perform an annual noise monitoring survey of the site operations and plant. The last

noise survey was conducted in November 2005. The report concluded that the facility

was compliant with the requirements of Condition 9 of the licence during each of the

sampling/monitoring periods. The results of the survey are outlined in AER 2005 and

have been included below.

Table 5 Noise monitoring summary Limit value

dB(A)

Measured

value –L90

(dB(A)

Measured

value -Leq

(dB(A)

Compliant

(Yes/No)

NSL1 Nov 2005 45day,

55night

40-43 41-50 Yes


55night

42-49 44-53 Yes


55night

43-45 44-47 Yes

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1.2 Indicate whether or not the activity is carried out on, or may be carried out on, or is located such that it is liable to have an adverse effect on:-

(a) a site placed on a list in accordance with Chapter 1 of S.I. No. 94 of 1997, or

(b) a site where consultation has been initiated in accordance with Article 5 of the EU

Habitats Directive (92/43/EEC). –

The Premier Proteins facility at Poolboy does not fall within either of these designations

however the River Suck is situated adjacent to the facility which is an area with scientific

interests and has been proposed as a Natural Heritage Area by the National Parks and Wildlife

Service (NPWS). There is little of scientific interest on the site itself with no rare or scarce plant

or animal species.

The facility has an on-site waste water treatment plant that discharges treated water into the

River Suck, which includes tertiary treatment for phosphorus removal. Compliance monitoring

indicates that the plant is operating at discharge values significantly lower than the emission

limit values (ELV’s) specified in the licence.

In light of the significant improvements in 2001 in the treated waste water quality brought about

by the installation of the waste water treatment plant as well as having regard to BAT and the

values set out in the Environmental Protection Act 1992 (Urban Waste Water Treatment)

Regulations 1994 the PD from IPC 592 specified a reduction in BOD/SS ELV’s from the

previous licence of 40/50 mg/l respectively, to 25/35 mg/l.

Surface waters runoff from the process vessels, wash-down and abatement systems and

rainwater runoff collected from the yards was previously discharged to the River Suck at the

back of the plant near the biofilter. This is now treated in the WWTP on a continuous basis.

Therefore no sampling of the surface water is currently undertaken as there is no direct emission

occurring.

1.3 Indicate whether or not the activity is liable to have an adverse effect on water quality in light of S.I. No. 258 of 1998 (Local Government (Water Pollution) Act, 1977 (Water Quality Standards for Phosphorus) Regulations, 1998). –

Please refer to Section 1.2 above.

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1.4 Indicate whether any of the substances specified in the Schedule of the EPA (Licensing)(Amendment) Regulations, 2004 (S.I. No. 394 of 2004) are discharged by the activity to the relevant medium and whether the emission of these substances are likely to have an adverse effect on the environment. –

The Premier Proteins facility produces emissions to Air and Water. However as described in

Section 1.1 above these emissions are monitored regularly and do not exceed the ELV’s and

conditions of the existing IPC licence P0045-03.

1.5 State whether the activity is an establishment to which the EC (Control of Major Accident

Hazards involving Dangerous Substances) Regulations, 2000 (S.I. No. 476 of 2000) apply.

NOT APPLICABLE

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2.0 Fit and Proper Person:

2.1 Indicate whether the applicant or other relevant person has been convicted under the PoE Act, the Waste Management Act 1996, the Local Government (Water Pollution) Acts 1977 and 1990 or the Air Pollution Act 1987.

In 1999, the Environmental Protection Agency took a case against Premier Proteins for water

pollution but no conviction was made as water treatment plant was installed. Premier Proteins

(2000) Ltd. paid costs.

2.2 Provide details of the applicant’s technical knowledge and/or qualifications, along with that of other relevant employees.

Summary of Site Qualification and Expertise

Noel Ryan (Rendering Director/General Manager) Over 43 years working in rendering / feed trade industry/ In-depth knowledge of all facets of rendering Certificate in safety, Environmental Law, Waste Water Treatment John Grenham (Production Manger) Graduate of Tralee IT (Analytical Chemistry) NISO certificate in Occupational Health and Safety foundation course Athlone IT Certificate in Environmental Science Environmental Law Waste Water Treatment, Confined Space Entry, Compress Gas safety, Laboratory Safety, Train the Trainer, First Aider Complete ILM Management Development Programme Completed 1.5 years work Experience with Premier Proteins (2000) Ltd. 2 Years working in FDA regulated Medial Device industry (Laboratory Analyst) 9 years working with Premier Proteins (2000) Ltd.- Laboratory analyst, Environmental Officer, Safety officer, IT / SCADA system coordinator and Production Supervisor. Vincent Lee (Laboratory Technician) Graduate of Tralee IT (Analytical Science and Applied Biology) FETAC Certificate in Quality Management Laboratory Safety

Worked with Premier Proteins (2000) Ltd. for 5 years Aine Naughton (Environmental, Health and Safety Officer) Graduate of Sligo IT (Occupation Health and Safety) Qualified Manual Handling Instructor First Aider, Worked for Murray Timber products for 3 years as safety officer Joined Premier Proteins (2000) Ltd. in January 2006 Ray Quinn (Maintenance Supervisor) Qualified Fitter Installed Rendering Plant and Machinery in Bagdad (Iraq ) for Liffey Dock yard (3 years) Worked as electrician on Premier Proteins (2000) Ltd. site (5 years) Worked as Maintenance foreman in St Bridget’s Mental Hospital (10 years) Joined Premier Proteins (2000) Ltd. in 1998. Gabriel Mitchell (Deputy Maintenance Supervisor) Qualified Fitter ( Bord Na Mona Apprentiship) Advanced Welding Confined Space Entry Compressed Gas Safety Forklift and Teleporter driver Has experience in Oil Refinery, Food and drinks industry and pharmaceutical Industry. Joined Premier Proteins (2000) Ltd. in 1999.

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2.3 Provide information to show that the person is likely to be in a position to meet any financial commitments or liabilities that may have been or will be entered into or incurred in carrying on the activity to which the application relates or in consequence of ceasing to carry out that activity.

Please see supplement No. I.1

3.0 Obligations as set out in the IPPC Directive (96/61/EC)

The Agency shall ensure that installations are operated in accordance with basic obligations as set out in Article 3 of the IPPC Directive (96/61/EC). Article 6 of the IPPC Directive (96/61/EC) specifies that a description of the measures in place to ensure compliance with the general principles of the basic obligations of the operator shall be part of the application.

Describe the measures proposed or in place to ensure that:

(a) The best available techniques are or will be used to prevent or eliminate or, where that is not practicable, generally reduce an emission from the activity;-

See Attachments No C.1, D.6 and E.1

(b) No significant pollution is caused; -

As mentioned previously the facility is currently operational under the conditions and

requirements of IPPC Licence P0045-03. It is currently in full compliance of the

Licence and intends to continue to work within the parameters of the licence, towards

the best environmental standards. Premier Proteins will in the future alter or modify any

aspect of its facility to the Best Available Techniques in order to maintain a high

standard of production without adversely impacting the environment.

(c) Waste production is avoided in accordance with Council Directive 75/442/EEC of 15 July 1975 on waste; where waste is produced, it is recovered or, where that is technically and economically impossible, it is disposed of while avoiding or reducing any impact on the environment;-

The table below outlines waste as per AER 2005

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European

Waste

Catalogue

Code

Hazardous

(Yes/No)

Description

of Waste

Hazardous

Waste Tag

Quantity

(t/year)

Disposal/ Recovery

Code

Location of

Disposal/

Recovery

Name of Waste

Disposal

Recovery

Contractor

Licence /

Permit

Reference for

Treatment

Facility

20 03 99 No

General Site

and Office

waste 23.19

D1 Deposit on, in or

under land. (b) Off-site Ireland

Kelly Waste

Disposal CW19

20 03 99 No

General Site

and Office

waste 5.76

D1 Deposit on, in or

under land. (b) Off-site Ireland Barna Waste CW74

20 01 40 No Scrap Metal 7.3

R4

Recycling/reclamation

of metals and metal

compounds (b) Off-site Ireland Hammond Lane WP-62-2004

14 06 03* Yes Lab Waste 0.18

D10 Incineration on

land (c) Off-site Abroad Indaver Ireland 36-2

14 06 02* Yes Lab Waste 0.025

D10 Incineration on


16 05 06* Yes Lab Waste 0.025

D10 Incineration on


16 05 06* Yes Lab Waste 0.055

D10 Incineration on


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(d) Energy is used efficiently; -

Please refer to Attachment G.1 – Energy Audit 2005

(e) The necessary measures are taken to prevent accidents and limit their consequences;

See Premier Proteins Safety Statement Attached in Supplement No I.2

See also the Hazard risk assessment form attached in Supplement No I.3

(f) The necessary measures are taken upon definitive cessation of activities to avoid any pollution risk and return the site of operation to a satisfactory state.

See Section H

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Supplement I.1

PREMIER PROTEINS FINANCIAL STATEMENT

2005

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Supplement I.2

Premier Proteins Safety Statement

September 2006

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Premier Proteins (2000) Ltd Revision: 1

1 of 56

Safety Statement

Of

Premier Proteins (2000) Ltd Poolboy,

Ballinasloe, Co. Galway

Compiled by Ms Aine Naughton (BSc) in association with employees.

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2 of 56

TABLE OF CONTENTS LEGISLATION REGISTER....................................................................................................................... 5 ORGANISATIONAL & REPORTING CHART OF PREMIER PROTEINS (2000) LTD ....................... 7 Part 1: SAFETY POLICY........................................................................................................................... 8

Safety Policy......................................................................................................................................... 8 Part 2: HEALTH & SAFETY RESPONSIBILITIES ............................................................................... 10

HEALTH & SAFETY RESPONSIBILITIES........................................................................................ 10 2.1 Managing Director – Mr Noel Ryan ................................................................................................ 11 2.2 Assistant Manager – Mr Des McDowell .......................................................................................... 12 2.3 Production Manager – Mr John Grenham ....................................................................................... 13 2.4 Environmental Health & Safety Officer - Ms Aine Naughton ........................................................ 15 2.5 Production Supervisors – Mr Brendan Dunne/ Mr Hugh Manton................................................... 16 2.6 Charge Hands-................................................................................................................................. 17 2.7 Maintenance Manager – Mr Raymond Quinn................................................................................. 18 2.8 Maintenance Employees.................................................................................................................. 19 2.9 Electrician – Mr Robert Stapleton (Powerguard) ....................................................................... 20 Electrical Engineer – Mr Joe Cunniffe................................................................................................... 20 2.10 General Operators ......................................................................................................................... 21 2.11 Laboratory Technician – Mr Vincent Lee .................................................................................... 22 2.12 Employees .................................................................................................................................. 23 2.13 Safety Representative - Mr Patrick Kelly..................................................................................... 24 2.14 Department of Agriculture Employees on site .............................................................................. 25 2.14 Hauliers ......................................................................................................................................... 25 2.16 Visitors ......................................................................................................................................... 28

Part 3: CONSULTATION ARRANGEMENTS....................................................................................... 29 3.1 Safety Consultation ......................................................................................................................... 29 3.2 Safety Statement Revision: ............................................................................................................ 29 3.3 Safety Representative ...................................................................................................................... 30 3.4 Internal Communication................................................................................................................. 31 3.5 External Communication................................................................................................................ 31 3.6 Safety Committee Meetings ........................................................................................................... 31

Part 4: TRAINING, INFORMATION & INSTRUCTION....................................................................... 32 TRAINING, INFORMATION & INSTRUCTION ............................................................................... 32 4.1 Compulsory Training: ..................................................................................................................... 32 4.2 Additional Training Needs .............................................................................................................. 33 4.2.1 Maintenance Personnel.................................................................................................................. 33 4.2.2 Laboratory Technician .................................................................................................................. 33 4.2.3 Supervisors/Charge Hands ........................................................................................................... 33 4.2.4 Machine/Mill Operators ............................................................................................................... 33 4.2.5 Vehicle Operators......................................................................................................................... 33 4.2.6 First Aiders................................................................................................................................... 33 4.2.7 WWTP Operators ......................................................................................................................... 33 4.2.8 Safety Representative ................................................................................................................... 33

Part 5: ACCIDENT/INCIDENT REPORTING & INVESTIGATION.................................................... 34 ACCIDENT/INCIDENT REPORTING & INVESTIGATION................................................................. 34 5.1 Emergency Information................................................................................................................... 34 5.2 Emergency Contacts:........................................................................................................................ 35 5.3 First Aid facilities............................................................................................................................ 35

Part 6: WELFARE ARRANGEMENTS................................................................................................... 35 6.1 Toilet & Washing Facilities ............................................................................................................. 36 6.2 Drinking Water................................................................................................................................ 36 6.3 Canteen............................................................................................................................................ 35 6.4 Smoking .......................................................................................................................................... 35

Part 7: FIRE & EMERGENCY PLANS ................................................................................................... 37 FIRE....................................................................................................................................................... 37 7.1 Fire Fighting Equipment .................................................................................................................. 38 7.2 Fire Exits & Assembly Points .......................................................................................................... 38

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7.3 Emergency Fire Drills ...................................................................................................................... 38 7.4 Emergency Lighting........................................................................................................................ 38 7.5 Fire Alarm ....................................................................................................................................... 38 7.6 Evacuation Procedures ..................................................................................................................... 39 7.7 Inventory of Fire Fighting Equipment.............................................................................................. 40

Part 8: PERMITS TO WORK................................................................................................................. 42 8.1 Introduction ...................................................................................................................................... 42

Part 9: ELECTRICAL SAFETY............................................................................................................... 43 Electrical Safety..................................................................................................................................... 43 9.1 Electrical Isolation Procedure.......................................................................................................... 44

Part 10: HAZARDOUS CHEMICALS & SUBSTANCES ...................................................................... 45 10.1 Chemical Safety On Site ................................................................................................................ 45

Part 11: CONFINED SPACES.............................................................................................................. 47 Confined Spaces..................................................................................................................................... 47

Part 12: HOT WORK................................................................................................................................ 49 Hot Work Permits................................................................................................................................... 49

Part 11: HEALTH ISSUES ....................................................................................................................... 50 11.1 Shiftwork........................................................................................................................................ 50 11.2 Stress .............................................................................................................................................50 11.3 Bullying...................................................................................................................................... 50

Definition ........................................................................................................................................... 50 Anti -Bullying / Harassment Policy ................................................................................................... 51

11.4 Violence ........................................................................................................................................ 51 11.5 Pregnant Employees...................................................................................................................... 52 11.6 Young Employees ......................................................................................................................... 52 11.7 Noise ............................................................................................................................................. 52 11.8 Vibration…………………………………………………………………………………………..52 11.9 Dust & Fumes................................................................................................................................ 53

11.10 Visual Display Units .......................................................................................................... 53 Part 12: AUDITING & REVIEWING PERFORMANCE....................................................................... 54

12.1 Safety Auditing ............................................................................................................................. 54 12.2 Safety Statement Review............................................................................................................... 54

Part 13: METHOD OF RISK ASSESSMENT.......................................................................................... 55 RISK ASSESSMENT METHODOLOGY ............................................................................................ 55 Table 1: Probability Scale ...................................................................................................................... 55

Almost certain .................................................................................................................................... 55 Improbable ......................................................................................................................................... 55

Table 2: Severity Scale........................................................................................................................... 55 Table 3: Frequency Scale ....................................................................................................................... 56

Frequency Index................................................................................................................................. 56 Table 4: Priority of Action ..................................................................................................................... 56

Priority Index ..................................................................................................................................... 56 High.................................................................................................................................................... 56 Immediate action ................................................................................................................................ 56

Qualitative Risk Assessment .................................................................................................................. 56 HAZARD IDENTIFICATION & RISK ASSESSMENT SHEETS Acid Scrubber…………………………………………………………………………………………….58 Air Cooled Condenser & Fat Scrubber………………………………………………………………… 59 Biofilter 1&2 and Humidifier Tanks……………………………………………………………………..60 Boiler Fuel Storage (LFO, TALLOW & DIESEL TANK)………………………………………………61 Boiler House…………………………………………………………………………………………… 62 Between Workshop & WWTP………………………………………………………………………….. 63 Canteen………………………………………………………………………………………………… 63 Changing Areas………………………………………………………………………………………….64 Control Room & Panel Room……………………………………………………………………………65 Cooker…………………………………………………………………………………………………...66 Crushing (Raw Material Area)……………………………………………………………………….67-69 Decanter Area……………………………………………………………………………………………70 Decanter Tallow Tanks………………………………………………………………………………….71 Yard…………………………………………………………………………………………………… 72 Hessions Field………………………………………………………………………………………….. 73 Laboratory…………………………………………………………………………………………… 74-76

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Loading Bays – Auxilary & Main…………………………………………………………………….77-78 Offices………………………………………………………………………………………………….79 Maintenance Store 2…………………………………………………………………………………..80 Meal Store Silo………………………………………………………………………………………..80 Millroom………………………………………………………………………………………… 81-83 Oil Store………………………………………………………………………………………………83 Pathogenic Area………………………………………………………………………………………84 Pathogenic Water Storage Area……………………………………………………………………..85 Press…………………………………………………………………………………………… 85-86 Pump House………………………………………………………………………………………….87 Underground pipes leading to sand filter room………………………………………………………87 Raw Material Intake………………………………………………………………………………….88 RMS………………………………………………………………………………………………89-90 Sand Filter……………………………………………………………………………………………91 Store 1………………………………………………………………………………………………..92 Store 2………………………………………………………………………………………………..93 Store 3………………………………………………………………………………………………..94 Store 4………………………………………………………………………………………………..95 Sweeneys Field & House…………………………………………………………………………….96 Tallow Filter Area……………………………………………………………………………………97 Tallow Scraper Tank…………………………………………………………………………………98 Tallow Sterilisation…………………………………………………………………………………..99 Tallow Storage Area……………………………………………………………………………100-101 Thermal Oxidiser……………………………………………………………………………………102 Trainors Field & House……………………………………………………………………………..103 Workshop………………………………………………………………………………………104-107 Waste Water Treatment Plant (WWTP)……………………………………………………… 108-109 General Risk Assessment Sheets Vehicle Movement & Operation………………………………………………………………111-112 Cleaning, Inspection & Maintenance of Machinery…………………………………………..113-114 Machinery – General…………………………………………………………………………..115-116 Conveyors…………………………………………………………………………………………..117 Abrasive Wheels……………………………………………………………………………………118 Elevated Platforms………………………………………………………………………………….119 Hand Tools………………………………………………………………………………………….120 Portable Electric Tools………………………………………………………………………………121 Fire………………………………………………………………………………………………… 122 Welding & Cutting…………………………………………………………………………………..123 Compressed Air…………………………………………………………………………………… 124 Compressed Gas Cylinders…………………………………………………………………………..125 Manual Handling…………………………………………………………………………………….126 Noise…………………………………………………………………………………………………127 Dust & Fumes………………………………………………………………………………………..128 Slips Trips & Falls………………………………………………………………………………… 129 Access to Heights……………………………………………………………………………………130 Chemical Substances……………………………………………………………………………… 131

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LEGISLATION REGISTER The following legislation and codes of practice are kept in the Environmental Health and Safety Officers office: 1. SI 10/2005 Safety Health & Welfare at Work Act 2005

2. SI 44/93- Safety Health & Welfare at Work (General Application) Regulations 1993.

3. SI 10/55 - Factories Regulations 1955

4. SI 185/56 Factories (Report of Examination of Air Receivers) Regulations 1956.

5. SI 357/78 Factories (Report of Examination of Steam Receivers) (Amendment) Regulations

1978.

6. SI 46/94 Safety Health & Welfare at Work (Biological Agents) Regulations 1994.

7. SI 248/98 Safety Health & Welfare at Work (Biological Agents) (Amendment) Regulations

1998.

8. SI 426/81 Safety in Industry (Vehicle Lifting Tables and Other Lifting Machines) (Register

of Examinations) Regulations 1981.

9. SI 251/89 European Communities (Protection of Workers) (Exposure to Chemical,

Physical & Biological Agents) Regulations 1989.

10. SI 78/01 Safety Health & Welfare at Work (Carcinogens) Regulations 2001.

11. SI 188/01 Safety Health & Welfare at Work (General Application) (Amendment)

Regulations 2001.

12. SI 218/01 Safety Health & Welfare at Work (Confined Spaces) Regulations 2001

13. SI 481/01 Safety Health & Welfare at Work (Construction) Regulations 2001.

14. SI 619/01 Safety Health & Welfare at Work (Chemical Agents) Regulations 2001

15. SI 218/00 Safety Health & Welfare at Work (Pregnant Employees etc.) Regulations 2000.

16. SI 11/00 Safety Health & Welfare at Work (Night Work & Shift Work) Regulations 2000.

17. SI 132/95 Safety Health & Welfare at Work (Signs) Regulations 1995.

18. SI 358/95 Safety Health & Welfare at Work (Miscellaneous Welfare Provisions)

Regulations 1995

19. SI 504/98 Safety Health & Welfare at Work (Children & Young Persons) Regulations

1998.

20. SI 30/81 Fire Services Act 1981

21. SI 318/2006 Safety Health & Welfare at Work (Work at Height) Regulations 2006

22. SI 371/2006 Safety Health & Welfare at Work (Control of Noise at Work) Regulations

2006.

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23. SI 370/2006 Safety Health & Welfare at Work (Control of Vibrations at Work)

Regulations 2006

24. SI 386/2006 Safety Health & Welfare at Work (Exposure to Asbestos) Regulations 2006.

Codes of Practice:

1. Code of Practice for Avoiding Danger from Underground Services.

2. Code of Practice for Access and Working Scaffolds.

3. Code of Practice for Working in Confined Spaces.

4. Code of Practice on Prevention of Workplace Bullying.

5. Code of Practice for Safety Health & Welfare at Work (Chemical Agents) Regulations

2001.

6. Code of Practice – Rider Operated Lift Trucks.

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ORGANISATIONAL & REPORTING CHART OF PREMIER PROTEINS (2000) LTD

Managing Director

Noel Ryan

Production Supervisors

Brendan Dunne Hugh Manton

Assistant Manager Des McDowell

Production Manager John Grenham Maintenance Foreman

Raymond Quinn

EH&S Officer Aine Naughton

Laboratory Technician Vincent Lee

All Production and General Operators

Fitters

Safety Rep + Safety Committee Aine Naughton John Grenham Patrick Kelly Vincent Lee

Brendan Dunne Pat Mulvhill

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Part 1: SAFETY POLICY Safety Policy We at Premier Proteins (2000) Ltd are committed to providing quality product, a safe and

healthy workplace for all our employees, contractors and visitors and minimising our impact on

the environment.

Our health and safety, management system aims to ensure the health and safety of our

employees and others that may be affected by our operations. Our management system is

documented in our safety statement, which is reviewed periodically to ensure continuous

improvement in the management of health and safety.

We at Premier Proteins (2000) Ltd., are aware of our legal obligations under the Safety Health

& Welfare at Work Act 2005 and remain committed to comply with them and all subsequent

health and safety legislation as is relevant to our organisation. We will communicate to all

employees their legal obligations under the Act.

The management of health and safety is an integral part of the company’s overall management

programme and we remain committed to providing adequate resources to ensure continuous

improvement in this area.

The matters to which this policy extends include:

� Managing and conducting all work activities so as to ensure the safety health and welfare of

people at work including the prevention of improper conduct or behaviour likely to put

employees at risk.

� Designing, providing and maintaining a safe place of work that has safe access and egress,

and use plant and equipment that is safe and without risk to health.

� Prevention of risks from the use of any article or substance, or from exposure to physical

agents, noise, vibration and ionising or other radiation’s.

� Planning, organising, performing, maintaining and, where appropriate revising systems of

work that are safe and without risks to health.

� Providing and maintaining welfare facilities for employees.

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� Providing information, instruction, training and supervision regarding safety and health to

employees, which must be in a form, manner, and language that are likely to be understood.

� Co-operating with other employers who share the workplace so as to ensure that safety and

health measures apply to all employees (including fixed term and temporary workers) and

providing employees with all relevant safety and health information.

� Providing appropriate protective equipment and clothing to all employees (and at no cost to

the employee).

� Appointing one or more competent persons to specifically advise the employer on

compliance with the health and safety laws.

� Ensuring that reportable accidents and dangerous occurrences are reported to the HSA.

� Ensuring adequate emergency plans are in place.

Signed: Date: Mr Noel Ryan Managing Director

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Part 2: HEALTH & SAFETY RESPONSIBILITIES HEALTH & SAFETY RESPONSIBILITIES

‘HEALTH & SAFETY IS EVERYONE’S RESPONSIBILITY’

All persons on site have a responsibility for safety health and welfare.

As employers we have a responsibility to our employees, to persons who may be contracted to

carry out work for the company and to any visitors to our company.

Employees, contractors and visitors have a responsibility to ensure they look after their own

safety, health and welfare and that of any other person who may be affected by their activities.

Directors, managers, supervisors, employees and contractors within the company must

incorporate their responsibilities for safety as an integral part of their job and ensure their

responsibilities are fulfilled.

These responsibilities are outlined in detail in Part 2 of this statement.

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2.1 Managing Director – Mr Noel Ryan The Managing Director is responsible for: � The overall occupational safety, health and welfare of his employees and all those who

enter the site

� Providing adequate resources and competent personnel to carry out the health and safety

management programme

� Reviewing the safety management programme and striving for continuous improvement

� Complying with the duties of the employer under the relevant health and safety legislation.

� Liaison with suppliers to ensure health and safety is incorporated into the design of all new

plant and equipment.

� Liaison with production and maintenance personnel to ensure health and safety is

incorporated into the design of all new plant and equipment.

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2.2 Assistant Manager – Mr Des McDowell The Assistant Manager is responsible for: � The safety health and welfare of all employees and all those who enter the site.

� Reviewing the safety management programme and striving for continuous improvement.

� Co-ordinate the activities of hauliers and contractors on site and advise them of the safety

procedures to be followed while on site.

� Devising job descriptions, which include health and safety responsibilities and ensuring

such responsibilities, are carried out.

� Co-ordinating production, maintenance, finance and sales departments to ensure decisions

made do not adversely impact on the company’s safety health and welfare commitments.

� Reviewing in conjunction with competent personnel and senior management the

effectiveness of the health and safety management system.





� Complying with the duties of the employer under the relevant health and safety legislation.

� Keep on file any communication to employees or other persons regarding health and safety

matters.

� Carrying out hazard identification and risk assessments in conjunction with relevant

personnel and assist in devising and implementing controls periodically on existing plant

and equipment, after modifications to existing plant and machinery and prior to new plant

and machinery coming into operation



� Reviewing accident and incident reports and implement corrective and preventative action

as required.

� Accompanying the Health and Safety Authority Inspector on plant tours.

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2.3 Production Manager – Mr John Grenham The site activities are co-ordinated by the Production Manager in conjunction with the Assistant Manager and he is responsible for: � Ensuring new employees and employees moving from one area to another receive adequate

information, instruction, training and supervision.

� Assigning experienced staff to train and supervise new employees until they are considered

competent.

� Ensuring Production Supervisors carry out their health and safety responsibilities.

� Ensuring that all machinery and equipment is safe to use and has a safe means of access and

egress.

� Carrying out hazard identification and risk assessments in conjunction with relevant


and equipment, after modifications to existing plant and machinery and prior to new plant

and machinery coming into operation.

� Ensuring that all employees carry out their work in a safe manner, wear the required

personal protective equipment and abide by the safety rules of the company.

� Devising and implementing safe systems of work for employees, hauliers and contractors

on site.




as required.

� Reviewing in conjunction with relevant personnel the effectiveness of the health and safety

management system.

� Ensure new plant and equipment have adequate features in place prior to been introduced

into production.





� Liaising with insurance company in health and safety matters and communication of any

issues to relevant personnel.

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� Ensuring all contractors and hauliers have adequate insurance details and ensure they are up

to date.

� Keep on file any communication to employees or other persons regarding health and safety

matters.


as required.

� Accompanying the Health and Safety Authority Inspector on plant tours.

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2.4 Environmental Health & Safety Officer - Ms Aine Naughton The Environmental Health & Safety Officer is responsible for ensuring that the rules and guidelines as set down in the safety statement are implemented and carried out. The EHS Officer is responsible for: � Advising the company of their duties under existing and new legislation regarding health

and safety

� All personnel are aware of the contents and location of the safety statement

� Scheduling and carrying out internal safety audits throughout the year

� Ensuring that accident report forms are completed and carrying out the necessary

investigation into any accidents/dangerous occurrences, with the assistant of the Assistant

Manager and Safety Representative.

� To provide induction safety training to new employees and evaluate the need for and

provide any further training to employees.

� As a manual handling instructor, to provide employees with manual handling training

� Co-ordinating consultation with the workforce and the appointed safety representative and

the provision of relevant information where required

� Scheduling, chairing and taking the minutes of the meeting of the safety committee

� Advise management if there is a need for outside consultation

� Purchasing of personal protective equipment

� Carrying out hazard identification and risk assessment in conjunction with relevant


and machinery

� Ensuring that all employees carry out their work in a safe manner, wear the required PPE

and abide by the safety rules of the company

� Reviewing in conjunction with management the effectiveness of the health and safety

management system

� Accompanying the Health and Safety Authority Inspector on plant tours

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2.5 Production Supervisors – Mr Brendan Dunne/ Mr Hugh Manton The Production Supervisors are responsible for: � Training new employees on site, both in the operations of the plant and the safety features

and hazards related to the plant and equipment on site

� Consult with employees on all matters which may affect their safety or health

� Address any health, safety or welfare concerns voiced by employees

� Supervising the employees on site in matters relating to safety and health

� Ensuring employees under their control adhere to safe systems of work

� Ensuring an adequate amount of personal protective equipment is on site at all times

� Assisting in hazard identification and risk assessment of existing and new plant and

equipment with the Production Manager and relevant employees

� Implement the accident/incident reporting and investigating procedure

� Checking all fire equipment is in an adequate state of repair and that all fire exits are clear

� Reporting defects in plant and equipment to the Production Manager and Maintenance

Manager as soon as possible

� Carrying out periodic safety inspections

� Cease any activity where a high risk hazard has been identified and the consequences could

be serious injury or death until suitable controls can be put in place to minimise risk

� Ensure all accidents are reported to the Environmental Health and Safety Officer and

Production Manager

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2.6 Charge Hands- The Charge Hands must comply with general employee responsibilities in conjunction with the following specifically related to Charge Hands: � Ensuring employees under their control adhere to safe systems of work

� Address any health, safety or welfare concerns voiced by employees

� Supervising the employees on site in matters relating to safety and health

� Implement the accident/incident reporting and investigation procedure

� Checking that all fire equipment is in an adequate state of repair and that all fire exits are

kept clear

� Reporting defects in plant and equipment to the fitter on call/maintenance manager

� Cease any activity where a high risk hazard has been identified and the consequences could

be serious injury or death until suitable controls can be put in place to minimise risk

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2.7 Maintenance Manager – Mr Raymond Quinn The Maintenance Manager is responsible for: � Ensuring that all maintenance and engineering work is carried out by competent personnel

� Ensuring that all machinery and equipment is of a safe design and have the appropriate

guarding and safety devices in place

� Advise on the installation of safety features and guarding which should be installed on new

and existing plant and machinery to minimise the risk of injury to employees and

maintenance personnel

� Scheduling and supervision of maintenance safety inspections and machinery and

equipment maintenance schedules

� Review the plans for new plant and machinery to ensure no features in the design will

compromise safety in other areas nor contribute significantly to noise levels in the factory.

� Assign experienced staff to train and supervise new maintenance employees until they are

considered competent

� Ensure the provision of safe access and egress to plant and equipment including access for

maintenance personnel

� Ensuring all maintenance personnel carry out their work in a safe manner, wear the required

personal protective equipment and abide by the safety rules of the company

� Instruct and supervise maintenance contractors who carry out work on site

� Ensure maintenance personnel and contractors carry out their health and safety

responsibilities

� Ensure only competent electricians carry out electrical work

� Ensure all maintenance personnel receive adequate training and consultation on health and

safety issues

� Ensure all reported defects relating to plant, machinery, guarding, walkways etc. are

prioritised, scheduled and repaired/maintained

� Investigate accidents and incidents involving defects in plant or equipment

� Preparation of safe system of work for all maintenance personnel

� Report any accident/dangerous occurrence to the EHS Officer and Production Manager.

� Ensure that all maintenance staff observes the Lock-Out-Tag-Out Procedure of the

company.

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2.8 Maintenance Employees The maintenance employees must comply with general employee responsibilities in conjunction with the following specifically related to maintenance: � Supervising maintenance apprentices/ new employees and ensuring they are made aware of

the hazards associated with any work they are carrying out

� Ensuring all maintenance and engineering work necessary for safety is carried out without

delay

� Not endangering any other workers by their acts

� Conducting periodic safety inspections on plant and equipment to ensure guarding and

safety devices are in place and working on a weekly basis and a record kept

� Ensuring that all safety devices and machine guards are correctly fitted, adjusted and

maintained

� Reporting accidents and incidents and any defective plant or equipment

� Carry out their work in a safe manner, wear the required personal protective equipment and

abide by the safety rules of the company

� Ensure all equipment after repair and maintenance is fully safe to use

� Cleaning up after themselves after carrying out any routine or non-routine work

� Keeping maintenance workshop clean and tidy

� Complying with safe systems of work especially hot work, confined spaces, machinery

equipment maintenance and repair

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2.9 Electrician – Mr Robert Stapleton (Powerguard) Electrical Engineer – Mr Joe Cunniffe The electrical engineer and electrician have specific responsibilities in relation to electrical work on site. These responsibilities include: � Ensuring all electrical maintenance and repair work necessary for safety is carried out

without delay

� Replacing any safety guarding or features if removed during maintenance/repair

� Not endangering any other worker by his acts

� Conducting periodic safety inspections on all electrical equipment and panels to ensure

electrical safety devices are functioning

� Reporting any defect in equipment as soon as possible after becoming aware of the problem

to the maintenance manager and supervisor of the area

� Communicating to personnel who may be working at or near the machine of any electrical

or safety hazards associated with the operation of the machine which may affect their

safety/health

� Installing and repairing all electrical equipment in accordance with ETCI guidelines

� Carry out all work in a safe manner, wear the required personal protective equipment and

abide by the safety rules of the trade and the company

� Complying with safe systems of work

� Cleaning up after oneself after carrying out any work

� Supervising any apprentice electricians and ensuring they are made aware of any hazards

associated with their work

� Advising management of any necessary electrical safety devices which would make

equipment or machinery safer to use

� Reviewing electrical safety of new, modified or existing equipment or machinery and

making recommendations to management

� Periodically check all electrical machinery, plant or equipment for faults, damage, wear or

tear including cables, panels etc.

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2.10 General Operators Only competent personnel will be requested to operate machinery Skill training and experience will define training. Each Operator is responsible for the following:

� Operating machinery without endangering the safety or health of any other person

� Reporting any defect in equipment/area as soon as possible after becoming aware of the

problem to the Production Supervisor/ Maintenance Personnel

� Communicating to others who may be working in or near their area of any safety hazards

associated with that area/machine which may affect their health or safety

� Conducting daily safety checks and weekly inspections on machinery in their area to

ensure all safety devices are in place and working

� Before carrying out any work which may involve the removal of material, guards or the

entry into the machine the Lock-Out-Tag-Out system must be adhered to

� Conducting daily safety checks and weekly inspections in their area to ensure all areas are

safe and free from hazards

� Ensuring all safety guards/safety devices are replaced after removal

� Keeping the area clean and tidy

� Before starting up any machinery ensure that no personnel are located near the danger

zones of the machine

� Ensure that all fire extinguishers are in place and if there is a problem with one it must be

taken to the maintenance stores as soon as possible

� Wearing any personal protective equipment required

� Reporting any accidents or incidents to the supervisor without delay

� Not bypassing or overriding any safety devices.

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2.11 Laboratory Technician – Mr Vincent Lee Only competent employees will be requested to carry out analysis in the laboratory. Skill training and experience will define competence. The Laboratory Technician has specific responsibilities in conjunction with his responsibilities as an employee they include: � Running the lab without endangering the safety or health of any other person

� Reporting any defect in the lab to the Production Manager/Maintenance Foreman

� Communicating to others who may be working in the lab of any safety hazards associated

with the lab which may affect their health or safety

� Ensuring all safety devices e.g. Fume hood are fully operating

� Keeping the lab area clean and tidy

� Ensuring all unnecessary machines are switched off before leaving the lab

� Wearing any personal protective equipment as required

� Ensuring all chemicals are labelled and stored in a safe place

� Any spillage’s must be cleaned up immediately

� Any breakage’s must be cleaned up immediately and adequately disposed of

� Reporting any accidents/incidents to Management without delay

� Ensuring that all chemicals in the lab have an up-to date MSDS (Material Safety Data

Sheet) on file

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2.12 Employees All employees have legal obligations under the Safety Health & Welfare at Work Act 2005. Prior to commencing work employees are informed of their legal obligations and their responsibilities within the company to ensure their own safety and the safety of others who may be affected by their acts or omissions. Employees are responsible for: � Taking care of their own safety and ensuring they do not endanger by their actions, the

safety of any other person on site

� Co-operating with management, health and safety officer and their supervisor in all matters

regarding safety, health and welfare

� Wearing any protective equipment given which include safety boots, overalls, ear

defenders, eye protection, dust masks

� Taking health and safety training, instructions and information into account while carrying

out their work

� Carrying out their work in a safe manner so as to prevent accidents and ill health

� Reporting any defective or faulty equipment to their supervisor or production manager

without delay

� Never recklessly interfering with any equipment supplied or provided for protecting health

and safety

� Report all work related accidents and incidents to the supervisor/assistant

manager/production manager /EHS officer immediately

� Discuss any concerns relating to safety, health or welfare with your supervisor/assistant

manager/production manager/ EHS officer

� Ensure you are not under the influence of any intoxicant to the extent that you could be a

danger to yourself or others while at work

� Submit to any appropriate, reasonable and proportionate tests for intoxicants by, or under

the supervision of a registered medical practitioner who is a competent person as may be

prescribed

� Not engage in improper conduct or other behaviour that is likely to endanger your safety or

the safety of others

� Reporting to management without delay if there is any unsafe work, any defect in place of

work, substance, article or any contravention of the relevant statutory provisions which may

endanger the safety, health and welfare at work of employees or that of any other person.

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� Employees shall not on entering into a contract of employment, misrepresent himself to an

employer with regard to the level of training, which has been acquired.

2.13 Safety Representative - Mr Patrick Kelly It is the responsibility of the safety representative to:

� Make representations on health and safety matters on his own behalf or on behalf of other

employees to the Assistant Manager/Production Manager/EHS Officer

� Carry out periodic safety inspections and report the findings to the Assistant

Manager/Production Manager/EHS Officer

� Facilitate in the carrying out of hazard identification and risk assessments

� Inspect the whole or any part of place of work subject to giving reasonable notice to

employer

� Investigate accidents/dangerous occurrences on site

� Investigate complaints relating to safety health or welfare made by any employee whom

you represent

� Accompany the HSA Inspector who is carrying out an inspection of the place of work

The employer will so far as is reasonable practicable comply with Regulation 25 of the

2005 Act regarding safety representatives.

The company will endeavour to provide

1. Heath & Safety Training to facilitate the safety representative to carrying out their duties

2. Information relating to HSA Inspections on site

3. Information regarding accidents and incidents

4. Information regarding to health and safety which may affect the employees

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2.14 Department of Agriculture Employees on site Department of Agriculture employees are on site 9am-5pm five days a week. We aim to

provide a safe working environment for Department of Agriculture employees on site.

Department of Agriculture employees will be expected to carry out their activities in a

safe manner so as not to endanger the health and safety of our employees or other persons

on the site. Department of Agriculture employees will be given written safety instructions

and a record will be kept on file.

Department of Agriculture employees are responsible for:

� Complying with any written or verbal safety instructions given by the company

� Obeying the instructions given by management or their representatives when on the

premises

� Reporting all accidents/incidents to management without delay

� Ensure all work is carried out in the safest possible way

� Consulting with representatives of the company on any safety issues that are concerning

you

� Following all procedures the company have in place concerning safety, health and welfare

� Only use Premier Protein equipment when given permission to do so by the company

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2.14 Hauliers As an integral part of our business, hauliers transport raw material into our yard and

also transports the end product out. We aim to provide a safe working environment for

them and equally we expect them to carry out their activities without posing a risk to the

safety and health of our employees and other persons on the company’s premises. All

hauliers will receive written safety instructions and a record of such will be kept on file.

Hauliers are responsible for:



premises

� Reporting all accidents or incidents on site to management without delay

� Driving at 10kmph or less when inside the company premises

� Maintaining a safe distance between themselves and any other vehicle in the yard

� Parking the truck in a safe place where it is unlikely to cause an obstruction

� Wearing high visibility vests/jackets while in the yard

� Wearing helmets where there is a risk of head injury due to falling objects

� All hauliers must use chocks when parking trailers in the yard

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2.15 Contractors Contractors carry out work within the company on a regular basis. We aim to provide a

safe working environment for all contractors on site.

Contractors will be expected to carry out all their activities in a safe manner so as not to

endanger the health and safety of our employees or other persons on site. Contractors

will be given written safety instructions prior to entry on site and a record will be kept on

file.

Contractors are responsible for:

� Providing the company with a copy of their insurance details as requested



premises

� Reporting all accidents or incidents to management without delay

� Ensure all work is carried out in the safest way possible

� Consulting with representatives of the company on any safety issues that are concerning

you

� Following all procedures the company have in place concerning safety health & welfare

� Only use Premier Protein equipment when given permission to do so by management

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2.16 Visitors The company has a strict policy in place to protect the safety of all visitors to the

company, due to the large amount of vehicles on site and the activity in the yard.

This policy is displayed in reception area and all visitors are directed to read it.

� All visitors must report to reception prior to entering the yard, a visitors log must be signed

before going down the yard for fire safety reasons

� No new visitor is to walk around the site unaccompanied by a member of staff

� There is a strict no smoking policy on site and all visitors must comply with this policy

� Visitors must wear any personal protective equipment given to them prior to entering the

site

� When walking in the yard always keep close to the buildings and avoid the main traffic

routes

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Part 3: CONSULTATION ARRANGEMENTS

3.1 Safety Consultation A critical element in the company’s health and safety management system is the manner in which health and safety matters are communicated between senior management, supervisors, employees, contractors, hauliers, visitor’s insurers and the Health & Safety Authority (HSA). The company will comply with the 2005 Act and the 1993 General Application Regulations in relation to consultation. Consultation arrangements aim to ensure employees: 1. are involved in reviewing and revising our safety statement especially in the management

of risks 2. are consulted when changes take place that affect safety and health in the workplace 3. are represented on health and safety matters. 3.2 Safety Statement Revision: An internal review of the safety statement and associated safety procedures will take place on an annual basis. Line management, supervisors, safety representative and relevant employees will carry out these reviews. All necessary changes will be discussed and implemented. All personnel affected will be informed of such changes. Reviews of the relevant areas may also take place as changes occur, or as a result of improvement suggestions made by employees, management, insurers and the HSA. The safety statement will be brought to the attention of all employees on site and also anyone on site who may be exposed to any specific risk to which the safety statement applies. A copy of the safety statement is available in the EHS Officers office, Reception, Factory Office and the Canteen. Risk assessments will be carried out initially by the safety officer in consultation with relevant employees, supervisors and the safety representative. Risk assessments must be reviewed at least annually and updated where changes occur, where new hazards emerge and in the light of relevant accident and incident data

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3.3 Safety Representative Any health and safety concerns employees, hauliers or contractors may have can be brought to the attention of the supervisors/production manager/health and safety officer or the assistant manager. Under the 2005 Act employees may elect a safety representative to represent them in consultation with management. It is the aim of the company to ensure any such safety representative will be allowed to carry out their functions in accordance with the 2005 Act and will be given the required information, training, information and time to do so. Management will where possible � take account of any suggestions made to them relating to safety health and welfare � respond to any representation made and provide information on its status � facilitate open and frank communication relating to safety health and welfare � comply with the relevant legislation regarding the provision of information to employees

or their safety representative Selection Process The election of a safety representative will take place every three years or in the event of retirement from the post, whichever is sooner. This period has been decided upon because of the resources given by the company in training such an individual. Employees will select candidates for election and the names of the willing nominated employees will be given to the Production Manager/Health & Safety Officer. The employees will carry out elections; both employees and management will be informed of the newly appointed safety representative. Each safety representative will be given adequate information, instruction and training by management to carry out their functions.

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3.4 Internal Communication Information flow from Employees to Management Employees may bring issues and concern relating to safety health and welfare to their safety representative/supervisor. Where possible the issue should be dealt with and resolved at this level. If not it should be discussed at the safety committee meetings and resolved where possible. An urgent matter needing immediate attention and authorisation or one where the above channels have been exhausted may be brought to the attention of the assistant manager/production manager/health and safety officer for appropriate action. Information flow from Management to Employees Issues, concerns or changes relating to safety health and welfare shall be brought to the attention of employees from management by their supervisor. The assistant manager/production manager/health and safety officer will inform supervisors, the safety representative or all of any decisions coming from senior management. 3.5 External Communication Insurers will communicate with the production manager who will communicate the information to the relevant personnel. The HSA will communicate with the health and safety officer. All information requested by the HSA will be compiled and submitted by the production manager and the health and safety officer. All other information coming into the company will be distributed to the relevant personnel. 3.6 Safety Committee Meetings Safety meetings will take place every 2 months on site. Discussion on specific safety issues, accident, incident reports and audits will take place each time a meeting is held. The health and safety officer will note the minutes of each meeting. Action items will be set for close out and followed up at consecutive meetings. The members of the safety committee are: Aine Naughton - EHS Officer John Grenham - Production Manager Patrick Kelly - Safety Representative Brendan Dunne - Production Supervisor Vincent Lee - Laboratory Technician Patrick Mulvihill - Fitter

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Part 4: TRAINING, INFORMATION & INSTRUCTION TRAINING, INFORMATION & INSTRUCTION The company expects their personnel to be competent in performing their daily tasks and to incorporate safety and health into all aspects of their work. We aim to provide the appropriate information, instruction and training to all employees in health and safety so that they fully understand the hazards present in the workplace, the precautions, controls and emergency procedures in house. By reviewing the training programme and monitoring our performance we can identify new information and training needs among our employees. We believe other people on site require safety information and have identified the need to provide safety instructions to all contractors, hauliers and visitors. We have defined competence in terms of education, training and/or experience. Compulsory safety training has been identified for all employees and additional training and instruction requirements have been identified for maintenance personnel, supervisors, machine operators, vehicle operators and first aiders. The health and safety officer will give initial induction training and noise awareness training. Each employee will receive a handbook informing them of the health and safety issues on site. This induction booklet is not an exhaustive list of hazards and employees will be given more detailed on the job training. Once an employee is placed in an area the supervisor of that section and other competent personnel will give on the job training. Other training needs will be met by contracting the services of competent personnel or by training specific employees to fulfil our training needs. 4.1 Compulsory Training: 1. Induction Safety Training Introduction to the company Overview of the safety statement contents Emergency Procedures Accident/Incident reporting Overview of the main hazards on site Personal protective equipment to be worn 2. Noise Awareness Training How noise affects the human ear Overview of the legislation regarding noise Compulsory wearing of hearing protection 3. Manual Handling The mechanism of action of the back and spinal column How lifting affects the back Legislation regarding manual handling of loads The principles of safe lifting Identification of hazardous lifts and assessment of the risks Demonstration of safe lifting techniques

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4.2 Additional Training Needs It is recognised that some employees due to the nature of their job may have increased responsibility in the area of health and safety or may be at greater risk as a result of their occupations and hence specific training and instruction must be given to those employees. Maintenance Personnel Laboratory Technician Supervisors Machine/Mill operators Vehicle Operators First Aiders WWTP Operators 4.2.1 Maintenance Personnel Maintenance personnel will need additional training and instruction in the procedures relating to hot work, confined spaces, electrical isolation, chemical handling and hazard identification and risk assessment. All new maintenance personnel receive additional supervision until considered competent. 4.2.2 Laboratory Technician The lab technician will require adequate information on chemical safety and handling, MSDS, and hazard identification and risk assessment. 4.2.3 Supervisors/Charge Hands Supervisors will need additional training in hazard identification and risk assessment, chemical safety, safety auditing and accident investigation. 4.2.4 Machine/Mill Operators Machine/Mill operators will require training and instruction in procedures relating to confined spaces, electrical isolation and chemical safety. New machine/mill operators will require a greater level of supervision and instruction by competent operators and supervisors until they attain the required competency of the equipment. 4.2.5 Vehicle Operators Forklift and Volvo operators will require specialised training in the safe operation of such vehicles. 4.2.6 First Aiders First Aid personnel must receive a certificate in Occupational First Aid. This cert lasts for three years. 4.2.7 WWTP Operators Waste Water Treatment Plant Operators must be given additional training in chemical safety and handling, MSDS’s, hazard identification and risk assessments. 4.2.8 Safety Representative The safety representative will be facilitated in attending a course in occupational safety and health. Additional training in the area of hazard identification and risk assessment and safety auditing should be given.

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Part 5: ACCIDENT/INCIDENT REPORTING & INVESTIGATION ACCIDENT/INCIDENT REPORTING & INVESTIGATION We define an accident as injury or damage to person, property or the environment, while an incident has the potential to cause injury or damage to person, property or the environment. The company wants to minimise the number of accidents that occur with our ultimate aim to eliminate them from happening altogether. We recognise that to achieve this we need to set up a system of reporting accidents and incidents, identifying the causes and putting in place corrective actions to prevent their reoccurrence. All accidents must be reported to the immediate supervisor. All accidents must be recorded in the accident logbook, which is located in the canteen. A serious accident is where outside medical assistance is sought or which results in time off work. Serious accidents must be reported as soon as possible after the event to the immediate supervisor/charge hand who will report it to the health and safety officer/production manager. The supervisor/health and safety officer and any person involved in the accident must complete an accident report form as soon as possible. The cause of the accident must be established, the corrective action identified and controls put in place to prevent reoccurrence. Accident report forms are available from reception, maintenance workshop and supervisors office. The company’s policy on First Aid is to use the local accident and emergency hospital. Minor cuts scraps, burns etc may be treated on site by designated First Aiders. Under the General Application Regulations 1993 the company have a statutory requirement to report any accident to the HSA which results in the person been off work for more than three consecutive days or results in a fatality on the required IR1 form. We will hold a copy of the report on our files for a minimum of ten years. A dangerous occurrence that requires notification will also be reported to the Authority should they occur. A dangerous occurrence is an unplanned and undesired occurrence which has the potential to cause injury and which may or may not cause damage to property, equipment or the environment. 5.1 Emergency Information In the event of a serious accident the following procedure must be followed; 1. Contact supervisor/health and safety officer/production manager immediately 2. Supervisor must take charge and observe the accident location and status of the injured

person. 3. If there is a risk of further injury move injured person to safety or provide protection. 4. If it is safe to move injured person and bring to local hospital, do so 5. If it is not safe to remove person to hospital - Call for immediate medical assistance or

emergency services 6. If possible first aid should be administered on site 7. If an ambulance is called arrange for someone to meet the ambulance on arrival and give

directions to injured person. 8. Establish location of hospital and appoint a suitable person to travel with the injured person 9. Notify the family of the injured person and if required arrange transportation to hospital for

them 10. Once casualty has been removed from the scene carry out an accident investigation

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11. Only when the initial accident investigation has been concluded and it is considered safe can production be resumed

12. If the injured employee is off work for more than 3 consecutive days as a result of the accident the HSA must be informed using the accident report form IR1.

The following information will be posted beside the first aid boxes, canteen, reception, control room, maintenance shop and the WWTP. 5.2 Emergency Contacts: Service: Telephone Number: Speed Dial No: Ambulance: Ballinasloe

09096 48200 7106

FireBrigade: Ballinasloe

Fire Officers home: 09096 42425 09096 42465

7107

Hospitals: Portiuncula

09096 48200

7106

GARDAI 090 9642123 7108 ALL EMERGENCY SERVICES:

Dial 999 112 from mobile

5.3 First Aid facilities The locations of the first aid boxes and first aiders are listed below: TRAINED FIRST AIDER: FIRST AID LOCATIONS: Trevor O’Shea Fitters office Michael Feury Factory office John Grenham Laboratory Des McDowell Main office Gabriel Mitchell Canteen Aine Naughton Seamus Brannelly

Part 6: WELFARE ARRANGEMENTS

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6.1 Toilet & Washing Facilities Changing facilities showers and toilets are provided for all employees on site. These facilities are cleaned on a weekly basis. It is imperative for the upkeep of these areas that employees clean up after themselves and maintain these areas to a good standard at all times. Any defects in these areas must be reported to management. Overalls and laboratory coats are cleaned on a weekly basis and provided to employees. 6.2 Drinking Water Potable drinking water is available to all employees in the main office. Tap drinking water, which is filtered and cooled, is also available to all employees in the canteen. 6.3 Canteen A canteen is located on site for all personnel. The canteen has adequate water boiling and cooking facilities. A kitchen is located in the main office where adequate water boiling facilities; microwave and cooker are provided. These areas are cleaned on a daily basis. It is imperative for the upkeep of these areas that employees clean up after themselves and maintain these areas to a good standard at all times. Any defects in these areas must be reported to management. 6.4 Smoking Smoking is strictly prohibited on site. Disciplinary action will be taken against anyone caught smoking on site.

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Part 7: FIRE & EMERGENCY PLANS FIRE At Premier Proteins (2000) Ltd the risk of fire is always considered high. All persons who enter the company must adhere to strict controls, arrangements and emergency plans to protect the company against fire. All persons entering the site will be made aware that smoking is prohibited throughout the site. The following are the controls in place to minimise the risk of a fire starting – 1. Smoking is strictly prohibited on site. Disciplinary procedures will be taken against those

found in breach of our strict ‘no smoking policy’. 2. Approved electrical contractors carry out all electrical installations and maintenance work. 3. Maintenance schedules are met for hydraulic and electrical equipment and for all

machinery. 4. Maintenance personnel and contractors must follow the safety guidelines and have a fire

extinguisher with them when carrying out hot work. 5. Fire fighting equipment is located in all areas and maintained under contract by Western

Fire Protection Ltd. 6. Diesel tanks are stored away from the main buildings. 7. All disposable rubbish is removed daily from offices and workshop. 8. Fire exits and fire-fighting equipment is kept clear at all times. 9. Walkways are kept clear of tools and general clutter. All waste should be cleaned up after

the shift is over. 10. All supervisors/charge hands must walk through their areas at the end of each shift to

ensure there are no possible fire hazards before leaving the site. 11. A fire alarm break glass system is in operation throughout the site. 12. All areas of machinery where bone meal has accumulated must be cleaned down at the end

of every shift 13. The bone meal located in stores must be sent for disposal as soon as possible so that a build

of bone meal does not take place causing a fire hazard 14. All flammable gases and oils are stored in their designated areas. 15. O2 and Acetylene gases must be stored in separate areas. 16. All employees must ensure all oils and gases are returned to their proper location when

work is completed. 17. All flammable chemicals are stored in a bunded area away from the main factory. 18. Staff hosting visitors are required to draw their attention to the fire safety arrangement, and

to guide them out in the event of an evacuation. 19. Fire Brigade can use our 1 million-gallon effluent tank in case of fire. The effluent tank is

closer than the river. 20. The thermal oxidiser has fire suppression steam ducting located every 5-10 metres in case

fire starts in the system.

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7.1 Fire Fighting Equipment Premier Proteins (2000) Ltd is adequately serviced with fire fighting equipment, which are inspected and maintained on a quarterly basis by an approved contractor. If a fire extinguisher is used or damaged it should be brought to the stores. The maintenance manager is responsible for reporting any problems with equipment to the approved contractor. The Safety Representative will carry out an inspection of fire extinguishers and hose reels on a monthly basis and report any defects to the maintenance manager. Western Fire Protection Ltd services all our fire equipment. Employees with specific roles to play in the event of a fire have received basic training in the use of fire equipment. They are instructed only to attempt to fight manageable fires if they feel it is safe to do so and relinquish responsibility for fire fighting to the Fire Brigade upon arrival. All other employees are directed to evacuate to assemble points in an orderly fashion and await further instructions from management and/or Fire Brigade. Emergency arrangements are in place and have been communicated to all employees. 7.2 Fire Exits & Assembly Points The company has adequate emergency exits in the main building and offices. The emergency exits are clearly identifiable with illuminous lighting in case of fire. The assembly point is in the car park at main entrance to building. 7.3 Emergency Fire Drills Annual emergency drills will be carried out and all employees will receive information on raising the alarm in the event of an emergency, evacuation procedures and the location of fire points in their area. 7.4 Emergency Lighting Emergency Lighting is located throughout the site and is checked on a regular basis to ensure it is working. 7.5 Fire Alarm A break glass system is in place on site. There is no actual detection system on site. A fire alarm test is carried out every Friday to familiarise personnel with the sound of the alarm and to ensure the system is operating accordingly. A different call point is activated every week. The activation is carried out by approved personnel. There is a fire alarm located throughout the entire site. This alarm is monitored by Nightguard Control. In order to avoid false alarms to the Gardai and Fire Services Nightguard Control must be contacted in the case of: 1. False Alarm 2. Alarm System Fault 3. Alarm Testing 4. Fire Drill 5. Alarm System Maintenance/Change/Upgrade. When any of the above have been completed Nightguard must be contacted immediately and informed that the system is back in service.

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7.6 Evacuation Procedures ON DISCOVERY OF A FIRE: • Raise the alarm (by breaking the break-glass call points) • Alert the supervisor • Leave the building immediately, do not stop to collect coats, belongings etc. • Go directly to assembly point and do not return. ON HEARING THE FIRE ALARM The Alarm system is to include RED FLASHING LIGHTS where noise is likely to drown out audible alarm. • Leave the building immediately. • Go directly to assembly point and do not return to the building until you have been

informed otherwise. RINGING THE FIRE BRIGADE • Dial the Emergency Services 999/112 • Inform the fire brigade operator of the location, nature and extent of the fire (if known) • After making the call the designated person will go to the front gates to direct the fire

brigade to the exact location of the fire. FIREFIGHTING Fire fighting is only to be attempted where fire is readily controllable and not life threatening. Dry powder and carbon dioxide extinguishers should be used in most cases. The use of water and fire hose is extremely dangerous giving the nature of the products on site and the number of electronic control panels in the factory area.

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7.7 Inventory of Fire Fighting Equipment No: Area: Wt

(kg): Type:

1 Main Office 4.5 Dry powder 2 Main Office 2 Dry powder 3 Main Office 2 CO2 4 Main Office 2 CO2 Main Office Fire blanket 5 Store 1 5 Dry powder 6 Store 2 9 Dry powder 7 Laboratory 2 CO2 Laboratory Fire blanket 8 Canteen 6 Dry powder Canteen Fire blanket 9 Changing Room 6 Dry powder 10 Fire Box in Yard 6 Dry powder 11 Fire Box in Yard 6 Dry powder 12 Store 3 6 Dry powder 13 Old Boiler House 6 Dry powder 14 Old Boiler House 6 Dry powder 15 New boiler house 9 Dry powder 16 New boiler house 9 Dry powder 17 New boiler house 6 Dry powder 18 New boiler house 6 Dry powder 19 New plant 2 CO2 20 New Plant 2 CO2 21 Workshop 9 Dry powder 22 Oil room 6 Dry powder 23 Power house 1 9 Dry powder 24 Loading bay 9 Dry powder 25 Panel room 6 Dry powder 26 Panel room 6 Dry powder 27 Panel room fire box 6 Dry powder 28 Panel room fire box 6 Dry powder 29 Power house 2 2 CO2 30 Power house 3 4.5 Dry powder 31 Crushing room 6 Dry powder 32 Crushing room 6 Dry powder 33 Crushing room 6 Dry powder 34 Crushing room 6 Dry powder 35 Crushing room 9 Dry powder 36 Crushing room 6 Dry powder 37 Press Room 9 Dry powder 38 Press Room 9 Dry powder 39 Press Room 9 Dry powder 40 Press Room 9 Dry powder 41 Computer room 5 CO2 42 Computer room 5 CO2

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43 Cooking room 9 Dry powder 44 Cooking room 6 Dry powder 45 Outside cooking room 9 Dry powder 46 Outside cooking room 9 Dry powder 47 Milling room 9 Dry powder 48 Milling room 9 Dry powder 49 Milling room 9 Dry powder 50 Milling room 9 Dry powder 51 Milling room 6 Dry powder 52 Milling room 6 Dry powder 53 Sterilisation Area 9 Dry powder 54 Sterilisation Area 9 Dry powder 55 Sterilisation Area 9 Dry powder 56 Sterilisation Area 9 Dry powder 57 Sterilisation Area 9 Dry powder 58 Sterilisation Area 9 Dry powder 59 Sterilisation Area 6 Dry powder 60 Sterilisation Area 6 Dry powder 61 Veterinary Office 2 CO2 62 New plant 6 Dry powder 63 New plant 6 Dry powder 64 Yard 6 Dry powder 65 Yard 6 Dry powder 66 Yard 4.5 Dry powder 67 Maintenance Stores SPARE 68 Maintenance Stores SPARE 69 Maintenance Stores SPARE 70 Maintenance Stores SPARE 71 New Building Power

House 5 kg Dry Powder

72 New Building Power House

6 kg Dry Powder

73 New Building Power House

6 kg Dry Powder

74 New Building (inside) 6 kg Dry Powder 75 New Building (inside) 6 kg Dry Powder 76 New Building (outside) 6 kg Dry Powder 77 New Building (outside) 6 kg Dry Powder

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Part 8: PERMITS TO WORK 8.1 Introduction A permit is required when maintenance and other work can only be carried out if normal safeguards are dropped or when new hazards are introduced by the work. Examples are entry into vessels (confined spaces), hot work and pipeline breaking. A permit to work system is a formal written system used to control certain types of work that are potentially hazardous. The Following table outline situations where a Permit to Work (PTW) is required Type of PTW Circumstances where PTW

required Examples

Hot work permit Work involving the production of Heat (e.g. Welding, cutting) where there are combustible materials present

Stores, Fuel tanks, Near lagged tanks Process area, Mill Area , RMS Area

Excavation and construction

Work involving the digging of holes and trenches or where there is construction or erection of structures

Repairing manhole of drains. Building. Installation of large machinery, gantries or tanks

Work with electricity Work on High Voltage panels Working in ESB panel room. Main Transformer

Working at height Any work over 2 meter ( Shoulder height) where the use of a ladders, scaffold or hoist is required

Painting, cleaning ductwork maintenance

Work over water Work over large open tanks , near rivers where there is a need to circumvent safety rails or get close to waters edge

Work on aerators or work beside river

Major lifts

Lift involving the use of a crane / teleporter with slings

Installation of tanks or machinery

Working with hazardous materials

Work involving the handling of Hazardous materials which are not used normally

Asbestos. Plant fumigation. De-scaling boiler. Use of caustic for infrequent cleaning

Work on pipes

Work on installed pipe which are or have been in service ( purpose of this is to ensure that line is depressurised or empty before breaking , and that associated pumped valve feeding or being fed by the pipe is isolated)

Tallow pipes, Fuel pipes, Hot/pressurised water pipes, Raw material pipes, air hose, Steam Line

Confined space entry Where work to be done requires entry into area / space which is not normally occupied by personnel AND where by virtue of the closed nature the risk and seriousness of the hazard are increase

Entry to tallow tanks, Effluent tanks Cooker meal bins.

Zero Energy Work Work which requires the shut down off power which may be vital for the operation of equipment other than what is being worked on

Shutting off power to plant for repair resulting in no power for WWTP >1hr or Computer systems. RMS ( may freewheel with no power)

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Part 9: ELECTRICAL SAFETY Electrical Safety The company is a large user of electricity and recognises that it can pose a hazard to all employees if electrical equipment is not properly installed or maintained. Approved competent electrical contractors working to the ETCI standards complete all electrical installations. The company employs a qualified contract electrician to carry out light installation, maintenance and repair work. The company employs an electrical isolation procedure when working on electrical equipment. The company adopts the following practices to further reduce the risk of injury or fire- 1. Only competent persons work on electrical installations.

Rubber or non-conductive protective equipment is used. Ensure equipment is checked and is ‘dead’ before carrying out repairs or works etc. Insulated tools and equipment must be used on site.

2. Step down transformers ensuring 110-volt supply should be used with portable electric equipment.

3. Trailing leads must be checked for any damage. Portable tools and cables should be checked for defects before use and any defects brought to the attention of the supervisor.

4. No cracks or missing pieces on machinery should exist. 5. Tools must be fitted with the correct plug, type and size. 6. All electrical sockets must be of the correct type. 7. Maintenance schedules must be met for all plant and machinery. 8. Any defects must be reported immediately to the maintenance manager.

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9.1 Electrical Isolation Procedure The company operates a ‘Lock Out Tag Out’ system when working on machinery. Fitters, electricians and machine operators will occasionally need to carry out work on the machinery. It is reasonable to expect that machinery may be started whilst work is being carried out on them hence resulting in serious if not fatal consequences for any person carrying out such work. Any employee carrying out such work will receive training on the equipment; the various control panels and the isolation procedures. Each fitter, electrician and machine operator likely to carry out work on a machine will receive their individual padlock, key and name tag. Machinery, which exists on site, is highly automated and is operated from control cabins where the operator in the control cabin cannot see the entire machine. All personnel, who carry out fault finding, maintenance or repair work, must operate the following procedure; 1. Before carrying out any work on the machine identify what machine or area needs to be

isolated and which control panel(s) must be locked out. 2. Inform the machine operators if feasible that the machine will be isolated. 3. Stop the electricity supply to the machine at the control panel, tag and padlock the panel. If

the control panel is already locked out with another padlock(s) continue to tag and lock out the panel with your own padlock.

4. Once the work has been completed on the machine remove your tag and padlock. 5. Never remove another person’s tag and padlock. 6. If a padlock has been left on the control panel and the responsible employee cannot be

located or has left the premises, the maintenance manager is responsible for removing the padlock using the spare key.

7. No padlock should be removed by any person until it has been established for certain that the person is not still carrying out the work and has simply left the area for a period of time.

Responsibility: All employees carrying out faultfinding, maintenance, repairs or removing blockages must comply with this procedure. The maintenance manager is responsible for ensuring that all machines are locked out or isolated before any maintenance or repairs is commenced.

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Part 10: HAZARDOUS CHEMICALS & SUBSTANCES Premier Proteins (2000) Ltd uses a number of hazardous chemicals on site due to the production process on site and the fact that we operate a laboratory for on site analysis. The majority of hazardous chemicals are used in the laboratory with a small number of chemicals used for the process and for cleaning and sanitation of the site. Chemicals are also used in the process, and employees have been trained in the hazards of the chemicals used. In legislation relating to chemical safety, any substance in gas, liquid or solid form, that can cause harm, is referred to as a hazardous or dangerous substance Maintenance personnel are also exposed to oils, lubricants and gases. Any chemical that comes on site must have a relevant and up-to date MSDS (Material Safety Data Sheet) with it and any employees using the chemical must read this. A copy of all MSDS’s will be kept in the EHS Officers office, canteen and maintenance stores. Routes of Entry of Dangerous Substances into the Body: 1. Ingestion – this may be through handling of food without having washed your hands after

using chemicals or by touching your mouth. 2. Inhalation – this happens when the chemical is in gas, vapour or fume form and you

breathe it in. 3. Absorption – this happens when the chemical comes into contact with and passes through

the skin, eyes or mucus membranes. The Dangers: Contact with, or exposure to, hazardous substances at work can result in discomfort, pain, and in extreme cases, death. If not used properly, hazardous substances can: � Catch fire or explode � Cause burns � Damage your health including asthma, dermatitis, cancer, damage to the central nervous

system, mutations � Cause environmental damage The effects of hazardous substances may be seen or felt immediately with symptoms such as dizziness, nausea and itchy eyes or skin; or the damage may occur gradually over a number of years, such as in the case of asthma, dermatitis or cancer. Dermatitis (or skin exposure) is one of the most common health problems as a result of chemical exposure. 10.1 Chemical Safety on Site

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The company recognises the hazards of chemical exposure to employees and have put the following procedures in place to minimise the hazards: 1. A fume hood is in place in the laboratory. 2. All MSDS are on file and a copy held in the EHS Officers office and the canteen. 3. Only approved chemicals are allowed on site. 4. All employees who handle chemicals have been given training and instruction in the

handling of them. 5. Only trained personnel are permitted to carry out analysis in the laboratory. 6. Chemical dispensers have been put in place wherever feasible. 7. All chemicals are stored away from the main factory. 8. No ignition sources are near the stored chemicals. 9. Chemicals are stored in a cool, dry ventilated area which is locked. 10. Adequate gloves, overalls, safety boots, eye protection and masks are available to all

employees and advised to wear them when handling chemicals. 11. Showers are located on site with emergency showers and eyewashes located in the main

buildings on site. 12. Chemicals are never to be transferred into unmarked containers. 13. Flammable chemicals are never used near sources of ignition. 14. Eating and drinking is prohibited when handling chemicals. 15. Smoking is strictly prohibited on site. 16. Any spillage’s are to be cleaned up immediately. 17. Dispose of all waste material in the approved manner. 18. All gasses are stored upright in the maintenance stores and all have adequate regulators

fitted.

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Part 11: CONFINED SPACES Confined Spaces The term confined space means any place including any vessel, tank, container, vat, silo, hopper, pit, bund, trench, pipe, sewer, flue, well, chamber, compartment, cellar or other similar space which by virtue of its enclosed nature creates conditions which give rise to a likelihood of accident, harm or injury of such a nature as to require emergency action due to: (a) the presence or reasonable foreseeable presence of

(i) flammable or explosive atmospheres (ii) harmful gas, fume or vapour (iii) free flowing solid or an increasing level of liquid (iv) excess of oxygen (v) excessively high temperature

(b) The lack or reasonably foreseeable lack of oxygen. The main hazards that make confined spaces potentially dangerous are: � fire or explosion � being overcome by gas, fumes or lack of oxygen � being overcome by an inflow of liquid or solid � being overcome by extremes of heat or cold There are a number of areas on site where confined space entry takes place. These are; 1. Tallow Tanks 2. Effluent Tanks 3. Cooker Meal Bins A PERMIT TO WORK MUST BE OBTAINED FROM AUTHORISED PERSON BEFORE

ANY CONFINED SPACE ENTRY IS CARRIED OUT ON SITE.

The following is a list of the procedures to follow before entering a confined space: 1. Access • A safe means of entering and leaving a confined space must be provided to ensure that

people can get in and out easily. • Clear and conspicuous signs should be posted alongside openings while work is in

progress; 2. Fire prevention • Fire prevention procedures are of even greater importance than usual when applied to work

in a confined space. • Keep flammable or potentially explosive materials stored in the confined space to an

absolute minimum. • Do not smoke • Take care to eliminate the possibility of static electricity build-up.

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3. Control of the Environment • Purging: a confined space which has been used for the storage of a volatile (say, a toxic,

flammable or potentially explosive) substance may need to be purged with nitrogen or other inert gas

• Ventilation: forced mechanical ventilation may well be necessary to ensure a plentiful supply of breathable air;

• Confined spaces may need to be physically isolated to prevent the ingress of substances which could pose a risk to those inside, or electrically and/or mechanically isolated to prevent someone outside the confined space inadvertently putting those inside at risk;

4. Equipment Any equipment for use in a confined space must be suitable for the purpose. This will include: - • Testing and monitoring the atmosphere: The nature of the work or the workplace may

demand that before entry the atmosphere inside the confined space be tested for oxygen level, hydrogen sulphide, hydrocarbons etc. This will inform decisions about respiratory protective equipment (RPE) and ventilation

• Electrical equipment may need to be certified as being safe for use in a flammable atmosphere, and earthed;

• The type of PPE will depend on the hazards identified, but could include safety lines, and harnesses, head and eye protection, and protective footwear. Piped gas supplies: at the end of any work period remove any such pipes and close all valves;

• Communication : if personnel could get into difficulties while out of sight of the main party, or if they must descend far into a confined space, or if the environment is noisy, then consider how they can continue to communicate easily with the outside, especially if they have to raise the alarm;

• Lighting; must be adequate for both the work and the workplace. Consider its physical robustness, and electrical integrity and protection. Position it so as to give illumination of the work and clearance for activity in both planned and emergency situations.

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Part 12: HOT WORK Hot Work Permits Due to the nature of business in the plant and the amount of hot work that is carried out, the company has come to the conclusion that hot work permits are an important part of the elimination of fire hazards. A hot work permit will be issued to maintenance personnel for an eight-hour period. After the eight-hour period a new permit must be obtained from authorised personnel. The gas cylinders for blowing down pipe lines are under lock and key and any person wishing to use this must obtain a hot work permit and follow the guidelines. A Hot Work Permit is required when welding, cutting, grinding, use of a gas torch or other heat sources needs to be carried out in an area where there are combustible materials. Contractors and Maintenance personnel are issued with the following safety instructions, which must be adhered to when carrying out hot work. Hot work permits do not apply to hot work being carried out in the maintenance shop. All persons carrying out hot work must ensure the following- 1. The location and adjacent areas are cleaned of dust and any ignitable material e.g. oil etc. 2. Where possible wet down the area 3. Ensure an appropriate fire extinguisher is at hand 4. Check the area during work and on completion for any signs of fire 5. Check the area 30 mins and 1-hour after completion of the hot work for any evidence of

fire. Responsibility: Contractors and Maintenance personnel who carry out hot work are responsible for following the above instructions every time hot work is carried out. The foreman/supervisor must check that anybody carrying out hot-work in the area they are supervising has adhered to the safety instructions and has a fire extinguisher at hand at all times. Anybody carrying out Hot Work is responsible for ensuring they obtain a Hot Work Permit from the Supervisor The following is the list of Authorised Hot Work Permit Issuers: 1. Ray Quinn 2. Gabriel Mitchell 3. Des McDowell 4. John Grenham 5. Aine Naughton 6. Brendan Dunne 7. Hugh Manton 8. Seamus Brannelly 9. Tony Loughnane 10. Trevor O’Shea 11. Pat Kelly 12. Any replacement charge hand on duty.

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Part 11: HEALTH ISSUES 11.1 Shiftwork The company adheres to their responsibilities under the 1997 Organisation of Working Time Act. Production operates 24 hours a day six days a week ceasing at 12 midnight on Saturdays. Three cycle shifts operate starting at 8 am. Three employees operate the evening and nightshift with a fitter on call at all times in case of breakdown. Offices operate Mon-Fri 9am – 5pm. All employees be available and work reasonable overtime as required by the company. Medicals by a local doctor are in place for all employees carrying out shiftwork on site. Employees experiencing difficulties at work or which may impact on their work are encouraged to discuss them with their supervisor or the production manager. 11.2 Stress The company recognises that employees may on occasion be under stress while carrying out their job, however serious efforts are made to ensure stress is not a consistent part of any job. Certain jobs can require greater physical or mental capabilities and the company endeavour to organise the work allowing for individual capabilities. As it is recognised that workplace stress can be caused from a variety of factors and its effects vary considerably among people, employees are actively encouraged to report problems, concerns and issues to their immediate supervisor so that appropriate action can be taken. General moral levels are high and the ‘open door’ policy of consultation and communication promotes a stress free environment. 11.3 Bullying Bullying in the workplace constitutes a real threat to the safety, health and welfare of people in the workplace. As it can arise in any situation where people are working together an effective Bullying Prevention Policy will be implemented as a precautionary measure and deterrent in this workplace. The key objective of this policy is to communicate clearly, so as to avoid any doubt, that instances of bullying will not be tolerated and that precautionary measures are in place both to prevent the occurrence of bullying and to deal appropriately with any cases that might arise. Bullying can be perpetrated by a person in a position of authority or by a work colleague against a person at any level in the workplace and it can be carried out by an individual or by a group. Bullying can also be perpetrated against an employee by the client, contractor, customer or other business contact of the employer. The Bullying Prevention Policy will be brought to the attention of all employees as well as to the attention of regular clients, contractors or other business contacts of the employer, with whom the employees will interface. Where bullying is occurring in the workplace it will, in general, result in an increased level of anxiety and stress for the victims. This may lead to an inability to concentrate causing errors and accidents and will result in health problems. Such health problems will result in increased blood pressure and cardiovascular disease in the long term. Behavioural changes may also occur such as an increased level of smoking or drinking perhaps resulting in an increased level of absenteeism in work. Definition Workplace bullying is repeated inappropriate behaviour, direct or indirect, whether verbal, physical or otherwise, conducted by one or more persons against another or others, at the place of work and/or in the course of employment, which could reasonably be regarded as

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undermining the individual’s right to dignity at work. An isolated incident of the behaviour described in this definition may be an affront to dignity at work but, as a once off incident is not considered to be bullying. (As defined in the Report of the Task Force on the Prevention of Workplace Bullying – published by the Stationery Office, March 2001) Anti -Bullying / Harassment Policy

• Premier Proteins (2000) Ltd. is committed to providing all its employees with a work place environment that is free from Bullying / Harassment.

• All employees will be expected to comply with this policy. • Management will take appropriate steps to avoid the occurrence Bullying / Harassment. • A Risk Assessment of the presence of specific behaviours and circumstances that can

result in Bullying / Harassment will be carried out and recorded. • All complaints of Bullying / Harassment received will be treated seriously,

confidentially, with sensitivity and as soon as is practicable • This policy applies to employees both in the work place and at work associated events

such as meeting, conferences and work related social events whether on the premises or off site.

• This policy applies to Bullying / Harassment by clients, customers, contractors or any other business contact to which an employee might be reasonably be expected to come into contact during the course of their employment

• Appropriate disciplinary action, including dismissal for serious offences, will be taken against any employee who violates this policy.

• Bullying / Harassment by non employees such as client, contractors and business contacts will not be tolerated and may lead to termination of contracts or suspension of services, or the exclusion from the premises, or the imposition of other sanction (as appropriate)

• In implementing this policy, management will make all employees and regular contractors aware of its existence

• Training and instruction will be provided to • Make employees aware of the hazards of Bullying / Harassment • Provide information of appropriate behaviour • Raise awareness among managers, supervisors and those in positions of authority • Each employee will be made aware of his/her responsibility not to place the health ,

safety and welfare of a colleague at risk by engaging in Bullying / Harassment • Each manager supervisor or person in a position of authority will be made aware of

his/her responsibilities both not to place the health , safety and welfare of a colleague at risk by engaging in Bullying / Harassment and to take appropriate measure to prevent its occurrence

• Each manager supervisor or person in a position of authority will be made aware of action to take if they become aware of an incident of Bullying / Harassment either by direct complaint or otherwise.

• Any Employee who makes a complaint or who gives evidence in proceeding will not be victimised. Regular checks will be made by the investigator to ensure this. Retaliation of any kind is a serious disciplinary offence.

• It is at the discretion of each employee to decide what behaviour is unwelcome irrespective of the attitude of other to the matter

If a complaint is found to be malicious then appropriate disciplinary action up to and including dismissal will be imposed.

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11.4 Violence Violence at work occurs when persons are verbally abused, threatened or assaulted in circumstances related to their work. The company considers the occurrence of violence at work to be low risk. Violent behaviour may result in disciplinary action up to and including dismissal. Supervisors and managers find themselves in situations where they may have to hand out a verbal disciplinary warning to a worker or involve themselves in conflict between co-workers. These risks are minimised by clear distinct lines of industrial relations, non-confrontational approaches and training in dealing with such situations. Abusive substances are a factor in many assaults. All abusive substances are banned on site and anyone found under the influence of these substances will be disciplined accordingly. Reporting an act of violence can be done in the following ways: 1. Report the incident to your immediate supervisor 2. Report the incident to the Production Manager 3. Report the incident to the Gardai The company undertakes to investigate any such acts of violence reported to us, with the co-operation of external agencies, if required 11.5 Pregnant Employees The majority of female workers are employed in the office. Employees should advise their supervisor of their condition. An immediate risk assessment will be conducted taking into account the new condition and appropriate safeguards and controls will be put in place where possible. The company will comply with their legal requirements under the appropriate legislation. 11.6 Young Employees The company uses the definition for child and young persons found under the Safety Health & Welfare at Work (Children & Young Persons) Regulations 1998. Occasionally the company may employ young persons from the age of 16 to carry out light seasonal work and recognises that young persons are likely to be at increased risk. The following provisions will be put in place to minimise the risks to the safety health and welfare of young employees – 1. No person under 18 years will be allowed to operate any machine 1. No person under 18 will be allowed to drive vehicles on site. 2. Young persons will receive adequate instruction and training prior to carrying out any

work. 3. Young persons will receive adequate supervision from supervisors and experienced staff. 4. Young persons will not be requested to carry out heavy physical or mentally fatiguing

work. 5. Young persons will be given adequate personal protective equipment and instructions on

their use. 6. Risk assessments will be conducted on all tasks to ensure they do not pose an increased risk

to young persons. 7. Young persons between 16-18 years will normally not work more than 8 hours a day or 40

hour week.

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8. Students may come on site for work experience. They will be assigned menial jobs such as painting and cleaning. They will not be allowed in the factory.

11.7 Noise At Premier Proteins (2000) Ltd., noise has been identified as a serious hazard with noise levels inside the mill above 80dB (A) and in some cases above 85-dB (A). While considerable effort has been made to reduce the noise levels especially during the purchase of new machinery the company have had limited success. The following are the measures taken by the company to reduce the risks associated with high noise levels. � Machine operators where possible, are located away from the nosiest parts of the machinery

and where feasible control rooms have been enclosed. � The compulsory wearing of hearing protection while in the mill is strictly enforced. � All employees have been given information regarding, the risks associated with high noise

levels and the wearing of hearing protection. � Appropriate signage is placed around the factory to inform people that compulsory hearing

protection is required. � Maintenance schedules are met for all equipment and machinery. � Equipment which becomes unusually noisy is reported to the maintenance manager for

repair � Prior to purchasing any new plant or machinery a serious effort will be made to source and

purchase equipment with low noise levels � Periodic noise surveys will be carried out 11.8 Vibration The company recognises that vibration hazards exist within the factory; however all the machinery that vibrates operates automatically. Platforms and walkways may vibrate slightly as a result of nearby machinery; however adequate breaks are taken throughout the day. Employees are not located beside a certain machine for a long period of time. 11.9 Dust & Fumes The company have monitored the dust and fume levels in the mill and found them to be below the OEL-8hr 10mg/m3 for dusts non-specific and 4mg/m³ for total inhalable respirable. Employees do not stay in these areas for long periods of time unless there is a breakdown. Extraction systems are in operation in these areas to reduce the levels as far as is reasonably practicable. Dust masks are available to all employees on site and must be worn when in these areas. 12.10 Visual Display Units Office staff use computers for the majority of their working day. Adequate breaks are taken from the computer. A computer is located in the control room also but this is intermitted usage at this computer.

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Part 12: AUDITING & REVIEWING PERFORMANCE

Auditing & Reviewing Performance

12.1 Safety Auditing The foremen/supervisors and safety representative are responsible for carrying out safety audits. Where possible the auditor will be independent of the area being audited. Audits will be conducted quarterly with areas of greater risk audited most frequently. EHS Officer will schedule and arrange such audits. The audit results will be given to the supervisor of the area, any hazards or risks found are to be resolved or eliminated as soon as possible. Both auditor and area supervisor will decide corrective actions where possible and the supervisor/manager is responsible for ensuring the corrective actions are implemented in the area. Outstanding corrective actions are brought to the attention of the safety committee and appropriate action taken. If additional expertise are required to resolve issues than management must be advised. Audit data will be held on file and reviewed to ensure corrective actions have been completed. The safety committee will periodically review audit checklists to ensure they include any new hazards, which may arise. 12.2 Safety Statement Review The safety statement will be reviewed annually by the safety committee to ensure it is kept up to date and relevant so as to reflect current company practice. Hazard identification and risk assessments will be reviewed annually or when new hazards are identified. Risk assessments will be carried out on new equipment or machinery or when changes occur.

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Part 13: METHOD OF RISK ASSESSMENT

RISK ASSESSMENT METHODOLOGY

The risk assessment method used is a simple qualitative method taking into account the factors of probability, severity and frequency on a scale of 1 to10 in each case. This gives a risk rating between 1 and 1000 which indicates the urgency or priority of action in respect of the particular risk. The risk rating was then related to the easily understandable qualitative method of high, medium and low. Risk Rating =probability x severity x frequency

Table 1: Probability Scale Probability Index Description

10 9 8 7 6 5 4 3 2 1

Inevitable Almost certain Very Likely Probable More than even chance Even chance Less than even chance Improbable Very improbable Almost impossible

Table 2: Severity Scale Severity

Index

Description

10

9

8

7

6

5

4

3

2

1

Death

Permanent total incapacity

Permanent severe incapacity

Permanent slight incapacity

Absent from work for more than 3 weeks with subsequent recurring

incapacity

Absent from work for more than three weeks but with subsequent

complete recovery

Absent from work for more than three days but less than three weeks

with subsequent complete recovery

Absent from work for less than three days with complete recovery

Minor injury with no lost time and complete recovery

No human injury expected

For

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EPA Export 26-07-2013:00:30:39


56 of 56

Table 3: Frequency Scale Frequency Index Description

10 9 8 7 6 5 4 3 2 1

Hazard permanently present Hazard arises every 30-sec. Hazard arises every minute Hazard arises every 30-min. Hazard arises every hour Hazard arises every shift Hazard arises once a week Hazard arises once a month Hazard arises once a year Hazard arises every 5 years

Table 4: Priority of Action Priority Index Risk Action to be taken

800-1000 600-800 400-600 200-400 Below 200

High High Medium Medium Low

Immediate action Action within the next 7 days Action within the next month Action within the next year No immediate action necessary but keep under review.

Qualitative Risk Assessment High risk means the likelihood of the event occurring is probable and the consequences from such an event could range from a serious injury to a fatal accident. The controls in place must be strictly adhered too, so as to prevent such an event occurring. Medium risk means the likelihood of the event occurring is probable and the consequences from such an event could range from a serious injury to a minor injury. Low risk means the likelihood of the event occurring is improbable and the consequences from such an event would lead to minor injury.

For

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EPA Export 26-07-2013:00:30:39

Attachment I - Supplement I.3 Hazard Identification and Risk Assessment Sheets

For

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EPA Export 26-07-2013:00:30:39

Premier Proteins 2000 Ltd Date: September 2006 Poolboy, Ballinasloe, Co. Galway. Hazard Identification & Risk Assessment Sheets

1 of 75

AREA: ACID SCRUBBER

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Ph probe calibration 2. Changing IBC 3. Cleaning Acid Scrubber 4. Forklift in operation.

• Chemical burns from handling of sulphuric acid /leaking from IBC. Can cause severe burns.

• Collision between forklift & IBC when changing IBC. Overturning of forklift while carrying IBC.

• Environmental risk of line rupturing and emptying IBC by siphon

• Environmental risk of pH probe not calibrated correctly resulting in too much/little acid being dosed.

• Entanglement in motor shaft or drive assembly.

• Shattering of glass pH probe when handling causing cuts to skin.

Medium Low Medium Low Low Low

IBC located in bund. Bund is inspected and emptied regularly. Safety gloves, overalls and glasses must be worn when changing/handling the IBC. Dosing off as per procedure for Scrubber. Adequate training of Forklift operator. Dosing line is located out of harms way-(fixed to workshop wall) Timer on dosing pump to limit acid dose. Motor adequately guarded Operator has been trained in the correct procedure for handling pH probes.

Installation of protective rail around IBC bund. Adequate PPE to be worn at all times when handling/changing IBC. Adequate warning sign and MSDS to be posted in the area. Inspection of motor guard to be carried out on a regular basis. Refresher training to be carried out with operator.

Maint. Dept

Operator

EHS Officer

Maint. Dept

Production Manager

1 month

Ongoing

1 Month

Ongoing

1 year

For

insp

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n pur

pose

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EPA Export 26-07-2013:00:30:40


2 of 75

AREA: AIR COOLED CONDENSER & FAT SCRUBBER

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Emptying cooker

vapour cyclone 2. Sampling

3. Falls from stairs/gantries/platform at inspection hatch causing injury.

4. Entanglement in motor shaft or drive assembles

5. Unguarded pathogenic sump- falls causing injury.

6. Poor lighting in area.

Medium Low Low

Handrails in place on all stairs/gantries and platforms. Hoop guard around ladder at air cooled condenser. Manhole covering sump. Adequate lighting installed in area.

Post use handrail stickers on handrails. Access to control house to be kept clear at all times. Access to fixed ladder gantry locked to prevent unauthorised access. Handrails to be inspected regularly. May be possible to make stairs less steep on stairs leading to roof of panel room. Use of manhole guard when manhole opened. Operator to report defects in lighting.

EHS Officer

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept

Operator

1 month

1 Month

Ongoing

6 months

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

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EPA Export 26-07-2013:00:30:40


3 of 75

AREA: BIOFILTER 1& 2 & HUMIDIFIER TANKS.

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Starting bio-filter &

fan. 2. Entering central

chamber 3. Cleaning tank 4. Sampling and

measuring 5. Clearing of heather 6. Traffic in area 7. Changing bio-filter bed 8. Maintenance of

machinery etc.

• Environmental risk odour- collision of forklift with duct support causing duct to collapse.

• Slips and falls due to slime growth on concrete adjacent to Bio filters.

• Falling into bio filters. • Entanglement in fan/moving

parts. • Entering Central Chamber-

Confined Space Entry. Slips, trips & falls.

• Biological hazard from cleaning

tank- infection through open wounds and cuts

Medium Medium Medium Medium Medium Low

Care to be taken when driving vehicles in this area. Concrete is power hosed on a regular basis. Adequate guard rails and ladders have been put in place. All moving parts and fans are adequately guarded. All cuts/open wounds are properly covered up. Adequate gloves are worn by operator.

Highlight/paint duct supports. Only trained forklift operators to operate forklift. Concrete to be power hosed on a regular basis. Guardrails and ladders to be inspected regularly and any defects reported to maintenance personnel. Ensure all guards are in place and any defects to be reported to maintenance personnel. CSE safe working procedure to be developed for operator. All cuts/open wounds to be properly covered up. Adequate gloves are worn by operator

Maint. Dept. General Operators.

General Operators

Env. Operator

Env. Operator

EHS Officer & Env. Operator

Production Manager/EHS Officer All employees

I month Ongoing

Ongoing

Ongoing

Ongoing

1 month

Immediate

Ongoing

For

insp

ectio

n pur

pose

s only

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4 of 75

AREA: BOILER FUEL STORAGE (LFO & TALLOW & DIESEL TANK):

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date; 1. Climbing stack 2. Maintenance of

machines, pipe & valves etc.

3. Cleaning of bunded area.

4. Filling of forklifts and loaders with diesel.

• Trespassers climbing and falling from stack.

• Falling/slipping on Plinth for

stack. • Fire/explosion due to diesel and

LFO Storage. • Rodents • Scalds from steam and water

pipes. • Slips/trips/falls

Medium Medium Medium Low Low Low

No access ladder available from ground level. Safety boots issued and worn by all personnel. No smoking area. Pest control contractor in use. Maintenance of pipes and joints. Adequate lighting in area.

Locking access to stack ladder. Wire mesh to prevent climbing of stack frame. Inspect that stack is being locked. Area to be further fenced off in case of trespassers. Area to be power hosed on a regular basis. No smoking sign to be placed in area. Fire extinguisher to be placed in area. Keep area clean and inspect for rodents. Regular inspection of pipes and joints. Highlight kerb for bund channel.

Maint. Dept.

General Operators.

Managing Director General Operators

EHS Officer

General Operators

Maint. Dept.

Maint. Dept.

Ongoing

Ongoing

1 month

Ongoing

1 month

Ongoing

Ongoing

1 month

For

insp

ectio

n pur

pose

s only

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EPA Export 26-07-2013:00:30:40


5 of 75

AREA: BOILER HOUSE

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Switching on/off

boilers 2. Filling salt tank 3. Sampling effluents 4. Sampling boiler water 5. Cleaning of area 6. Maintenance of

machinery, pipes, valves etc.

7. Electrical work.

• Manual handling • Falls from ladders and gantries

• Fire

• Boiler explosion

• Slips/trips/falls • Environmental risk of water

treatment chemicals spilling onto floor and into drains

• Scalds from hot water/steam

• Burns from hot pipe work etc. • Skin irritation from chemicals

• Burns from lance

Low Low Low Low Low Low Low Low Low Medium

Employees have carried out manual handling training. Handrails and gantries protected by handrails. Extinguishers located in area. Designated no smoking area. Certified vessel automated pressure control- over pressure safety valve. Regular inspection of area for tidiness. Any spillages must be cleaned up immediately. Chemicals stored in bund. Proper fittings used and maintained. Operators are trained in the correct start up and steam usage procedures. All pipe work is lagged and maintained. Chemicals stored in bunded areas. MSDS of chemicals to be stored area. Raw steam is used in the lance so care must be taken when using it to clean.

Handrails and gantries to be inspected and any defects reported to management. Any defects in pipes/fittings must be reported immediately to maintenance personnel. Operators and lab analyst to wear gloves and safety specs when sampling. MSDS’s of chemicals to be stored in the area. The lance must be used with the greatest of care. Only the person using it may be in the vicinity when using the lance. Lance must always be directed to the ground. Adequate gloves, overalls and safety boots to be worn when using the lance.

Maint. Dept.

General

Operators

Operator & lab analyst

EHS Officer

Supervisor Operators

Ongoing

Ongoing

Ongoing

1 month

Ongoing

For

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6 of 75

AREA: BETWEEN WORKSHOP AND WWTP

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Vehicle movement in

area 2. Maintenance of pipes

etc. 3. Cleaning of area.

• Environmental risk of odour from waste skips and bins.

• Slips/trips/falls due to untidy storage of scrap.

• Falling into uncovered manholes • Steep embankment

Medium Low Low Low

Skip emptied when full. Skip to be emptied every 2-3 weeks. Area inspected and tidied regularly. Manhole covers replaced immediately after use. Embankment is power hosed on regular basis to prevent build up slime etc.

Bins to be cleaned thoroughly before storing outside. Area to be inspected on regular basis and kept tidy. Manhole guard to be put in place when manhole is to be left off for any length of time unsupervised. Warning sign to be put in place.

Env. Operator

Env. Operator /General Operator. General Operator

EHS Officer

Ongoing

Ongoing

Ongoing

Ongoing

AREA: CANTEEN

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Cleaning of canteen. 2. Cooking in area. 3. Eating and drinking in

area.

• Scald from berco boiler • Extraction hood- build up of

grease fat etc. • Food poisoning from poor

storage/hygiene

• Greasy floor causing slips

• Fire hazard

Medium Medium Low Low Low

Stainless steel extractor in place. All perishable goods to be placed in fridge. Canteen cleaned daily. All rubbish is placed in bins provided. Anti-slip flooring in place. Mats also in place and changed on a weekly basis. Fire extinguisher and fire blanket located in canteen. Grill/Heating plate in good condition. Bins emptied on a daily basis. Grill washed after use.

Sign to be put in place warning users of the dangers of boiler. Extractor to be cleaned on a weekly basis. Canteen to be cleaned daily and rubbish to be placed in bins. Any spillages to be cleaned immediately. Floors to be cleaned daily. Heating plate/grill to be switched off after use. Sign to be put in place to warn users.

EHS Officer

Cleaner

Cleaner and canteen users.

Cleaner and canteen users

Canteen users EHS Officer.

1 Month

Ongoing

Ongoing

Ongoing

Ongoing 1 month

For

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EPA Export 26-07-2013:00:30:40


7 of 75

AREA: CHANGING AREAS

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date:

1. Cleaning of area. 2. Showers. 3. Storage of items in

lockers.

• Fire risk • Rodents • Scalds from hot water

• Slipping on inclined floor when

wet.

• Objects falling from lockers

• Skin irritation from cleaning agents

Low Low Low Low Low

Area cleaned daily. No eating permitted in changing area. Thermostatically controlled water temperature. Floor cleaned on daily basis. Employees not to store sharp objects etc in lockers. Lockers to be kept tidy at all times. New chemical approval procedure in place.

Temperature to be checked by cleaner on regular basis. Locks must be available on all lockers. Any employees who have a problem with the cleaning agents supplied must report this to management.

Cleaner

Production Manager.

Employees

Ongoing

6 months

Ongoing

For

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s only

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EPA Export 26-07-2013:00:30:40


8 of 75

AREA; CONTROL ROOM & PANEL ROOM


1. Inspection of alarms 2. Starting presses 3. Starting air cooled

condenser 4. Starting pathogenic

steriliser 5. Use of computer 6. Cleaning of area.

• Electrocution from electrical panels

• Eye strain from VDU.

• Poor Ventilation

• Slipping on greasy floor • Fire – combustible material • Panel room at control room- high

tension electrical equipment- risk of electrocution.

• Poor environment for employees and equipment due to the heat.

Medium Low Medium Medium Low Medium Medium

Doors on all panels. Operators only use computers for short periods of time. VDU protected from build up of dirt grease etc. Ventilation system in place but air is taken in from outside and on hot days there is very poor ventilation. Floor is cleaned on a regular basis. Fire extinguishers provided and bins emptied on a regular basis. All panels’ doors to be kept closed at all times. Doors must be able to be locked. All electrical work carried out be qualified electrician.

Stickers to be placed on all panel doors to instruct employees to keep doors closed. Ventilation system must be reviewed and adequate system put in place due to the heat in this area. Floor to be inspected and cleaned on a regular basis. All doors must be lockable. Good ventilation system to be put in place for room.

EHS Officer

Managing Director

Control Room

Op

Electrician

Managing Director

1 month

Immediate

Ongoing

Immediate

6 months

For

insp

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n pur

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Conse

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EPA Export 26-07-2013:00:30:40


9 of 75

AREA: COOKER


1. Checking raw material bins.

2. Heating cooker (bleeding steam) checking and clearing magnets

3. Inspection of cooker 4. Maintenance of

machine, pipes, valves etc.

5. Electrical work carried out.

• Burn/scald from steam condensate valves protruding into area where personnel walk by frequently.

• Slips/trips/falls on

greasy/untidy floors and gantries.

• Burns & scalds from steam pipes etc.

• Entanglement in unguarded motor shaft/drive assemble for RCD Shaft/Discharge Screw

• Falls from stairs • Noise

• Burns and scalds from hot

surfaces at inspection windows/ discharge end (screw) and bleed pipe.

• Head injuries from low pipes etc.

• Checking and clearing

magnets- burns, scald and cuts from metal objects.

Medium Medium Low Low Low Low Low Low Low

Steam pipe at top of cooker blow steam out but when steam hits floor it blows back into operators face. Regular washing of the area is carried out. Hoses are put back in place after use. Maintenance of all pipes. All motors and shafts adequately guarded. Handrails on stairs and stairs are cleaned on a regular basis. Ear protection worn in this area. Gloves and overalls worn when operating the cooker. Bled pipe steam directed to ground. Bump caps issued to all employees and must be worn at all times while operating the cooker. Gloves and safety specs provided. Cooker discharge is switched off when clearing/cleaning magnets.

Valves to be moved out of pedestrian way or else change pedestrian access. Pipe to be located to a safer position where steam will not blow back. Hoses to be put back in proper storage immediately after use so as not to cause a trip hazard. Inspection of steam pipes on a regular basis. Any defects to be reported to maintenance dept. Any defects in guards to be reported to maintenance department. Use handrail sticker to be placed on handrail. Ensure employees are wearing adequate hearing protection while operating in this area. Gloves to be worn at all times when operating the cooker Discharge screw to be insulated. Danger stickers to be placed to warn employees of hot surfaces. Bump caps to be worn at all times. Ensure adequate gloves and safety specs are worn by operators when cleaning/clearing magnets.

Maint. Dept.

General Operators

General Operators

EHS Officer EHS Officer &

Supervisors

Employees Maint. Dept. EHS Officer

Employees

Supervisor/Char

ge Hand

1 month

Ongoing

Ongoing

6 months

Ongoing

6 months

Ongoing

Ongoing

For

insp

ectio

n pur

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s only

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EPA Export 26-07-2013:00:30:40


10 of 75

AREA: CRUSHING (RAW MATERIAL AREA)


1. Changing of screw conveyors .

2. Starting crushers/conveyors

3. Freeing crushers 4. Freeing conveyors 5. Checking and clearing

magnets 6. Clearing drain blockages 7. Checking bins 8. Traffic in area 9. Maintenance of all

machinery.

• Falling objects from elevated platforms.

• Electrocution from electrical

panels. • Slips/trips/falls on

greasy/untidy floors/steps.

• Falls from stairs and platforms

• Entanglement in moving parts/ Ejection of material from fine crusher

• Trip hazards caused by hoses.

• Biological infection through

cuts and scrapes

• Noise

• Changing of screw conveyors- 1. Chain clock failure when lifting objects. 2. Falls from height 3. Head injury from head height hazards.

Medium Medium Medium Low Low Low Low Low Low Medium Low

Bump caps provided and must be worn by all employees in this area. Doors on all electrical panels. Operators aware that electrical panels must not be sprayed with water when cleaning. Floors and stairs are cleaned on a regular basis. Hand rails provided. Lid installed on crusher. All moving parts are adequately guarded. Isolators installed on all machinery. Designated storage areas when not in use. All open cuts and wounds are treated and covered. Ear defenders issued to all personnel working in this area. Only trained personnel to lift objects. All lifting appliances to be fully certified. Use of proper lifting appliance. Ensure bucket is pinned onto forks. Bump caps supplied.

Ensure toe boards are installed along all elevated work platforms. Ensure all personnel in the area are wearing bump caps. Stickers to be placed on doors to ensure they are kept closed. Floors and stairs to be kept clean. Ensure handrails on stairs and platforms are in good condition. Ensure lid is being used at all times Ensure guards are on all moving parts. Lock-out tag out procedure to be introduced. Hoses to be put back in designated storage area when not in use. Good personal hygiene when working in this area. Ensure personnel wear ear-defenders when working in this area. Signs to be posted.

Maint. Dept.

EHS Officer

General Operator

Maint. Dept

Operator Supervisor/EHS

Officer

Operator

All personnel

EHS Officer Supervisors

EHS Officer

Immediate

1 Month

Ongoing

Ongoing

Ongoing Immediate

Ongoing

Ongoing

Ongoing

Immediate

For

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EPA Export 26-07-2013:00:30:40


11 of 75

4. Cuts & scrapes from sharp edges. 5. Trips over trailing cables/tools. 6. Collision of Forklift truck with person/ overturning/shedding the load. 7. Lifting at angle with chain blocks- pulling hoist off rails/warping rail, load swing uncontrollably, heavy load swing could strike/trap person. 8. Fire – personal injury/property damage 9. Tools causing personal injury and electrocution.

• Freeing crushers/conveyors/clearing/checking magnets

1. entanglement in moving parts 2. sharp metal objects-

cuts/scrapes 3. biological hazard- infection

• Clearing drain blockages - open manholes/biological hazards

Low Medium Low Low Low Low Medium Medium Medium Low

Gloves safety shoes and overalls provided and worn. Tools kept tidy. Restricted access to area. Trained personnel operate truck. Restricted access. Use of hoist by trained operator (fitter). Restricted access. Flame retardant overalls provided. Hot work permits in place. No combustible material located in this area. Adequate fire extinguishers are on site. Only qualified personnel operate high powered tools. Adequate PPE is provided. Isolator on all machinery. PPE provided to all employees. All moving parts guarded. Gloves provided. All platforms and stairs have adequate handrails.

Ensure all lifting appliances are certified. Ensure bucket is pinned onto forks. Bump caps to be worn. Restricted access to area when carrying out lifting. Ensure adequate PPE is worn Tools to be kept tidy at all times so as not to cause a trip hazard. Restricted access to area. Ensure only trained personnel operate forklift truck. Ensure all lifting appliances are certified. Ensure the lifting of the object is done in a safe manner so as to avoid the hazards listed in no 7. Ensure adequate PPE is worn. No combustible materials to be near by. Ensure adequate fire extinguisher is at hand. Ensure welding mask is worn when welding. Ensure safety goggles are worn when grinding. All tools to be inspected before use to ensure they are in good condition. 110V tools only to be used. Ensure gloves are worn at all times when freeing conveyors/crushers. Lock out tag out procedure to be introduced.

EHS Officer.

Operator

Operators

Operators

Operator

Operator

Operator

Operator

Operator

EHS Officer Supervisor

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Immediate

For

insp

ectio

n pur

pose

s only

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EPA Export 26-07-2013:00:30:40


12 of 75

• Checking bins- falls from height.

Low

All open wounds/cuts to be treated and covered. Operators to be instructed in the safe operating procedure for the hazards listed. Gloves to be worn at all times. Manhole guards to be put in place when manhole lid is removed to prevent personnel falling into manhole. All open wounds to be adequately covered and treated. All handrails to be inspected and any defects to be reported to management.

Operator

Supervisor

Operator

Maint. Dept.

Operator

Supervisor

Ongoing

Ongoing

Ongoing

6 months

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

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for a

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EPA Export 26-07-2013:00:30:40


13 of 75

AREA: DECANTER AREA

Tasks carried out: Hazards : Risk: Controls: Recommendations: Responsibility: Action Date:

1. Sampling tallow 2. Cleaning of Decanter. 3. Cleaning of area 4. Maintenance of

electrics, machines, valves and pipes etc.

• Serious burns and scalds from hot water reservoir.

• Slips/trips/falls on greasy/untidy floor

• Burns and scalds from hot water/tallow.

• Pipes and supports at head height. Head injuries.

• Entanglement in motor shaft or drive assemble

• Noise • Fire (from use of blow torch and

gas to blow tallow lines).

• Electrocution

Medium Low Medium Low Medium Low Medium Low

Use new hot water system instead of reservoir. Regular washing of the floor is carried out to prevent build up of grease. Safety boots are provided to all employees. Buffer tank has an overflow pipe fitted so it is directed away from personnel traffic. All employees are aware of the danger of hot tallow and water on site. Bump caps issued to all personnel on site and must worn when in this area. All motor shafts and drive assembles are adequately guarded. Ear protectors provided. Hot work permit in place. Gas cylinder kept under lock and key to restrict access. Exercise caution when cleaning near wires.

Ensure floor is cleaned regularly. Ensure hoses are not left training along floor when not in use. Ensure adequate PPE is worn by all personnel in the area. All new employees must be trained in the hazards of this area. Remove tipping tray from front of decanters and replace with pipe directing flow into tank. Bump caps to be worn by all personnel in this area. Any defects with guards must be reported to maintenance personnel without delay. Ear protectors to be worn when operating in this area. Ensure hot work permit in place. Exercise caution when cleaning near electrical wires. Any defects in wiring to be reported to electrician

Supervisor Operator

Supervisors

Supervisors

Maint. Dept.

Supervisors/ Operators

Supervisor / Operators

Operators/ Supervisors Supervisor

Operator

Ongoing Ongoing

Ongoing

Ongoing

6 months

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

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EPA Export 26-07-2013:00:30:40


14 of 75

AREA: DECANTER TALLOW TANKS

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Sampling tallow 2. Blowing tallow lines 3. Heating oil in 6 ton

buffer tank 4. Cleaning of area 5. Maintenance of

pipes, machine, valves and electrics.

• Environmental risk of overflow at oil tanks.

• Fire in lagging of oil tanks.

• Burns and scalds from sampling of hot tallow

• Slips on slippery surface

• Noise

• Blowing tallow lines – risk of

fire and scalding.

• Overheating of tallow in 6 ton buffer tanks – risk of fire

Low High Low Medium Low Medium Medium

High level cut out and manhole covers. Temperature control by steam reducer. Fire extinguishers in place. Adequate PPE provided to lab analyst. Area cleaned regularly. Safety boots provided and worn. Ear protection provided. Hot work permit in place. Only authorised persons to blow lines. Tank not permitted to overheat (›100ºC). tallow temperature to be checked regularly

Check operation of high level cut-outs. Remove lagging – arrange lagging to eliminate possibility of it becoming soiled with tallow. Ensure adequate PPE is worn. Ensure area is cleaned regularly. Hot work permit to be obtained and adhered to. Tallow temperature to be checked regularly – not permitted to go above100ºC.

Maint. Dept.

Production Manager

Operators/Lab Analyst

Supervisor Operators/Superv

isors

1 month

Immediate

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 26-07-2013:00:30:40


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AREA: YARD

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1.Strimming 2. Brushing & Washing

yard 3. Painting 4. Cleaning gutters &

drauins 5. Lining of bulk

containers 6. Vehicle movement in

yard.

• Collision with pedestrians at entrance to offices, lab, canteen etc.

• Inclined surfaces- causing

slips/trips.

• Falling into unguarded manhole

• Poor lighting in yard- may cause fall/collision.

• Cracks and holes in surface

joints causing slips/trips/falls

• Slips, trips and falls

• Working at height

Medium Low Low Low Low Low Low

High visibility vests to be worn by employees when walking in the yard. 10 kmph speed limit. Safety boots to be worn when walking in the yard. Yard is cleaned on a regular basis to prevent build up of grease etc. Adequate lighting provided and maintained. Surface maintained regularly. Fire hose used to clean the yard. This is manned by two operators. Nozzle used so that water can be turned off quickly. A safe platform is used for personnel working at height.

Barriers to be erected outside office doors. Speed restriction signs to be updated. Sign to be put in place to warn personnel of the inclined surface and the fact that it may be slippy. Manholes to be covered at all times. Manholes to be painted an illuminous colour. Manhole guard to be made and used when manhole has to be left open for a long period of time. Any defects in lighting to be reported to management without delay. Surface condition to be inspected frequently. Ensure nozzle is working. Ensure a trip hazard is not caused by hoses.

Maint. Dept

EHS Officer

EHS Officer

Operator.

General Operators.

Maint. Dept.

All personnel

Assistant Manager

Operators

Immediate

Immediate

6 months

Ongoing

6 months

6 months

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

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AREA: HESSIONS FIELD

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1.Walking in field. 2.Cutting of grass in

field.

• Unauthorised access to the site.

• Uneven surface on land – slips, trips and falls.

Medium Low

Fence around boundary of site. Personnel are on site around the clock – 6 ½ days per week. No reason for personnel to enter field. Any person entering it must be accompanied by management.

Signs to be posted on gates to inform personnel of unauthorised access to the land. Fence to be checked to ensure it is adequate.

Managing Director Immediate

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 26-07-2013:00:30:40


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AREA: LABORATORY

Tasks to be carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Handling chemicals 2. Carrying out tests 3. using furnace 4. Heating flammable

solvents. 5. Using electrical

equipment. 6. Handling tallow and

MBM 7. Handling WWTP

samples. 8. Handling volatile

solvents 9. Handling acids and bases 10. Heating concentrated

acids 11. Use of thermometer

with laser light 12. Cleaning of area 13. Storage of equipment

and chemicals.

• Fire

• Burns and scalds from hot plates and heater

• Damage to eyes from infrared thermometer with laser light.

• Poisoning from ingestion of

chemicals.

• Inhalation of chemical fumes causing lung irritation

High Medium Medium Medium Medium

Bins provided and emptied regularly. All electrical equipment is switched off at end of the day. Good housekeeping in lab. All flammable chemicals stored separately. Only qualified personnel permitted to operate in lab. Flammable solvents used under extractor hood. No naked flame in lab. Fire extinguishers provided and maintained. Furnace used by trained lab technician. Corrosive and flammable materials are handled safely. Hot plates and heaters switched off when not in use. Access restricted to lab. Lab technicians aware of the hazards. Oven gloves used when removing material from oven. Lab technician aware of the hazards of this machine. Chemicals are adequately labelled. No eating or drinking in the lab. Good hygiene with regards washing of hands. Safe practices adopted when handling chemicals. Fume hood provided for extraction

Good housekeeping to be maintained at all times. All flammable solvents to be used under the extraction hood. Only qualified personnel to operate in lab. Laser not to be pointed at face or eyes at any time. Ensure good hygiene at all times. Strictly no eating or drinking in the lab. Ensure all MSDS’s are on file. Respirator and masks available to lab technician and must be

Lab Technician

Lab Technician

Managing Director

Lab Technician

Lab Technician

Lab Technician EHS Officer

Lab Technician

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

6 months

Ongoing

For in

spec

tion p

urpo

ses o

nly.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

EPA Export 26-07-2013:00:30:40


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• Slips/trips/falls

• Chemical burns from chemicals causing eye/skin irritation.

• Cuts and scrapes from broken glassware

• Poor working environment

• Falling objects- head injury

• Inhalation of dust and fine

Low Medium Low Low Low Low

– used when handling fuming chemicals. All chemicals adequately labelled. All MSDS are on file. Safer chemicals used where possible. Lab is kept tidy on a continuous basis. Bins are kept emptied. Mats are provided on floor – there are changed every week. Safety boots worn in the lab. All glassware to be stored in an appropriate area. Safety goggles, lab coat and gloves worn when handling chemicals. Proper handling techniques used. Safer chemicals used where possible. First aid kit located in lab. Cold running water available in lab. Proper hygiene practice to be followed. All broken glass is swept and discarded immediately. Any cracked glassware is discarded immediately also. Central heating in lab. Window and door in lab for ventilation. Fume hood with extractor in lab also. Folders stored correctly and not overloaded. Shelves packed correctly and not over packed.

worn when handling dangerous chemicals. Bins to be emptied on a continuous basis. Ensure no trip hazards in the lab. Proper PPE to be worn at all times while in the lab. Safe handling techniques to be adopted when heating corrosive acids. Adequate emergency shower wash must be installed in Laboratory. Ensure all broken glassware is discarded adequately. Refer to MSDS for chemicals used.

Lab Technician

Lab Technician

Lab Technician

Lab Technician

Managing Director

Lab Technician

Lab Technician

Ongoing

Ongoing

Ongoing

Ongoing

Immediate

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

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chemicals- skin/lung irritation.

• Electrocution from electrical appliances

• Burns from hot tallow • Suspect biological agents

from tallow and MBM.

• Handling of cumulative chemicals-(e.g. Cadmium, potassium chromate, mercury compounds). – Accumulation of chemicals in the body – chronic and toxic effects.

• Sampling bio filter and

WWTP samples – high TVC- Bacterial.

Medium Low Low Low

Proper handling techniques used to avoid generation of dust. Safer chemical used where possible. Gloves, safety specs and lab coat worn at all times when in the lab. All devices earthed. RCD device. All electrical equipment is checked before use for any damage. Lab technician is aware of the hazards. Gloves, lab coat and safety specs are used when in the lab. Lab technician is aware of the hazards. Adequate PPE worn. Safer chemicals used where possible. Safe handling techniques used. MSDS consulted when chemicals in use. Adequate PPE worn.

All electrical equipment to be checked for defects before use. Any defects in equipment to be reported to electrician immediately. Ensure adequate PPE is worn when handling hot tallow. All open cuts and wounds to be treated and covered at all times. Ensure the controls listed are followed. If in doubt contact the supplier of the chemical. Ensure adequate PPE is worn at all times. Ensure adequate PPE is worn at all times. Good hygiene practice to be followed. Lab technician is aware of the hazards

Lab Technician

Lab Technician

Lab Technician

Lab Technician

Lab Technician

Lab Technician

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

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AREA: LOADING BAYS – Auxiliary and Main

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Sealing bulk containers 2. Loading meal tankers 3. Operating belt container 4. Starting conveyors 5. Cleaning loading bay 6. Filling mini bulk 7. Sweeping and Cleaning area 8. Reversing on off trailer 9. Cleaning conveyor belt 10. Unblocking small hopper 11. Traffic in area 12. Maintenance of machinery,

pipes and valves.

• Burns & scalds from steam water heater in auxiliary loading bay.

• Collision with Forklift • Dust – causing lung function

disorders. Risk of fire and explosion.

• Entanglement in meal loading conveyor.

• Electrocution from live electrical panels or panels with doors open.

• Falls from stairs and gantries


• Entanglement in unguarded

Medium Low Medium Medium Medium Low Low Low

Maintenance of pipes and joints. Forklift operators trained . Dust mask provided and worn when loading trucks. Any accumulation of dust is cleaned up immediately. No smoking permitted in this area. Extinguishers located in the area. Loading operator and lorry driver to stand clear from conveyor when in operation. Conveyor adequately guarded. Emergency stop located on conveyor. Belt adequately guarded. Doors on all electrical panels. Doors kept closed at all times. Handrails on all gantries and stairs. All in good condition.

Ensure adequate maintenance of pipes and joints. Only trained operators to operate forklift. Adequate PPE to be worn. Good housekeeping in the area. Dust mask to be worn when cleaning area to prevent inhalation of dust. Operator and lorry driver to keep safe distance from conveyor at all times. Inspect moving parts are guarded. Instruct operator to ensure that no one is working or sampling from machinery before start up. Doors to be inspected regularly and any defects to be reported to electrician. Stickers to be placed on door warning personnel to keep them closed. Any defects found in stairs/gantries/platforms must be reported to maintenance dept without delay. Good housekeeping to be

Maint. Dept.

Loading Operator

Loading Operator

Loading Operator

Loading Operator

Loading Operator

EHS Officer

Loading Operator

Loading Operator

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

1 month

Ongoing

Ongoing

For in

spec

tion p

urpo

ses o

nly.

Conse

nt of

copy

right

owne

r req

uired

for a

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motor or shunting screw conveyor

• Head height hazards from

unblocking meal silo/checking for blockages.

• Sealing/lining of bulk containers- falls from height.

• Forklift truck overturning/collision/ shedding load when filling mini bulk.

• Collision with trailer.

• Irritation of skin from

handling meal.

• Unblocking small hopper –

head height hazards, falls, inhalation of meal dust.

Low Medium Low Medium Low Low

Good housekeeping maintained in this area. All motors and screw conveyors adequately guarded. Bump caps issued to all personnel and must be worn. Only trained operators operate forklift. Loading bay operator stays a safe distance away from trailer. Loading bay operator directs lorry driver into the area. High visibility vest to be worn by operator`. Lorry driver to apply brakes when being loaded so as to avoid lorry inadvertently moving backwards or forwards. Gloves provided and worn when handling meal. Safety boots, gloves, mask and bump cap to be worn when unblocking hopper.

maintained in this area. Any defects in guards to be reported to maintenance dept. immediately. Bump caps to be worn at all times. Any bulk container coming on site must have safe access with platform and handrails. Only trained operators to operate forklifts. Operator to keep a safe distance from trailer. High visibility vest to be worn by operator. Lorry driver to apply brakes when being loaded so as to avoid lorry inadvertently moving backwards or forwards. Gloves to be worn when handling meal. Ensure adequate PPE is worn. Provide safe means of access to remove small hopper.

Loading Operator

Loading Operator Assistant Manager

Assistant Manager

Loading Operator

Loading Operator

Lorry Driver

Loading Operator

Loading Operator Maint. Dept.

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

6 months

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

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AREA: OFFICES

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: 1.Cleaning of area. 2.Use of computer. 3. Use of electrical

equipment.

• Manual handling injuries


• Entanglement of loose hair/clothing in shredder

• Falling objects from shelves causing

injury

• Fire

• Hand and finger injuries from hand tools such as pencils, staplers, scissors, photocopier, office stationery

• Musculoskeletal injuries • Visual impairment from V.D.U

work

Low Low Low Low Low Low Low Low

Lifting and replacing of water bottles is not performed by Female employees. Person changing bottles wear steel toe capped boots. Offices are cleaned regularly. No trailing cables across floors. Mats provided for offices and changed on a weekly basis. Office staffs are aware of hazards. Shelves not over packed. Larger files are stored on bottom shelves. A ladder is available for retrieving files from higher shelves. One person to hold ladder while the other retrieves the files. Bins are emptied daily. All electrical equipment is switched off at the end of the day. Care taken when using office equipment and manufacturers’ instructions must be followed at all times. Office chairs are ergonomically designed and adjustable. VDU’s have anti-glare, anti-static, and anti-radiation screen. Staff working on VDU’s should structure their workload so that they take a ten-minute break every two hours from V.D.U. work to perform some other task. Photocopiers are well ventilated and regularly serviced. All waste material and bins must be removed from the office daily

Manual handling training for all employees. Floor box cable to be position correctly so as not to cause a trip hazard. Shelves not to be over packed. Larger files to be stored on bottom shelves. A ladder must be used for retrieving files from high shelves. One person to hold ladder while the other retrieves the files. Any defects in electrical equipment must be reported to electrician immediately. Care taken when using office equipment and manufacturers’ instructions must be followed at all times. VDU’s to have anti-glare, anti-static, and anti-radiation screen.

EHS Officer

Electrician

Office Staff

Office Staff

Office Staff

Office Staff

Managing Director

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

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23 of 75

AREA: MAINTENANCE STORE 2

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1.Storing of gas cylinders 2. Handling of gases

• Fire & explosion from gas cylinders.

• Tripping on untidy floor.

Medium Low

Bottles stored up right. Shed with gas bottles is kept locked at all times. Good housekeeping maintained in area.

Bottles to be moved to outside storage area with Oxygen and Acetylene stored apart. Bottles to be inspected regularly for proper storage and leak test. Fire extinguisher to be moved to outside. (See also hazard identification and risk assessment sheets on compressed gases). Good housekeeping to be maintained in area. All combustible material to be stored in oil store.

Maint. Dept.

EHS Officer

Maint Dept.

Maint. Dept.

Immediate

1 month

Ongoing

Ongoing

AREA: MEAL STORAGE SILO

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Checking under silo

for blockages. 2. Unblocking silo 3. Entering into silo.

CSE. 4. Unblocking

discharge screw.

• CSE Hazards

• Falls from height • Entanglement in discharge

screw/conveyor

High Medium Low

Only personnel trained in the procedure are permitted to enter silo. Management must be informed of this. Hand rail in place on ladder. Discharge screw half guarded.

Up date CSE procedure- instruct and inspect that personnel follow CSE procedure when entering silo. Access to silo roof to be locked. Instruct and inspect that personnel that precautions when working on silo roof. Discharge screw to be fully guarded. Area into conveyor to have a gate placed on it to restrict access to area- pallet blocking passage now.

Supervisor Operator

Maint. Dept.

Maint. Dept.

Maint. Dept.

Ongoing

1 month

6 months

6 months

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

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her u

se.

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24 of 75

AREA: MILLROOM

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1.Sampling MBM 2. Starting mill shakers and conveyors 3.Inspecting shaker screens 4. Magnet checks 5. Cleaning mill floor 7. Clearance of meal in meal storage room 8. Maintenance of electrics, machines, pipes, valves etc.

• 1st Shaker (steel cables) risk of cable breaking and screen falling.

• Entanglement in shovelling screw conveyor

• Fire/dust explosion from

accumulation of dust

• Moving parts in shaker and mill screen – risk of striking operator.

• Falls – trap door under

slow and fast bin – guard rail missing.

• Low head clearance at

buffer bin and screen conveyors and platforms.

• Chute under mill screen

has very long inspection hole- entrapment of tool or arm in bucket elevator


Medium Medium Medium Medium Medium Low Medium Medium

Regular inspection and replacement of cable hook pins etc. No smoking in this area. Area is cleaned on a regular basis to prevent build up of dust. Hot work permits in force in this area. Bump caps provided and worn by employees. 2 bolts in floor under main dust bin. No cables/hoses to be left trailing

Regular inspection of cables Cover exposed conveyor with very coarse mesh to protect against entrapment while still being able to shovel MBM. Isolator to be placed closer to conveyor. Strictly no smoking in this area. Hot work permits to be obtained when carrying out hot work in this area. Area to be cleaned on a regular basis. Guards to be installed on screen. Operator to be advised to stay a safe distance away from screen when in operation. Guard rail to be replaced. Bump caps to be worn by all employees in this area. Decrease size of hole. Employees not to carry out any maintenance until machine is locked out. These bolts must be highlighted. All tools etc. must be removed once maintenance is finished.

Maint. Dept.

Maint. Dept.

Supervisor All personnel

Operators

Maint. Dept. Supervisor

Maint. Dept.

Supervisor

Maint. Dept. Maint. Dept.

Operators

Maint. Dept. Maint. Dept.

Operators

Ongoing

Immediate

Ongoing Ongoing

Ongoing

1 month Ongoing

Immediate

Ongoing

Immediate Ongoing Ongoing

6 months Ongoing

For in

spec

tion p

urpo

ses o

nly.

Conse

nt of

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uired

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25 of 75

• Eye injuries caused by particles ejected from shaker and mill screen entering the eye.

• Inaudible fire alarm due to noise levels.

• Electrocution from electrical panels.

• Lung function disorder

from dust and fumes.

• Entanglement in machinery – due to incorrect isolator switch being switched on.

• High noise levels

• Sampling MBM- head

height hazards, skin irritation, dust inhalation, trip hazards, and entanglement in machinery.

• Exposed moving parts and automation of machinery.

• Cuts and scrapes from magnet checks.

• Head height hazards

Medium High Low Medium Medium Medium Low Medium Low Low

along floor. Safety glasses provided to employees Stroble lights installed and checked on a regular basis. All electrical panels have doors and locks to prevent inadvertent use. Dust masks provided to all employees. All isolator switches are labelled. Ear protectors are issued to all personnel. Employees in the mill room must wear ear protectors at all times when in this area. Lab analyst supplied with safety boots, bump cap, safety glasses and mask. All PPE worn by lab analyst. All moving parts guarded. Operator ensures that no work is being carried out on machinery before start up. Gloves provided and worn when carrying out magnet checks.

Cable to mill panel on ground- re route cable- inspect condition of cables regularly. Ensure safety glasses are worn when inspecting screen. Stroble lights checked on a regular basis. Ensure all electrical panel doors are lockable. Any employees with a lung disorder must inform management. Ensure all isolator switches are labelled correctly. Lock out tag out system to be put in place. Ear protectors to be worn in this area. Ensure lab analyst wears adequate PPE. Any defects in guards to be reported to management. Guard rail to be installed around shaker. Guard to be placed around exposed belt under meal bin. Operator to exercise caution when removing metal from magnet. Adequate gloves to be worn. Ensure bump caps are being worn.

Electrician Maint. Dept.

Operators

Electrician

Electrician

Employees

Electrician

Supervisors Operators

Lab Analyst Operators

Maint. Dept.

Operators

Supervisor Operators

Ongoing Ongoing

Ongoing

6 months

Immediate

1 month

On-going

On-going On-going

1 month

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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MEAL STORAGE ROOM • Entanglement in

conveyors.

UNDER STAIRS TO MILL • Storage of tallow

samples- attract rodents • Fire

Medium Medium Low

Bump caps provided and worn by all personnel working in mill room area. Covers placed along all conveyors- but covers are not permanent and bolts are missing in a number of them. Pest contractor baits and monitors area. Good housekeeping in area. Number of tallow samples limited. Fire extinguisher located in area.

New covers to be made for the conveyors to provide adequate protection. Guard rail to be placed around discharge screw just inside the door to prevent access to it.

Maint Dept.

Immediate

AREA: OIL STORE

Tasks carried out: Hazards: Risk: Controls: Recommendations; Responsibility: Action Date: 1. Handling of oils. 2. Storage of oil drums. 3. Cleaning of bund. 4. Lifting of drums.

• Skin irritation/dermatitis from oils and grease oils etc.

• Inhalation of fumes

• Manual Handling of drums

• Environmental risk of oil getting into drainage system

• Slipping on greasy floor.

• Flammable chemicals causing

fire

Low Low Medium Low Medium Low

Gloves provided to maintenance employees. Oils and grease kept in dedicated store. Masks provided to employees. Oil store well ventilated. Forklift truck to be used when lifting oil drums. Manual handling training carried out by employees. Oil stored in bunded area. Retaining wall across door way. Safety shoes issued to all personnel. No smoking area. Room ventilated so no build up of chemicals. Fire extinguishers located in store in case of fire.

Gloves to be worn by personnel when handling oils and greases etc. MSDS’s of oils etc to be stored in workshop. Manual handling training to be given to all employees. Oil only mats to be provided for store. Good housekeeping.

Maint. Employees

EHS Officer

EHS Officer

Maint. Manager

Maint. Dept.

Ongoing

6 months

6 months

1 month

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

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r req

uired

for a

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AREA: PATHOGENIC AREA


1. Start up of raw material pump. 2.Resetting tripped motors 3.Cleaning area 4.Traffic in area 5.Cleaning of blockages and machines 6. Maintenance of electrics, machines, valves and pipes.

• Electrocution from electric panels.

• Infection from biological agents • Raw material pump- person

stumbling into ram when cover is off.

• Entanglement in unguarded motor

and shafts.

• Infection from biological agents

• Slips/trips and falls

• Falls from heights

• Pressurised vessel – pathogenic water steriliser.

Medium Low Medium Medium Low Low Medium Low

Doors on all panels. All open cuts covered. Gloves provided for all personnel. Cover not left off ram while unsupervised. All motors and shafts guarded. All cuts and scrapes are covered. Good hygiene is practiced. Good housekeeping in area. Hoses not to be left trailing across floor causing a trip hazard. All gantries and ladders have handrails. All operators have been trained in its use. Machine certification. Automatic control of steam pressure.

Ensure doors are in place on all panels and lockable. Only qualified electricians to carry out electrical work. Ensure all open cuts are treated and covered. Ensure good hygiene when working in this area. Hinges to be placed on cover. Inspection of shafts and motors to ensure all guards are in place. Any defects in guards must be reported to maintenance manager without delay. Motor for pathogenic water steriliser is moving apart – must be fixed. Ensure all open wounds are treated and covered adequately. Ensure good hygiene practice. Good housekeeping to be maintained in this area. Hoses not to be left trailing when not in use. All ladders and gantries to be inspected to ensure adequate handrails and protection. Adequate access to be provided to 2 Pathogenic C valves. Ensure all operators are trained in its use before operating it.

Electrician

All employees

Maint. Dept.

Maint. Dept.

All employees

Maint. Dept.

All employees

Operators

Operators

Maint. Dept.

Maint. Dept.

Production Manager

6 months

Ongoing

1 month

Immediate Ongoing

Immediate

Ongoing

Ongoing Ongoing

Ongoing

Immediate

Immediate

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

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AREA: PATHOGENIC WATER STORAGE AREA

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility; Action Date: • Falling from height/unauthorised

access to platform.

• Burns to hand from hot discharge pipe from sterilised tank

• Slips on greasy surface.

Medium Low Low

Ladder has hoop guard and handrail. Only authorised personnel to use ladder. Pipe lagged. Area cleaned on regular basis.

Access ladder to be locked to prevent unauthorised access. Pipe to be lagged.

Maint. Dept.

Maint. Dept

Immediate

6 months

AREA: PRESS

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Inspection and cleaning of

shaker screen. 2.Inspection of cake 3.Checking fines 4.Cleaning press area 5. Cleaning floors etc. 6. Cleaning of blockages and

machines. 7. Maintenance of electrics,

machines, valves and pipes etc.

• Burns & scalds from hot surfaces/cake and greaves.

• Slips/trips/falls on greasy/untidy walking surfaces.

• Falls from stairs

• Burns and scalds from pipes

carrying steam which are exposed and in close proximity to where work is carried out.

• Entanglement in motor and drive

assemblies

• Head height hazards.

• Noise

Low Medium Medium Medium Low Low Low

Gloves and overalls provided for all employees. Area washed on regular basis. Adequate safety boots to be worn. Handrails on stairs. Area washed regularly Pipes could be lagged if it cannot be moved. All motors and drive assemblies adequately guarded. Bump caps provided and worn by employees working in this are. Ear protectors provided to employees in this area.

Signage to be put in place to instruct employees of the dangers. Area to be washed on regular basis. Hoses not to be left trailing across floors causing a trip hazard. Stairs to be washed on regular basis. All handrails to be inspected. Inspect pipes to see if they can be moved /lagged. Inspect if all motors and drive assemblies are guarded. Any defects in guards must be reported to maintenance department without delay. Bump caps to be worn at all times while working in this area.

Supervisor

Operators

Operators .Maint Dept

Operators.

Maint. Dept.

Maint. Dept. Operators/ Supervisor

Operator

/Supervisor

6 months

Ongoing

Ongoing Ongoing

Ongoing

Immediate

Ongoing Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

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• Inspection and clearing of shaker

screens- burns from hot tallow.

• Inspection of cake- falling, head injuries, splashing of cake into eye.

• Checking Fines- manual handling,

splashing of hot material.

• Asbestos roof over the Presses.

Low Medium Medium Low

Safety specs and visor provided for this task and must be won. Handrails installed on all platforms and stairs. Safety specs and bump caps provided to all employees. Manual handling training carried out by employees. Operator turns off feed to presses before inspection. Safety specs provided and worn. Asbestos intact on roof. Any damage to roof must be reported to Management who will employ competent personnel to test and remove asbestos if required.

Ear protectors to be worn by all employees in this area. Safety spec/visor to be worn when carrying out this task. Operator to be instructed to turn off feed to presses before inspection to avoid splashing. Ensure adequate PPE is worn. Handrails to be inspected. Manual handling training to be given to all employees. Operators to be instructed to turn off feed to presses before inspection to avoid splashing with material. Safety specs to be worn when carrying out this task. Any damage to roof must be reported to Management who will employ competent personnel to test and remove asbestos if required.

Operator/ Supervisor

Supervisor

Supervisor Maint. Dept.

EHS Officer

Supervisor

Operators

All employees Management

Ongoing

Immediate

Ongoing Immediate

6 months

Immediate

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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AREA: PUMP HOUSE

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Inspection of manholes. 2. Maintenance carried out

on pipes, valves, machines etc.

• Falling into unguarded open manhole and pits.

• Rodents • Access and egress from pump house

Poor lighting and walkway coming Over grown.

• Trips/slips/falls in pump house.

Low Medium Medium Low

All manholes and pits covered. Pest contractor contracted and monitors area. Walkway very overgrown. Good housekeeping in area

Ensure manholes and pits are covered when unsupervised. Adequate lighting to be put in place and grass to be strimmed. Good housekeeping to be maintained in pump house.

Maint. Dept.

Maint Dept.

Maint Dept

Ongoing

1 month

Ongoing

AREA: UNDERGROUND PIPES LEADING INTO SAND FILTER RO OM


1. Maintenance of underground pipes.

Working underground in a confined space. Inhalation of Asbestos on pipes and ground.

Medium High

When personnel work in this area all pipes and valves are isolated to avoid influx of water and steam. Asbestos contractors are coming on site to carry out monitoring and remove the asbestos.

Two personnel to work in this area at any time. Persons working in this area must be contactable by phone at all times. No personnel to go into this area until asbestos has been removed fully.

Maintenance Manager.

Maintenance Manager

Ongoing Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

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AREA: RAW MATERIAL INTAKE

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Driving of front end loader 2. Inspecting loader pins 3. Unloading of lorries 4. Traffic in area. 5. Maintenance of pipes

valves electrics etc. 6. Washing of area 7. Washing of lorries 8. Washing of area with

caustic soda.

• Slips, trips & falls on floors. • Burns from caustic soda • Infections from biological

agents. • Collision of Front end loader

with vehicle/pedestrians.

• Entrapment in doors

• Overturning of vehicles in raw materials intake – due to slope on floor.

Low Low Medium Low Medium

Floors kept clean. Safety boots provided and worn. Adequate PPE worn. Adequate procedure to be carried out- procedure is written up and must be followed by all personnel carrying out caustic cleaning. All open wounds and cuts are treated and covered. Good hygiene practices followed. Gloves and overalls provided to all employees and worn. Trained operators on loader. New raw material shed in place. New unloading bays also in place. Greater view for operators and lorry drivers. Sensor wires are located on doors so doors will not shut when person/vehicle is under them. The lorry must be located on one level before unloading the load. Lorry must not be located on slope at any time.

Ensure floors are kept clean. Ensure safety boots are worn. Adequate procedure to be carried out when carrying out caustic cleaning. Signs to be posted to warn lorry drivers of the hazard. Hoses not to be left across walkways. Ensure operators are aware of the hazards. All open wounds to be treated and covered immediately. Gloves and overalls to be worn at all times. Care to be taken when lorry drivers/pedestrians are in the area. Loader to be in good condition with flashing beacon and reversing alarm. New loader to be purchased with reversing camera. Ensure lorry drivers are aware of the dangers.

Operators

Operators

EHS Officer

Operators

Operators

Managing Director

Operators

On-going

On-going

6 months

On-going

On-going

Immediate

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

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r req

uired

for a

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AREA: RMS

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1.Filling of Telescope 2. Inspection of Machines,

valves, pipes etc. 3. Clearing of blockages 4. Cleaning of area.

• Filling telescope - moving part very exposed- risk of entrapment.

• Falls from stairs and gantries.

• RMS rotates during emptying and throws hot material out to discharge screw – risk of burns to hot material.

• Electrocution from

electric panels.

• Entanglement in unguarded chain drives and belt drives.

• Trip hazard caused by warped walking surfaces.

• Burns and scalds from

steam and tallow.

• Slips, trips & falls.

• Burns and scalds from hot meat and bone meal.

Medium Medium Medium Medium Medium Low Low Medium Low

Hand rail on all stairs and gantries. Protective door over discharge end closed. Doors inspected by operator to ensure they are closed. Interlock devise installed to halt arms if door is open. Regular inspection of panels. All panels to have lockable panels. All belt drives and chain drives adequately guarded. All hand rails in place and all walking surfaces in good condition. Good maintenance of steam pipes. Cleaning hoses not to be left trailing along walkways at any time. Slippy floors and walkways to be cleaned on a regular basis. Gloves and overalls provided to operators.

Use ‘hand rail’ stickers to be posted on hand rails and gantries. Doors to be inspected by operator to ensure they are closed. Inspect doors and panels for defects. Ensure all belt drives and chain drives are adequately guarded. Any defects in guards to be reported to maintenance without delay. All handrails and walkways to be inspected. Area to be inspected fro steam leaks. Warning sign to be in use when operating hose. Ensure operators are wearing adequate PPE and are aware of the dangers.

EHS Officer

Operator

Electrician

Maint. Dept.

Maint. Dept.

Maint. Dept.

Operator

Supervisor

1 month

Ongoing

Immediate

Immediate

6 months

6 months

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

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• Explosion of pressurised

vessel

• Entanglement in RMS.

• Noise

• Freeing RMS Telescopic

loading shute – entrapment in moving parts, elevated work platform, unable to isolate air operated systems.

• Clearing RMS doors- entanglement in moving parts, potential pressure in vessel, hot meal, and elevated work platform.

• Heating RMS – burns and scalds from hot pipes/water/steam.

Low Low Low Medium Medium Low

Certified vessel – automated pressure control – over pressure safety valve. Adequate guards around machine. Ear protection provided to employees. All machinery is placed on manual stop from SCADA system by control room operator. Gloves to be worn when using steel rod to fee Telescopic Shute. RMS placed on local control. Visor provided to personnel. Gloves provided to all personnel. Condensate bleeds away from valves.

Inspect vessel as per statutory requirements. Ensure adequate guards around machine. Any defects must be reported to maintenance without delay. Ear protection to be worn by operators in this area. Install means of isolating air, RMS and screw conveyor at loading point. All isolators to be labelled. Instruct operators on safe procedures to unblock telescope. Modify loading mechanism to prevent blockages. Operator to wear gloves and visor. Operator to fully isolate RMS when door is in position. Gloves to be worn when heating RMS.

Maint. Manager

Operators

Supervisor/ Operators

Electrician

Electrician Supervisor

Maint. Dept.

Operator

Operator

Ongoing

Ongoing

Ongoing

1 month

1 month Ongoing

1 month

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

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AREA: SAND FILTER

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Maintenance of pipes. 2. Maintenance of

machines, electrics etc.

• Electrocution from control panel and wires.

• Open pit – access to steam duct.


• Asbestos underground

along pipes. – this area is wetted down at all times so small risk of asbestos entering the sand filter room.

Medium Medium Medium High

Handrail placed around pit but there is still a risk of personnel slipping into pit. Employees are not to enter underground without a permit from Management. Adequate PPE to be worn. Personnel appointed to clear out this area.

Control panel to be replaced and all wires to be tidied. Some bare wires above panel. Immediate attention to these. Toe guard to be put in place around pit. Poor housekeeping in area. Housekeeping to be improved. Qualified personnel appointed to come on site to carry out risk assessment and remove asbestos.

Electrician

Maint. Dept.

Operators

Managing Director

Immediate

1 month

Immediate

Immediate

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

owne

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uired

for a

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AREA: STORE 1

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Lifting of materials etc. 2. Stacking of materials. 3. Use of Forklift in area. 4. Electrical work. 5. Cleaning of area

• Slips, trips and falls on untidy floor.

• Manual handling

• Head injury caused by objects falling from shelves.

• Fire

Low Medium Low Low

Good housekeeping in area. Pathway to end of store kept clear. Avoid leaning objects against walls/shelves. Heavier objects are stored at bottom of shelves for easy access. Forklift available for lifting heavy objects. Slings also available and must be used. Objects stored in a safe position on shelves. Objects also stored on pallets. All electrical work carried out by a qualified electrician. Fire extinguisher in store. No chemicals stored in this area.

Good housekeeping to be maintained in this area. Ensure all objects are stored in a safe position on shelves and pallets. Electrical wiring and fittings to be checked on a regular basis.

Maint. Dept.

Maint. Dept.

Electrician

Ongoing

Ongoing.

Immediate

For

insp

ectio

n pur

pose

s only

.

Conse

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AREA: STORE 2

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Lifting of materials etc. 2. Stacking of materials. 3. Electrical work. 4. Handling of cleaning

chemicals and paints.


• Manual handling


• Fire

• Irritant chemicals

Low Low Low Low Low

Good housekeeping in area. Pathway to end of store kept clear. Avoid leaning objects against walls/shelves. Heavier objects are stored at bottom of shelves for easy access. Forklift available for lifting heavy objects. Slings also available and must be used. Objects stored in a safe position on shelves All electrical work carried out by a qualified electrician. Fire extinguisher in store. No flammable materials stored in store. General cleaning products stored in this store. All stored in safe position and labelled adequately.

Good housekeeping to be maintained in this area. Ensure all objects are stored in a safe position on shelves. Electrical wiring and fittings to be checked on a regular basis. Gas cylinders to be stored in well ventilated area outside. Cleaning products to be stored in safe area.

General Operator

General Operator

Electrician

General Operator

General Operator

Ongoing

Ongoing.

Immediate

Immediate

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

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AREA: STORE 3

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Lifting of materials etc. 2. Stacking of materials. 3. Use of Forklift in area. 4. Electrical work. 5. Storage of IBC’s and

chemicals. 6. Manual Handling. 7. General Maintenance

carried out in area.


• Manual handling

• Head injury caused by objects falling.

• Fire

• Hazardous chemicals - Chemical burns, inhalation causing respiratory problems, skin irritant.

Low Low Low Low Low

Good housekeeping in area. Pathway to end of store kept clear. Avoid leaning objects against walls/shelves. Heavier objects are stored on ground for easy access. Forklift available for lifting heavy objects and IBC’s. Slings also available and must be used. Objects stored in a safe position on floor. All electrical work carried out by a qualified electrician. Fire extinguisher in store. Chemicals stored in this store. Waste chemicals also stored in this area. Adequate shelving for IBC’s. MSDS’s on file for all chemicals. All stored in safe position and labelled adequately. Waste material from lab located in adequately labelled drums in a bunded area in the store. Only personnel who are aware of the hazards of the chemicals are permitted to handle them.

Good housekeeping to be maintained in this area. Only trained personnel to operate Forklift. Only employees aware of the dangers of the chemicals are permitted to move the IBC’s. Ensure all objects are stored in a safe position in the store. Electrical wiring and fittings to be checked on a regular basis. Termin 8 no longer in use and a number of IBC are still in this store. To be disposed off adequately as soon as possible. 2 barrels of waste is located on top shelf – these are not labelled and must be done so as soon as possible. Ensure all MSDS’s are on file and have a copy located in the store also. Bund to be put in place for IBC’s.

General Operator

General Operator

General Operator

Electrician

Production Manager

EHS Officer

EHS Officer

Production Manager

Ongoing

Ongoing.

Ongoing

Immediate

6 months

Immediate

1 month

6 months

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

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for a

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AREA: STORE 4

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Lifting of materials etc. 2. Stacking of materials. 3. Use of Forklift in area. 4. Electrical work. 5. Storage of material.


• Manual handling


• Fire

• Injury from concrete slab falling on personnel.

• Hazardous chemicals.

Low Low Low Low Medium Low

Good housekeeping in area. Pathway to end of store kept clear. Avoid leaning objects against walls/shelves. Heavier objects are stored at bottom of shelves/on the ground for easy access. Forklift available for lifting heavy objects. Slings also available and must be used. Objects stored in a safe position on shelves. All electrical work carried out by a qualified electrician. Fire extinguisher in store. No flammable materials to be stored in store. Slab in bad position. Chemicals not to be stored in this area. Store 3 used for storing hazardous chemicals.

Poor housekeeping in area. To be improved. Only trained personnel to operate Forklifts. Objects to be stored in a safe position in the store. Electrical wiring and fittings to be checked on a regular basis. Slab to be removed safely to prevent injury. No chemicals to be stored in this store.

General Operator

Operators

General Operator

Electrician

General Operator

All employees

Ongoing

Ongoing

Ongoing.

Immediate

Ongoing

Ongoing.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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39 of 75

AREA: SWEENEYS FIELD & HOUSE

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Cleaning of house. 2. Walking in field. 3. Rolling of field.

• Unauthorised access to boiler stack from field.

• Uneven surface in field – tripping hazard

• Fire - house.

Medium Low Low

Sweeney’s field is fenced all around. Holes filled in where necessary No flammable material stored in house. Hose locked at all times.

Lock to stack to be installed to prevent access. Instruct and inspect that access to stack is being locked. Adequate fencing to be continued around stack to prevent access to stack and site. Warning signs to be put in place also. Holes to be filled in where necessary. Field rolled after grazing. Electrics in house to be checked by electrician to ensure they are safe.

Maint. Dept.

Managing Director

Production Manager

Electrician

Immediate

Immediate

On-going

6 months

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

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se.

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40 of 75

AREA: TALLOW FILTER AREA

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Blowing tallow lines 2. Cleaning/Changing

filters. 3. Maintenance of

machinery, valves, pipes, electrics etc.

4. Cleaning of area.

• Slips trips and falls on greasy/untidy floor/walking surfaces/stairs.

• Burns and scalds from hot water/tallow.

• Entanglement in

unguarded motor shaft/drive assembly.

• Noise

• Blowing tallow lines – risk of fire and burns.

Medium Medium Low Low Medium

Area washed down on a regular basis. Handrail on stairs. Overalls and gloves provided to all employees. Hand and face protection to be worn when handling tallow filters. Motor shaft and drive assemble all adequately guarded. Ear protectors provided to and worn by employees. Hot work permit in place. Only authorised personnel to blow lines. Fire extinguisher located in area.

Ensure area is washed down regularly. Check condition of handrails on a regular basis. Ensure employees are wearing adequate PPE and are aware of the hazards. Ensure all guards are checked on a regular basis. Any defects to be reported to management. Ensure ear protectors are worn by all personnel working in this area. Hot work permit to be obtained and adhered to.

Supervisor

Supervisor

Maint. Dept.

Supervisor

Operator / Supervisor

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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41 of 75

AREA: TALLOW SCRAPER TANK

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Maintenance of

machine, pipes, valves and electrics.

2. Inspection of tanks.

• Entrapment in moving scraper.

• Falls from stairs and

platforms. Falls from height.

• Burns and scalds from

steam pipes and hot tallow and water.

• Inhalation of fumes- lung function disorder- asthma.

• Noise

• Head injury from

protruding motor and mount.

Low Low Low Low Low Low

Mesh guard installed. Number of isolators increased. Stairs protected by handrails. Area cleaned on regular basis. Gloves and overalls provided to employees. High ventilation rate 10-12 air changes per hour. Ear protection issued to personnel. Bump cap provided to all personnel.

Erect warning signs. Area to be cleaned on regular basis. Any defects in handrails to be reported to management without delay. Ensure employees are wearing gloves and overalls when working in this area. Erect more signage to warn of the dangers. Maintain cooking temperatures below 120ºC. Ensure personnel wear ear protectors when operating in this area. Bump cap to be worn by all personnel when working in this area. Paint motor and mounting an illuminous colour to highlight hazard.

EHS Officer

Supervisor

Supervisor

EHS Officer

Supervisor

Supervisor

Supervisor

Immediate

Ongoing

Ongoing

6 months

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

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42 of 75

AREA: TALLOW STERILISATION

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Heating tallow

steriliser 2. Operating tallow

steriliser. 3. Maintenance of

machines, valves, electrics and pipes.

• Slips trips and falls from stairs and gantries.

• Burns and scalds from hot tallow/water/steam

• Pressurised vessel-

explosion.

• Noise

• Operating tallow steriliser – overflow of tanks.

Medium Medium Low Low Low

All stairs and gantries have handrails. Hoses to be put away after use. Hoses not to be left trailing along walkways. Adequate PPE provided to employees. Operators to be instructed of the dangers of heating the steriliser – draining potential of hot condensate to floor. Certified vessel. Automated pressure control – over pressure safety valve. Ear protection provided to personnel. Level sensors on all tanks. Instruct operator not to select tanks which does not have adequate capacity.

Ensure all handrails and platforms are in good condition. Any defects to be reported to maintenance personnel without delay. Hoses not to be left trailing along walkways at any time. Ensure adequate PPE is worn by operators. Ensure ear protection is worn by operators. Instruct operator not to select tanks which does not have adequate capacity.

Maint. Dept.


Operators


Supervisors

Supervisor

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

owne

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uired

for a

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43 of 75

AREA: TALLOW STORAGE AREA

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Cleaning tallow tank 2. Cleaning outside of

tallow storage area 3. Emptying bund with

mobile pump 4. Sampling tallow 5. Cleaning bunded area 6. Blowing tallow lines 7. Returning tallow

bottoms 8. Loading road tankers 9. Inspection of road

tankers 10. Maintenance of

machinery, pipes, valves and electrics.

• Slips trips and falls.

• Burns and scalds from hot tallow/steam.

• Entanglement in unguarded motor and shafts.

• Confined space entry

• Electrocution

• Blowing of tallow lines – risk of fire, burns.

• Loading tallow – haulage contractor. – Burns and scalds from hot tallow.

Medium Medium Low Medium Low Medium Low

All stairs and platforms have handrails. Adequate side protection on all platforms provided. Regular washing of the floor to be carried out to prevent build up of grease and dirt. Gloves and overalls provided to employees. Lab analyst to wear adequate PPE when sampling. All motors and shafts are adequately guarded. A permit to work must be obtained before any confined space work is carried out All electrical work is carried out by a qualified electrician. Only trained personnel to blow lines. Adequate PPE must be worn. Hot Work permit to be obtained. Fire extinguisher located in area.

Any defects in handrails or platforms to be reported to management. Ensure area is washed regularly. Manholes very slippy, guard to be placed around them. Large manhole under stairs must be kept covered. Ensure operators are wearing adequate PPE. Ensure all motors and shafts are adequately guarded. Any defects in guards are to be reported to maintenance Dept. without delay. CSE procedures to be revised. Any defects in equipment must be reported to electrician. Hot work permit to be obtained. The insulation on the tallow tanks is soaked in tallow and causes a major fire risk. This must be looked into asap.

Operators

Supervisor

Maint. Dept.

Supervisor/ Operators

Maint. Dept.

Operators

Management

All employees

Operators/ Supervisors

Managing Director

Ongoing

Ongoing

Maint. Dept.

Ongoing

Immediate

Ongoing

Immediate

Ongoing

Ongoing

Immediate

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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EPA Export 26-07-2013:00:30:42


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• Returning tank bottoms- tank overflow.

Loading Road Tankers

• Working at height- falls. • Hot tallow- burns & scalds

Medium Medium

It is the responsibility of the haulier to ensure the coupling is in good working order before use. Safety gloves to be worn by haulier. Operator aware of the hazards. Operator exercises extreme caution when returning tallow. Tank is not over filled. All tankers must have handrails on tanker. Care to be taken when climbing on/off tankers. Gloves to be worn.

A direct pipe from production to fuel storage area is to be put in place. Ensure safety gloves are worn by haulier. Instruct operator to exercise extreme caution when returning tallow – not to overfill. All tankers must have adequate handrails-operators not to get up on tanker without handrails.

Managing Director

Haulier

Supervisor


6 months

Ongoing

Immediate

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

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45 of 75

AREA: THERMAL OXIDISER

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Maintenance of

machinery, valves, pipes and electrics.

2. Cleaning of tanks – CSE.

3. Inspection of Thermal Oxidiser.

4. emptying of tanks


• Falls from height

• Electrocution

• Lack of training on operating instructions on the machine resulting in injuries etc.

• Burns and scalds from hot pipes, steam, water and tallow.

• Fire/explosion

Medium Medium Low Low Low Low

Area cleaned on a regular basis. Any spillages to be cleaned up immediately. Confined Space permit required before entry to any chamber in Thermal Oxidiser. Only trained personnel to carry out maintenance on thermal oxidiser. Adequate guardrails and handrails on walkways and ladders of thermal oxidiser. All electrical work has been carried out by qualified electricians. Babcock Watson to give training to Premier Proteins employees as regards the safe operating of the machine. The operating of the machine is computerised. All pipes are adequately insulated. Any defects in pipes to be fixed immediately. Gas tank and pipes have been put in place by Calor Gas. These have all passed the appropriate testing. No smoking permitted in this area.

Area to be cleaned on a regular basis. Ensure confined space permit is received before entering any chamber. Any defects in handrails/guardrails to be reported to maintenance personnel without delay. Babcock Watson to give detailed training to Premier Proteins employees on the safe operating of the machine. Ensure no smoking in this area.

General operators

All employees

All employees

Babcock Watson

All employees

Ongoing

Ongoing

Immediate

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

owne

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uired

for a

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AREA: TRAINORS FIELD & HOUSE

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Walking in field. 2. Rolling of field 3. Cutting of grass. 4. Maintenance carried

out in house. 5. Electrical work carried

out in house.

• Storage of bio filter heather – fire, damage to overhead power lines, infestation of rodents.

• Uneven surfaces in field- tripping hazard.

• Combustible material in house- files etc. – risk of fire.

• Calor Gas tanks – risk of explosion/fire.

Low Low Low Low

Pest contractor baits and monitors area. Heather does not be stored adjacent to power lines. Holes filled as necessary. Field rolled after grazing. No smoking signs posted in this area. Area adequately fenced off. Calor gas fitted the tanks and pipes on site and all the necessary testing was carried out.

Ensure heather is not stored adjacent to power lines. Provide proper shelving for files; consider installing smoke detector and linking to central alarm. Ensure area around gas tanks are adequately fenced off.

Production Manager

Managing Director

Managing Director

Ongoing

6 months

Immediate

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

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AREA: WORKSHOP

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Use of bandsaw 2. Use of lathe 3. Use of benchdrill 4. Use of grinding

wheel 5. Use of thread cutter 6. Welding 7. Use of hoist 8. Use of portable tools. 9. Washing of tools 10. Cleaning of area.

• Hot work – risk of fire and burns.

• Slips trips and falls

• Head injury due to material falling from shelves.

• Chemicals – maintenance personnel use oils and coolants.

• Noise Workshop Bandsaw

• Exposed cutting blade – loss of limb, injury to personnel

Low Low Low Low Low Low

Fire extinguishers located in workshop. Overalls and gloves supplied to operators. Bar heater in office to be switched off when unattended. A small amount of oils and coolants are stored in the store area. All cables etc must be put back in a safe area so as not to cause a trip hazard. All spills to be cleaned up immediately. Foot stool and ladder provided for personnel reaching for items on high shelves. All materials are stored securely on shelves. The heavier objects are stored on the bottom shelves for easy access. Workshop is tidied on a regular basis. Material safety data sheets (MSDS) for all substances used by maintenance personnel must be kept on file in the workshop. All precautions as outlined in the MSDS must be adhered to. Ear protection provided to all personnel.

No combustible material /flammable chemicals to be stored in workshop. Combustible material to be removed from workshop on a daily basis. Ensure the amount of chemicals stored is kept to a minimum. Ensure care is taken when lifting material from high shelves. Ensure all MSDS are on fil Ensure adequate guards are placed on all machinery in workshop.

Maint. Dept.

Maint. Dept.

EHS Officer

Maint. Dept.

Ongoing

Ongoing

6 months

Immediate

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

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uired

for a

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tripping/falling across blade.

• Coolant – could cause irritation to skin.

Workshop Bench Drill

• Drill bit breaking and ejected at high speed- injury to eyes/face.

• Swarf ejecting at high speeds- risk of eye injury/cuts from swarf.

• Vice/clamp not being used correctly- vice/clamp and part spinning and striking operator.

• Entanglement in

moving/rotating part.

• Foot pedal- possible to start accidentally while working on clamp/chuck. Risk of injury to operator.

Workshop Grinding Wheel

• Disintegration/bursting of wheel- injury to operators/passers by.

• Foot pedal carried 380 V and is located on ground which may become wet- risk of electrocution.

• Moving/rotating wheel at high RPM – risk of cuts/finger loss/nips.

Low Medium Medium Medium Medium Low Low Low Low

No tripping hazard in the area of the bandsaw. Authorised users to operate it. Eye protection provided to employees. Ensure MSDS for coolant is on file. Only authorised personnel to operate this machine. Adequate face shield and eye protection provided to employees. Overalls provided to all employees. Foot pedal encased to prevent inadvertent use. Main switch to be switched off when not in use. Grinding wheel to be checked before use. Face shield to be worn when operating this machine. When grinding adequate distance between fingers and grinding wheel must be maintained. Adequate gloves are worn when operating this machine.

Ensure MSDS for coolant is on file. Ensure adequate face protection is used when operating this machine. Only authorised personnel to use this machine. Adequate face protection to be used when using this machine. No loose clothing to be worn when operating this machine. Main switch to be switched off when not in use. Grinding wheel to be checked before use. Face shield to be worn when operating this machine. Ensure rest is proper distance from stone.

EHS Officer

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

1 month

Ongoing

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

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for a

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• Injury to eyes and face due to

sparks and ejected material. Workshop Lathe

• Storage of tools on machine- risk of knocking tools accidentally onto rotating assembles causing high speed rebound at operator.

• Chuck key being left in chuck

when lathe started- risk of key hitting operator at high speed.

• Entanglement in rotating parts.

• Injury to eyes from shavings

Medium Medium Medium Medium Medium

Face shield provided to employees. No tools to be left on machine. Adequate storage available for tools in workshop. Only trained operators to operate machine. Overalls provided to employees. No loose clothing worn when operating this machine. Authorised personnel only to operate this machine. Face shield provided and won when operating this machine. Only trained operators to operate this machine.

24 V relay to be used to wire foot pedal. When grinding adequate distance between fingers and grinding wheel must be maintained. Only trained operators to operate machine. Face shield to be worn by employees when operating this machine. Install transparent guard across grinding wheels. No tools to be left on machine Spring loaded key to be obtained and used. No loose clothing to be worn when operating this machine. Post moving parts sticker at spindle end. Face shield to be worn when operating this machine.

Electrician

Maint Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

1 month

Ongoing

Ongoing

6 months

Ongoing

Immediate

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

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r req

uired

for a

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Work shop Thread Cutter • Entanglement of passer

by/operator if bar/part gets caught in something it could cause thread cutter to overturn.

• Tools/off cuts becoming

trapped in machine – injury to operator- damage to machine.

• Entanglement in rotating parts.

Work Shop Welding

• Welding fumes

• Fire

• Photokeratitis (arc eye) Workshop Hoist

• Load falling and hitting operator/passer by.

• Electrocution • Lifting objects at an angle –

load swing uncontrollable/ pulling hoist off rails/warping rail/ serious injury to operator or passer by

Medium Low Low Low Low Low Medium Low Medium

Stand to hold long bars. Area to be checked first and screen put around area before cutting take place. Only authorised personnel to operate machine. Only trained operators to operate machine. Off cuts discarded off after use. Tools not left on machine. No loose clothing worn by operators. Overalls provided and worn. Welding face shield worn when carrying out welding activities. All combustible material to be removed from area when welding. Good housekeeping maintained in area. Fire extinguishers located in area. Welding mask provided and worn by employees when carrying out welding. Hoist and slings certified. Retainer to be in good condition. Wiring carried out by qualified electrician. Only authorised users to operate hoist. Safe operating instruction to be followed.

Screen put around area before work commences to protect passers by. Ensure no tools are left on machine and off cuts are discarded off after use. No loose clothing to be worn by operators. Ensure welding face shield is worn. Ensure good ventilation in the area. Ensure no combustible material is in area when welding. Ensure welding mask is worn. Check retainer is in good condition. Signage for max weight to be posted. Any defects in wiring to be reported to electrician. Only authorised users to operate hoist. Hoist to be put back in safe position after use.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Maint. Dept.

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

ny ot

her u

se.

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AREA: WASTE WATER TREATMENT PLANT (WWTP)

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Replacing chemicals 2. Dosing Lime 3. Entry into Buffer Tank 4. Maintenance on

Aerators and Submerged mixers

5. Cleaning of area 6. CSE entry into tanks 7. Maintenance on pipes,

machines and valves.

• Electrocution

• Slips, trips and falls.

• Chemical burns and skin irritation from 1. Lime 2. Ferric Chloride 3. Polymer 4. Caustic Soda.

• Bursting of air compressors.

• Biological agent – infection through cuts and scrapes.

• Drowning in deep tanks

• Entanglement in machinery and moving parts

Medium Medium Medium Low Low Low Low

Doors on all electric panels. All open manholes covered to prevent persons falling into them. Open manholes must not be left unsupervised at any time. Warning tape to be placed around area. All hoses to be put away in safe area after use. Hoses not to be left trailing along walkways safety boots provided and worn by operator. Any spillages on floor are cleaned up immediately. Material safety data sheets (MSDS) are on file. Adequate PPE must be worn when handling chemicals. Lab analyst to wear adequate PPE when handling chemicals. Safety glasses to be worn when inspecting decanter bins. Statutory inspections carried out on air compressors. Gloves are provided to operator and worn. All cuts and scrapes are treated and covered to prevent infection. Signage and handrails around tanks. Hedge plant around rest of tank. A permit to work must be obtained for any work carried out in the tanks. Life jacks are located at tank.

Ensure doors on all panels are kept closed. Manhole guards to be purchased and placed around open manholes. Good housekeeping to be maintained and any spillages to be cleaned up immediately. MSDS for each chemical must be kept on file in the WWTP. Operator to be aware of hazards. Eye wash facility and emergency shower to be provided in WWTP. Statutory inspection to be carried out on sir compressors. All cuts and scrapes are treated and covered. A permit to work must be obtained for any work carried out in the tanks.

Env. Operator

Production Manager

Env. Operator

EHS Officer

Managing Director

Maint. Dept.

Env. Operator

All employees

Ongoing

Ongoing

Ongoing

Immediate

Immediate

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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for a

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• Noise

• Confined Space Entry

• Working in isolation The environmental operator works a good distance away from other employees.

• Work on aerators and submerged mixers – deep tanks –risk of drowning.

Low Medium Low Low

All machinery and motors are adequately guarded. Ear protectors provided to operator and worn. A permit to work must be obtained before any confined spaces entry take place. DECT phone is provided to operator and must be switched on at all times. Fitters not to work alone in tank. Aerator and mixer isolated before work commences. Work permit to be issued and adhered to. Harness to be worn when in tank and harness to person above tank in case of emergency rescue. Life jackets available along tank.

Any defects in guards must be reported to maintenance personnel without delay. A permit to work must be obtained before any confined spaces entry take place. Ensure DECT phone is switched on at all times. Fitters not to work alone in tank. Aerator and mixer isolated before work commences. Work permit to be issued and adhered to. Harness to be worn when in tank and harness to person above tank in case of emergency rescue

Env. Operator

Maint. Dept.

Env. Operator

Maint. Dept.

Ongoing

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

owne

r req

uired

for a

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General Risk Assessment Sheets

For

insp

ectio

n pur

pose

s only

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Conse

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VEHICLE MOVEMENT & OPERATION

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Movement of Trucks,

Forklifts, Teleporters, cars, vans etc around the yard.

2. Movement of vehicles in raw material shed.

3. Movement of pedestrians in all areas.

4. Using forks as a working platform.

• Collision with pedestrians, moving and stationary vehicles.

• Manoeuvring vehicles

with obstructed vision.

• Loads falling from Volvo or Forklift

• Driving at speed in confined spaces.

• Heavy or unbalanced loads causing vehicles to overturn or lifting mechanism to fail.

• Using forks as a working platform.

• Carrying person on Forklifts and Volvos

• Poor visibility in the yard

• Inhalation of exhaust fumes

Medium Medium Low High Low Medium Low Low Low

Forklift Volvos and Telporter to be driven by trained and experienced drivers. Any trailer which is stopped must have adequate breaks applied. Any trailer left in the yard must apply chocks to wheels to prevent trailer from rolling. If vision is obstructed reverse with load or use person to give directions. Greater care must be taken when pedestrians are in the vicinity. Ensure loads are secure on forks or in Volvo grab before moving off. Drivers should maintain a steady speed of 15 kmph when driving in confined spaces. The driver must ensure the load does not exceed the vehicles maximum capacity. When unloading loads ensure the vehicle is located on level ground. A steel framed crate is located on site for use as a working platform for the Forklift. Volvo and Forklift drivers are prohibited from carrying passengers in their vehicles except for training purposes.

Forklift and Volvo drivers to be giver certified training. Adequate barriers must be put in place along office doors. Strict enforcement of speed restrictions for all drivers. Speed restriction signs must be placed in the yard. Ensure when unloading that the vehicle is on level ground. A safety harness must be worn when working in a steel framed crate. Enforce the wearing of high visibility vests. Maintenance schedule to be adhered to.

EHS Officer

Managing Director

Supervisors EHS Officer

Production Manager

Vehicle drivers

Operators

Supervisor/ EHS Officer

Maint. Dept

1 month

6 months

Ongoing

Immediate

Ongoing

Ongoing

Ongoing

Ongoing

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

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r req

uired

for a

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• Stability of vehicles and loads due to yard surface

• Poorly maintained forklifts and Volvos

Low High

All drivers and personnel in the yard must wear high visibility vests. Adequate lighting in the yard and raw material intake. Stationary vehicles to be switched off. Vehicle maintenance schedules to be adhered to. Daily safety checks to be carried out. Any defects in the vehicle must be reported to maint. Dept immediately. Under the Factories Act annual inspection of lifting mechanisms’ must take place on all lifting appliances. Yard surfaces shall be repaired as damage deems necessary. Good quality surfaces must be maintained. Volvos in very bad condition. Not road worthy at all. Forklifts require new tyres and hand brake.

Safety checks to be carried out by drivers daily. Annual inspection of lifting appliances. Volvos to be repaired adequately or new Volvo to be purchased. Adequate maintenance to be carried out on Forklifts.

Drivers

Insurance co.

Managing Director

Managing Director

Ongoing

Annually

Immediate.

Immediate.

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

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r req

uired

for a

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CLEANING, INSPECTION AND MAINTENANCE OF MACHINERY

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Cleaning,

Inspection and Maintenance of all machines on site.

2. Cleaning Inspection & Maintenance of all pipes valves etc on site.

3. Electrical Maintenance carried out on electrical appliances and wires.

4. Cleaning Inspection and Maintenance of all hydraulic equipment on site.

• Machinery could cause serious harm when running. Isolate machinery before maintenance work.

• Removing guards during inspection or jogging of machinery exposes maintenance personnel to moving parts

• Operating machinery without safety devices functioning may increase the risk of injury from machinery.

• Risk of electric shock

whilst handling faulty electrical equipment.

• Movement of hydraulic equipment after machinery has stopped

Medium Medium Medium Medium Medium

Isolate machinery prior to carrying out any maintenance work. Only experienced maintenance personnel will carry out work on equipment without the appropriate guarding or safety devices in place. Safe working practices must be adopted and work must be carried out in pairs. Unguarded machinery must not run for longer than necessary and will not be left unattended for any reason. Safety devices will be functionally checked after replacement/repair. After maintenance completion covers and guards will be replaced on machinery. Only qualified electricians carry out work on electrical equipment and work should be carried out in accordance with ETCI guidelines. Maintenance, supervisors and machinery operators should be made

Lock out tag out procedures to be written up for each machine and operators trained. Only experienced maintenance personnel will carry out work on equipment without the appropriate guarding or safety devices in place. Safe working practices must be adopted and work must be carried out in pairs. Unguarded machinery must not run for longer than necessary and will not be left unattended for any reason. Safety devices will be functionally checked after replacement/repair. After maintenance completion covers and guards will be replaced on machinery Refresher information given regarding possible

Electricians EHS Officer

Maint. dept.

Maint. Dept.

Maint. Dept.

6 months

Ongoing

Ongoing

Immediate

For

insp

ectio

n pur

pose

s only

.

Conse

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may cause crush/trap injuries.

• Cleaning equipment may result in particles being ejected from machinery.

• Wearing of loose fitting clothing may become entangled in moving parts of machinery.

• Bursting of hydraulic hoses/pipes whilst inspecting or maintaining equipment with the risk of oil being injected under the skin.

Medium Low Low

aware of hydraulic hazards on equipment. All residual hydraulic power should be released after isolating equipment prior to carrying out any work with machinery. Machinery must be stopped prior to cleaning. Adequate PPE to be worn. All employees wear overalls. No loose/torn clothing to be worn. Care should be taken when working with worn or defective pipes. No handling of pipes should be carried out whilst machinery is running. Gloves, glasses and long sleeved overalls should be worn.

hydraulic movement in each machine after use. Machinery to be stopped prior to cleaning. No loose/torn clothing to be worn. Formal Lockout and Tagout (LOTO) system to be adopted by the company. Procedures for the system in the safety statement.

All employees

All employees

Production Manager/

Supervisors/ Electrician/ EHS

Officer.

Ongoing

Ongoing

6 months

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

copy

right

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uired

for a

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MACHINERY – GENERAL

Tasks carried out: Hazards Risk Controls Recommendations Responsibility: Action Date: 1. Starting up &

operating of all machinery on site.

2. Maintenance of machinery.

3. Removing blockages in machinery

4. Fault finding of machinery.

5. Operation of machinery.

• Trapping between parts of machinery

• Entanglement in

unguarded, rotating or moving parts

• Ejection of objects • Contact with moving parts

causing friction, burns or cuts

• Excessive exposure to

high noise levels • Removing blockages or

materials without switching off machinery

• Maintenance or fault

finding without locking out machinery

• Inexperienced operators,

who may not be fully aware of the hazards associated with the machine

Medium

Medium

Medium

Low

Medium

High

High

Medium

Medium

Machinery purchased must conform to machinery safety standards and must be inspected by maintenance manager to ensure it complies with appropriate legislation. Maintenance schedules for machinery must be adhered to. All guards and safety devices must be regularly inspected to ensure they are in place and working. Any defects or faults with machinery must be reported to the supervisor and maintenance personnel without delay. Machinery operators must receive adequate training, regarding the operation and hazards associated with such machinery. All persons operating machinery must be properly trained on the safe system of work which must be practiced whilst operating machinery. Inexperienced operators must be supervised and shadowed by an experienced competent operator until they are considered competent to operate the machine

Operators should inspect machinery to ensure all guards are in place and safety switches are in working order at the start of each shift. Maintenance Schedule to be drawn up for inspection of machine safety devices. Refresher training for all machine operators on the hazards associated with their machines and safe working practices to be adopted. Lock out tag out procedures to be drawn up for each machine.

Supervisors

Maint. Dept.

Production Manager / Supervisor

Supervisor/ Electrician/ EHS

Officer

Ongoing

1 month

6 months

6 months

For

insp

ectio

n pur

pose

s only

.

Conse

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• Carelessness and /or lack of concentration whilst operating machinery

• Horseplay around

machinery

Low

alone. Safe access and egress to and from machinery and suitable safe working platforms must be provided. All machines must be fitted with an emergency stop buttons and operators must stop the machine before attempting to free blockages. All maintenance staff must lockout machinery before working on them. Any fault finding or jogging of machinery which must take place whilst machine is operating must be done by an experienced fitter in the presence of another person. Horseplay or dangerous activity around machinery is prohibited and subject to disciplinary action. Hearing protection must be worn when operating machinery. Adequate lighting and heating must be provided and maintained around machine/operator locations.

For

insp

ectio

n pur

pose

s only

.

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CONVEYORS Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date:

1. Maintenance of conveyors

2. Operation of conveyors.

3. Fault finding of conveyors.

4. Freeing blockages on conveyors.

• Trapping between rollers

• Entanglement in

unguarded, rotating or moving parts

• Head or body injuries

caused by material falling from conveyors

• Head or body injuries

from passing underneath conveyors

• Contact with moving

parts causing friction burns or cuts.

Medium

Medium

Medium

Medium

Low

All moving parts, motors and pinch points are adequately guarded. Install covers/guards in positions where there is a possibility of materials falling or where a conveyor passes over an operators position or walkway Cover all conveyor rollers or belts if not at a sufficient height to prevent contact where personnel cross under conveyors Do not attempt to remove an obstruction or carry out maintenance when the conveyor is moving. If it is necessary that the conveyor remain operating then another person must be present. Ensure conveyors are not overloaded. Walking or riding on conveyors is prohibited. Safety helmets are available to persons working under conveyors.

All conveyors should be checked for appropriate guarding. In areas where personnel cross under conveyors and head contact is likely, the conveyor belts require covering. Screw conveyors in mill store room require urgent attention.

Maint. Dept.

Maint Dept.

Maint. Dept

1 month

Immediate

Immediate

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

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uired

for a

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ABRASIVE WHEELS Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date:

1. Use of abrasive wheels in workshop and around the site.

Abrasive wheels are used in the maintenance workshop. • Entanglement in the wheel

when it is rotating. • Injuries sustained from

contact with the abrasive surface.

• Ejection of sparks and debris

• Ejection of particles due to disintegration of the wheel

Medium

Low

Medium Low

Wheels should be examined prior to use Wheels must be stored on their edge not flat Only trained and competent people must mount wheels on the grinding machine. The wheel must always be in position and properly adjusted. Eye protection must be worn Work rests must be kept adjusted as close as possible to the wheel Turning and dressing of wheels must only be carried out by the appointed competent person

Abrasive wheels training to be carried out by maintenance personnel. Only trained personnel to operate abrasive wheels.

Immediate Managing Director

For

insp

ectio

n pur

pose

s only

.

Conse

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ELEVATED PLATFORMS

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: • Working on platforms

and stairs. • Injuries to persons working on the

platform resulting from a slip or fall onto a lower level or into moving machinery.

• Head injuries caused by tools or other objects falling from platforms to lower level.

• Slips or trips on the stairs.

Medium

Medium

Medium

Guard rails and toe boards are installed around all open sided platforms. Objects and tools are not left lying on top of platforms. Persons working beneath elevated platforms must wear protective headwear. All personnel are prohibited from throwing objects from the higher level during working hours. Running is not permitted in the factory especially on elevated platforms. Protective barriers or guard rails should be in place where dangerous moving parts are operational along walkways.

Check all guardrails and toe boards are in place and in a good state of repair. Stairways must have handrails and steps must be appropriate distance apart. (sterilisation area) Prior to installation of new machinery adequate walkways, platforms guardrails and toe boards must be in place. All outdoor steps and walkways should be painted with slip resistant paint.

Maint. Dept.

Maint. Dept.

Maint. Manager

Maint. Dept.

Immediate

Immediate

Ongoing

6 months

For

insp

ectio

n pur

pose

s only

.

Conse

nt of

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right

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uired

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HAND TOOLS Tasks carried out: Hazards; Risk: Controls: Recommendations: Responsibility: Action Date:

1. Use of all hand tools on site.

Hand tools are used mainly for maintenance activities and the main hazards associated with their use are: • Ejection of the material

being worked on • Sharp edges/blades • Injuries resulting from

defective tools or parts • Injuries resulting from

lack of training or experience

Low

Low Low

Low

The correct type, size and weight of tool should be selected for the job and manufacturer’s instructions should be followed. Defective or unsuitable tools can cause injury and maintenance of such tools is critical. Grease and dirt should be cleaned off tools. Cutting edges and points of tools should be kept sharp and protected when not in use. Handles of tools should be smooth finished and maintained in good condition. When work with a hand tool is completed the tool should be removed and stored in appropriate storage. Only trained and experienced employees are permitted to use hand tools. Appropriate maintenance supervision must be given to trainees until such time as they are considered competent. Any defects must be reported immediately and defective equipment taken out of service and fixed or replaced.

All hand tools examined and any defective tools fixed, maintained or replaced.

Ongoing Maint. Dept.

For

insp

ectio

n pur

pose

s only

.

Conse

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PORTABLE ELECTRIC TOOLS Tasks carried out: Hazards; Risk: Controls: Recommendations: Responsibility: Action Date:

1. Use of all portable electric tools on site

Portable electric tools are used mainly by employees involved in maintenance work. The main hazards are; • Electric shocks • Contact with moving parts of

the tools.

Medium Medium

Safe work practices must be adhered to by all personnel using electric tools. Tools should be inspected prior to use. Cables, plugs or connectors should be in good condition and free from cracks, breaks or exposed wires. Manufacturer’s instructions for use must be followed. Electrical sockets must be of the industrial type in the mills. Portable tools must operate only on 110V power supply. A residual current circuit breaker (RCB) should be used at the socket or mains even if the power supply is 110V. Portable electric tools should be used for their designed purpose. Cables must not be allowed trail on the floor or in/near water. Portable electric tools must never be connected to lighting sockets. In addition to visual inspection prior to use the portable electric tools will be subject to a three monthly service and maintenance programme carried out by competent electrician.

Any sockets which are domestic type sockets must be replaced by industrial sockets. All portable electric equipment must be inspected and any faults or defects repaired.

Electrician

Electrician

6 months

1 month

For

insp

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FIRE

Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date: 1. Hot Work 2. Use of flammable

chemicals in lab. 3. electrical

maintenance.

Fire risks exist throughout the premises and the risk is considered medium due to the combustible nature of the products produced and stored on the premises.

Medium Smoking is prohibited on site. Electrical installations, machines and equipment are subject to routine maintenance and inspection. Electrical work carried out by a qualified electrician. Permit to Work scheme is in place for hot work. Fire fighting equipment is available throughout the premises. Emergency Plans have been drawn up and are in place.

Fire fighting equipment to be inspected every 3-4 months by Western Fire Protection. Training to be given to employees on the use of the fire extinguisher. Strict enforcement of these controls. Any tanks with tallow encased in the insulation must be replaced as this is a serious fire risk.

Ongoing

Immediate

Immediate

Immediate

Western Fire Protection

Managing Director

Managing Director

Managing Director

For

insp

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WELDING & CUTTING

Tasks carried out: Hazards; Risk: Controls: Recommendations: Responsibility: Action Date: • Welding and

cutting carried out throughout the site.

• Potential fire hazard • Potential explosive hazard • Inhalation of welding fumes

and gases • Burns • Photokeratitis (‘arc eye’) • Noise • Body Strain

Medium Low Low Low Low Low Low Low

Electric arc welding and oxy-acetylene gas welding are carried out where possible in the workshops to reduce the fire hazard. Use of the ‘Hot Work Permit’ scheme, which must be used by all employees and contractors carrying out welding or hot work, controls the fire risk. A portable fire extinguisher ( dry powder/CO2) must be brought to the location where the welding is being carried out and the area must be adequately ventilated. The area must be cleaned of dust and wetted down where possible. Check the area during and after completion of work for signs of fire or potential smouldering in the area. Employees who have been properly trained must only use welding equipment. In the event of a fire where compressed gas cylinders become hot, ensure they are not moved and inform the emergency services of their location. If possible cool the cylinders with cold water without disturbing them. Gas cylinders are colour coded with the main gases used on site being oxygen (black), and acetylene (maroon) , pressure regulators and flashback arrestors are used on both cylinder types. Hoses are checked regularly for wear and tear. Cylinders are chained during transport. Those carrying out welding must wear welding face shields. Persons involved in cutting or grinding must wear eye protection.

Ensure ‘Hot Work Permit’ system is in operation.

Maint. Dept. Supervisors EHS Officer

Immediate

For

insp

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n pur

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COMPRESSED AIR Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date:

1. use of compressed air to blow down machinery.

• Injuries resulting from burst hose or pressure vessels.

• Cleaning machinery could result in an injury or accident i.e. particles blown into eyes.

• Misuse of compressed air, blowing down clothing, which could result in air bubbles in the blood via access through broken skin (cuts, grazes).

• Inhalation of dust particles • Slips, trips and falls over trailing air

hoses. • Noise from compressed air could

cause hearing impairment.

Low

Low

Medium

Low Low

Medium

Routine maintenance, cleaning and lubrication is carried out on compressors. Prior to blowing down machinery the area should be clear of other employees and the operator should wear dust mask and safety glasses. Employees are prohibited from blowing down clothing with compressed air. Dust masks are provided Airlines should be coiled and put away safely after use. Operators to wear hearing protection.

Employees to be made aware of the dangers of compressed air.

Supervisor/ EHS Officer

Immediate

For

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COMPRESSED GAS CYLINDERS Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date:

1. Maintenance personnel use compressed gas cylinders for welding and cutting etc.

2. use of gas cylinder with blow torch.

Compressed Gases used include oxygen, acetylene and argon. • Fire and explosion • Release of toxic or noxious

materials • Injuries to feet, fingers, and

back caused by lifting, moving or transporting cylinders

Medium Low

Medium

Cylinders must be inspected upon arrival for damage and transported around the premises in a secure manner using trolleys. Cylinders must be stored upright on dry surfaces and securely fastened their designated area when not in use. The cylinder valves must in good condition, have pressure regulators attached and must be kept free of oil or grease as this may ignite. Excessive force must not be used when opening cylinder valves; they should be opened slowly and closed only sufficiently to shut off the gas. Leaking cylinders must be reported immediately to the maintenance manager. Hoses and equipment used with compressed gases must be regularly inspected for leaks or damage. Compressed gas cylinders must never be moved if they have become hot as they are liable to explode, they must be cooled sufficiently before moving i.e. fire. Information sheets on the gases must be available in the maintenance workshop. Hot work permit to be obtained for any hot work.

Ensure cylinders are stored securely fastened in their designated area. All cylinders and hoses must be checked for damage. Safety data sheets for the compressed gases must be available or posted in the workshop.

Maint. Dept.

Maint. Dept.

EHS Officer

One month

One month

One month

For

insp

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n pur

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MANUAL HANDLING


1. Lifting of objects 2. Stretching 3. Pushing objects 4. Pulling objects. 5. Moving objects.

Any manual handling of loads can pose a hazard to employees. • Strains or sprains of the arm, back

or legs • Foot injuries from falling loads • Head injuries from falling loads

High

Medium Medium

Mechanical lifting equipment (forktrucks) are available and must be utilised in preference to manual handling whenever feasible. Machinery is automated where possible to avoid manual handling. Hoists and pulleys are used where possible. Block and tackle equipment is used in a planned and co-ordinated manner only were other mechanical lifting equipment cannot be used. Training in manual handling must be given to all employees this training must include information on assessments of loads, safe lifting techniques and lifting and handling material so as not to endanger others. All employees involved in manual handling activities must wear safety footwear. All work areas including walkways must be kept free of obstructions and tripping hazards. Walkways and floors must be maintained in a safe condition and defective areas reported immediately to the production manager. Incidents and accidents must be reported. Provide where possible light manual handling activities for employees who suffer from manual handling injuries or require restricted duties as a result of injury.

Training in Manual Handling must be provided for all employees involved in such activities. All employees should receive information on safe manual handling techniques until such time as training is provided. All employees in the production and yard areas must wear safety footwear.

EHS Officer

EHS Officer

All employees

6 months

Immediate

Ongoing

For

insp

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s only

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NOISE Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date:

1. Working in noisy areas.

2. Working with noisy machinery.

High noise levels may cause; • Hearing impairments • Stress • Lack of concentration

High Low Low

The wearing of appropriate hearing protection in all production areas is compulsory for all personnel. Information, instruction and training will be given to all employees regarding the noise hazard in the company, the possible effects it may have on the individual and the means in place for controlling the risk and the wearing of hearing protection. Locating employees away from high noise level areas where possible. Machinery and equipment will be subject to regular maintenance to ensure noise levels are kept to a minimum. When purchasing new machinery or equipment every effort will be made to ensure it will not cause a significant increase to the noise levels. Employees must regularly check their ear defenders fit snugly over the ears and head and also for visible signs of damage or deterioration. Defects in hearing protection must be reported to the supervisor and appropriate action taken.

New signs must be erected indicating compulsory wearing of hearing protection. Employees given information regarding the effects of high noise levels. Noise monitoring to be carried out once the Thermal Oxidiser is up and running.

Production Manager

EHS Officer

Managing Director

6 months

6 months

6 months

For

insp

ectio

n pur

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s only

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DUST & FUMES Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date:

1. Working in mill room where dusts are generated.

2. Working in raw material shed where fumes are being generated.

3. Fumes generated throughout the factory.

Dust is generated from the production and storage of the meat bone meal. The hazards associated with dusts are: • Upper respiratory

problems • Dermatitis Maintenance personnel may also be exposed to dusts from grinding activities. Ammonia fumes are also produced in the process.

Low Low

Inhalable particulate matter in the factory is below the OEL for ‘Dusts non-specific’ as set out in the 2001 Code of Practice for the Chemical Agents Regs. 1994. All areas of the site are cleaned on a regular basis paying particular attention to areas where the accumulation of sawdust is frequent. All dust extraction systems will be cleaned and inspected regularly. Dust masks are available to all employees. Suitable dust masks will be worn when blowing down equipment. Maintenance personnel must wear appropriate respiratory and eye protection. Ammonia levels for each operator is measured on a continuous basis. Respirators are available to all employees on site.

Ammonia levels to be monitored for personnel exposure levels on a regular basis or when complaints arise.

EHS Officer

Ongoing

For

insp

ectio

n pur

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s only

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Conse

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SLIPS TRIPS & FALLS Tasks carried out: Hazards; Risk: Controls: Recommendations: Responsibility: Action Date:

1. Walking around the factory and site.

2. Using cleaning hoses.

3. Walking up and down stairs.

Injuries to the head and body

Medium All workplaces should be kept clean and tidy. Boards and waste material is removed after every shift. Leads from portable tools, office equipment etc. should not be allowed to trail. Any spillage should be cleaned up immediately. Damage to floor surfaces should be reported immediately to the supervisor. Running is prohibited in the factory. Guardrails are in place around machinery and damage to guard rails or stairways must be reported immediately. All slippery areas are cleaned on a regular basis. Hoses must not be left trailing across walkways.

All guardrails and stairways to be inspected for damage and repaired where necessary.

Maint. Dept. Immediate

For

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ACCESS TO HEIGHTS Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date:

1. Working at height Maintenance personnel and contractors on site use ladders to access areas not within normal reaching distance. Forklifts have been used as a working platform for maintenance personnel. • The hazards arising

from such work include head and body injuries from slips and falls from height and head injuries from falling objects.

Medium

Ladders will be maintained in good condition and defective ladders repaired or replaced. A suitable safety harness must be worn whenever working at height. Ladders should be rested against a solid surface and on stable ground. The ladder should be capable of extending at least one meter above the landing place. The ladder must be adequately secured at the top and bottom. When working at height another person must be present. The ladder should be at a suitable angle to minimise risk (ideally 1m from building for every 4m in height). Working platforms must be secure and unable to shift. Working platform must have adequate guarding around the edge of platform to prevent falls and objects falling to the ground. Any person below somebody working at height must wear a safety helmet. Contractors working on site must provide their own ladders and comply with safe work practices.

Inspection of all ladders on site for defects. Contractors working on site must provide their own safety equipment and ladders etc for working at height.

Maint. Dept.

Managing Director

Immediate

Ongoing

For

insp

ectio

n pur

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CHEMICAL SUBSTANCES Tasks carried out: Hazards: Risk: Controls: Recommendations: Responsibility: Action Date:

1. Use of chemical substances on site.

2. Use of chemical substances in the lab.

Maintenance personnel are exposed to oils and coolants. Diesel fuel is stored in a storage tank on site for forklifts. The WWTP Operator is exposed to the following chemicals; Lime, Polymer, Ferric Chloride and Caustic Soda. The hazards arising from such materials include; • Fire • Irritation of the skin, eye

and respiratory system.

Medium Low

Material safety data sheets (MSDS) for all substances used on site are available from the EHS Officer. Employees dealing with substances are given information and training relating to; Hazards, PPE, MSDS, safety precautions and spill control and emergency procedures. All substances must be correctly labelled at all times. No substances should be transferred to unlabelled containers. Spillage and damage to substance containers must be reported to the maintenance manager and production manager immediately. Storage of flammable materials must be in cool areas away from any possible ignition sources.

Ensure all MSDS are on file. Eye wash facilities and emergency showers to be provided in the WWTP.

EHS Officer

Managing Director

1 month

Immediate

For

insp

ectio

n pur

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s only

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Conse

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EPA Export 26-07-2013:00:30:44

14 ! ipc il - environmental protection agency · information requested regarding application for...

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