1 Updated Non Technical Summary Appendix A1 Figure · PDF fileUpdated Non Technical Summary 2...

Table of Contents

1 Updated Non Technical Summary Appendix A1 Figure A.1.2 Schematic of Coolers 2 NMP 3 Emissions to Surface Water 4 Application Form Section B 5 Waste Improvements 6 Copy of Discharge Licence

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Duffy Meats LtdShillelagh

Co. Wicklow05394 29200

APPLICATION (Requested Information) DECLARATION

To Whom It May Concern,

The contents of the hardcopy forms (Requested Information) is a faithful reproduction of (i.e.identical to) the electronic files on the accompanying CD-ROM.

Yours Sincerely,

Pat Sheahan General Manager

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Kerry Foods Shillelagh August 2007IPPC ApplicationRequested InformationUpdated Non Technical Summary

1

ATTACHMENT A1

UPDATED NON TECHNICAL SUMMARY

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A1 Updated Non Technical SummaryThe Kerry Group was formally established as Kerry Co-operative CreameriesLimited in 1974, in Kerry County, Ireland. The Cooperative combined the dairyand dairy processing interests of a number of the region's dairy farms, including adairy and dairy ingredients processing plant opened in Listowel, Ireland, in 1972.In less than 30 years, the company would grow from this small provincialcreamery to one of the world's leading specialist food ingredients producers anddistributors. The introduction of the company on the Dublin and London stockexchanges in the mid-1980s made millionaires out of many of the co-op'sfounding members.

A primary component in Kerry growth was its steady expansion throughacquisition, as well as a willingness to invest in new production and otherfacilities. Through the 1970s, Kerry grew to include a large number of dairy farmsand processing plants in the counties of Cork, Killarney, Galway, and Limerick,supplying to the company's Dairy Disposal Company, established in 1974 as theoriginator of the later Kerry Foods division. By the mid-1980s, the Kerry Co-opcounted several thousand members.

In the early 1980s, Kerry began branching out from its dairy core into other foodproduct categories. An early addition was the pork products category, which thecompany entered with the acquisitions of two prominent Irish pork productsproducers, Duffy Meats and Henry Denny & Sons, both acquired in 1982. Themove into food processing raised Kerry to a prominent position in Ireland's foodindustry. By the middle of the decade, Kerry's annual sales topped IR£200million.

Principal Subsidiaries: Castleisland Cattle Breeding Society Ltd.; Dawn DairiesLtd.; Duffy Meats Ltd.; Glenealy Farms (Turkeys) Ltd.; Grove Turkeys Ltd.; HenryDenny & Sons Ltd.; Kerry Holdings Ltd.; Kerry Ingredients Ltd.; KerryAgribusiness Holdings Ltd.; Kerry Creameries Ltd.; Kerry Farm Supplies Ltd.;Kerrykreem Ltd.; Snowcream (Midlands) Ltd.; A.E. Button & Sons Ltd. (U.K.);G.R. Spinks & Co. Ltd. (U.K.); Kerry Foods Ltd. (U.K.); South West Meat Ltd.(U.K.); Henry Denny & Sons (NI) Ltd. (Northern Ireland); Kerry Group BV(Netherlands); Pegromar Sp.z. O.O. (Poland); Ciprial S.A. (France); KerryIngredients France S.A.; G.I.A.L. S.r.l (Italy); Gasparini S.r.l (Italy); KerryIngredients GmbH (Germany); Kerry Ingredients Australia Pty. Ltd.; KerryIngredients (New Zealand) Ltd.; Kerry Inc. (U.S.A.); Kerry (Canada) Inc.; KerryIngredients S.A. de C.V. (Mexico); Kerry Ingredients (S) Pte. Ltd. (Singapore).

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Kerry Foods Shillelagh is primarily a pork processing plant but also processessmall quantities of white meat. It operates within the Kerry Group. The Shillelaghplant is located in south Wicklow on the outskirts of the village of Shillelagh onlevel ground on the R725, Carlow to Gorey Regional route and the River Derry(NGR 299 290E, 167 758N). The site was developed from a green field site in1991.

See Appendix A1 Figure A1.1 for site location map.

The site installation comprises of a manufacturing plant, services, wastewatertreatment plant, storage and car parking and covers an area of approximately20,000 m2. The Shillelagh plant has developed from a green field site since 1991 and is nowthe flagship food facility in the Kerry Group and one of the largest in the country.

The plant employs approximately 1000 people from the surrounding towns &villages.

Kerry Foods Shillelagh manufactures pork products both cooked & raw & whitemeat products for supply to the domestic & UK markets.

The plant operates 24 hours a day, 6 days a week all year round. These 24hours consist of approximately 16 hours production & 8 hours clean down.The major products produced include rashers, sausages, pre packed slicedcooked meats, bulk hams, action packs, puddings and rolls producing over 500Tof product per week.

Kerry Foods Shillelagh places significant emphasis on environmental aspects ofthe business and is committed significant to environmental protection.In addition, the company places considerable emphasis on identification of waysto reduce the potential for environmental impact and this is achieved through thestructured framework of an Environmental Management System. The plants Environmental Management System (EMS) achieved certification toISO14001 in 2004 and May 2006 achieved ISO14001 accreditation to the new2004 standard.

The plants quality management system implements the company policy onhygiene and quality control.Kerry Foods Shillelagh has achieved higher level EFSIS Accreditation in 2003and is also Bord Bia accredited.

The role of training as a central function in delivering product quality, processsafety and environmental protection has been recognised by Kerry FoodsShillelagh through the implementation of a training management system inaccordance with the requirements of the Excellence Through People Standard,which is certified by FAS.

Process Description

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The major products produced include rashers, sausages, pre packed slicedcooked meats and bulk hams.

Cooked Meats Process Description

Raw materials are delivered to the site by approved suppliers. They are taken inand quality checked prior to use. These raw materials are stored in variouswarehouses & chills on site.The raw meat is deboxed and boned or trimmed and muscles are sorted into alarge bin according to a product recipe. Waste bone produced from the boningprocess is taken off site to a rendering facility for processing. Once the meat isboned and sorted to suit the different recipes it is cured using a brine solution. When the curing process has taken place the meat is filled into various pot sizesand shapes, they are racked according to cooking specifications and storedunder chilled conditions before being placed in the cookers.All products are cooked to a specified cooking programme. After cooking allproducts are cooled in a shower. The cooling shower is a stainless steel cabinetmeasuring approx 2.5 m*2.5m*3m. Freshly cooked product is removed from thesteam cookers and requires immediate cooling. This is achieved by placing theproduct racks in the coolers and through a combination of refrigeration coolingand water spraying the product temperature is reduced from approximately 80degrees to 4 degrees Celsius.A typical cooling programme would be as follows:Turn on water shower only for 20 minutesTurn off shower and refrigerate for 30 minutesRepeat above until set point of 2 degrees Celsius is achieved.Water spray is activated by turning on a water solenoid which supplies water tothe shower heads at 2.5 bar pressure. The refrigeration system consists of anumber of fans attached to a refrigeration evaporator. When the refrigeration ison the fans run and a refrigeration liquid and suction valve supply refrigerant tothe evaporator and reduces the temperature difference across the evaporator by5 degrees. This temperature difference absorbs heat from the product into theevaporation and this heat is ejected through the centralised refrigerationcondensers located on the roof of the services building. All waste water exits theshowers through a drain at its base and flows to the raw effluent sump where it istransferred to the effluent treatment plant for treatment. A schematic of theshower is outlined in Appendix A1 Figure A.1.2All cooked and cooled product are held under chilled conditions until required. The cooked meat is then depotted or stripped of all casing & racked for furtheruse. The cooked product can be roasted or smoked depending on the customerspecification. After roasting or smoking the product is cooled. It is then storedunder chilled conditions until required.

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Bulk hams are bagged and vacuum packed, weighed and labeled with allrelevant information required by the customer. They are boxed, palletised andsent to storage until dispatched to the customer.

Cooked product can also be sliced into thin slices of varying quantity, which areplaced into a plastic tray. Another length of plastic is sealed to the tray to producea modified atmosphere i.e. oxygen is removed from the pack and replaced withcarbon dioxide and nitrogen. This helps to preserve the product during its life.A label is then placed on the packaging according to customer specifications.The packs are weighed, boxed and palletised before being sent to storage. Theywill then be dispatched to the relevant customer.

Sausages Process Description

In the Sausage department fresh or frozen meat is minced. Sausageformulations are weighed into barrows. This includes ingredients and meat.Seasoning is added to the formulation and the formulation is mixed or blendedtogether. Sausage mixes / formulations are filled into bins and transferred into the fillingroom. The bins are emptied into filling machines. Prepared casings are filled withsausage mixes on line. Skinless sausage mixes are filled into prepared casingsand are then cooked to the specified temperature. Skinless sausages are cooledto the specified temperature. Sausages are linked and stacked before beingpacked / wrapped and sealed. The packs are then weighed and passed througha freezer. The wrapped product is packed into boxes, placed on pallets or placedinto trays and stored in the warehouse until dispatched to customers.

Rashers Process Description

Cured meat is delivered to the site from approved suppliers. It is then storedunder chilled conditions until required. This meat is inspected to ensure that itconforms to all quality standards and specifications. It is racked and pressed intothe required shape for slicing. The meat is then sliced into slices of varying thickness and quantity. They areplaced into a plastic tray. Another length of plastic is sealed to the tray to producea controlled atmosphere i.e. oxygen is removed from the pack and replaced withcarbon dioxide and nitrogen. This helps to preserve the product during its life.A label is then placed on the packaging according to customer specifications.The packs are weighed, boxed and palletised before being sent to storage. Theywill then be dispatched to the relevant customer.

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Cooked Poultry Process Description

Feedstock is received at Intake from Kerry Foods in Glenealy (a sister site) andstored in chills. The chicken fillets are dipped in vegetable oil prior to beingcooked on the Echo oven. On the High-Risk side the product is stacked in steelmesh trays and cooled in High-Risk chills. Once fully cooled the product ischopped into pieces and packed into gas flushed packets. The Inner fillets areseared, dipped in oil and cooked on the echo belt. They are packed into gasflushed packets. The gas mix in the packets is maintained with O2 levels below0.5% and CO2 levels between 25% and 55% to inhibit microbiological growth. The packets are metal detected on line. The packet temperatures are maintainedat <4°C. The products are then packed into cardboard boxes, palletised andbrought to despatch.

Waste Streams

Waste generated on site include waste waters, waste meat, packaging, oil,general waste, chemical waste, batteries, fluorescent tubes and other wastestreams as detailed in the content of the application.Wastewaters generated during the process are conveyed to the onsitewastewater treatment plant for processing. The final treated effluent is thendischarge to the River Derry under the discharge license L/5/98 conditions.Interceptors are also in place prior to final discharge to river. The recentintroduction of a centrifuge within the wastewater treatment process will improvethe overall final effluent quality. Waste generated in the wastewater treatmentplant includes sludge, which is landspread by a licensed contractor.

Regulation (EC) No. 1774/2002 lays down the health rules concerning animal by-products. The purpose of this regulation is to clarify and strengthen the rulesgoverning the products that may be used as part of the feed for farmed or petanimals. The regulation divides animal by-products into three categories.Category 1 (C1), Category 2 (C2) & Category 3 (C3). Kerry Foods, Shillelagh we are only concerned with C2 & C3 waste.

Therefore meat waste must be classified as follows;C2 waste is meat found on floors or meat found to be discoloured, malodorous,mouldy, or visibly contaminated. All waste by-product categorised as above mustbe transferred into bins labelled C2 – Not for Animal Consumption. This waste isthen removed from the site to a rendering facility for processing.C3 waste is waste generated that cannot be used for human consumption due tomanufacturing or packaging defects. All waste by-product categorised as abovemust be transferred into bins labelled C3 – Not for Human Consumption. Thiswaste is then segregated and removed from the site for further processing asanimal feed.

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Kerry Foods Shillelagh are members of REPAK and cardboard is recycled. Allother packaging plastic waste is currently landfilled but other options arecurrently being investigated as part of the sites waste management plan. Otherpackaging waste such as chemical drums, ingredient drums and laboratorychemical bottles are returned to the supplier where possible.

Kerry Foods Shillelagh is in operation with Chep Ltd when by wooden pallets arerented from the supplier.

Waste oil and chemicals are removed from the site by licensed contractors andare stored under the specified bunded conditions. Chemicals on site are usedmainly for cleaning and sanitisation with the exception of the laboratory chemical,which are stored in a certified bunded store.

Waste batteries and fluorescent tubes are stored in the allocated containers andremoved from site by licensed contractors.

All general waste generated during the process is landfilled.

Kerry Foods Shillelagh has achieved ISO14001: 2004 accreditation for theenvironmental management system in place, This EMS clearly identifiessignificant environmental impacts which are rated and programmes have beenput in place to continuously improve the impact they have on the surroundingenvironment.

There is a programme being undertaken to reduce energy waste throughout theprocess, which will incorporate boiler and steam generation, compressed airusage, water usage, refrigeration, lighting, ventilation and heat. This is a longterm project that forms part of the environmental management plan.

The necessary measures are taken to prevent accidental releases to thesurrounding environment. Chemicals are stored in bunded areas which are notadjacent to surface water drains. Spill kits, booms and soakage material arelocated throughout the site when chemicals & oil are stored. Employees havebeen trained on the prevention of accidental releases. Internal procedures are inplace to deal with the consequences of a release. Spill drills are completedperiodically to test response times and effectiveness of procedures.

The necessary measures to be taken for the cessation of the activity are outlinedin the Business Continuity Plan for the site.

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Economic Contribution

Kerry Foods Shillelagh is a significant employer in South Wicklow, directlyemploying approximately 1076 people. In addition to salaries and local economic contribution through purchase ofsupplies and services, significant expenditure has been made at the plant interms of new processes and modernisation.

Management Structures

Kerry Foods Shillelagh has a structured management approach to the operationof the business in terms of product quality, process control, environment,safety, training and analytical capability. Training of personnel is a key function inthe successful operation of the plant.Central to this structured approach is the quality management system, whichprovides the structured framework for operational and quality control at the plant.An environmental management system provides a similar structured frameworkfor the maintenance and improvement in the plants environmental performance.Both environmental and quality management systems are audited on an ongoingbasis by a combination of internal audits and external certification surveillanceaudits.

Management Systems Kerry Foods Shillelagh

Year Obtained Standard Certification Body2003 EFSIS Higher Level QMS EFSIS2004 ISO14001 EMS SGS2003 Excellence Through People FAS

See Appendix A1 Figure A1.3 for accreditation certificates.

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Appendix A1

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Figure A1.1

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Appendix A1 Figure A.1.2 Schematic of Cooler

REFRIGERA

TION

COOLER

AND FANS

WATER

SUPPLY

WATER

SPRAY

NOZZLE

WATER

SPRAY

NOZZLE

WATER

SUPPLY

PRODUCT

RACKS TO

BE COOLED

DRAINALL WASTE

WATER TO

EFFLUENT

TREATMENT

PLANT

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Figure A.1.3

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Kerry Foods Shillelagh August 2007IPPC ApplicationRequested InformationNo. 2

REQUESTED INFORMATION

NO. 2

CONFIRM THAT THE LAND BANKS AVAILABLE FOR THE DISPOSAL OF THE WASTE WATER

TREATMENT SLUDGE ARE ADEQUATE

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* m t d)

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Area of Interest

r- r

_I Area Of Interest Field Bwndary

Landfeeds Environmental Unit 16, Hebron Ind. Est. Kilkenny, . .

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Plots Report Code FarmC-03 Address Millbrook,

Castlederrnot, Co. Kildare

Cmrfacfs Robin or Alister

Name GmeneRobIn Phone 087-248241 9-abn Account RGOI 01 F a E m d Reference Kildare

Holding Code Address Grid Ref Farm Code 03 Millbrook, Castledennot 2736E, 1881N

Piot RGOl 01 3.78 3.78 3.8 220.6 3.5 5.3 RG0102 10.98 10.98 4.35 202.3 3.5 5.2 RGOlO3 2.8 2.8 4.4 204.3 3.5 5.2

Tot. Area ha SprdArea ha PmgA K mgA L t/ae SoilpH

RGOlM 10.23 10.23 4.4 238.25 3 5.3 RGO105 5.94 5.94 3.9 233.95 3 5.3 RGO106 7.5 7.5 4.6 218 3 5.3

RG0109 21 -6 16.34 3.65 228.27 3 5.3

RGO107 2 2 4.2 203.6 3.5 5.2 RG0108 27.82 27.82 3.85 226 3.5 5.3

RGO110 15.11 14.22 4.7 221.56 3 5.2 RG0113 7.33 7.33 3.5 205.5 3 5.25 RGOl14 12.05 9.98 3.5 205.5 3 5.25 RGOll5 3.37 2.33 3.2 218.2 2.5 5.4 RGOll6 1.96 1.93 3.3 209.1 2.5 5.4 Toiais: 132.4? 123.15 Piocs: 14

12 Febmary 2#7

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Waste Recycling by Landspreading Year: 2007

Land Owner: Gmne Robln

Map Reference: Farm Code 03

Fkld ID Total Usabb Soil P Yesl

National Grid Reference: 2736E, 1881N

Stocking Rate: NA

Crop Soil P Volume of Estimatsd P in Volume m-Farm P Applied in Total Volutw of P Reqmt On-Farm Slurry On-Farm O W a m impwtdorganlc

Returned Slurry organk waats cganlc waste waste per plol ( M a l h31

ROBltlt Date

12-Feb47 12-F-7 12-FeMl7

12-Feb47 1 2-Fe W7 12-Feb-07 1 &Few7 12-Feb-07 12$&07 IWUM1z 12-FebQ7 12-Feb-07

1 2-Fe W7

Index

m a 35.00 35.m 25.00 35.00 35.00 35-00 25.00 35.00 35.00 35.00 0.00 55-00 35.00 25-00

(kg p w 36.00 35.m 25.00 35.00 35.00 95.00 25.00 35.00 35.00 35.00 0.00

55.00 35.00 25.00

. . RGO1 01 RGOlM RG0103 RGOlW WO105 RGOlOB Re0107 RGO108 RGOloP ROO1 10 RGOlll RG0113 RGOi 14

3.7B 3.78 3.60 10.98 10.90 4.35 280 2.80 4-40 1013 10.23 4.40 5.94 5.04 3.90 7.50 7.50 4.60 2.00 2.00 42a 27.82 27.82 3.85 21.80 10.34 3.65 t5.11 t4.22 4.70 2.36 1.90 2B.m 7.33 7.33 3.50 12.05 9.98 3.50

Winter Wheal Wnter Whsd

Gmsc130kgsNlh&$r Winter Wheal Winterwheat Winter Wheal

Grass cl 30 kgs N / h W Winter Wheat m e r Wheat Wmter Wheat

Grass 4 3 0 kgs Nlhaty~ Beet

Wmter Wheal G m 4 3 0 kgs IJlha/y~

2 2 2 2 2 2 2 2 2 2 5 2 2 2

32.35 93.98 17.11

50.83 64.18 12.22

238.07 139.83 121.8B 0.00

2215.11 1 91 9.23 14.24

5006.37

87.54

0.00 0.00 0.m 0.m 0.00 0.m 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

8.58 8.56 6.1 1 8.56 8.58 8.56 0.11 8.56 8-54 8.56 0.00

302.20 192.31 6.1 1 N i l 5 3.37 2.33 310 12-Fsb-07

Total volume of organlc waste that can ba importsa on to the farm (m31

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EPA Export 25-07-2013:22:08:34

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