Annual Environmental Report 2010 - Dunbia Kilbeggan P0820-01 · Title: Microsoft Word - Annual...

ANNUAL ENVIRONMENTAL

REPORT

DUNBIA (IRELAND)

Licence Number PO820-01

Calendar Year 2010

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Submitted March 2011 Annual Environmental Report Content Introduction

Contents (i). Emissions from the Installation .......................................................................... 4 (ii). Waste Management Record ............................................................................... 4 (iii). Resource Consumption Summary ...................................................................... 4 (iv). Complaints Summary ......................................................................................... 5 (v). Schedule of Environmental Objectives and Targets .......................................... 5 (vi). Environmental Management Programme 2010 ................................................. 5 (vii). Environmental Management Programme Proposal 2011 .................................. 5 (viii). Pollutant Release and Transfer Register 2011 ................................................... 5 (ix). Pollutant Release and Transfer Register 2011 ................................................... 5 (x). Noise Monitoring Report Summary ................................................................... 5 (xi). Tank and Pipeline Testing and Inspection Report ............................................. 6 (xii). Reported Incidents Summary ............................................................................. 6 (xiii). Energy Efficiency Audit Report Summary ........................................................ 6 (xiv). Assessment of the Efficiency of Use of Raw Materials in Processes and Reduction in Waste Generated ....................................................................................... 6 (xv). Progress and Proposals to Minimise Water Demand and Volume of Trade Effluent Discharged ....................................................................................................... 7 (xvi). Review of Decommissioning Plan ..................................................................... 7 (xvii). Measures Relating to Prevention of Environmental Damage and Remedial Actions ........................................................................................................................... 7 (xviii). ELRA Review .................................................................................................... 8 Conclusion ..................................................................................................................... 8 Appendices Appendix A: Environmental Policy Appendix B: Company Organisation Structure Appendix C: Emissions from the Installation and PRTR Appendix D: Emissions Calculations Appendix E: Resource Consumption Appendix F: Objectives & Targets 2010 – 2011 Appendix G: Environmental Incidents Summary Appendix H: Complaints Summary 2010

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Introduction Name: Dunbia (Ireland) IPPC Licence Number: P0820-01 Address: Dunbia (Ireland)

Clara Road Kilbeggan Co. Westmeath

Description of Activities: Under Section 83(1) of the EPA Acts 1992 to 2007, Dunbia (Ireland) carry on the following activity:

“Treatment or processes for the purpose of the production of food products from animal raw materials (other than milk) with a finished production capacity greater than 75 tonnes per day.”

Company Environmental Policy: See Appendix A for Environmental Policy Company Organisation Chart: See Appendix B for Company Organisation Structure Dunbia (Ireland) received its IPPC Permit on 23rd May 2008. Information within this report reflects the period from 01 January 2010 – 31st December 2010.

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(i). Emissions from the Installation Details of emissions can be found in Appendix C. As requested in the AER Returns Worksheet if a total has been calculated by a method not recognised in the guidance documents a brief description of method used for this estimation should be included in the paper AER. Please see Appendix D for these calculations. Mass emissions (total kg) for licensed parameters from January to December 2010, storm water and foul discharge monitoring results are included in Appendix C. Emissions from the boiler unit are also monitored annually (tested on 30/03/2010) and results were in full compliance and significantly below the maximum measurable (400 ppm) for NOx, having a result of nitrogen oxide to be 107 ppm on High Fire and 76ppm on Low Fire. An ELV for NOx is not stipulated in the IPPC Licence. Summary Tables for Resource Consumption are set out in Appendix E of this report and detail figures for Electricity, Gas and Water Usage. Summary Tables for Mass Emissions for Effluent Discharge are contained in Appendix C of this report. The PRTR Workbook details waste generation for Dunbia (Ireland) in 2009 and 2010. Summary table is laid out below for Boiler Emissions in 2010: Table 1 Boiler Emissions 2010 (NOx) NOx (ppm) 2009 2010 Low Fire 76 76 High Fire 107 104

(ii). Waste Management Record Details of waste transferred off site can be found in the PRTR Workbook.

(iii). Resource Consumption Summary Tables of consumption of electricity, gas and water have been included in Appendix E of this report. These tables include figures from January to December 2009 and 2010. Summary Tables for Mass Emissions for Effluent Discharge are contained in Appendix C of this report. The PRTR Workbook details waste generation for Dunbia (Ireland) in 2009 and 2010.

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(iv). Complaints Summary Complaints received are detailed in Appendix H of this report. A communications log is maintained at the Security Hut on-site and by the EHS Officer and a procedure is in place detailing how to log and address complaints relating to operations at Dunbia (Ireland). A total of eleven complaints were received in 2010 at the Dunbia (Ireland) site.

(v). Schedule of Environmental Objectives and Targets As required in condition 2.2.2.2 of the licence a copy of the objectives and targets agreed by Senior Management for Dunbia (Ireland) are in Appendix F of this report.

(vi). Environmental Management Programme 2010 This report takes into consideration how Dunbia (Ireland) has performed with regard to the objectives and targets agreed by site management in 2010. The report detailing this performance can be found in Appendix F in the comments section.

(vii). Environmental Management Programme Proposal 2011 A proposal for the targets scheduled to be completed in 2011 can be found in Appendix F.

(viii). Pollutant Release and Transfer Register 2011 The PRTR spreadsheet is a separate attachment to this document and it entitled P0820_2010(1).

(ix). Pollutant Release and Transfer Register 2011 No changes to the materials emitted are envisaged by site from the Pollutant Release and Transfer Register of 2010, though it is hoped concentrations are reduced with additional practice of Best Available Techniques (BAT).

(x). Noise Monitoring Report Summary A noise survey was carried out in January 2010 and the report is currently being finalised – this will be submitted to the EPA as soon as Dunbia (Ireland) receive the final report from the noise consultant.

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A Noise Reduction Programme has also been drafted and will be finalised to take into account the findings of the Noise Survey conducted in January 2011 and submitted immediately after to the EPA.

(xi). Tank and Pipeline Testing and Inspection Report This testing was completed in 2009 and a report was submitted to the EPA in March 2010.

(xii). Reported Incidents Summary Appendix G details all the incidents that have occurred at site listing a cause and a corrective action for each incident. The majority of reported incidents are from emissions to sewer and reporting period is from the 1st January 2010 until 31st December 2010, as per requirements of the IPPC licence, condition 11.3. Dunbia (Ireland) are aware of the importance of reducing the frequency of incidents and as a results have completed a tender process for a new Effluent Treatment plant including buffer tank and biological treatment, which should help mitigate against these incidents. The proposal to install a new effluent treatment plant is currently under consideration by Westmeath County Council planning department.

(xiii). Energy Efficiency Audit Report Summary This audit was completed and submitted to the EPA in March 2010 as per requirements of the IPPC Licence, condition 7.1.

(xiv). Assessment of the Efficiency of Use of Raw Materials in Processes and Reduction in Waste Generated

Propane is used to fuel the boiler on-site for the production of hot water. As per schedule C.1.2 of the licence, site has serviced the boiler and tested it for the Nitrogen Oxide content and the efficiency; these details are held on file at site. As per requirement of Condition 7.4 of the licence there have been a number of targets proposed in the Schedule of Environmental Objectives and Targets to be completed in 2011. Proposed activities include waste audit with view to improving recycling performance on-site, installation of cistern displacement devices, implementation of energy policy and setting out energy efficient equipment details in purchasing policy. Projects completed during 2010 include implementation of start up / shut down procedures, completion of a water audit, investigation of energy efficient improvements of refrigeration system. Findings from the refrigeration review will be implemented in 2011. Water Usage decreased by an average of 9.5% during 8 months of 2010. However, water usage increased due to increased production in the final two quarters of the

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year. Monthly electricity usage decreased by an average of 7.3% during 4 months of 2010. Gas usage decreased, on average, by 20% during 6 months of 2010.

(xv). Progress and Proposals to Minimise Water Demand and Volume of Trade Effluent Discharged

Water meter readings are carried out daily and documented onto an electronic spreadsheet. The Maintenance Department are currently reviewing options to reduce water usage. The feasibility of potential saving opportunities are being reviewed and once finalised, will be transferred to the Environmental Management Programme for tracking and close-out.

(xvi). Review of Decommissioning Plan A decommissioning plan was submitted in January 2009 to the EPA, as per IPPC Licence condition 10.2.1. This decommissioning plan was reviewed in March 2011; no changes of significance were noted within the report.

(xvii). Measures Relating to Prevention of Environmental Damage and Remedial Actions

Dunbia (Ireland) have taken a number of measures to prevent any environmental damage occurring at site. These measures include the addition of checks to the effluent sampler in the Preventative maintenance schedule that members of the maintenance team complete daily. In 2010, Dunbia (Ireland) secured a dedicated EHS Officer for the site. Additional chemical storage / bunding was also installed on-site to contain at least 8 drums (200 litre in size). A Weekly environmental checklist is completed by the EHS Officer at site. This list includes checks for damage to tanks and leaks from tanks and pipes etc. Annual servicing of the boiler ensures that the efficiency is kept to an optimum level and also keeps Dunbia (Ireland) in compliance with the IPPC licence. There are a number of operational procedures within the Environmental Management System at Dunbia (Ireland) that are in place to help reduce the possibility of an incident occurring. A procedure is also in place for actions that should be taken in the case of an environmental incident at site. An incident log book exists at site and will be completed by the EHS Officer; part of this form takes into consideration what the remediation actions would be to prevent the incident occurring again.

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Environmental Awareness is included in Employee Inductions with the aim of educating personnel so as to avoid incidents. Additional employees were trained in Spillage Response.

(xviii). ELRA Review The Environmental Liabilities Risk Assessment was submitted in January 2009 by an independent consultant as required within condition 12.3 of the license. Review of the ELRA will be carried out as necessary, or in any case, by January 2012. There have not been changes of a significant nature at the site during 2010.

Conclusion In 2010, Dunbia (Ireland) have demonstrated a commitment to improving environmental performance. Water and energy audits were conducted late in 2010 and feasibility study of project implementation is in progress. Feasible projects from the audits will be transferred to the 2011 Environmental Management Programme. Chemical storage capacity at Dunbia (Ireland) was increased during 2010 with the provision of two additional bunds and conversion of an existing enclosed area to chemical storage. Dunbia (Ireland) also hired a dedicated EHS Office to maintain and develop the environmental management system on-site. There were zero environmental complaints relating to Dunbia (Ireland)’s activities in 2009 but this increased to eleven in 2010. The majority of these complaints related to noise from the facility and were reported in the latter half of the year, one complaint related to employee behaviour on-site. It should be noted that all complaints were logged subsequent to the date that Dunbia (Ireland) submitted a planning application to Westmeath County Council for an extension to the existing facility. This planning application also includes an effluent treatment plant which comprises chemical, biological and mechanical treatment. A noise reduction programme was drafted late in 2010 and is currently being finalised, pending inclusion of findings from a noise survey conducted for Dunbia (Ireland) in January 2011. Production rates increased at the Dunbia (Ireland) facility during the latter part of 2010. Water usage decreased by an average of 9.5% during 8 months of the year. Monthly electricity usage decreased by an average of 7.3% during 4 months of 2010. Gas usage decreased, on average, by 20% during 6 months of 2010.

General Manager Padraig Browne

IT Programme Manager

Karen Butler

HR/Training Manager

Patricia Smith

ROI Maintenance

ManagerSeán Cullen

Appendix B: Dunbia (Ireland) Management Organogram

Group Health & Safety ManagerJoy McFarland

Group Purchasing Manager

John Jennings

General Operatives

Group Engineering Manager

Austin Weir

Group Technical Manager

Gavin Morris

Group Environment & Efficiency Manager

Denver Willis

Group Environmental OfficerMichael Campbell

Personnel

Group Procurement Manager

Stan Aryton

Agricultural Research Manager

Jonathan Birnie

Group Senior Environmental Officer

Victoria Kerr

Production Manager

Phonsie Daly

Personnel

Supervisors

Group Refrigeration

EngineerDenver Jardine

Senior Management Team

Key EMS Responsibility

XYZ

Purchasing Co-ordinatorOwen Duffy

Internal Audit Co-ordinatorMonica White

Group Process Improvement

ManagerVictor Hazelton

IT Operations Manager

Clive Arnold

Customer Service & ROI Technical Manager

Gerry McNally

Site Technical ManagerRosemary Carpenter

Environmental,Health & Safety

OfficerMiriam

O’Looney

Financial Accountant

Robin Jackson

IT, Administration & Accountant

Personnel

Sales ManagerPadraig Browne

(Temp.)

Personnel

Maintenance Foreman

Paddy McAuley

Maintenance Personnel

Security/Reception

QCs / Cleaners

Factory ManagerLiam Dempsey

DICR MO Issue 5, Issue Date: October 2010

DICR/MO Author: M. O'Looney Issued by: L. Dempsey

Appendix C - Emission Summary 20102010 COD pH

14/01/2010 <20 8.104/02/2010 8 COD not analysed for04/03/2010 <20 7.208/04/2010 24 7.906/05/2010 <20 803/06/2010 <20 808/07/2010 440 705/08/2010 24 8.102/09/2010 334 7.408/10/2010 32 7.830/11/2010 13 7.601/12/2010 Sample broken in transit

Average 13.00 7.60

Appendix C - Emission Summary 2010

DateCOD BOD Total

PhosphorousSuspended

SolidsFats, Oils, Greases

pH

mg/L mg/L mg/L mg/L mg/L04/01/2010 117 31 7.105/01/2010 111 7.406/01/2010 239 6.907/01/2010 388 102 7.408/01/2010 378 8.611/01/2010 84 7.212/01/2010 1670 7.113/01/2010 304 7.114/01/2010 600 4.98 196 154 9.415/01/2010 <20 472 7.318/01/2010 217 7.319/01/2010 180 7.320/01/2010 758 7.121/01/2010 705 216 7.122/01/2010 398 6.925/01/2010 430 6.826/01/2010 297 6.927/01/2010 198 7.228/01/2010 796 204 7.529/01/2010 102 7.501/02/2010 18 6.702/02/2010 36 703/02/2010 118 7.404/02/2010 269 130 20 7.405/02/2010 22 7.408/02/2010 22 7.209/02/2010 16 7.310/02/2010 56 7.411/02/2010 339 86 7.212/02/2010 54 7.415/02/2010 44 7.216/02/2010 37 7.217/02/2010 46 7.518/02/2010 280 53 7.519/02/2010 44 7.522/02/2010 86 7.223/02/2010 228 724/02/2010 112 7.825/02/2010 534 100 7.826/02/2010 222 7.701/03/2010 58 702/03/2010 56 6.803/03/2010 76 6.804/03/2010 655 62 6.905/03/2010 70 6.908/03/2010 56 7.809/03/2010 42 7.910/03/2010 196 7.511/03/2010 1890 84 6.712/03/2010 86 6.715/03/2010 128 7.516/03/2010 178 6.8

Parameters

DateCOD BOD Total



pH

mg/L mg/L mg/L mg/L mg/L

Parameters

17/03/2010 214 718/03/2010 140 7.119/03/2010 765 246 7.422/03/2010 152 7.323/03/2010 118 7.624/03/2010 204 7.525/03/2010 588 104 7.226/03/2010 288 11.129/03/2010 130 7.430/03/2010 110 7.231/03/2010 156 8.101/04/2010 491 110 7.902/04/2010 46 8.105/04/2010 84 8.206/04/2010 89 7.507/04/2010 201 7.908/04/2010 378 216 1.81 158 34 709/04/2010 137 7.612/04/2010 82 7.213/04/2010 72 7.114/04/2010 76 7.215/04/2010 756 68 7.116/04/2010 52 7.219/04/2010 102 9.120/04/2010 350 7.821/04/2010 256 8.122/04/2010 571 120 7.423/04/2010 140 7.526/04/2010 54 7.427/04/2010 208 7.728/04/2010 364 7.529/04/2010 726 114 7.230/04/2010 56 7.303/05/2010 40 704/05/2010 868 7.305/05/2010 322 7.106/05/2010 810 262 7.107/05/2010 294 7.110/05/2010 236 6.811/05/2010 184 7.112/05/2010 308 7.113/05/2010 1970 490 6.814/05/2010 560 7.117/05/2010 100 718/05/2010 70 719/05/2010 65 7.120/05/2010 659 129 721/05/2010 94 7.124/05/2010 68 7.425/05/2010 184 7.226/05/2010 248 6.927/05/2010 975 204 6.928/05/2010 138 6.831/05/2010 180 7.7

DateCOD BOD Total



pH


Parameters

01/06/2010 108 702/06/2010 294 703/06/2010 990 118 7.204/06/2010 122 7.407/06/2010 330 6.908/06/2010 412 6.809/06/2010 129 710/06/2010 834 197 7.111/06/2010 139 714/06/2010 86 7.115/06/2010 137 7.516/06/2010 190 7.817/06/2010 889 172 7.718/06/2010 138 8.121/06/2010 114 6.922/06/2010 184 723/06/2010 151 6.924/06/2010 507 106 6.925/06/2010 165 8.228/06/2010 340 6.929/06/2010 200 730/06/2010 426 7.801/07/2010 444 82 7.702/07/2010 428 7.605/07/2010 144 6.806/07/2010 264 7.107/07/2010 264 6.808/07/2010 1180 6.76 300 41 6.709/07/2010 370 7.212/07/2010 152 7.713/07/2010 124 7.514/07/2010 207 7.215/07/2010 603 266 7.016/07/2010 112 7.219/07/2010 132 8.620/07/2010 186 7.321/07/2010 104 7.122/07/2010 1600 568 7.023/07/2010 106 7.226/07/2010 336 7.227/07/2010 276 7.428/07/2010 48 7.329/07/2010 762 92 8.730/07/2010 204 7.602/08/2010 168 9.403/08/2010 134 8.104/08/2010 87 7.805/08/2010 754 260 7.806/08/2010 67 7.909/08/2010 171 8.210/08/2010 140 6.611/08/2010 122 7.512/08/2010 658 130 7.513/08/2010 138 7.6

DateCOD BOD Total



pH


Parameters

16/08/2010 140 9.917/08/2010 37 8.318/08/2010 154 8.219/08/2010 262 156 56 8.120/08/2010 158 8.023/08/2010 250 8.624/08/2010 136 8.825/08/2010 96 8.226/08/2010 767 164 8.527/08/2010 82 8.130/08/2010 291 7.131/08/2010 141 7.001/09/2010 142 7.202/09/2010 515 164 7.203/09/2010 260 7.506/09/2010 116 7.507/09/2010 78 7.508/09/2010 32 7.109/09/2010 11 22 7.310/09/2010 23 7.213/09/2010 11 7.814/09/2010 13 7.715/09/2010 177 7.116/09/2010 779 186 7.517/09/2010 74 6.820/09/2010 154 6.821/09/2010 36 7.022/09/2010 37 8.223/09/2010 48 8.324/09/2010 58 8.327/09/2010 28 7.728/09/2010 30 7.529/09/2010 61 7.130/09/2010 82 45 7.201/10/2010 77 7.004/10/2010 315 9.905/10/2010 244 7.506/10/2010 725 166 7.107/10/2010 96 7.208/10/2010 198 7.211/10/2010 125 7.712/10/2010 86 8.113/10/2010 314 6.814/10/2010 938 286 6.815/10/2010 476 6.918/10/2010 325 7.919/10/2010 240 7.620/10/2010 131 7.621/10/2010 470 90 7.622/10/2010 308 7.625/10/2010 59 7.326/10/2010 73 7.227/10/2010 72 7.628/10/2010 52 7.5

DateCOD BOD Total



pH


Parameters

29/10/2010 57 7.501/11/2010 742 6.502/11/2010 461 9.603/11/2010 442 178 3.134 198 12 7.204/11/2010 226 7.405/11/2010 136 7.408/11/2010 273 7.309/11/2010 225 7.410/11/2010 110 7.311/11/2010 522 172 7.312/11/2010 74 7.115/11/2010 52 7.116/11/2010 52 7.217/11/201018/11/2010 438 74 7.219/11/2010 3180 6.822/11/201023/11/2010 427 7.324/11/2010 270 725/11/2010 1060 352 7.226/11/2010 1000 6.929/11/2010 228 6.930/11/2010 228 6.901/12/2010 110 902/12/2010 560 134 9.103/12/2010 112 8.906/12/2010 108 9.307/12/2010 136 6.908/12/2010 200 7.309/12/2010 660 296 6.910/12/2010 104 7.213/12/2010 696 7.314/12/2010 1110 6.715/12/2010 2070 6.216/12/2010 642 6.817/12/2010 322 720/12/2010 144.5 7.121/12/2010 29 7.122/12/2010 586 9.323/12/2010 2170 554 9.524/12/201027/12/201028/12/2010 971 9.329/12/2010 662 9.530/12/2010 2840 1440 7.531/12/2010 711 9.4

No ProductionNo Production

Appendix D Calculations for Emissions Data 2010

Parameter

IPPC Licence ELV

Average Value 2010

Average Value 2010

Volume Discharged to Kilbeggan WWTP 2010

Quantity Produced 2010

Units mg / l mg / l kg / l l kgCOD – 747 0.000747098 15,763,989 11,777BOD 300 449 0.000449 15,763,989 7,078Suspendeed Solids 150 221 0.00022122 15,763,989 3,487Fats, Oils, Greases 50 60 0.00006025 15,763,989 950Total Phosphorus 6 4 0.00000402 15,763,989 63

Average Value in mg/l taken from STL analytival results from Jan - Dec 2010

Volume discharged to Kilbeggan WWTP Jan - Dec 2010 taken from Effluent Meter readings recorded by Security

Appendix C - Emission Summary 2010

Foul Discharge Results (SE1)

ParameterMass Emissions (kg) 2009

Mass Emissions (kg) 2010

Licenced Mass Emissions (kg) Frequency

Volume (L) 12,574,531 15,763,989 35,040,000 DailypH 7.40 7.47 6.0 to 8.0 DailyCOD 8,215 11,777 Not Licensed WeeklyBOD 7,078 7,078 10,950 QuarterlySuspendeed Solids 2,995 3,487 5,475 DailyOils, fats & Greases 68 950 1,825 QuarterlyTotal Phosphorus 43 63 219 Quarterly

AER/ES March 10

Appendix D Calculations for Resource Consumption Data 2010

Dunbia (Kilbeggan): Consumption Calculations 2010

kWh Usage MWh Usage Litres kWh Usage MWh UsageJanuary 190,628.13 190.63 12,212 85,240 85February 202,805.71 202.81 7,067 49,328 49March 205,574.57 205.57 9,353 65,284 65April 210,335.25 210.34 7,997 55,819 56May 206,885.88 206.89 5,042 35,193 35June 225,788.69 225.79 11,794 82,322 82July 264,349.06 264.35 7,005 48,895 49August 240,330.34 240.33 6,256 43,667 44September 244,336.18 244.34 8,073 56,350 56October 237,943.21 237.94 8,688 60,642 61November 234,783.53 234.78 7,133 49,788 50December 219,337.62 219.34 13,952 97,385 97

Total Electricity Usage 2,683,098.17 2,683.10 104,572 729,913 730

Figures taken from Electricity Bills for Dunbia (Kilbeggan)

Electricity (kWh) 2,683,098.17Propane Gas (litres) 104,572

Primary Energy (kWh) 6,976,055.24Propane Gas (kWh) 729,913

CO2 Produced (kg) 316,015.30

CO2 Produced (kg) 156,340

Conversion factor of 0.21419 as per www.defra.gov.uk

From invoices

Electricity Usage 2010 Gas Usage 2010

Taken from electricity bills

Conversion factor of 2.6 (taken from www.cclevy.com)

Conversion factor of 0.0453 (taken from www.cclevy.com)

Multiply by 6.98 as per www.carbontrust.co.uk

Appendix E Resource Consumption 2010

Month

2009 2010 % Difference 2009 2010 % Difference 2009 2010 % DifferenceJanuary 3212 2,660 -20.75 205.46 190.63 -7.78 52.9429 85.2398 61.00February 2971 2,874 -3.38 227.49 202.81 -12.17 70.7694 49.3277 -30.30March 2879 2,878 -0.03 214.415 205.57 -4.30 57.4613 65.2839 13.61April 2806 2,491 -12.65 205.273 210.34 2.41 62.2410 55.8191 -10.32May 2758 3,050 9.57 216.939 206.89 -4.86 41.1951 35.1932 -14.57Jun 2587 2,484 -4.15 207.807 225.79 7.96 69.1456 82.3221 19.06Jul 3192 2,444 -30.61 218.771 264.35 17.24 25.2607 48.8949 93.56Aug 2654 3,197 16.98 205.589 240.33 14.46 73.1134 43.6669 -40.28Sep 2632 2,619 -0.50 225.999 244.34 7.50 40.8421 56.3495 37.97Oct 2814 2,707 -3.95 200.089 237.94 15.91 71.7367 60.6422 -15.47Nov 2520 3,507 28.14 193.129 234.78 17.74 55.0115 49.7883 -9.49Dec 2548 2,813 9.41 195.309 219.34 10.96 79.2485 97.3850 22.89Total 33573 33,724 0.45 2516.27 2683.10 6.22 698.9682 729.9126 127.6683

Cells highlighted in greed show months where reductions were achieved

Electricity Usage (MWh)Mains Water (m3) Gas (MWh)

AER/RES Mar 10

Dunbia (Ireland) Environmental Managment Programme

Appendix F - Objectives & Targets: Report on Targets 2009 and Proposals 2010 - EMP reportObjective To reduce water consumption across

the site by end 2010 by 2%

Responsibility Liam Dempsey- Factory Manager

Target Number Target Completion Responsibility

3Start Up and Shut Down Procedure developed and Implemented for Tray Wash

31.08.2010 Liam Dempsey

Feasibility of cistern Displacement Devices in Toilet cisterns 31.08.2010 MOL

Install cistern displacement devices. 30.04.2011 MOL / SC

Completed in 2010In ProgressProposed Completion 2011

Indicator: Water consumption (cubic metres) per tonne production

4Report

Comments

Traywash SOP amended to include startup and shutdown actions

Spreadsheet calculations completed

Action scheduled with Maintenance to be completed in 2011

Report / Feedback

Procedure

DICR/OTMPPage 1 of 7

Issue No: 2Author: V. Kerr

Issued: Feb 10Authorised by: L. Dempsey

Target Reduce Energy Consumption by 3% by end 2010

Responsibility Liam Dempsey - Factory Manager

Target Number Target Completion Responsibility Report / Feedback Comments

1 Develop departmental start up / shut down procedures and check lists. 17.09.2010 Department Supervisors / Seán Cullen

Report Checklists available as part of PMS system

3 Investigate energy efficiency improvement opportunities for refrigeration systems. 30.09.2010 Report Operating settings compiled and relevant personnel trained

Review of system improvements 30.04.2011 ReportReview of electricity meters needed to monitor refrigeration equipment effectively 30.04.2011 Report

Refrigeration Plant operating parameters to be incorporated into monthly preventative maintenance schedules

30.09.2010 Maintenance Report Checklists available as part of PMS system

4 Identify recommended energy efficient equipment for inclusion in purchasing policy.

30.09.2011 MOL Report

Indicator: Electricity (kWh) per tonne productionIndicator:Diesel (litres) per tonne production


Group Refrigeration

Engineer




Target Reduce Energy Consumption by 3% by the end of 2010Responsibility

Liam Dempsey- Factory Manager

Target Target Completion Responsibility Report / FeedbackImplement the Energy Policy and Strategy

1. Finalise the Policy and strategy document2. Submit to Management Board for endorsement3. Publicise4. Keep people informed5. Set up energy reporting structure

3 Undertake an Energy Map Training programme with SEAI 30.09.2011 MOL Organise with SEAI6

Install Daylight Sensor in Tray Store.

On Hold - Review with EHS Officer. SC Visual

9 Organise an energy awareness campaign to ensure that all unnecessary electrical equipment is switched off during the weekend. 30.09.2011 MOL Photographs & Report


Reports generated through monitoring of Energy usage30.09.2011 MOL

1 As part of ISO 14001, a written draft Energy Policy and Strategy has been prepared. The strategy includes statements on all aspects of energy use. A key to all energy management activities is to identify areas of investigation, identify the people and their responsibilities and management reporting.Commitment from top management reinforces the Company's commitment to controlling and reducing energy use. This is the best way forward because without senior management involvement, actions will not have a positive outcome. The savings are based on a nominal 3% reduction of total energy use.



Issued Feb 10Authorised by L.Dempsey

Objective To reduce the amount of waste going to landfill by the end of 2010

Responsibility Liam Dempsey- Factory Manager


4 Repair broken sewer on F4 line 31.03.2011 SC

5 Conduct Waste Audit and streamline waste management on-site. Identify further recycling opportunities.

31.12.2011MOL/ LD

Indicator: tonnes waste (specify) per tonnes productionIndicator: % waste sent to landfill as % of total waste generated (regardless of disposal route)


Sccheduled for week commencing 04/04/2011.

Report / Feedback

Report




Objective Improve staff environmental awareness

Responsibility Denver Willis- Environment & Efficiency Manager


1 Internal ISO14001 Auditor training for Site Environmental Representative

Complete Group Environment and Efficiency

Manager


Certificates of succesful completion

Report / Feedback Comments

Training completed


Issue No. 2Author V. Kerr

Issued Feb 10Authorised by L. Dempsey

Objective

Responsibility

IPPC:


2 Annual Report 31st March, Annually

MOL

3 Water Audit Annually SC

4 Waste Audit 30.06.2010 MOL

17 Firewater risk management programme developed & fully implemented

VK

20 Installation of a buffer tank with 260m3 capacity.

JD/PB/RC/VK

25 Weekly inspection of drainage system, bunds, over ground pipes carrying anything other than water for leaks, & properly maintained.

Weekly MOL

26 Weekly visual inspection of storm water discharge for colour & odour & log maintained.

Weekly MOL

30 Prepare & Report a Pollutant Release & Transfer Register (PRTR)

As part of AER

MOL

Document

Action Specification for WWTP compiled. Planning for buffer tank

and WWTP submitted to Westmeath Co. Council

Report

Weekly Checklist

Weekly Checklist

Complete

Fulfil IPPC & EMS Requirements

Liam Dempsey- Factory Manager

Report / Feedback

Completion of Waste audit report and recommendations

Comments

Complete

Report & Recommendations

Report

Report

Completion of Water audit report and recommendations

Report Awaiting Kilbeggan WWTP Upgrade

Document


Issue No. 2Author: V. Kerr

Issued: Feb 10Authorised by L. Dempsey

Target Number Target Completion Responsibility Report / Feedback Comments

41 Report of monitoring of sewer emissions to be submitted to Westmeath CC. Including Sample date, monitoring results, name & address of analysis lab.

Every Quarter

MOL

42 Report of monitoring of sewer emissions to be submitted to EPA.

In AER MOL

46 Analysis of NOx and combustion efficiency.

Annually PMA

47 Test storm water for pH and COD monthly.

Monthly PW

49 A sufficient composite sampler is to be installed.

LD

50 ELRA Review 31/12/2011 MOL

Indicator: Completion of all Improvement Conditions by deadlines issued by Environmental Protection AgencyJD Managing DirectorPB General ManagerLD Factory Manager

PMA Maintenance ManagerPS HR & Training Manager

RC/PW Environmental RepresentativeVK Environmental OfficerRJ Financial Controller

Proposed Completion 2011In ProgressCompleted in 2010

Indicator: Improvement Conditions completed on schedule

Document

Print out from Engineer

AER

Quarterly Report

DocumentSpecification for new composite

sample obtained. Composite sampler to be purchased and

installed in 2011.

Specification for new composite sample obtained. Composite sampler to be purchased and

installed in 2011.

External lab report

Report

Report

Document


Issue No. 2Author: V. Kerr

Issued: Feb 10Authorised by L. Dempsey

Non-Compliance: ELV Exceedence ELV

(mg/l) (mg/l)

NH3 05/01/2010Refrigeration Plant Room

42kg/minute over max. 30 period N/A

Low water level at site due to unscheduled mains water shut off by WMCoCo. This caused pressure relief valve to release NH3 vapour for approx. 30 seconds prior to pressure relief valve shutting down Refrigeration System.

Improvement of water monitoring system. Replacement of safety switches.

SS 06/01/2010 SE1 239 150 Discharge Limits on SE1 too stringentDiscussions on-going with Westmeath County Council with a view to reviewing present discharge limits.

pH 08/01/2010 SE1 8.6 6-8 Discharge Limits on SE1 too stringentDiscussions on-going with Westmeath County Council with a view to reviewing present discharge limits.






BOD 14/01/2010 SE1 311 6-8 Discharge Limits on SE1 too stringentDiscussions on-going with Westmeath County Council with a view to reviewing present discharge limits.

pH 14/01/2010 SE1 8.1 150 Discharge Limits on SE1 too stringentDiscussions on-going with Westmeath County Council with a view to reviewing present discharge limits.








Dunbia (Ireland) - Non Compliance Report for 2010

Date Emission PointMeasure Exceedence Cause Corrective Action


(mg/l) (mg/l)Date Emission PointMeasure Exceedence Cause Corrective Action












pH 26/03/2010 SE1 11.1 6-8 Anomaly

We believe that this incident was an anomaly. On the day in question, we had a site audit and our only conclusion is that the days previous to this there may have been additional cleaning carried out in certain areas which therefore may have lead to the use of additional chemical and therefore resulted in a high pH result. We are examining our use of chemical during times of above and beyond the normal levels of cleaning performed as a company.



















BOD 06/05/2010 SE1 451 300 Discharge Limits on SE1 too stringentDiscussions on-going with Westmeath County Council with a view to reviewing present discharge limits.






















P 08/08/2010 SE1 6.76 6 Discharge Limits on SE1 too stringentDiscussions on-going with Westmeath County Council with a view to reviewing present discharge limits.





























SS 30/08/2010 SE1 291 150 Discharge Limits on SE1 too stringent

Installation of Friendly Systems unit to reduce BOD and TSS. Discussions on-going with Westmeath County Council with a view to reviewing present discharge limits.







BOD 03/09/2010 SE1 260 300 Discharge Limits on SE1 too stringent










pH 22/09/2010 SE1 8.2 6-8 Discharge Limits on SE1 too stringent






























No Sample 17/11/2010 SE1 Sample not taken. N/A New person taking samples. New person retrained.No Sample 20/11/2010 SE1 Sample not taken. N/A Sampler not operating correctly. Maintenance checked and repaired sampler.





























pH 01/12/2010 SE1 9 6-8 Discharge Limits on SE1 too stringent






























pH 22/12/2010 SE1 9.3 6-8 Discharge Limits on SE1 too stringentSS 22/12/2010 SE1 586 150 Discharge Limits on SE1 too stringentpH 23/12/2010 SE1 9.5 6-8 Discharge Limits on SE1 too stringentSS 23/12/2010 SE1 554 150 Discharge Limits on SE1 too stringentpH 28/12/2010 SE1 9.3 6-8 Discharge Limits on SE1 too stringentSS 28/12/2010 SE1 971 150 Discharge Limits on SE1 too stringentpH 29/12/2010 SE1 9.5 6-8 Discharge Limits on SE1 too stringentSS 29/12/2010 SE1 662 150 Discharge Limits on SE1 too stringentSS 30/12/2010 SE1 1440 150 Discharge Limits on SE1 too stringentpH 31/12/2010 SE1 9.4 6-8 Discharge Limits on SE1 too stringentSS 31/12/2010 SE1 711 150 Discharge Limits on SE1 too stringent

Water supply to be reconnected to Friendly Systems unit (works to reduce BOD and TSS); section of water system being replumbed presently due to damage from freezing weather conditions.Correspondence with Westmeath County Council with a view to reviewing the present discharge limits.Friendly Systems unit was not been operating during this time due to frozen pipework to the system – once pipework has been fixed and water connected to the system again, exceedences not likely.Once ELV limits reviewed by WMCC, not likely.

10/09/2010 22:30 EPA Letter

EPA informed Dunbia (Ireland) of complaints received by them, from two neighbours to

the Dunbia (Ireland) facility, of noise from lorry movements after 22:30 on 09/09/2010

and two further complaints relating to 10/09/2010 and 13/09/2010.

17/09/2010 22:20 Phone Call Noise pollution from despatch area

17/09/2010 23:30 Phone Call Noise pollution

21/09/2010 02:15 Phone Call Noise pollution from despatch area

23/09/2010 N/A Email Noise at night time relating to complaint on 17/09/2010

26/10/2010 22:50

Phone Call /

EPA Letter Personnel behaviour on-site / Noise pollution from trucks



Total Eleven (11)

Date

Time of

Noise

Dunbia (Ireland) - Complaints Summary 2010

Contact

Type Content of Complaint

PRTR:

P0820_2010(1)

DUNBIA (Ireland)

PRTR

Calendar Year 2010

2010 AERPRTR Emissions Data XML Return Tracking Number:

93fa751f8138688555c69b89d04ddc11

| PRTR# : P0820 | Facility Name : Dunbia (Ireland) | Filename : P0820_2010(1).xls |

Return Year : 2010 | 5067 31/03/2011 16:15

Guidance to completing the PRTR workbook

Version 1.1.11

REFERENCE YEAR 2010

1. FACILITY IDENTIFICATION

Parent Company Name Dunbia (Ireland)

Facility Name Dunbia (Ireland)

PRTR Identification Number P0820

Licence Number P0820-01

Waste or IPPC Classes of Activity

No. class_name

7.8(a)

animal raw materials (other than milk) with a finished product

production capacity greater than 75 tonnes per day

Address 1 Clara Road

Address 2 Kilbeggan

Address 3 County Westmeath

Address 4

Country Ireland

Coordinates of Location -7.50955 53.3659

River Basin District IEGBNISH

NACE Code 1089

Main Economic Activity Manufacture of other food products n.e.c.

AER Returns Contact Name Mr. Padraig Browne

AER Returns Contact Email Address [email protected]

AER Returns Contact Position Managing Director

AER Returns Contact Telephone Number 057 936 9000

AER Returns Contact Mobile Phone Number 086 600 2251

AER Returns Contact Fax Number 057 933 2486

Production Volume 0.0

Production Volume Units

Number of Installations 1

Number of Operating Hours in Year 0

Number of Employees 0

User Feedback/Comments

Web Address

2. PRTR CLASS ACTIVITIES

Activity Number Activity Name

8(b)(i) Animal raw materials (other than milk)

3. SOLVENTS REGULATIONS (S.I. No. 543 of 2002)

Is it applicable? No

Have you been granted an exemption ?

If applicable which activity class applies (as per

Schedule 2 of the regulations) ?

Is the reduction scheme compliance route being

used ?

AER Returns Workbook

http://www.epa.ie/downloads/advice/aerprtr/completinguploadingtheprtrworkbook/

4.1 RELEASES TO AIR Link to previous years emissions data | PRTR# : P0820 | Facility Name : Dunbia (Ireland) | Filename : P0820_2010(1).xls | Return Year : 2010 | 31/03/2011 16:15

8 9 17 17 25 25 6 6 6 6 6 6 9

SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS

Please enter all quantities in this section in KGs

QUANTITY

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year

03 - Carbon dioxide (CO2) Carbon Dioxide C ETS See Appendix D to AER 156340.0 156340.0 0.0 0.0

08 Nitrogen oxides (NOx/NO2) C OTH

NOx measured and length

of emission applied to

measured value. 1374.0 1374.0 0.0 0.0

* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button

SECTION B : REMAINING PRTR POLLUTANTS


QUANTITY


0.0 0.0 0.0 0.0


SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence)


QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year

0.0 0.0 0.0 0.0


Additional Data Requested from Landfill operators

Landfill: Dunbia (Ireland)Please enter summary data on the

quantities of methane flared and / or

utilised

additional_pollutant_no T (Total) kg/Year M/C/E Method Code

Designation or

Description

Facility Total Capacity

m3 per hour

Total estimated methane generation (as per

site model) 0.0 N/A

Methane flared 0.0 0.0 (Total Flaring Capacity)

Methane utilised in engine/s 0.0 0.0 (Total Utilising Capacity)

Net methane emission (as reported in Section

A above) 0.0 N/A

Method Used

For the purposes of the National Inventory on Greenhouse Gases, landfill operators are requested to provide summary data on landfill gas (Methane)

flared or utilised on their facilities to accompany the figures for total methane generated. Operators should only report their Net methane (CH4) emission

to the environment under T(total) KG/yr for Section A: Sector specific PRTR pollutants above. Please complete the table below:

Method Used

Method Used

RELEASES TO AIR

POLLUTANT METHOD

Method Used

POLLUTANT

RELEASES TO AIR

RELEASES TO AIR

METHOD

POLLUTANT METHOD

4.2 RELEASES TO WATERS Link to previous years emissions data | PRTR# : P0820 | Facility Name : Dunbia (Ireland) | Filename : P0820_2010(1).xls | Return Year : 2010 | 31/03/2011 16:15

8 8 16 16 24 24 6 6 6 6 6 6

SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this only concerns Releases from your facility


QUANTITY


0.0 0.0 0.0 0.0


SECTION B : REMAINING PRTR POLLUTANTS


QUANTITY


0.0 0.0 0.0 0.0


SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)


QUANTITY


0.0 0.0 0.0 0.0


Method Used

POLLUTANT

Method Used

POLLUTANT

POLLUTANT

RELEASES TO WATERS

Method Used

RELEASES TO WATERS

RELEASES TO WATERS

4.3 RELEASES TO WASTEWATER OR SEWER Link to previous years emissions data | PRTR# : P0820 | Facility Name : Dunbia (Ireland) | Filename : P0820_2010(1).xls | Return Year : 2010 | 31/03/2011 16:15

8 8 16 19 6 6 6 6 16

SECTION A : PRTR POLLUTANTS


QUANTITY


13 Total phosphorus M CRM ISBN 0117532444 63.0 63.0 0.0 0.0


SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)


QUANTITY


303 BOD M CRM ISBN 011 7522120 7078.0 7078.0 0.0 0.0

314 Fats, Oils and Greases M CRM ISBN 087 553-131-8 950.0 950.0 0.0 0.0

240 Suspended Solids M CRM ISBN 011 751957X 3487.0 3487.0 0.0 0.0

306 COD M CRM ISBN 011 7519154 11777.0 11777.0 0.0 0.0


OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER

Method Used

Method Used

POLLUTANT METHOD

POLLUTANT METHOD

4.4 RELEASES TO LAND Link to previous years emissions data | PRTR# : P0820 | Facility Name : Dunbia (Ireland) | Filename : P0820_2010(1).xls | Return Year : 2010 | 31/03/2011 16:15

8 8 16 16 6 6 6 6

SECTION A : PRTR POLLUTANTS


QUANTITY

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year

0.0 0.0 0.0


SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)


QUANTITY

Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year

0.0 0.0 0.0


POLLUTANT METHOD

Method Used

RELEASES TO LAND

RELEASES TO LAND

POLLUTANT METHOD

Method Used

5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0820 | Facility Name : Dunbia (Ireland) | Filename : P0820_2010(1).xls | Return Year : 2010 | 31/03/2011 16:15

5 12 Please enter all quantities on this sheet in Tonnes 0

Quantity

(Tonnes per

Year)

Haz Waste : Name and

Licence/Permit No of Next

Destination Facility Non

Haz Waste: Name and

Licence/Permit No of

Recover/Disposer

Haz Waste : Address of Next

Destination Facility

Non Haz Waste: Address of

Recover/Disposer

Name and License / Permit No. and

Address of Final Recoverer /

Disposer (HAZARDOUS WASTE

ONLY)

Actual Address of Final Destination

i.e. Final Recovery / Disposal Site

(HAZARDOUS WASTE ONLY)

Transfer Destination

European Waste

Code Hazardous Quantity T/Year Description of Waste

Waste

Treatment

Operation M/C/E Method Used

Location of

Treatment Name and Licence / Permit No. of Recoverer / Disposer / Broker Address of Recoverer / Disposer / Broker Name and Address of Final Destination i.e. Final Recovery / Disposal Site (HAZARDOUS WASTE ONLY) Licence / Permit No. of Final Destination i.e. Final Recovery / Disposal Site (HAZARDOUS WASTE ONLY)

Within the Country 20 03 01 No 113.6 mixed municipal waste D1 M Weighed Onsite in Ireland

Advanced Environmental

Solutions (Ireland) Ltd.,WCP

OY/08/601/01

Cappincur,Tullamore,Offaly,.

,Ireland

To Other Countries 02 02 03 No 1762.0

materials unsuitable for consumption or

processing R3 M Weighed Abroad Linergy Ltd.,REN/575/07

Granville Industrial

Estate,Dungannon,Dungann

on,BT70 1NJ,United

Kingdom

To Other Countries 02 02 02 No 3965.3 animal-tissue waste R3 M Weighed Abroad Linergy Ltd.,REN/575/07

Granville Industrial

Estate,Dungannon,Dungann

on,BT70 1NJ,United

Kingdom

Within the Country 20 01 21 Yes 0.0

fluorescent tubes and other mercury-

containing waste R5 M Weighed Offsite in Ireland

Irish Lamp Recycling Co.

Ltd.,WCP-DC-08-1115-01

Woodstock Industrial

Estate,Athy,Kildare,.,Ireland

Irish Lamps Recycling

Ltd.,WFP-KE-08-0348-

01,Woodstock Industrial


Woodstock Industrial


Within the Country 15 01 01 No 18.438 paper and cardboard packaging R3 M Weighed Onsite in Ireland

Recycling Solutions,WCP

OY/06/408/ 02

Rosemount Business

Park,Ballycoolin

Road,Dublin 11,.,Ireland

Within the Country 15 01 03 No 17.916 wooden packaging R3 M Weighed Onsite in Ireland

Recycling Solutions,WCP

OY/06/408/ 02

Rosemount Business

Park,Ballycoolin

Road,Dublin 11,.,Ireland

Within the Country 13 02 08 Yes 0.75 other engine, gear and lubricating oils R9 M Volume Calculation Onsite in Ireland Enva,WCP-DC-08-1116-01

Clonminam Industrial

Estate,Portlaoise,Co.

Loaise,.,Ireland

Enva,184-1,Clonminam

Industrial


Loaise,.,Ireland



Loaise,.,Ireland

Within the Country 13 05 07 Yes 2.1 oily water from oil/water separators R9 M Volume Calculation Onsite in Ireland Enva,WCP-DC-08-1116-01



Loaise,.,Ireland

Enva,184-1,Clonminam

Industrial


Loaise,.,Ireland



Loaise,.,Ireland

* Select a row by double-clicking the Description of Waste then click the delete button

Link to previous years waste data

Link to previous years waste summary data & percentage change

Method Used

Annual Environmental Report 2010 - Dunbia Kilbeggan P0820-01 · Title: Microsoft Word - Annual...

Documents

Transcript of Annual Environmental Report 2010 - Dunbia Kilbeggan P0820-01 · Title: Microsoft Word - Annual...