Kepak Clonee - P0167-02 Annual Environmental Report · PDF fileKepak Clonee Annual Environmental Report Page 1 All the data and information presented in this report has been checked

3/27/2017

KEPAK CLONEE - P0167-02 ANNUAL

ENVIRONMENTAL REPORT 2016

Kepak Clonee Annual Environmental Report

Page 1

All the data and information presented in this report has been checked and certified as being accurate. The quality of the information is assured to meet licence requirements. __________________________ Mark Gethings EHS Manager Kepak Clonee 27/03/2017


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1. Company Details ....................................................................................................................................................... 4

2. The Environmental Policy of Kepak (Clonee) Ltd ................................................................................................ 5

Principles ............................................................................................................................................. 5

Actions ................................................................................................................................................. 5

3. Overview .................................................................................................................................................................... 6

4. Environmental Management ................................................................................................................................... 6

5. Schedule of Objectives and Targets ................................................................................................................... 7

Five Year Objectives & Targets ........................................................................................................... 7

6. Environmental Management Programme (EMP 2015 Report) ........................................................................... 8

7. Environmental Management Programme (EMP 2016) ...................................................................................... 10

List of targets for the year 2016……………………………………………………………………………10

8. Resource Consumption Summary......................................................................................................................... 11

9. Emissions to Sewer CE-1 – Fingal County Council Sewer .................................................................................. 12

Licence and Emission Limit Values ................................................................................................... 12

Volume ............................................................................................................................................... 12

10. Sewer Emissions from the Installation................................................................................................................ 13

Quality of Final Effluent. ................................................................................................................... 13

Summary of Effluent Results for 2015 ............................................................................................... 15

11. Emissions to Air .................................................................................................................................................... 18

12. Surface Water Monitoring ................................................................................................................................... 21

13. Reporting ............................................................................................................................................................... 22

14. Energy Efficiency Audit Report Summary ........................................................................................................ 22

15. Waste Management Record ................................................................................................................................. 23

16. Complaints Summary........................................................................................................................................... 24

17. Noise Monitoring Report Summary .................................................................................................................... 24

18. Ambient Monitoring Summary ........................................................................................................................... 24

19. Tank and Pipeline Testing and Inspection Report ............................................................................................ 24

20. Reported Incidents Summary .............................................................................................................................. 25

21. Proposed Energy Saving Projects ....................................................................................................................... 25

22. Efficiency of Use of Raw Materials in Processes and the Reduction in Waste Generated ............................. 26

Water Consumption ........................................................................................................................... 26


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Electricity Usage ............................................................................................................................... 26

23. Report on Progress Made and Proposals Being Developed to Minimise Electricity Demand ....................... 27

Proposed Water and Electricity Saving Projects ............................................................................... 27

24. Review of Residuals Management Plan .............................................................................................................. 28

Equipment & Machinery .................................................................................................................... 28

Building Materials ................................................................................Error! Bookmark not defined.

Oils and Chemicals ...............................................................................Error! Bookmark not defined.

25. Statement of Measures in Relation to Prevention of Environmental Damage and Remedial

Actions (Environmental Liabilities) .......................................................................................................................... 28

26. Report on progress made and proposals being developed to minimise water demand and the

volume of trade effluent discharge. ........................................................................................................................... 28

APPENDIX 1 .............................................................................................................................................................. 29


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Company Name: Kepak (Clonee) Licence Register Number: P0167-02 NACE Code 1011 Address: Clonee Co. Meath Class of activity: 7.4.1: Food and Drink

Processing and preserving of meat. Operation of a slaughterhouse with a carcass production capacity greater than 50 tonnes per day.

Site Manager: Claire Donoghue Technical Manager: Dearbhla Shanahan Maintenance Manager: Danny Graham EHS Manager: Mark Gethings


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Kepak Clonee recognises that environmental management forms an integral part of our business. Responsible environmental management enhances our business and activities. We are committed to the protection of the environment and the well-being of the community in which we operate. We will use clean and efficient processes at all stages of our production, continually monitor energy costs, minimise waste and reduce impact on the environment. We will continually seek to improve our environmental performance.

We have developed and will strive to improve our Environmental Management System so that all activities on the site are managed and controlled in an environmentally responsible manner. We will make available to the public and customers, information on our environmental performance including information to and from the Environmental Protection Agency and Local Authorities. We will train and develop our staff and contractors in the best environmental and health and safety practices. We will comply with all environmental regulations as laid down by the EPA in the Acts of 1992 and 2003, directive 96/61 EC and other regulatory bodies, and co-operate fully with such bodies. All new activities, products and processes shall be assessed to identify and eliminate possible environmental impacts. Site response procedures are established to prevent accidental emissions of materials or energy on the site. In addition, corrective action procedures are established in the event of detection of non-compliance with this policy. Recycling of waste will be carried out wherever possible to aid us in our efforts to minimise and reduce waste. _____________ Claire Donoghue (Site Manager)


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This is the company’s 16th Annual Environmental Report. This report relates to the environmental performance of the company for the year ending 31st December 2016. It has been compiled as per the EPA’s revised Guidance Notes for Annual Environmental Reports. The company is located on the N3 at Clonee, Co. Meath. GPS 53.412077, -6.433042. The IPPC licence was granted on the 10th October 2007 under section 90(2) of the Environmental Protection Agency Acts, 1992 and 2003. During 2016, the company continued to improve compliance with conditions in its Industrial Emission P167-02.

The Site Manager is responsible for the implementation of the Environmental Policy, overall environmental management of the site and allocation of resources. The EHS Manager is responsible for the day-to-day environmental operations and monitoring of the site, and the management of the Industrial Emissions licence. The Maintenance Manager is responsible for the day-to-day plant operation of the wastewater treatment plant and other abatement systems on the site. Environmental Management Chart:

Claire Donoghue

Site Manager

Danny Graham

Maintenance Manager

Dearbhla Shanahan

Technical Manager

Mark Gethings

EHS Manager

Eimear Reilly

Environmental Consultant

Production Managers

QA


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Licence Objectives Date Licensee targets

WWTP performance parameters to adhere to IPPC license

2013-2018

Consistent IPPC adherence by means of o Daily verbal communications between Environmental

Officer and WWTP operators. o Good operating procedures using the WWTP Manual o Regular consultation with R.E.C o Environmental Officer continues to analyse and review

daily sample analysis and lab results.

Control of Fugitive odorous emissions to air

2013-2018

Close communication with neighbours. The Environmental Officer has been designated to liaise with the local community. Environmental Officer is responsible to ensure odours from the site are controlled. The bio filter will be monitored and managed in accordance with the IPPC licence.

Reduction in water consumption 2013-2018

2013-2018. To reduce consumption relative to production levels. o Monitoring water consumption per unit per department

daily. o Maintenance to reduce water wastage through leaks. o Production to reduce water wastage through processes. o Monthly continuous improvement meetings which

include water reduction projects.

Stability in Electricity Consumption 2013-2018

2013-2018. To reduce consumption relative to production levels. The monitoring & targeting system is installed. It enables monitoring of individual areas of consumption of electricity in each department. Casey Technology is now contracting on efficient energy management with Kepak Group. ISO 50001 standard is achieved for Kepak Clonee. Carry out quarterly energy audits to identify area of improvements. Site plan to install solar panels on site.

Increase Recycling Quantities & Reduce landfill waste

2013-2018

o To increase use of usable plastic trays o To increase the amount of cardboard being recycled o To increase the amount of plastic being recycled o To increase amount of Dry Recycled Goods being

recycled

Environmental Incidents 2013-2018

There was no environmental incidents in 2016 o Target to maintain zero environmental incidents year

on year.

Environmental Reporting 2013-2018 Submit all environmental reports in a timely manner.


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Kepak Clonee is committed to the responsible environmental management and the operation of its business activities in an environmentally responsible manner. Targets were outlined in the EMP 2016 (AER 2015) to improve the environmental performance of the company. The EMP details the environmental improvements which the company propose to implement in the coming 12 months with the Agencies approval. The progress of these targets was as follows:

Target Time Achievements

To ensure compliance with all license limits as per license IE P0167-02.

Jan- Dec 2016

Daily sample analysis to ensure compliance with all license limits as per

license P0167-02. There were no breaches to any

of license limit. No breach to ELV was noted.

To reduce consumption of energy resources trough energy saving projects throughout the Kepak

Clonee site.

Jan- Dec 2016

Continuous Improvements Projects. 2 Energy projects

completed in 2016. ISO 50001 accreditation

retained in September. LED lighting installed in

20% of the factory and on-going.

Control of Fugitive odours emissions to air.

Jan- Dec 2016

Daily odour monitoring. Environmental officer is

responsible to ensure odours from the site are

controlled.

Reduction in water consumption.

Jan- Dec 2016

Continuous water consumption monitoring and leaks repairs. Weekly water usage comparison.

Stability in Electricity Consumption

On-going focus on stability over the next 5 years.

Electricity usage reduction. Changes in customer specification have impact in energy

usage- Contracting Casey Technology group wide to

look after long term energy plan.

Increase Recycling Quantities & Reduce

landfill waste. Jan- Dec 2016

Project completed in 2015. New recycling

service provider. More focus on waste


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segregation.

Environmental Incidents- to focus on zero target for environmental incidents.

Jan- Dec 2016

There was no environmental incident

noted in 2016.

Environmental Reporting- ensure that all

environmental reports are submitted in timely manner to the EPA.

Continuous All reports submitted on

time.

Reduce hot water usage in the Abattoir

Jan-Dec 2016

Unnecessary sterilisers removed from area. Water

usage reduced and UV sterilisation being trialled.

Reduce cold water usage for truck wash.

Jan-Dec 2016 Continuous Improvement

Project.

Chill performance monitoring.

Jan-Dec 2016

Weekly energy usage review. Daily check to

ensure most efficient chill usage.


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Kepak Clonee is aware of its responsibility to protect the environment. As a result we are committed to fulfilling its environmental obligations to preventing pollution to our environment according to the Best Available Techniques (BAT) regulations. The company is committed to fulfilling its environmental obligations and being responsible to the community in which it operates. Kepak Clonee believes that responsible environmental management is good business practice. We will use the Kepak Clonee EMP to ensure waste minimisation, IPPC adherence and to minimise the adverse effect on the environment of our activities. In 2016 numbers of projects were in place to ensure energy & water is used in the most efficient manner. Energy projects 2016:

LED lighting installation in 20% of factory Site energy reduction project Trial of UV sterilisers to reduce hot water usage A site management plan of installing solar panels in the next 3 years

This document outlines the different areas being addressed, setting targets, the means and time within which they will be achieved and designating responsibility to achieving these targets.

Ensure compliance with license limits as per Industrial Emission license P0167-

02

Jan- Dec 2017

Ensure all environmental reports are submitted on time to the EPA.

Jan- Dec 2017

To maintain ISO 50001 Standard Jan- Dec 2017 To achieve ISO 14001 standard Jan- Dec 2017 Continue to increase quantity of

recyclables and reduce landfill waste. Jan- Dec 2017

Continue to reduce energy consumption across the site through saving projects.

Jan- Dec 2017

Continue to focus on zero targets for environmental incidents and odour

complaints.

Jan – Dec 2017

WWTP performance parameters to adhere to IPPC license

Jan- Dec 2017

To reduce hot water consumption by 50%

Jan – Dec 2017


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Clonee Electrical Comparison

Natural Gas usage

Kepak Clonee Water Intake


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All waste water from production areas passes into onsite waste water treatment plant. The treated effluent discharges to the Fingal County Council Sewer. The following table is a list of the discharge emission limit values granted in the licence:

Parameter Emission Limits

from 1st May 2010

Quantity/Time period Total KGs - 2016

Flow 1,300 m3/Day 100 m3/Hour 140,467 m3

BOD 1,500 mg/Litre 1,950 kg/Day 69815.16 kg

COD 3,000 mg/Litre 3,900 kg/Day 107563.53kg

Suspended Solids 1,125 mg/Litre 1,462.5 kg/Day 15869.21kg

Sulphates 300 mg/Litre 390 kg/Day 4659.75kg

Phosphates 100 mg/Litre 130 Kg/Day 2276.33kg

Fats, Oils and Grease 100 mg/Litre 130 kg/Day 3285.72kg

pH Limits 6 -10 6 - 10 6.6-7.3

Detergents 100 mg/ Litre 130 kg/ day 203.13kg

Maximum Temperature 42oC 42oC --

Waste water emission to sewer CE-1 Period 2016 2015 2014 2013 2012 2011 2010 Volume

m3

126,322 M3

122,529 m3

140,467 m3

128,615 m3

134,630 m3

144,492 m3

172,557 m3

During 2016 a total volume of 126,322 m3 of waste water was treated. This is a increase from 2015. Increased/decreased water emission is mainly due to increased/decreased number of cattle slaughtered and increased/decreased rain fall comparing to previous years. There was project closed in late 2016 where water usage for power washing was reduced and further changes were made to reduce water consumption for cleaning process by purchasing new equipment for night cleaners which will cut down on water out to sewer in 2017. There has been a significant reduction in water usage in the facility since the water usage reduction programme began in 1999, in which 310,328 m3 was treated. However, changes to customer specifications and requirements will offer further challenges in the future. There have been further improvements made in certain areas, such as:


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Staff awareness and training of water usage, in addition to a zero tolerance on water wastage will help reduce volumes further. A reduction in water usage on yard area washing, by utilising steam condensate/vapour. Water recycling in green offal area. Recycled water been used to clean offal. New water meters which can shut down flow itself. Brand new washing equipment for night cleaners which focus on minimising water usage. Continuous improvement projects are continuously being implemented in order to reduce usage.

In accordance with IE licence requirements, effluent analysis was carried out on a monthly basis by an external independent laboratory. The quality of final effluent has been within license limits during the year. Kepak Clonee utilise ALT Laboratories, Boxer House, Newbridge for all external analysis. Spot check samples were carried out by the EPA and Fingal County Council during 2016. All final effluent results were within the limits.


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The wastewater treatment process at Clonee involves the following processes:

Clonee Effluent

Sump & rotary screen (1.5mm)

Covered Balancing tank (1200m3)

Primary Settlement

Solids

DAF Sludge Tank

Liquid

Belt Press

Sewer CE-1

Land spreading


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PH results were within licence limits for the year 2016 – ph range from 6.6 – 7.4 – as per results submitted on quarterly reports. All results within range 6-10.

BOD results were within licence limits for the year 2016 -all <1500 limit values

0

1

2

3

4

5

6

7

8

Kepak Clonee Effluent ph 2016

PH

0

200

400

600

800

1000

1200

1400

1600

Kepak Clonee BOD 2016

BOD

Jan- Dec 2016


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COD results were within licence limits for the year 2016– all <3000 limit value

Suspended Solid results were within licence limits for the year 2016 – all <1125 limit values

Sulphate results were within licence limits for the year 2016– all <300 limit values

0

500

1000

1500

2000

Kepak Clonee COD 2016

COD

0

100

200

300

400

Kepak Clonee Suspended Solids 2015

Suspended Solids

0

10

20

30

40

50

60

70

Kepak Clonee Sulphate 2016

Sulphate


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The Phosphate results were within licence limits for the year 2016 – all values tested were <100 license limit values

Oils, Fats and Grease results were within licence limits for the year 2016– all values were within license limit values- < 100 limit values

0

5

10

15

20

25

30

35

Kepak Clonee Phosphate 2016

Phosphates

0

20

40

60

80

100

Kepak Clonee Oil, fat, greases

Oils, fats, greases


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Boiler Emissions The air from boiler A1-1 is monitored in this report as per licence schedule B.1. and as per EPA approval. The air is released from the boilers which use boiling water to create steam to heat the heat exchangers which then supply the energy and heat to all water systems throughout the plant. Steam is released from the boilers and this is then assessed by monitoring contractors bi-annually. The air is analysed for the parameters as cited in Schedule B.1 of the licence. The first Boiler Monitoring for 2016 was carried out by Air Scientific Ltd. in May 2016.

First Half Monitoring Boiler 1 (A1-1)

Parameter Units Emission Limit Value mg/Nm3

CO mg/m3 N/A

NOx mg/m3 600

SO2 mg/m3 1700

Volumetric Flow Rate m3/h 9170

The second Boiler Monitoring for 2016 was carried out by Air Scientific Ltd. in December 2016. Results as follows:

Second Half Monitoring Boiler 1 (A1-1)

Parameter Units Emission Limit Value mg/Nm3

CO mg/Nm3 N/A

NOx mg/Nm3 600

SO2 mg/Nm3 1700


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Volumetric Flow Rate

m3/h 9170

Nitrogen oxides and Sulphur dioxide results are within limit as per schedule B’’ of IE license. All results and Air emissions Compliance Monitoring Report are available for review. Kepak Clonee continues to carry out daily environmental checks and preventative maintenance on equipment to ensure that potential fugitive emissions are identified onsite and controlled.


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Bio-filter The bio-filter from the DAF shed was monitored for the parameters as cited in Schedule C.1.1 of the licence. May:

December:


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SW1, SW2, SW3 and SW4 surface water emission points are discharged to the Tolka River. It is a licence requirement that it be laboratory tested on a monthly basis. However there may not always be flow from certain SW drain outlets. The following table is an average of results for SW1, 2016:

SW 1 2016- average Ph COD Ammonia Total nitrogen Conductivity 7.2 21 0.22 2.04 736

SW1 only flows when there is very heavy rain at the time of sampling. It takes the runoff water from the driveway leading up to the group offices and the driveway leading into the factory (relatively small catchments area). The following table is an average of results for SW2, 2016:

SW2 2016- average Ph COD Ammonia Total nitrogen Conductivity 7.5 18 0.10 12.05 877

SW2 drains water from agricultural lands to the rear of the factory. It also drains the area outside the factory dry goods store at the front of the site. The following table is an average of results for SW3, 2016:

SW3 2016 Ph COD Ammonia Total nitrogen Conductivity 7.4 30 0.53 16.1 612

SW3 drains the concreted outside at the right and front of the factory, and some of the roof areas. Laboratory test results for SW4 2016 were as follows:

SW4 2016 Ph COD Ammonia Total nitrogen Conductivity 7.3 16 0.91 2.6 238

SW4 flows into a surface water drain beside the lairage. The catchment area of SW4 is the lairage roof.


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Ground Water (Well Water) analysis was carried out by ALT as an annual requirement. Results as follows:

Result

20.06.2016 Result

20.06.2016

Parameter Well 1 Well 2 Units

Nitrate <2.2 <2.2 mg/L

pH 7.5 7.7 pH units

Conductivity 677 732 uS/cm

Ammonia 0.06 0.08 mg/L N

COD 7 4 mg/L N

Total Nitrogen

0.6 2.3 mg/L N

Total Coliforms

0 0 cfu/per 100ml

Escherichia 0 0 cfu/per 100ml

As can be seen, all parameters are within EU Groundwater Water Regulations.

A Nutrient Management Plan was compiled for lands owned by Ben Dillon, Girley, Co. Meath, for the proposed land spreading of organic waste and submitted to the agency in February 2017.

An energy efficiency audit was carried out during 2016 by Casey Technology and improvements for energy savings identified during that audit were implemented resulting in the reduction in electrical consumption through projects implemented to target energy reduction. Energy monitoring is carried out through the energy management system to closely monitor resource consumption on site and identify areas of improvement. There is also weekly energy usage review to identify any inefficiency in the system and to take actions if required. Energy efficient equipment and motors are sourced and used where possible to reduce electrical loading on site. Continuous improvement projects are utilized to identify and estimate savings and energy reductions achievable prior to projects being implemented.


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Kepak Clonee utilised the following waste handling companies for off-site waste in 2016:

Product Destination Destination Licence

No. Transporter EWC Code

Total Tonnes - 2016

Bellygrass B. Dillon N/A M. Murtagh 02 02 99 1694

Sludge B. Dillon N/A M. Murtagh 02 02 04 1202

SRM College Proteins NWCPO 08-06361-02 P. Donohue 02 02 02 3996.04

Bones College Proteins NWCPO 08-06361-02 P. Donohue 02 02 02 2394.35

Offal College Proteins NWCPO 08-06361-02 O' Donohue 02 02 99 2487.05

Waste Blood College Proteins NWCPO 08-06361-02 John Power 02 02 03

0

Bovine Blood

Regal Processors REN/241/89 Brian Kehoe 02 02 99

1007

Waste oil for recycling

Enva Ireland, Mc Anulty Specialist. W0196-01 Enva Ireland 13 02 05

1.42

Recycled Cardboard

Envirogreen/ Vincent

MC Guinness WMEX 22/113 Envirogreen 15 01 01

21.26

Recycled Plastic - Hard

Envirogreen/ Vincent

Mc Guiness WMEX 22/113 Envirogreen 15 01 02

3.48

Hard plastic

AES Environmental W131-02 AES 15 01 02

15.7

General Waste

AES Environmental W0131-02

AES Environmental 02 02 03

99.88

Wood David

Burlington 131-2 Midland Waste 20 01 38

47.62

Metal St Margaret

Recycling WCP-FG 10-00012-

01 St Margaret

Recycling 17 04 05 5.48

Dry Goods Recycling Panda Waste 140-3 Panda Waste 20 03 01

22.16

Lab vials Indaver Ireland W0167-02

WM. Cyril McGuiness

LTD 16 05 06

0.035

There were no rejected wastes. All wastes were disposed of by approved and licensed contractors. Waste collection permits, data and licences are kept on file in the technical department.


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Kepak received no complaints related to odour during 2016. Kepak Clonee received no complaints from Fingal County Council during 2016 regarding final emissions from CE-1. Results are held on file for all external analysis.

The night-time levels at all locations do not exceed the EPA Guideline levels for noise sensitive receivers when the ambient noise levels are stripped out. The day-time levels at all locations do not exceed the EPA Guideline levels for noise sensitive receivers when the ambient noise levels are stripped out. Presently Kepak Clonee does not present a noise issue in the surrounding environment in regard to LAeq daytime or night time readings. No noise complaints have been received by Kepak Clonee during 2016.

Odour checks are carried out daily as part of the daily environmental monitoring programme. Odour monitoring points are located at (i) the front gate, (ii) behind the treatment plant and the side of the Lairage, No odours have been detected outside the perimeter.

Underground CCTV pipe survey was carried out by McBreen Environmental, Co. Meath in 2016. During this survey it was noted that some cracks were evident. Repairs were carried out to the affected line. Survey report and DVDs are kept on file in Technical Office at Kepak Clonee. CCTV checks were completed during 2016 and any necessary corrective actions were implemented. Integrity testing of bunds was carried out in 2016 by Danny Graham, Maintenance Manager, Kepak Clonee. There were also monthly planned preventative maintenance pipework audits carried out by the maintenance department. Integrity tests were also completed on further bunds during 2016 and results are held on file.


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An environmental incident log is maintained in the Technical Office at Kepak Clonee. There were no environmental incidents associated with the Kepak Clonee site during 20156

Kepak Clonee is committed to delivery of quality products to our customers at competitive prices and manufactured with minimum effect on Environment. We are committed to Continuous improvements in energy performance and we use our systems as framework to achieve this by regular review and setting of our energy objectives and targets. We commit to the success of our Energy Management System including our ISO 50001 Certification and to ensure success we commit to:

1. Make available at all times the necessary information and resources to ensure that we meet our energy objectives and targets.

2. Ensure that all of the activities we undertake are fully compliant with the legal requirements and other requirements to which we subscribe relevant to our energy use, consumption and efficiency.

3. Support the purchase of energy efficient goods and services and design for energy performance improvement.

Improved energy performance is critical to our long term business and Kepak management ensure that its importance is communicated at all levels of the group. 2016 Energy saving Projects:

Chill performance review. Continuous Improvement Project. Review

current chill loading process and chilling regimes.

Reduce 85 degree water usage in abattoir up to 50%

LED light replacements all around the factory


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Environmental awareness is a top priority for Kepak which is outlined in our environmental policy. Recycling is the key in all Kepak plants. During 2015 a project was put in place to increase amount of recycled cardboard and plastic on site and to minimise landfill waste. Kepak Clonee has implemented colour coded bin system to separate clean plastic and cardboard from landfill waste. Kepak Clonee is currently under review of packaging usage. There is project in place to review current box fill to minimise usage of cardboard packaging and increase usage of plastic reusable trays however changes in customer specifications will offer further challenges in the future.

Source Unit 2016 2015 2014 2013 2012 2011 2010 2009 2008 On-site

ground water Well 1 +2

m3

118,012

144,502 154,252 162,013 121,078 162,666 157,866 161,787 185,410

There was a decrease in the water intake in 2016; this is mainly due to continuous improvement in water efficiency, identification and elimination of leaks, continuous improvement projects and changes to customer specification and a continual monitoring and reporting system.


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During 2016 further improvements were made on electricity usage in the facility however the annual electricity consumption in 2016 was increased. This was mainly due to increased number of cattle slaughtered compare to previous years and the infrastructure improvements made on-site over the year.

Over the course of 2016 Kepak will strive to reduce energy consumption. Kepak’s energy system will identify key areas of energy usage and help to find areas where energy can be saved. Our target reduction in overall energy for 2017 usage is 15-20%. The main areas to target with regards to electrical usage are Beef chills and hot water sterilisers. Kepak Clonee installed a Chochran Termax steam boiler to produce hot water using natural gas and has stopped HFO consumption. HFO boiler is now kept in stand-by mode and will be used as a backup only in event of gas boiler malfunction. 85 degree water saving in abattoir project was open in early 2016. The target is to save 3m3 per day. This will have significant reduction in water and gas consumption. Moving to UV sterilisers may be a completed project also in 2017, which will see a large reduction in energy usage on-site.


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In the event of Kepak Clonee ceases its production a decommissioning plan has been identified. This plan is in accordance with closure plan 2009.

A comprehensive Environmental Management System is in place to prevent potential damage to the environment. Remedial actions have been documented and measures put in place. This will be updated in accordance with the ELRA. The ELRA / CRAMP reports were finalised by Rowan Engineering Consultants and submitted during May 2009. The documents have been reviewed as per condition 10.2.2 and no amendments are to be made to the proposal.

A substantial reduction in water usage has been made by Kepak Clonee on reduction of water demand and volume of trade effluent being discharged to Fingal County Council. Since the monitoring programme was introduced in 1999 a 52.2% reduction has been achieved in water being discharged to sewer. During 2016 overall water consumption was decreased again like the previous year. Its IE licence in 2007 well water consumption has been reduced by 39%. In order to reduce this figure further it is proposed to introduce further water saving initiatives through good work practice and daily monitoring of water consumption in each department and utilization of new eco-friendly equipment around the factory. Kepak Clonee installed water meters in the abattoir to measure exact water usage for each work stations and to ensure water consumption will be minimized.


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| PRTR# : P0167 | Facility Name : Kepak Clonee | Filename : prtr return 2016.xls |

Return Year : 2016 |

Guidance to completing the PRTR workbook

Version 1.1.19

REFERENCE YEAR 2016

1. FACILITY IDENTIFICATION

Parent Company Name Kepak Clonee

Facility Name Kepak Clonee

PRTR Identification Number P0167

Licence Number P0167-02

Classes of Activity

No. class_name

- Refer to PRTR class activities below

Address 1 Clonee

Address 2

Address 3

Address 4

Meath

Country Ireland

Coordinates of Location -6.433664591 53.41210264

River Basin District IEEA

NACE Code 1011

Main Economic Activity Processing and preserving of meat

AER Returns Contact Name Mark Gethings

AER Returns Contact Email Address [email protected]

AER Returns Contact Position EHS Manager

AER Returns Contact Telephone Number 086022544

AER Returns Contact Mobile Phone Number

AER Returns Contact Fax Number

Production Volume 63309.0

Production Volume Units 71482

Number of Installations 1

Number of Operating Hours in Year 5610

Number of Employees 285

User Feedback/Comments Reduction in water usage due to ongoing energy reduction projects.

Web Address www.kepak.com

2. PRTR CLASS ACTIVITIES

Activity Number Activity Name

8(a) Slaughterhouses

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

Is it applicable? No

Have you been granted an exemption ? No

If applicable which activity class applies (as per

Schedule 2 of the regulations) ? N/A

Is the reduction scheme compliance route being

used ? N/A

4. WASTE IMPORTED/ACCEPTED ONTO SITE Guidance on waste imported/accepted onto site

Do you import/accept waste onto your site for on-

site treatment (either recovery or disposal

activities) ? No

This question is only applicable if you are an IPPC or Quarry site

PRTR Returns Workbook


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SECTION B : REMAINING 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

0.0 0.0 0.0 0.0

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

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: Kepak Clonee

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

POLLUTANT

RELEASES TO AIR

RELEASES TO AIR

METHOD

POLLUTANT METHOD

ADD NEW ROW DELETE ROW *


ADD EMISSION POINT

ADD EMISSION POINT

4.2 RELEASES TO WATERS Link to previous years emissions data | PRTR# : P0167 | Facility Name : Kepak Clonee | Filename : prtr return 2016.xls | Return Year : 2016 | 28/03/2017 15:26

8 9 17 17 25 25 6 9 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

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 Emission Point 2 Emission Point 3 Emission Point 4

T (Total)

KG/Year

A

(Accident

al)

KG/Year

F

(Fugitive)

KG/Year

12 Total nitrogen M

EN ISO 11905-

1:1998 2.04 12.05 16.1 2.6 32.79 0.0 0.0

76 Total organic carbon (TOC) (as total C or COD/3) M EN 1484:1997 21.0 18.0 30.0 16.0 85.0 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


RELEASES TO WATERS

Method Used

RELEASES TO WATERS

RELEASES TO WATERS

Method Used

POLLUTANT

Method Used

POLLUTANT

POLLUTANT




ADD EMISSION POINT

ADD EMISSION POINT

ADD EMISSION POINT


Page 32

4.3 RELEASES TO WASTEWATER OR SEWER Link to previous years emissions data | PRTR# : P0167 | Facility Name : Kepak Clonee | Filename : prtr return 2016.xls | Return Year : 2016 | 28/03/2017 15:26

8 10 18 23 6 6 6 6

SECTION A : PRTR POLLUTANTS


QUANTITY


13 Total phosphorus M

EN ISO 15681-1 to

2:2004 2081.11 2081.11 0.0 0.0

12 Total nitrogen M EN 12260:2003 6788.91 6788.91 0.0 0.0

76 Total organic carbon (TOC) (as total C or COD/3) M EN 1484:1997 32699.43 32699.43 0.0 0.0


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


QUANTITY


303 BOD M OTH 55877.02 55877.02 0.0 0.0

306 COD M OTH 113445.48 113445.48 0.0 0.0

314 Fats, Oils and Greases M OTH 2879.17 2879.17 0.0 0.0

240 Suspended Solids M OTH 13958.36 13958.36 0.0 0.0

308 Detergents (as MBAS) M OTH 199.91 199.91 0.0 0.0

343 Sulphate M OTH 43323.0 43323.0 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


ADD EMISSION POINT

ADD EMISSION POINT

4.4 RELEASES TO LAND Link to previous years emissions data | PRTR# : P0167 | Facility Name : Kepak Clonee | Filename : prtr return 2016.xls | Return Year : 2016 | 28/03/2017 15:26

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

ADD NEW ROW

ADD NEW ROW

DELETE ROW *

DELETE ROW *

ADD EMISSION POINT

ADD EMISSION POINT


Page 33

5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0167 | Facility Name : Kepak Clonee | Filename : prtr return 2016.xls | Return Year : 2016 |

5 20 Please enter all quantities on this sheet in Tonnes

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

Transfer Destination

European Waste

Code Hazardous Description of Waste

Waste

Treatment

Operation M/C/E Method Used

Location of

Treatment

Within the Country 15.7 wastes not otherwise specified Plastic R5 M Weighed Offsite in Ireland AES,W0131-02 Navan ,.,.,.,Ireland

Within the Country 3996.0 animal-tissue waste SRM D8 M Weighed Offsite in Ireland College Proteins,R911

Nobber Co.

Meath,.,.,.,Ireland

Within the Country 2394.35 animal-tissue waste Bones D10 M Weighed Offsite in Ireland College Proteins,R911

Nobber Co.

Meath,.,.,.,Ireland

Within the Country 1640.0 animal-tissue waste TALLOW R3 M Weighed Offsite in Ireland Walko Foods,800319 Waterford ,.,.,.,Ireland

Within the Country 1202.0 sludges from on-site effluent treatment R10 M Weighed Offsite in Ireland Murtagh,WCP/MH/2002/401

Nobber Co.

Meath,.,.,.,Ireland

Within the Country 2487.05 waste not otherwise specified OFFAL D10 M Weighed Offsite in Ireland College Proteins,R911

Nobber Co.

Meath,.,.,.,Ireland

Within the Country 1007.0 waste not otherwise specified Bovine Blood R3 M Weighed Offsite in Ireland APC Ltd,241/89 Armagh ,.,.,.,Ireland

Within the Country 1694.0 waste not otherwise specified Belly grass R10 M Weighed Offsite in Ireland Murtagh,WCP/MH/2002/401

Nobber Co.

Meath,.,.,.,Ireland

To Other Countries 5.48 iron and steel R4 M Weighed Abroad Envirogreen,WMEX 03/68

227 Battleford

Road,Armagh,Co

Armagh,BT71 7NN,United

Kingdom

To Other Countries 21.26 paper and cardboard packaging R3 M Weighed Abroad Envirogreen,WMEX 03/68

227 Battleford

Road,Armagh,Co


Kingdom

Within the Country 3.48 plastic packaging R3 M Weighed Offsite in Ireland

Panda waste

Services,W140-3

Rathdrainagh,Rathdrainagh,

Beaurparc,Meath,Ireland

Within the Country 47.62 wood other than that mentioned in 20 01 37 R3 M Weighed Offsite in Ireland Envirogreen,WMEX 03/68

227 Battleford

Road,Armagh,Co


Kingdom

Within the Country 99.88

materials unsuitable for consumption or

processing D1 M Weighed Offsite in Ireland AES,W0131-02 Navan ,.,.,.,Ireland


mineral-based non-chlorinated engine, gear

and lubricating oils R9 M Weighed Offsite in Ireland

Mc Anulty Specialist

Underground Services,W196-

1

John F. Kennedy Industrial

Estate ,John F. Kennedy

Road,Naas Road,Dublin

12,Ireland


laboratory chemicals, consisting of or

containing dangerous substances,

including mixtures of laboratory chemicals D10 M Weighed Offsite in Ireland Indaver Ireland,W0167-02

Carranstown,Carranstown,D

uleek,Meath,Ireland

Within the Country 22.16 mixed municipal waste R3 M Weighed Offsite in Ireland

Panda waste

Services,W140-3

Rathdrainagh,Rathdrainagh,

Beaurparc,Meath,Ireland

Method Used


Documents

Kepak Clonee - P0167-02 Annual Environmental Report · PDF fileKepak Clonee Annual Environmental Report Page 1 All the data and information presented in this report has been checked