p0173-01 2008 aer sss - environmental protection agency · 2014-12-16 · co-ordinator martin lane...

Contents

1.0 Introduction ………………………………………………………… 3 1.1 Licence Details ……………………………………..………………... 1.2 Summary Data Table…………………………………………….. …... 1.3 Company Profile………………………………………………… .. .. . 2.0 Schedule of Objectives & Targets & EMP 6 2.1 Objectives & Targets 2008 - Progress Report 7 2.2 Objectives & Targets 2009 2.3 EMP Summary Update 11 3.0 Emissions to Water Summary 24

4.0 Surface Water Monitoring Summary 25 4.1 Details of Non-Compliances 26

5.0 Groundwater Monitoring Summary 26 5.1 Details of Non-Compliances ..........................................................

6.0 Waste Management 27

6.1 Organic Waste Management 36 7.0 Resource Consumption...................................................................

7.1 Summary Energy Consumption 38 7.2 Water Usage................................................................................. 38

8.0 Complaints Summary 40 9.0 Reporting Incidents Summary 40

10.0 Pollutions Emissions register 40

11.0 Environmental Liabilities Risk Assessment

Charleville Foods March 2009

Annual Environmental Report 2008

IPPC Licence Reg. No. P0173-01 2

Appendix 1 Electronic AER Submission Sheets

Appendix 2 Environmental Monitoring Results 2009

Tables:

1. List of projects in EMP 2008

2. Objectives and Targets 2009

3. EMP 2009 4. Main steps in nutrient management plan 5. Treated effluent emissions

6. Summary of mass emissions

7. Surface water analysis results 8. Ground water monitoring results 9. Hazardous/Non Hazardous waste 10. Hazardous waste sent off site.

11. Non Hazardous waste sent off site 12. Organic Waste arising 13. Summary energy and water consumption data. 14. Plant water consumption.

Figures:

1. Oil Usage 2. Oil/Tallow Usage

3. Electricity Usage

4. Comparison of Non hazardous waste arising 07 & 08.

5. Comparison of Hazardous waste arising 07 & 08.

6. Organic waste generated 07 and 08.

7. Water Usage 07 and 08




Introduction

This document is the eight Annual Environmental Report (AER) covering environmental performance at Charleville Foods.

This report updates the information contained in the last AER to the end of December 2008 and summarises all data for the 2008 monitoring period and makes comparisons with year 2007 results. This document updates the following sections of the monitoring period 2008 AER: Section 2.0 Schedule of Objectives & Targets & EMP Section 3.0 Emissions to Water Summary Section 4.0 Surface Water Monitoring Summary Section 5.0 Groundwater Monitoring Summary Section 6.0 Waste Management Summary Section 7.0 Resource Consumption Summary Section 8.0 Complaints Summary Section 9.0 Reported Incidents Summary Section 10.0 Pollutions Emission register. Section 11.0 Environmental Liabilities Risk Assessment. Details of the achievements of the Environmental Management Plan is included as Sections 2.0.to 2.3.

1.1 Licence Details

Licensee: Charleville Foods

Location of Activity: Ardnageehy, Charleville, Co. Cork

IPPC Licence Register No.:P0173-01.

1.2 Summary Data Table Current IPPC Licence annual reporting requires the submission of summary monitoring, resource use, complaints and waste management information in the form of a spreadsheet, which is transmitted to the Agency electronically. A print out of this summary data spreadsheet is included as Attachment A to this AER. The spreadsheet has been submitted electronically to the EPA at http://aer.epa.ie/prtr

1.3 Company Profile




Company History Charleville Foods is a subsidiary of the Dawn Meats Food Group and was acquired in January 2004 from the Dairygold Co-Operative

Society Ltd. The company was founded in the 1930s by the Ryan family and has undergone major investment particurely in recent years. This has included the

addition of a new Boning Hall complex, Slaughter line and product chills. The

company now has the capacity to slaughter and process 2000 cattle per week in one of the most modern and progressive beef plants in the country. This places

Charleville Foods in a commanding position to be able to service customer requirements with top quality Irish beef sourced from farmers in the surrounding hinterland. With a strong export orientated customer base in the UK, Europe,

Scandinavia and the Middle East, Charleville Foods is well placed to meet future market demands. Other facilities include beef plants, which are located at,

Ballyhaunis, Rathdowney, Midleton, Grannagh, Carrolls Cross. We also have beef

processing facilities in the UK and on the Continent The primary environmental emissions at the plant relate to the discharge of

treated wastewater and the generation of organic waste as sludge, which is land

spread. The environmental performance of the facility is regulated under an

IPPC licence (Reg. No. 173-01). Environmental management at the site, including compliance with the IPPC licence, is achieved through a structured

Environmental Management System (EMS).




Charleville Foods

Operations Manager

Noel Donworth*

Procurement Managers Paul Mullaney

Maintenance Manager

Matt Twomey Dispatch Manager

John o Neill Sales Department Cathal Considine Ray o Regan Ed Fitzgerald Tadgh Lane

Technical Manager Michael Betts**

Group Health & Safety Manager John Kearney

Health & Safety Co-ordinator

Martin Lane

Financial Controller Tim Barry

Slaughter Hall Training Supervisor Paul Stafford

Loading Bay Supervisor John O Brien

Group Technical Manager Brian Hyland

Environmental Co-ordinator & Assistant Environmental Co-ordinator

Matt Twomey Michael Betts

Group Environmental Manager

Charlie Coakley

Group IT Shane Slattery

Boning Hall Derek Daly

CEO Niall Browne

Plant Operatives




2.0 Schedule of Objectives and Targets 2008 and 200 9 Plans. This section includes (2.1) progress achieved in meeting deadlines set for the 11

Objectives and targets from the 2008 Schedule. Section 2.2 contains the objectives

and targets for 2009. While section 2.3 details the Environmental Management

Programme and Objectives and Targets as outlined in section 2.2 .

2.1 Schedule of Objectives and Targets Objectives & Targets – 2008 Table 1: List of Projects in EMP 2008

Section Project Title

2.1 Reduce waste water consumption operating vac pac system 2.2 Reduce water consumption at tripe washing 2.3 Increase use of tallow usage as fuel source 2.4 Reduce electricity usage by operating outside peak times 2.5 Instal variable speed electrics to conserve electricity 2.6 Bund and pipeline testing 2.7 Boiler testing 2.8 Staff training 2.9 Reduction in waste paper 2.10 Evaluate packaging for recycle content

2.11 Internal Audits.




2.1 Project: Installation of new vac pac syst em to reduce water

consumption

A new vac pac system has been installed in boning hall one to reduce

the amount of water required to shrink wrap packaging. This is

reflected in the reduction in water usage between 2007 and 2008.

2.2 Project: Installation of new tripe system to reduce water consumption.

A new tripe wash system was installed, which has been installed has a

water re-cycling system in the final polisher. The water conserved is

then used for the first wash, this system has reduced the amount of

water used in the tripe production process.

This is reflected in the reduction in water usage between 2007 and

2008.Through the installation of a water recycling facility as part of the

tripe processing system. Figure 7 demonstrates a reduction in water consumption between 2007 and

2008 of 3.2%. 2.3 Project: The increase use of tallow as a fuel source.

The use of tallow has been a major fuel source in 2008 at a level of

2817779 Kwh this again reduces the need for commercial fuel such as

200 SEC fuel oil, thus of benefit in working towards the carbon footprint.

Figure 1:

Oil Usage

0500000

1000000150000020000002500000300000035000004000000450000050000005500000

Year

kW

2007

2008




The use of fuel oil has been reduced by 40% between 2007 and 2008.

Figure 2:

Oil/Tallow v Oil Usage

0

1000000

2000000

3000000

4000000

5000000

6000000

Year

Kw

2008

2007

When comparing the fuel oil usage for 2007 with the combined fuel oil and

tallow oil usage for 2008 there is a saving of 108769 Kwh in 2008.

2.4 Project: The use of “ Max” demand energy programme to reduce

electricity usage.

The “Max” demand electricity programme is operated between 5.00

pm and 7.00 pm between November and February, where all

production is completed within a specified time and all equipment can

then be switched off to conserve electricity.

2.5 Project: Installation of variable speed electrics to reduce electricity

usage,

Variable speed electrics have been installed in the W.W.T.P, Offal line

and have contributed the saving in electricity usage.




Figure 3:

Electricity Usage

0

1000000

2000000

3000000

4000000

5000000

6000000

Year

KW

2007

2008

Projects 2.4 and 2.5 have contributed to a 124338 Kwh saving in

electricity between 2007 and 2008. 2.6 Project: Bund and pipeline control.

This procedure applies to all over ground and underground pipelines,

bunds and sumps. In the case of over ground pipework a weekly visual

inspection is carried out and any leaks are noted. In 2007 the three yearly programme of underground pipeline and bund

integrity testing was carried out. In summary no pipelines were found to show

any signs of leaking. 2.7 Project: Boiler test control.

The boilers were tested in 2008 and a decision was made to replace

one of the boilers with a hot water boiler to improve energy efficiency

and reduce water heating costs.

2.8 Project: Staff Training

Project Summary




The training requirement of all staff was reviewed and a training matrix

has been prepared indicating the training status of all employees.

This matrix identified both specific and non-specific environmental

training.

This training focused on the environmental issues such as:

� IPPC Licence

� Waste Management.

� Site Environmental Policy

� Environmental procedures

It also mentioned any environmental issues specific to the jobs they

would be doing. All new employees received this training, which was

carried out as part of their induction. All managers received training in

relevant standard operating procedures during 2008.

This training was carried out in conjunction with the quality and health

and safety training provided on the site. 2.9 Reduction in waste packaging.

The aim of this project was to reduce the amount of packaging

produced on the site. It involved identifying where waste segregation

can be improved and where packaging could be substituted by

reusable trays. In 2007 7.4 tonnes of plastic and 24.68 tonnes of

cardboard were produced. In 2008 16.44 tonnes of plastic and 17.66

tonnes of cardboard were produced. The amount of cardboard was

reduced in 2007 compared to 2008 due to increased awareness and

a move away from cardboard to reusable plastic trays. The programme of reducing the amount of plastic used in the process

is ongoing and is included in the EMP for 2009. 2.10 Evaluation of packing for re-cycled content.

Suppliers have been contacted to evaluate the re-cycled content ( ie

amount of used packaging re-cycled) in the product supplied ,this

project is ongoing and will be evaluated further. This project will also be

included in the 2009 EMP. 2.11 Internal Audits

This project was undertaken to verify the site environmental

performance and compliance on a regular basis through scheduled

structured and objective internal corporate environmental audits.

These audits incorporate a comprehensive identification and

evaluation of all significant environmental impacts and issues relevant

to the organisation.




The non – conformances raised in both the on – site and external audits

were to be included in Corrective Action Record form and also in the

Corrective Action Status Log if the issue could not be resolved

immediately.




2.2 Schedule of Objectives and Targets Objectives & Targets – 2009 Objective 1: Prevention of incidents with the poten tial for Environmental

Consequences . Table 2: Schedule of objectives and Targets 2009.

Projects Target Summary Deadline

Responsibility Indicators Status

EMP 01 Pipeline Testing

Underground pipelines

Programme of testing underground pipelines.

Every 3 years Due 2010

Maintenance Manager

Reports Completed in 2007 ( re test by May 2010)

EMP 02 Bund Integrity Testing

Tallow, Diesel, Generator and central heating Bund

Programme of testing bunds.

Every 3 years Due 2010

Maintenance Manager

Reports Completed in 2007. (re test by May 2010)

EMP 03 Preventative Maintenance

Include all new WWTP equipment in maintenance programme

Review maintenance Programme to ensure all new equipment is included

June 2009

Maintenance Manager

Maintenance Records

Ongoing

EMP 04 Boiler Testing

Boiler testing Ensure boiler is operating efficiently and safely.

June 2009 Maintenance Manager

Reports, Records

Ongoing




Objective 2. - Waste Management (Reduction, recycli ng, reuse, & safe

disposal)

Projects Target Summary Deadline Responsibility Indicators Status EMP 05 Plastic Recycling

Segregation of plastic materials for recycling

Recycling Bins for more efficient segregation and collection of plastic materials.

April 2009

Environmental Manager

Bins on site Ongoing

EMP 06 Landfill Management

Reduce the volume of waste going to landfill

Ongoing review of possible alternative destination for waste reuse / recycling.

May 2009

Department Managers and Supervisors

Records Ongoing

EMP 07 Treatment of Organic Waste

Organic Waste Investigate on and off site treatment for organic waste streams such as anaerobic digestion and composting.

December 2009

Group Environmental Manager

Group tracking and investigation of options to stabilise waste streams

Ongoing

EMP 8 Develop Landbank Capacity

Increased Landbank Capacity

Continue process of identification and evaluation of suitable Landspread areas to ensure sustainability of land application

May 2009 Environmental Manager

Landbank hectares approved by EPA

Ongoing




Objective 3. - Risk Control / Legislative Compliance – compliance with

relevant environmental legislation



EMP 9 Waste Contractor Review

Waste Contractors and Transport Companies

Ongoing review of waste contractors licenses and register of licenses held on file.

Aug 2009


Records Ongoing

EMP 10 Suppliers

Supplier Awareness

Issue copy of supplier questionnaire and environmental policy to all suppliers

Nov 2009


Correspondence File

Ongoing

EMP 11 Legislation

Legislation file. Review of current legislation and an assessment of its relevance to site activity and legislation file

April 2009 Technical Manager,

Register of Legislation

Ongoing




Objective 4. – Energy Efficiency / Reduction in Carbon Footprint



EMP 12 ReduceEnergy Usage.

Reduced electricity usage by operating outside peak times

Max Demand Electricity conservation programme.

December 2009

Maintenance Manager

Reduced electricity usage

Ongoing

Installation of variable speed electrics to conserve electricity

All equipment operated by variable speed electrics

December 2009

Maintenance Manager


Ongoing

Improve Energy Efficiency

Track energy consumption. Monitor and evaluate oil and electricity usages

July 2009 Maintenance Manager

KPI’s Records, Weekly Energy Usage

Ongoing

Improve Energy Efficiency

Review the number of light units used within the plant and take out every second light where practicable, including chills and corridors.



Ongoing

Steriliser System

Replace current sterilisers with energy saving units.


Reduce oil usage heating water.

Ongoing

Air Leaks Maintenance operatives to check air line to identify and repair any leaks.


Reduce electricity usage

Ongoing

New boiler system to improve energy efficiency.

Install new boiler system to improve hot water heating system.


Reduce oil usage heating water.

Ongoing

Investigate the use of Wind Power

Evaluate the use of windmills as a source of electricity

July 2009 Group Environmental Manager

Reduce Electricity Usage

Ongoing




Objective 5. - Conservation of Natural Resources

Projects Target Summary Deadline Responsibility Indicators Status EMP 13 Paper Recycling

Recycled/ shredding Paper

Evaluate office paper for recycled content

Aug 2009 Purchasing Mgr Supplier Specs Ongoing

EMP 14 Water Usage

Reduce Water Usage

Attach spray nozzles to open ended nozzles to restrict flow of water for yard hoses.

April 2009 Maintenance Mgt All yard hoses fitted with nozzles.

Ongoing

Reduction in hydraulic loading on WWTP

Ongoing monitoring of water usage throughout plant and comparison at group level to industry usage levels

Ongoing

All manager and supervisors

WWTP records, water records

Ongoing




Objective 6. - Promotion of Environmental Awareness



EMP 15 Staff Training

Staff Induction Training

All Staff induction training to be detailed on a matrix

July 2009

Technical Manager

Matrix containing the training details of all staff

Ongoing

EMP 16 Staff Awareness

Staff awareness Environmental awareness

Place Carbon Footprint

signs throughout the plant

to indicate environmental

awareness.

April 2009

Environmental Manager and Technical Manager

Carbon foot print signs in place.

Ongoing

EMP 17 Environmental Procedures

Supervisor’s and Operatives SOPs

Review of supervisors and Operatives SOPs to ensure that they are current and signed off on training records.

July 2009 Environmental Manager, Technical Manager, Department Managers & Supervisors

Amended SOPs Ongoing




2.3 Environmental Management Programme and objectives and targets – Summary

Charleville Foods Environmental Management Programme and Objectives and

Targets are committed to ensuring a significant effort and more attention is paid

to improvements in efficiency at the plant, in terms of energy consumption,

water use and waste generation. The focus of the 2009 EMP will be largely in these areas, using the EMP as a management tool for planning and tracking the

implementation of projects on site which lead to the overall achievement of the

Dawn Group Environmental Policy, while ensuring compliance with the IPPC license remains a high priority.

A number of long-term on-going programmes initiated at the site will continue

on an on-going basis to ensure compliance with the conditions of the IPPC

licence and the site environmental management system.

The progress and plans for the future in meeting these objectives and targets

are summarised below.

Table 3 Lists of Projects in EMP

List of 2009 EMP’s

EMP 1

Pipeline Testing EMP 9 Waste Contractor Review

EMP 2

BundTesting EMP 10

Supplier Awareness

EMP 3

Preventative Maintenance EMP 11

Legislation

EMP 4

Boiler Testing EMP 12

Energy Efficiency

EMP 5

Plastic Recycling EMP 13

Paper Recycling

EMP 6

Landfill Management EMP 14

Water Usage

EMP 7

Treatment of Organic Waste EMP 15

Staff Training

EMP 8

Develop Landbank Capacity

EMP 16

Staff Awareness

EMP 17

Environmental Procedures




EMP 01: Pipeline Testing

Project Summary A maintenance operative is assigned to complete the pipeline distribution systems

visual inspection each month.

The inspection comprises a visual inspection along the length of the pipeline system. Particular attention is paid to flanges, joints, seals and glands and

through wall runs. The condition of pipe is noted with regard to corrosion and

wear. The condition of any lagging is noted.

In the event that any leak is detected or significant corrosion/wear observed, the Maintenance Manager is notified. It is the responsibility of the Maintenance

Manager to initiate and sign off on Corrective Action and in circumstances of

significant leak or risk, notify the Technical Manager.

An external consultant is due to carry out a Pipeline inspection in 2010.

Status: This project is ongoing.

EMP 02: Bund Integrity Testing

Project Summary

Underground Tank and Bunding: An external consultant is due to carry out a Bund integrity assessment on the tallow,

diesel, central heating bunds and underground tank test in 2010.

Status:

This project is ongoing.




EMP 03: Preventative Maintenance

Project Summary

Review maintenance programme for WWTP to ensure that all new

equipment is included and details of scheduled work is completed.

Status:

The project will be completed by June 2009.

EMP 04: Boiler Testing

Project Summary

This project is completed on an annual basis by an external contractor to

ensure that the boilers are operating efficiently and safely.

Status:

The project will be completed by June 2009

EMP 05: Plastic Recycling

Project Summary

The segregation of all plastic materials for recycling wil include the

identification of all plastic waste generated and putting collection bins in

place to collect used bottles in the canteen.

Status:

The project will be completed by April 2009.

EMP 06: Landfill Management.

Project Summary

This project will look at the type of waste going to landfill and the

potential recycling opportunities if determined feasible.




All office personnel have been instructed to reduce their paper usage and

think before they print.All department heads and supervisors have

received instructions and training on this procedure; to think before waste is binned. The canteen management have also been included in this

training.

Status:

This project will be completed by May 2009.

EMP 07: Treatment of organic waste.

Project Summary This project will investigated at group level to investigate the potential on

and off site treatment of organic waste streams such as anaerobic

digestion and composting.

Status:

This project will be completed by December 2009.

EMP 08: Develop Land Bank Capacity

Project Summary

It has been decided at management level that any Landbank being added

to the approved Landbank will only be accepted for a NMP once a year. An

environmental consultant deal with the NMP’s and submissions are made

in one lot as requested by the EPA.

Factors such as does the farmer own the land, distance from the plant

and other factors such as REPS are taken into consideration. This process then allows Charleville Foods to increase if necessary the land bank.

The nutrient Management plan is submitted to the Agency on an Annual

basis. (Please note, a total review in line with the Nitrates Directive and S.I. No. 378 of 2006 have resulted in a complete overhaul of existing

NMP’s.




Table 4 - Main Steps in Nutrient Management Plan

Step 1 Sampling - soils to calculate soil P levels.

Step 2 Testing of sludge for nutrient levels

Step 3 Application rate per sample location ~ 2 hectares

Step 4 Mapping of the land bank

Step 5 Communications of the plan to the relevant

personal

Step 6 Implementation of the plan

Step 7 Co-ordinating between the plant, farmers and

contractors.

Step 8 Records, of all documentation

Step 9 Establish a Register of Organic Waste for Land

spread

Status

Ongoing – Annually

EMP 09: Waste Contractor Review

Project Summary There is an ongoing review of waste contractors licences and register of

waste contractors. This is kept on file in the Technical Department.

Status:

August 2009

EMP 10: Supplier Awareness

Project Summary

As part of the ongoing process of increasing environmental awareness all

suppliers to Charleville Foods will be issued a copy of the company’s

supplier questionnaire and environmental policy.

This policy is signed off by the CEO of Dawn Meats Group.

Status: November 2009




EMP 11: Legislation Review.

Project Summary

Review current and proposed legislation and an assessment of its

relevance to site activity.

This is completed by the group environmental manager on a monthly

basis.

Status:

Quarterly 2009

EMP 12: Reduce Energy Usage

Project Summary

• Reduced electricity usage by operating outside peak times • All equipment operated by variable speed electrics • Track energy consumption., Monitor and evaluate oil and electricity usages • Review the number of light units used within the plant and take out every

second light where practical, including chills and corridors. • Replace current sterilisers with a more energy efficient unit. • Investigate the use of wind power as a source of energy • Maintenance operatives to check air line to identify and repair any leaks • Install a new hot water boiler system to improve energy efficiency.

Status: February to Dec 2009

EMP 13: Paper Re Cycling

Project Summary

This project involves contacting the suppliers of paper and requesting

certificates which demonstrate the recycled content of paper. This was

part of the 2008 EMP programme, since certs were not received from all

suppliers, it has now been raised as part of the 2009 EMP programme.

Status:




August 2009 EMP 14: Reduce Water Consumption

Project Summary

Water usage is monitored weekly and complied into weekly utility figures.

Strategic water audits are carried out on our water softening and extra

metering has been installed. Monitoring is continuing on an ongoing

basis. This data is trended to identify variations in the correlation between

kill statistics and water use. The company will continue trending water

use over time.

Status:

Ongoing

All hoses in the yard to be fitted with spray nozzles

Status:

April 2009.

EMP 15: Staff Training

Project Summary

All staff training to be documented on a detailed training matrix.

Status:

July 2009

EMP 16: Staff Awareness

Project Summary Environmental awareness carbon footprint signs to be put in place around

the plant to highlight awareness in relation to energy conservation.

Status:

April 2009 EMP 17: Supervisors and Operatives SOP’s.

Project Summary

Review of supervisor and operator standard operating procedures to ensure

all current and training records signed off.




Status: July 2009 3.0 Emissions to Water Summary

Environmental monitoring data for the period January to December 31,

2008 is summarised in the following sections. All raw data has been

submitted to the EPA over that 12-month monitoring period in

accordance with the reporting requirements specified in Schedule 5 (i)

of the IPPC Licence.

Treated process wastewater is discharged into the Shruhaveballiv

stream.

Emissions to water are regulated under Condition 6 and Schedule 1 of

the IPPC as follows:

Table 5:Treated Effluent Emissions – (ELV’s)

Emission Point Reference No.: SW-1

Name of Receiving Waters: Shruhaveballiv

Location: Charleville, Co. Cork Volume to be emitted:

Maximum in any one day:

Maximum rate per hour:

800 m3

40 m3

Parameter Emission Limit Value

pH 6-9

BOD (mg/l) 10

Suspended Solids (mg/l) 15

Total Nitrogen (as N) (mg/l) 30

Total Ammonia (as N) mg/l 10

Total Phosphorus (as P) (mg/l) 2

Table 6 Summary Mass Emission Data EW-1

Parameter Mass Emission

2007 (kgs) Mass Emission

2008 (kgs) Permitted Mass Emission (kgs)

Flow (m3) 48,862 54502 292,000

BOD 268 226 2,920

Suspended Solids 411 366 4,380




Total Nitrogen 841 781 8,760

Total Ammonia (as N) 109 137 2,336

Total Phosphorus (as P) 29 23 584 * Permitted mass emissions based on discharges at ELV and maximum daily flow

All monitoring paramater’s have been reduced in 2008, with the

exception of ammonia which is marginally higher than 2007.

All monitoring paramater’s are expected to be reduced further in 2009

due to the extensive capital investment programme in the W.W.T.P that

was undertaken in 2008. 3.1 Details of Non-Compliance’s

There were two non compliant samples recorded in the January to

December 2008 monitoring period and these were documented in the

monthly returns to the EPA.

These issues are documented in the March and December reports for

2008, follow up action was taken to ensure full compliance with the

standard.

4.0 Surface Water Monitoring Summary

Surface water runoff collected from clean yard and roof area

discharges by gravity to the stream at Emission Point Ref’s SW- 2, SW-3

and SW-4. This stream discharges to the Shruhaveballiv stream, at a

point downstream from Charleville Foods.

Analysis is carried out on a monthly basis for pH, Total Ammonia, BOD,

Total Nitrogen and conductivity. Also a visual inspection is carried out

weekly in accordance with Schedule 3(i) off the site IPPCL.

Table 7 Surface water analytical results SW -2, 3 a nd 4

Parameter

Emission Ref. Conductivity Total N

pH BOD (mg/l)

NH3 (mg/l)

2008 495 1.17 8.39 0.63 <0.1

2007 389 1.88 8.05 1.23 <0.1 • - Results based on average monitoring results over the 12-month monitoring period.




The 2008 analysis results were compared with the results from 2007.The

total nitrogen and BOD returns were reduced in 2008,the PH and

Conductivity level was marginally higher and ammonia was absent.

In addition, a visual examination at the surface water discharge point is

carried out on a daily basis and inspection logs are maintained under

the EMS documentation system.

There was no visual evidence of contamination of surface water during

the 12-month inspection period ending December 2008. 4.1 Details of Non-Compliance’s

There are no emission limit values for surface water parameters set out

in the IPPC licence.

5.0 Groundwater Monitoring Summary

There are three wells on – site GW-1, GW-2 and GW-3.

• The borehole GW - 1 according to attachment 18 of the IPC

application form was the designated test borehole.

The results indicated that there was no evidence of contamination.

These results proved to be within specified limits in all cases.

Table 8 Groundwater Monitoring Results 2008 GW –1.

Concentration Parameter

10.03.08 07.11.08 pH 7.3 7.5 BOD <4 mg/l <2 mg/l Nitrate 4.7 mg/l 2.3 mg/l Total Ammonia <0.05 mg/l <0.05 mg/l Total Nitrogen 4.4 mg/l 2.3 mg/l Conductivity 480 uS/cm 806 uS/cm Total Coliform Count <1 mpn/100ml <1 mpn/100ml Faecal Coliform Count <1 mpn/100ml <1 mpn/100ml




6.0 Waste Management

Management of solid non-hazardous and hazardous wastes are

recorded in accordance with Condition 7 of the IPPC Licence.

Summary data from the waste management register are tabulated on

Table 9. Totalled annual data is set out below:




Table 9: Hazardous/non-Hazardous Waste

Waste Type 2007 2008

Total quantity of waste produced in calendar year (Tonnes)

18,199

16148.69 Total quantity of waste disposed of on-site

0

0

Total quantity of waste disposed of off-site

92

101.76

Total quantity of waste recovered on-site

0

0

Total quantity of waste recovered off-site

18,107

16046.93

Non-Hazardous 2007 2008 Quantity of non- hazardous waste produced in calendar year (T)

14,080

16147.13

Quantity of non-hazardous waste disposed of on-site

0

0

Quantity of non-hazardous waste disposed of off-site

92

101.76

Quantity of non-hazardous waste recovered on-site

0

0

Quantity of non-hazardous waste recovered off-site

13,988

16045.37

Hazardous 2007 2008 Quantity of hazardous waste produced in calendar year (Tonnes)

4,119

1.56 Quantity of hazardous waste disposed of on-site

0

0

Quantity of hazardous waste disposed of off-site

0

0

Quantity of hazardous waste recovered on-site

0

0

Quantity of hazardous waste recovered off-site

4,119

1.56

(The above data includes organic waste arising at the site.)




Organic waste management is carried out in accordance with a

Nutrient Management Plan (copy of which has been submitted to the

EPA under separate cover).

The information tabulated on Table 8 below has been extracted from

the AER electronic report format, a copy of which has been

transmitted to the Agency via e-mail.

The following materials are considered to be by-products of the

slaughtering process, and accordingly, were not included in the waste

tables:

o Pet Food (lungs, liver, trachea, tripe, greaves and head & heart)

o Hides

A comparison of summary information on non-hazardous and

hazardous wastes between 07 and 08 is presented graphically on

Figures 4 and 5 below, while a detailed breakdown is presented in

tables 9, 10 and 11.

As can be seen the quantity of hazardous and non - hazardous waste

decreased on site.

The information tabulated below has been transmitted to the Agency

via e-mail



IPPC Licence Reg. P0173-01 32

Table 10: Hazardous sent off site Hazardous Waste sent off site for Recovery/Disposal 2008

Reporting Period

Waste Material

EWC Code

T/LT Description and Nature of Waste

Haulage Contractors

Recovery Contractor

Disposal Contractor

Jan 08 to Dec 08

Hydraulic Oil 130208 1.480lt Waste Oil

Enva Ireland Ltd. Enva Ireland Ltd. Enva Ireland Ltd.

Sludge Oil 130793 NA Tank Cleanings

Enva Ireland Ltd. Enva Ireland Ltd. Enva Ireland Ltd.

Fluorescent Tubes 200121 0.089 Fluorescent Tubes

Irish Lamp Recycling Co. Ltd



Specified Risk Material

020203 3812 Bovine Animal Slaughtered

Wards Transport Dublin By-Products. Dublin By-Products, Dunlavin, Co Wicklow




Table 11: Non-Hazardous sent off site Non-Hazardous Waste Sent Off-Site for Recovery/Disposal 2008

Reporting Period

Waste Material

EWC Code

T Description & Nature of Waste

Haulage Contractor

Recovery Contractor

Disposal Contractor

Jan 08 to Dec 08

ETP Primary weir contents

020204 ETP Primary weir contents

Agrilife Ltd Lyre, Lismore, Co Waterford

Farmers as listed in the Organic Waste Registers

Agrilife Ltd Lyre, Lismore, Co Waterford

Bovine Slurry 020106 WWTP Bovine Slurry Cattle Paunch

Contents 020106 2239 Cattle Paunch Contents

Truck Wash Solid Waste

020106 WWTP Truck Wash Solid Waste Straw

De-watered Sludge

020204 830 De-watered Sludge from belt press

DAF Sludge & brush screen solids

020204 Included with Bovine Slurry

DAF Sludge & brush screen solids

Offal/Fat

020202 3581

Offal/ Fat Ward Transport Western Proteins Western Proteins, Ballyhaunis, Co Mayo

Bone 020299 4567 Bone Ward Transport Western Proteins Western Proteins, Ballyhaunis, Co Mayo

Blood for rendering

020202 959 Blood for rendering Brian Kehoe APC Technologies APC Technologies, Lurgan

Blood for rendering

020202 20.01 Blood for rendering Ward Transport Waterford Proteins Waterford Proteins, Waterford




Reporting Period

Waste Material EWC Code T Description & Nature of Waste

Haulage Contractor Recovery Contractor

Disposal Contractor

As Above Non-soiled Cardboard

150101 17.600 Non-soiled cardboard Sure freight CKWMC 191/03

Newpark Materials ABC/MRF/RES01

Newpark Materials recycling facility,orchard way Antrim

Scrap Metal 150104 3.320 Scrap Metal Cork Metal Company Cork Metal Company

Cork Metal Company

Domestic Waste 200108 101.76 Canteen & yard Munster Waste Management

N/a Munster Waste Management

Steel Drums 150104 see scrap metal

Empty steel drums Johnson Logistics Cork Metal Company

Cork Metal Company

Plastic Drums 150102 NA Production areas Johnson Logistics Rilta Environmental Ltd.

Disposable protective clothing

150201 NA Production areas Munster Waste Management


Meat Rope 200104 NA Boning Halls Munster Waste Management


Drink Cans 150104 Canteen Green Dragon Recycling

Green Dragon Recycling

Green Dragon Recycling

Clean Plastic 150102 16.440 Clean Plastic Panther Waste Mnagement

Sure freight CKWMC 191/03

Newpark Materials recycling facility,orchard way Antrim




Figure 4 Comparison of Non Hazardous Waste Arisings 07 & 08.

Non Hazard Waste

0

1000

2000

3000

4000

5000

6000

Offal Bone Blood

Tonn

es 2007

2008

0

5

10

15

20

25

30

Plastic Cardboard

Tonn

es 2007

2008




SRM

3600

3700

3800

3900

4000

4100

4200

2007 2008

Ton

nes

Specified Waste Material (SRM) which comprises the skull including the brain and

eyes, the tonsils, the spinal cord of bovine animals aged over 12 months, was

previously reported as a hazardous waste material.

This is now reported as a non-hazardous waste under the terms of the EWC

codes and is covered under the Animal by-products regulations

All non hazardous waste material was reduced between 2007 and 2008,ie SRM,

offal, bone, blood and cardboard with the exception of plastic which increased, this

can partially attributed to the increase packaging being re-cycled and increase

production of product where plastic packaging is used. The reduction plastic usage

and recycling is one targets in the 2009 EMP programme.

Figure 4 (Summary) Comparison of Non Hazardous Waste Arising 07 & 08

Non Hazardous Waste

12500

13000

13500

14000

14500

15000

15500

16000

16500

2007 2008

Ton

nes




The Non Hazardous waste produced increased from 13988 tonnes in 2007 to 16147 tonnes in 2008,due to the re-classification of SRM as being non hazardous. Figure 5 Comparison of Hazardous Waste Arising 07 & 08

Hazardous Waste

0

500

1000

1500

2000

2500

3000

3500

4000

4500

2007 2008

Ton

nes

In 2007 a total of 4119Kgs of hazardous waste was produced, while in 2008

this figure was 1.56.

The reduction in hazardous waste is primarily attributed to re classification of

SRM material which was the largest contributor of the three(waste oil, lamps

and SRM) sources of hazardous material in 2007.




6.1 Organic Waste Management

Organic waste at the facility arises from the treatment of process

wastewater and from the storage of paunch material of slaughtered

animals.

Liquid effluents from the processing and washing operations drain to an

on-site wastewater treatment plant. The plant is a biological treatment

(activated sludge) system. Settled solids from the treatment plant are

dewatered on a belt press, with the excess water returned to the

treatment plant. Approximately 1500 tonnes of pressed sludge per

annum is removed from the treatment plant.

Paunch contents are stored in an on-site paunch holding area. An

estimated 2,500 tonnes of paunch and truck wash waste is collected in

the paunch holding area.

The quantity of organic waste generated in 2007 was 3790 tonnes and

in 2008 it was 3069 tonnes. This Organic waste is land spread in

accordance with a Nutrient Management Plan (NMP).

The quantity of organic waste arising for the calendar year 2008 is

tabulated on Table 12 ,while figure 6 indicate the reduction in waste

between 2007 and 2008.




Table 12 Organic Waste Arising Jan - Dec 2008

Month Total (Kgs)

Jan --

Feb --

Mar --

Apr 1051

May --

Jun --

Jul --

Aug --

Sep 2018

Oct --

Nov --

Dec --

Total (Kgs) 3069 Figure 6: Comparison of Organic waste generated in 07 & 08

Organic waste

0

500

1000

1500

2000

2500

3000

3500

4000

2007 2008

Ton

nes




7.0 Resource Consumption

Data relating to energy consumption (electricity and fuel oil) and

water for the 2008 reporting period are summarised in the following

sections.

Data for the same period last year are provided for comparison

purposes.

Data are presented as annual totals and per head of cattle

slaughtered.

7.1 Summary Energy Consumption

Table 13 Summary Energy and Water Consumption Data

Oil Consumption (kW) Electricity Consumption (kW) Year

Total Usage Kw/Head Total Usage

2008 4787506 77.3 5369195 86.8

2007 4896275 76.1 5493533 85.4

Analysis of the data indicates that there was a significant decreases in

both oil and electricity usage. The number of animals slaughtered

declined while the quantity of quarters boned increased, thus

accounting for the marginal increase in Kw/Head.

Figures 1, 2 and 3 reviewed indicate the reduction in energy

consumption in both oil and electricity between 2007 and 2008.

7.2 Water Usage

Water consumption for the site for the 2008 reporting period is

summarised on Table 13. Plant water demand is met from the

company’s own well supply, while the town’s public water supply is

used for the canteen.

Plant water usage is typically directly related to production levels.




Table 14 Plant water consumption

Water Consumption (m 3) Year

Total Usage m 3/head

2008 103145 1.66

2007 106454 1.65

There was a 3.2% decrease in Total water usage over the 07 - 08 period, while

there was no decrease in the figure per head of cattle slaughtered. This is due

to a large increase in the percentage of bone in beef being taken in from

sister sites for de-boning and the opening of the second line in boning hall

two.

Figure 7: Water usage in 2007 and 2008.

Water Usage

0

20000

40000

60000

80000

100000

120000

Year

M3 2008

2007




8.0 Complaints Summary

There was one complaint received during the period January to December 2008, where a local resident alleged that there was a odour issue, the issue was logged and investigated by both Matt Twomey and Michael Betts. On investigation there was no odour present, Michael Betts contacted the resident and discussed the findings, the resident was satisfied and the issue was closed.

9.0 Reported Incidents Summary There were no environmental incidents at the factory or associated

wastewater treatment plant during the 2008 reporting period.

10.0 Pollution Emissions Register A PER report is not generated as agreed with the Agency as the site

does not use substances which would require a PER.

11.0 Environmental Liabilities Risk Assessment

A Closure Plan and Environmental Liabilities Risk Assessment are currently

being prepared for Charleville Foods.

Charleville Foods will ensure there is adequate financial provision and

insurance cover to address any potential environmental liabilities, and

decommission the site in the event of an unforeseen closure.

The facility has an Environmental Management Programme (EMP) in

place. The EMP serves as a guidance document for facility staff and

describes operational control and management practices that are

applied at the facility. The EMP is also the core element of the

Environmental Management System (EMS) for the facility and is

designed to ensure that management of site activities complies with

regulatory requirements and best practice. The EMS includes a detailed

Emergency Response Procedure which sets out the steps to be taken in

the event of an incident at the facility with the potential to cause

environmental damage.

In addition to the abovementioned Charleville Foods implements a

comprehensive monitoring programme which will highlight any potential

environmental incidents with the potential to cause environmental

damage.

A full copy of the report will be issued to the Environmental Protection

Agency under separate cover Report

p0173-01 2008 aer sss - environmental protection agency · 2014-12-16 · co-ordinator martin lane...

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