SMITHFIELD PACKING COMPANY BMPs Training Conference 2013 – Chicago, IL 1

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SMITHFIELD PACKING COMPANY BMPsTraining Conference 2013 – Chicago, IL

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Training Conference 2013 – Chicago, IL

SMITHFIELD PACKING COMPANY BMPs

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Smithfield Packing CompanyBMPs

• Sustainability Ideations– Tar Heel

• Critical Control Point Operational Controls– Wastewater Operations

• EMS Training for Plant Managers & Senior Staff

• Weekly Environmental/Sustainability Call• Entering PMs related to Significant Aspects

in SAP

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SUSTAINABILITY

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Company E-mail

Joel Miller Smithfield Packing joelmiller@smithfield.com

Keith Bailey Smithfield Packing keithbailey@smithfield.com

Ruth Debrito Smithfield Packing ruthdebrito@smithfield.com

Paul Wright Smithfield Packing paulwright@smithfield.com

Wayne Cain Smithfield Packing waynecain@smithfield.com

Kirby Elkins Smithfield Packing Kirbyelkins@smithfield.com

Frank Jackson Smithfield Packing kennethjackson@smithfield.com

Jarred Turner Smithfield Packing jarredturner@smithfield.com

Buddy Harris Smithfield Packing robertharris@smithfiield.com

Tom Green Smithfield Packing tomgreen@smithfield.com

Bethany McLean Smithfield Packing bethanymclean@smithfield.com

Walter Wardlaw Smithfield Packing walterwardlaw@smithfield.com

Calvin Held Smithfield Packing calvinheld@smithfield.com

Lee Casey Smithfield Foods leecasey@smithfieldfoods.com

Rocky Beem Smithfield Foods rolandbeem@smithfieldfoods.com

Scott Schoolmeesters US Energy sschoolmeesters@usenergyservices.com

Nick Franco US Energy nfranco@usenergyservices.com

Neil McAdam World Water Works Neil.mcadam@WorldWaterWorks.com

Bill Reingans Hydro Thermal breingans@hydro-thermal.com

Wade Turner Reid Engineering wturner@reidengineering.com

Rob Henderson Chem Treat robh@chemtreat.com

Travis Hitchcock Waste Industries Travis.hitchcock@wasteindustries.com

Roy Carawan Water Reuse Specialist rcarawan@nc.rr.com

Jimmy Smith Four County jimmysmith@fourcty.org

Sean Fallon McGill Environmental Service sfallon@mcgillcompost.com

Stephanie Richardson Dontech Industries stephRich@aol.com

DL Catton Dontech Industries dl@dontechindustriesinc.com

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Plant Overview

• Year Built: 1992• Property Size: 888 acres• Building Size: 1million sq ft• Capacity (5 day wk):

• Fresh Pork – 191,000 hd/wk• Converted Lbs – 11,725,000 lbs/wk• Marination - 250,000 lbs/wk• Lbs Distributed – 33,000,000 lbs/wk

• Headcount: – Hourly = 4,439– Salary = 300

• Union status: 56 % Union• Average Wage Rate (Oct 2012)

– Hourly = $11.85/hr– Loaded = $19.75/hr

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Surface Water Plant

Main Engine Room

Back-up Generators

WW Water Plant

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Relevant Info• Local Fueling Cost ~ $3.80 / gal diesel (non highway grade)• Refrigerated Storage Trailer $1500.00 / month• Utility Cost

– Natural Gas $5.57 / MCF– Electric $0.0756 / KWH– Water $2.02 / 1000gal

• Utility Usage– Natural Gas 759,642 MCF/yr– Electric 155,731,838 KWH/yr– Water 809,712 1000gal/yr

• Spotter Service – Internal

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PLANT TOUR

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TEAMSTeam #1 Team #2 Team #3

Facilitator Miller Bailey Wright

Scribe Green DeBrito Turner J

Members

Henderson Richardson DL Catton

Schoolmeesters Carawan Beem

Franco Held McLean

Casey Jackson Harris

Reingans Cain Wardlaw

Smith McAdam Turner W

Elkins Hitchcock Fallon

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Identified Opportunities

• Plastic Recycling / Recycling Hub – Waste Industries

• Shipping Condensers – Switch to Final Effluent versus Potable Water

• Cryovac Bag Tails-Recyclable

• Heat Exchanger- Boiler Blowdown Water and Boiler Feed Water

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Brainstorming

• Generates large number of ideas• Goal is for participants to create new ideas

off of other ideas• Seems like a “no brainer,” but right

approach can improve idea outputRules for Brainstorming No one interrupts, censors, criticizes, or praises Questions are allowed only to clarify and idea Hitchhiking off other ideas is encouraged Freewheeling, unrelated ideas are okay here

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How to Brainstorm• Write a description of the brainstorming objective

– Leads to more effective session

• One person records the ideas so all can see– Flip chart, white board, or computer/projector will all work

• Each person can offer one idea per turn– Avoiding “shout outs” keeps all participants actively

involved

• People can pass on one turn but come back in later if they think of something– Someone else’s idea may trigger a new idea later on

• When everyone passes on a turn, the session is over• Compile the idea list for future use

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Determining ComplexityConstraint: 0 1 2 3 Total

Technical Difficulty The opportunity is a single problem that is well understood

The opportunity is a made up of a number of problems some of which are well understood

The opportunity is a made up of a number of problems none of which are well understood

The opportunity is made up of problems that we have applied rigorous analysis to but still don’t understand

Resources Needed to Deliver Savings

Internal Internal plus local suppliers/contractors

External within supply chainExternal within supply chain & external suppliers/contractors

Time Needed to Realize Savings

<3 months 3-6 months 6-9 months >9 months  

Level of Capital/Expense Required

Expense Only <$100,000 Capital (Richter Approval only)

>$100,000 and <$1,000,000 Capital

>$1,000,000 Capital  

**Assess the constraint against the criteria on the right & apply the score in the "Total" column which best describes it. After scoring all 4 constraints, total up the complexity score at the bottom & apply to the O&A column 0. 0

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• Tar Heel Combined Ideation List.xlsx

INPUT/OUTPUT

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Critical Control PointsWastewater Operations

• Critical Control Points (CCP) are areas in a process where something is measured to determine

• Examples of CCPs in a wastewater system are:– Flow– pH– Turbidity– Oxygen Concentration– MLSS– Chemical Feed

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• Grayson\2013 Critical Controls Grayson052413.xlsx

CCP Example – Grayson, KY

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Plant Manager Training• What is EMS• Benefits of EMS• Goals of EMS• Key Components of EMS

– Roles– Environmental Aspects– Training– Communication– Controls– Monitoring & Measuring– Corrective Actions

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Plant Manager Training• Reviewed NOVs• Identified Root Causes

– Mechanical– Program Execution

• Corrective Actions– Equipment Upgrades– Equipment PMs in SAP– Identify Critical Spares– Improve EMS Training– Improve Awareness– Improve Participation– Improve Communication– Weekly Calls with PM

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Weekly Environmental/Sustainability Call

• Held each Tuesday qt 1130– VPs, Plant Managers, ECs

• Agenda– NOVS– Spills/Releases– SMS Events– Regulatory– ISO 14001– “SOP Of the Week”

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PMs in SAP

• Prior top SAP, PMs were in Tab Ware• Included

– Air Pollution Control Equipment for Title V Compliance

– Weekly/Monthly Inspections for SWPPP and SPCC compliance

– WW Equipment

• Quick transition to SAP resulted in these items not being programmed into SAP

• Ongoing effort to migrate these items and more into SAP