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.* Attachment HiI

MATERIALS HANDLING Raw Materials, Inteymediates, Products Handling

Glanbia Food Ingredients (Ballyragget) Ltd. Revised IPPCL Application

Project Ref: OES1044~01

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Glanbia Food Ingredients (Ballyragget) Ltd. Revised IPCL Application Attachment H.l

August 2005

H.l Materials Handling

For the purpose of describing materials handling arrangements on site, the range of materials onsite can be categorised as follows:

> Raw Materials (Food Grade) > Intermediate Products and Finished Products > Chemicals (Ancillary Materials) g Fuels and Lubricants > Waste

The handling - receipt, storage, internal distribution, bunding and containment - of each category of material is described in the following sections.

HI.1 Raw Material

Raw materials (food grade) at the site includes fresh whole milk, whey and whey concentrate, cream, oils and food ingredients, the latter being predominately solid or semi-solid in nature.

Bulk raw material is stored in a number of silo areas depending on material type. Raw milk is stored in bulk milk storage silos. From here the milk is pumped to the areas where it is required.

Food ingredients are stored in the general store and are transported to the relevant departments as required.

HI .2 Intermediate Products and Finished Products

Intermediates such as cream, skim milk, whey, butter oil and vegetable oil are stored in a variety of tanks and silos depending on the production route in which they are used.

These tanks are generally located at the intake area and in the immediate vicinity of the production buildings.

All product packaging is stored in the general stores and also in the production areas where it is intended for use.

Depending on the final product produced, finished products are stored in different areas of the plant as follows:

l Butter - Cold store l Spreads - Cold store l Cheese - Cold store l Powders - Powder store

HI .3 Chemicals (Ancillary Materials)

All chemicals in use at the plant are stored in dedicated containers or storage tanks, which are bunded to retain the contents of the tank in the event of a spill.

OES Consulting Page 1 of 2

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Glanbia Food Ingredients (Ballyragget) Ltd. Revised IPCL Application Attachment H.l

August 2005

All chemicals are segregated according to their individual properties and stored appropriately. Large volumes of chemicals used on site are stored in storage tank farms, while smaller containers are stored outdoors close to the point of use.

HI .4 Fuels & Lubricants

The primary fuel in use at the plant is natural gas, which is not stored on site.

Small quantities of gas oil are stored on site to provide for backup fuel in the event of a gas outage.

These fuel oil tanks are located in a bunded compound to the rear of the boiler house building.

HI.5 Waste _

Dedicated waste management areas have been allocated at the whey plant and Plant 1 for the sorting and baling of wastes prior to collection for disposal/recovery by a permitted waste contractor.

Organic Waste

Organic waste is stored during winter months and periods not suitable for landspreading at a dedicated on farm storage area, which is currently being upgraded.

HI .6 Internal Distribution

Bulk liquid and raw materials and intermediates are generally distributed throughout the plant via a network of above ground pipelines. These pipelines are visually inspected for leaks on an ongoing basis.

Before use at the site the Health and Safety and the Environmental Departments sign off all materials after evaluation from a risk and control perspective.

The Quality Control Department also checks all food ingredients prior to use.

HI.7 Bunding and Containment

Details of all onsite bunding and containment are included in Attachment J.


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Table H. I. I Tank and Silo Register

No. 1LocationlDescription IContents ICapacity (fn3)

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No. Location/Description Contents

88 SKIM-TRE Skim Milk 273 89 CREAM-BUTOIL Butter Oil 26 90 CREAM-BUTOIL Butter Oil 26 91 BUTTER LAYOUT Serum 20 92 BUTTER Butter Oil 5

93

94

LAYOUT/BUTOIL-5 BUTTER LAYOUTIBUTOIL-5 BUTTER LAYOUT/BUTOIL-5

Whey Cream 100

Butter Oil 17

95 (VATS (Milk I 32

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EPA Export 25-07-2013:16:27:37

No. Location/Description Contents Capacity (m3)

128 (SKIM TANKS (Skim Milk 114

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Attachment H.2

WASTE HANDLING


Project Ref: OES1044~01

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Glanbia Food Ingredients (Ballyragget) Ltd. Revised IPCL Application Attachment H.2

August 2005

H.2.1 Waste Arisings

Glanbia Food Ingredients, Ballyragget are involved in the dairy processing industry.

The annual throughput at the Ballyragget plant is of the order of 2.5 million m3 of dairy liquids (milk, whey, cream). Waste arisings at the plant are classified under the broad European category of EWC 0205.

Despite the large raw material and product throughput, very small quantities of process solid wastes arise. The only solid wastes of volume significance are biological sludges associated with the effluent treatment process and some inorganic mineral concentrates from certain process. The remaining solid wastes are packaging wastes generated during the production process.

Taking 2004 figures, the total quantity of solid waste arising at the installation was 20,737 tonnes, of which 697 tonnes (or 3.4%) was recovered or disposed off-site. The balance (96.6%) was organic waste, which was landspread in accordance with the NMP.

From an economic viewpoint, loss management control is utilised to prevent or recover as much product as possible, but a certain base loss is attributable to each process.

These losses comprise of liquid, protein, lactose, inorganic minerals, other carbohydrates and fats, in varying types, and amounts. Due to the large scale of operations with multiple products, a significant level of emission variation can occur throughout the annual cycle, which is often unpredictable.

The market place further’ dictates that the relative distribution of particular products vary considerably from year to year, for example butter oil, whey powders, skim powders, acid versus rennet casein, all have market swings in annual production. These factors add to the variance that can be witnessed in the waste streams generated at the Ballyragget plant.

The waste streams at the site can be broadly categorised under the following headings:

Non Hazardous Waste

9 Production Waste (e.g. sludges, powder). 9 Packaging Waste (e.g. incoming materials, product packaging, pallets, drums

etc). 9 General Waste (e.g. office, canteen).

Hazardous Waste

9 Waste oil from maintenance 9 Fluorescent light bulbs. 9 Laboratory Waste (e.g. spent reagents, containers). 9 Occasional asbestos (on identification and removal as part of

construction/demolition).

OES Consulting Page I of 4

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August 2005

The quantities of waste generated in 2004 are summarised ion Table H2.1 below.

Parameter Quantity (t) 2003 Quantity (t) 2004

Sludge 18,351 17,536 Whey Permeate 3,463 2,505 Solid Waste 411 488 Waste Oil I 9.9 I 8.5 Fluorescent Light Bulbs] 0.160 I 0.260 Scrap Metal I 29.42 I 62.32 Hazardous Lab Reagents 0.1075 0.1

Waste Pallets 134 100.5 Packaging OCC 39.56 32.82 Packaging Plastic 3.52 2.065 Glass 0.5 0.28 Office Paper Recycling Total

0.3 1.17 22,443 20,737

The total quantity of waste generated in 2004 was approximately 7.6% lower than in 2003, primarily due to decreases in organic waste arisings (8.1% lower in 2004)

Sources of Waste

The-wastes that arise through the different production processes at the plant are dealt with in a variety of ways. Waste management is based on a hierarchy of Prevention, Minimisation, Recycling and Safe Disposal. The following list briefly summarises solid waste management practices followed at the plant:

9

9 9

9 9

9 9 9 9

Pallets are sanitised and/or re-used. Buttermilk is a by-product of the churning/working process. It is drained and separated, with the cream being pasteurised and returned into cream silos and the buttermilk stored, and eventually packed off When a batch of packaging material is found to be unsatisfactory, then the material is rejected and returned to the Supplier. Sludge discharge from clarifiers consists of fines, which are returned to the cheddar master. Skim, if present, is recycled to a buttermilk storage tank and is sold on. Non-crystal delactosed whey is pumped to storage and goes for further treatment in the whey plant. In extreme circumstances it might be necessary to sell skim to pig farmers. Problems experienced with the dryer resulting in casein burning in the drier. In this case, the drier is stopped; the casein is swept out, put into bags and sold for industrial casein. Waste product from screens is put into bags and sold as industrial casein. The curd is usually swept up, put into bags and sold to appropriate customers, Downgrade cheese is sold on to appropriate customers. Damaged blocks/cartons are re-bagged sold on to appropriate customers. Build up of lactose on exhaust duct of dryer - lactose is swept off the exhaust duct and put into bags for and sold as animal feed.


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August 2005

9 When finished testing cheese samples are bagged and sold on as curd. 9 When a batch of packaging material is found to be unsatisfactory, then the

material is rejected and returned to the supplier. 9 Torn bags, plastic, damaged foil other debris is picked up, put into rubbish bags

and disposed of to landfill. This includes hairnets and shoe covers. 9 Ceilings, walls, etc. are cleaned down regularly. Dust/dirt, debris, etc. is swept

up, put into rubbish bags and disposed of to landfill. 9 Particulate filters are changed regularly. All waste, e.g. foreign matter or old filters

are put into rubbish bags and disposed of to landfill. 9 Major leaks of product from driers to the surrounding atmosphere due to a

breakdown/other malfunction in the plant, usually end up on the floor and are recovered to industrial sacks as soon as possible.

9 Occasionally, it may be necessary to box off butteroil due to plant problems and there may be losses of packaging, all waste/damaged packaging being picked up, put into rubbish bags and disposed off to landfill.

H.2.2 Waste Storage

Non- Hazardous Waste

Non-Hazardous wastes generated on site are stored in bins and skips, which are located at a number of locations internally and externally.

Hazardous Waste

Waste oils are stored externally in steel drums.

Fluorescent bulbs are stored internally, in a designated area prior to disposal.

Laboratory chemicals are collected in designated containers for subsequent specialist disposal.

Occasional asbestos waste is handled in accordance with recognised procedures for the collection bagging and disposal of this material and in accordance with Agency approvals

H.2.3 Periods of Generation

The grass based milk production cycle lead to a peak to valley ratio from winter milk lows to late spring/summer highs. The waste cycle at the plant is dependant upon the seasonal production of the dairy industry.

Owing to reduced milk handling and lower processing intensity during the winter months, and corresponding decreases in waste water treatment plant flows, the quantities of sludge generated tend to be reduced between November and February.


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August 2005

H.2.4 Waste Management Contractors

The following table contains details of all waste contractors used at Glanbia Ingredients Ballyragget:

Table H.2.2 Details of Waste Contractors

Name Address

AES Advance Environmental Solution (Ireland) Ltd. Atlas Environmental Ireland Ltd. T/a Atlas Ireland, Atlas Oil. Conservation Technology Ltd. T/a Contec Ire-Well Pallets Ltd.

Kilkenny/Carlow & District farm relief services. Laois Co. Council Landfill.

Shannon Environmental Services Ltd. T/a Solchem Ltd. Tommy Ward t/a Al Metal Recycling Vicky Heslop

Camphill Community

KMK Metals Recycling Ltd.

Unit 16, Hebron Industrial Estate, Kilkenny.

Clonminam Industrial Estate, Portlaoise, Co. Laois. Davitt Road, Dublin 12.

Wells, Gorey, Co. Wexford. Barrack Street, Kilkenny Kyetalesha, Portltioise, Co. Laois. Smithstown Industrial Estate, Shannon, Co. Clare. Acrager, Mount Mellick, Co. Laois. Tooracurragh, Ballymacarbry, Co. Waterford.. Camphill Community, Ballytobin, Callan, - Co. Kilkenny. Cappincur Ind. Est, Daingean Road, Tuliamore, Co. Offaly.

Waste Permit No.

WCP/KK/076(A)/05

WCP/KK/059(A)/05

WCPIKWI 08(A)iO5

WCP/KWl 1 g(A)/05

26-2

WCP/KK/085/02

WCP/MH/2001/62B

WPiO6102

WP/O5/2000

WCP/KW069/02 Waste licence 113- 1


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Apperidix H.2.1 Summary Waste Information

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Summary Information on Waste Streams

DIO Incineration on land

ubstances which are not used as

inorganic materials

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Attachment H.3

WASTE DISPOSAL BY ON-SITE LANDFILLING


Project Ref: OESI 044-00

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August 2005

H.3 Waste Disposal by on-site Landfilling

Attachment H.3 is Not Applicable

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