ANNUAL ENVIRONMENTAL REPORT 2016 For Arrow Group, The Maudlins Industrial Estate

52 Pages·2017·0.92 MB·English

ANNUAL ENVIRONMENTAL REPORT

2016

For

Arrow Group,

The Maudlins Industrial Estate,

Naas,

Co. Kildare

IE Licence No. P0812-01
Arrow Group Annual Environmental Report 2016
Table of Contents

1 INTRODUCTION............................................................................................................3
1.1 COMPANY DETAILS.................................................................................................…3
2 ENVIRONMENTAL POLICY.......................................................................................4
3 SITE DESCRIPTION ......................................................................................................5
3.1 PREVIOUS SITE HISTORY ..............................................................................................5
3.2 COMPANY BACKGROUND ............................................................................................5
3.3 DESCRIPTION OF EQUIPMENT ......................................................................................5
3.4 MANUFACTURING PROCESS ........................................................................................6
4 MONITORING SUMMARY ..........................................................................................8
4.1 FOUL SEWER EMISSIONS .....................................................................................8
4.2 STORM WATER EMISSIONS .......................................................................................10
4.3 EMISSIONS TO AIR ....................................................................................................12
4.4 NOISE EMISSIONS………………………………………………………….......14
5 WASTE MANAGEMENT ........................................................................................... 21
6 RESOURCE CONSUMPTION ....................................................................................28
6.1 ENERGY ....................................................................................................................28
6.2 ENERGY EFFICIENCY ...................................................................................…..28
7 ENVIRONMENTAL INCIDENTS & COMPLAINTS .............................................30
7.1 ENVIRONMENTAL INCIDENTS ....................................................................................30
7.2 ENVIRONMENTAL COMPLAINTS ................................................................................30
8 EPA INSPECTIONS AND NON-COMPLIANCES ..................................................34
8.1. EPA SITE INSPECTIONS/AUDITS……………………………………………. 34
8.2 NON-COMPLIANCES……………………………………………………….......34
9 MANAGEMENT OF THE ACTIVITY ......................................................................37
9.1 ENVIRONMENTAL MANAGEMENT PROGRAMME (EMP) REPORT ..............................37
10 TANK AND PIPELINE TESTING AND INSPECTION REPORT ........................38
11 REPORT ON THE EFFICIENCY OF USE OF RAW MATERIALS……….…….38
12 PROGRESS MADE TO MINIMISE WATER DEMAND………………………….38
13 REVIEW OF RESIDUAL MANAGEMENT PLAN……………………………….. 39
14 ENVIRONMENTAL LIABILITIES RISK ASSESSMENT REVIEW…………….39
15 SLUDGE REGISTER………………………………………………………………… 39

Table 4.1.1 Results of WEP2 Monitoring carried out by the Arrow Group 2016….……........8
Table 4.1.2 Results of Foul Sewer Monitoring by the EPA 2016.…………...…………….. ..9
Table 4.2.1 Results of SEP1 Monitoring carried out by the Arrow Group 2016…………….10
Table 4.3.1 Results of Atmospheric Emissions Monitoring by Air Scientific.........................12
Table 4.3.2 Results of Atmospheric Emissions Monitoring by Fitz Scientific…….………...12
Table 4.4.1 Methodology for Determination of Site Specific Noise…………………….…...15
Table 4.4.2 Specific Noise Levels………………………………..…………………………...16
Table 5-1 Details of Waste Disposal for 2016……………………………………………......22
Table 5-2 Details of Hazardous Waste Disposal for 2016…………………………………....26
Table 6-1-1 Details of Energy Consumption (2009 to 2016)…. ............................ ………… 28
Table 6-1-2 Details of Water Consumption (2009 to 2016)………………………………….28
Table 6-2-1 Energy Efficiency per unit of production…………………………….…………28
Table 7-1 Summary of Environmental Incidents .....................................................................31
Table 7-2 Summary of Complaints ..........................................................................................32
Table 8-2-1 Additional Non-Compliances issued in 2016…………………………………...35
Arrow Group Annual Environmental Report 2016
1.0 Introduction
1.1 Company Details
Company Arrow Group
Address The Maudlins Industrial Estate
Town Naas
County / City Co. Kildare
IE Classification 7.8 (a) (b): Food Manufacturing
Description of Classification “The treatment and processing, other
than exclusively packaging, of the
following raw materials, whether
previously processed or unprocessed,
intended for the production of food or
feed from: only animal raw materials
(other than exclusively milk) with a
finished product production capacity
greater than 75 tonnes per day; For the
purposes of clause (a), packaging shall
not be included in the final weight of the
product. Clause (a) shall not apply where
the raw material is milk only”.
Employees 880
Contact Name Ms. Eibhlis Crowley
Position Environmental Manager
Telephone [phone]
Fax [phone]
Email [email protected]

IE Registration Number P0812-01

It shall be noted that all information contained herein, refers to the period from January 2016
to December 2016, unless otherwise specified. Please note that Vitner Products ceased
operating on the Arrow Group site on the 5th January 2012. The information and data
outlined in this report will refer to the other five companies operating on the site.

The Arrow Group now operate under an Industrial Emissions Licence since the 16th
December 2013. The IPPC Licence was amended to conform with the provisions and
requirements of Council Directive 2010/75/EU.

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Arrow Group Annual Environmental Report 2016
2.0 Environmental Policy
Section No.: 3 The Arrow Group, Issued By: Env. Department
Date of Issue: 2nd March 2015 The Maudlins, Approved By: Eibhlís Crowley
Rev. No.: 02 Naas, Page: 1 of 1
Co. Kildare
ENVIRONMENTAL POLICY

The Arrow Group based at the Maudlins Industrial Estate in Naas is made up of five separate food manufacturing activities specialising in the
manufacture and supply of meat products, pasta products and soup stocks The companies operating under the Arrow Group include Dawn Farms Plants
1 and 2, Meat & More, Simply Soups and Pasta Concepts.

It is the policy of the Arrow Group to ensure that our business practices protect the environment of our customers, our employees and the
community in which we operate.

The Arrow Group have developed and adopted the following principles:

 Continual assessment of the aspects and impacts of our activities, functions, products and services.

 Adopting appropriate measures to manage and continuously improve environmental performance throughout all aspects of our business.

 Minimise the environmental impact of our activities and processes on all environmental media through good environmental practices and
setting of objectives and targets which include targets relating to emissions to air, water and land.

 Prevent pollution by continuously monitoring and assessing our activities.

 Monitor / minimise our use of natural resources such as oil, energy and water.

 Minimise packaging and raw material usage, avoid waste and recycle / reuse where possible.

 We will adhere to all applicable Local and EU environmental legislation and will maintain close liaison with all regulatory authorities.

 Promote environmental awareness amongst employees, customers and contractors through training and involvement with our

environmental programmes.

 Ensure that our Environmental policy is communicated to all employees and contractors and is made available to the public.

 The Arrow Group is committed to reducing our carbon footprint and associated greenhouse gases through reduced energy consumption

and the installation of energy efficient technology.

The above principles are met through an Environmental Management System based on ISO 14001.

Signed: ________________________________ Date: _______________________________

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Arrow Group Annual Environmental Report 2016
3.0 Site Description
3.1 Previous site history
The site was originally a greenfield site before any development took place. The first
company to be set up was QK Coldstores in 1981. In 1991 the site was further developed
with Dawn Farms being established. QK Meats was founded in 1992 with the site being
further developed. In 1993 International Meat Ingredients (now referred to as Dawn Farms
Plant 2) was set up, with Simply Soups following in 1994. Finally in 1996 Pasta Concepts
was established with further development taking place on site. Throughout the years the site
has undergone development and modification. In June 2008, the site was granted an IPPC
licence under the Arrow Group name. The licence changed to an Industrial Emissions
Licence in December 2013 to comply with the Industrial Emissions Directive 2010/75/EU.

3.2 Company background
Arrow Group is now comprised of five different companies operating on their site at the
Maudlins Industrial Estate, Naas, Co. Kildare. These five companies are as follows:
 Dawn Farm Foods Plants 1 and 2
 Simply Soups
 Meat & More
 Pasta Concepts

Each company is involved in the production or preparation of processed foods, with each
company operating independently of each other.

3.3 Description of equipment
The main energy consuming equipment is as follows:
 Refrigeration Plant (mainly compressors). Heaviest user of refrigeration is freezers,
voltator and room coolers
 Cookers – these use gas, steam and electricity
 Odour Abatement Systems
 Chargrillers
 Production equipment – specifically blenders, decanter, grinders and Rising Film
Evaporator
 Armor Inox (Water bath cooking system)
 Boilers
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Arrow Group Annual Environmental Report 2016
 Large Motors
 Air Compressors

3.4 Manufacturing process
Due to the nature of the site, with five plantsoperating slightly different manufacturing
processes, each company will be undertaken individually to describe the manufacturing
process:

Dawn Farm Foods:
Dawn Farms Plant 1 specialise in the production of individually quick frozen (IQF) and
chilled cooked meat ingredients for supply to ready meal manufacturers, frozen and chilled
pizza manufacturers, the sandwich industry and the foodservice sector. They also supply a
range of delicatessen meat and ready to eat snack products to the retail and foodservice
sectors.
Dawn Farms Plant 2 is involved in the preparation of cooked meat ingredients, primarily
fermented meat products for use as Pizza Toppings. Pepperoni and Salami products are
available in a range of diameters, presliced or in stick form.

Simply Soups:
Simply Soups produce a range of chilled and frozen natural stocks as an ingredient in the
soups / sauces and ready meals industry. The stocks are simmered gently and then reduced to
the required percentage of solids (Brix level) by evaporating the liquid to the required brix.
The evaporation process is a reduction method under vacuum where the evaporated water is
condensed in an enclosed system.

Meat & More:
Meat & More specialises in protein based “Ready to Cook” meal solutions across all 4
species for the wholesale and retail marketplace.

Pasta Concepts:
Pasta Concepts is engaged in the manufacture of frozen pasta components/sauce for supply to
the food service industry and ready meal manufacturers in the UK and mainland Europe. The
company’s products – principally filled pastas such as ravioli and cannelloni – are supplied to
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Arrow Group Annual Environmental Report 2016
manufacturers who typically place them in trays with other ingredients such as sauces for
onward supply to the retail trade, restaurants and other outlets.

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Arrow Group Annual Environmental Report 2016
4.0 Monitoring Summary
4.1 Foul Sewer Emissions
Please refer to Table 4.1.1 below for weekly monitoring results for the period 1st January
2016 to 31st December 2016. The sampling point for effluent discharge is as follows:

 WEP2- discharge to local authority sewer from waste water treatment plant

The samples were analysed by T.E. Laboratories in Carlow.

Table 4.1.1 Results of WEP2 Monitoring carried out by the Arrow Group in 2016

ELVs as
per IPPC
Licence
70 400 760 15 10 6 - 9 600 20
mg/l (from
1st June
2009)
Max
Allowable 84 480 912 18 12 6 - 9 720 24
Limit
Ammonia Oils, Fats & Suspended Total
Date BOD COD Orthophosphate
as (N) Greases pH Solids Phosphorous
Sampled (mg/l) (mg/l) (mg/l)
(mg/l) (mg/l) (mg/l) (mg/l)
07/01/2016 0.21 13 83 8.1 < 2 7.2 36 16
14/01/2016 <0.08 5 37 6.8 < 2 7.2 19 10
21/01/2016 0.18 34 68 12 < 2 7.8 34 18
*26/01/2016 1.0 5 40 4.3 6 7.4 8 6.3
04/02/2016 0.13 9 62 4.2 5 7.1 24 10
11/02/2016 <0.08 6 49 5.2 5 7.3 23 6.8
18/02/2016 <0.08 7 62 6.7 < 2 7.7 35 8.5
25/02/2016 <0.08 8 71 9.8 < 2 8.5 39 14
03/03/2016 <0.08 12 49 5.9 2 7.2 27 7.8
10/03/2016 0.10 6 53 6.2 < 2 7.4 25 6.8
16/03/2016 <0.08 16 89 5.8 8 7.7 64 9.0
24/03/2016 <0.08 15 64 5.1 6 7.6 32 8.8
31/03/2016 <0.08 17 93 3.9 8 7.6 12 5.0
07/04/2016 0.08 12 54 8.9 < 2 7.6 24 10
14/04/2016 <0.08 10 57 7.8 < 2 7.7 31 7.8
21/04/2016 < 0.08 12 54 6.6 < 2 7.6 28 8.3
28/04/2016 0.13 32 85 6.7 < 2 7.0 47 14
05/05/2016 <0.08 2 57 9.0 < 2 7.2 32 14
*12/05/2016 <0.08 5 52 9.8 < 2 7.1 12 11
19/05/2016 0.09 11 50 7.6 < 2 7.0 16 8.3
26/05/2016 0.13 < 2 69 12 2 7.8 29 15
02/06/2016 <0.08 8 66 14 < 2 7.9 19 15
09/06/2016 1.1 9 80 15 < 2 7.8 32 17
14/06/2016 <0.08 6 65 11 < 2 7.8 15 12
23/06/2016 0.15 6 59 9.0 < 2 7.6 24 9.6
30/06/2016 0.22 15 86 11 7 7.7 40 27
07/07/2016 <0.08 5 38 11 < 2 7.7 13 21
14/07/2016 <0.08 5 61 13 6 7.6 20 13
21/07/2016 0.09 7 242 15 9 7.5 120 16
28/07/2016 <0.08 4 47 13 4 7.4 14 14
04/08/2016 3.5 7 76 13 < 2 6.3 31 17
11/08/2016 0.12 5 65 8.6 < 2 7.4 24 11
18/08/2016 0.17 6 50 3.7 < 2 7.4 23 7.3
25/08/2016 < 0.08 4 46 8.0 < 2 7.3 13 9.5
01/09/2016 1.1 9 71 12 6 7.4 23 14
08/09/2016 0.84 27 144 14 < 2 7.3 63 17
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Arrow Group Annual Environmental Report 2016
15/09/2016 1.1 13 133 8.2 < 2 7.3 55 12
22/09/2016 0.11 6 110 12 < 2 7.3 74 12
29/09/2016 0.33 4 67 14 8 7.6 11 16
06/10/2016 0.14 9 78 11 < 2 7.4 14 13
13/10/2016 0.15 3 44 9.0 7 7.3 6 9.0
20/10/2016 0.20 8 50 15 9 7.4 17 18
27/10/2016 0.12 3 49 15 8 7.2 11 21
03/11/2016 0.09 7 59 12 < 2 7.4 16 14
10/11/2016 0.58 15 101 7.7 4 7.3 48 11
17/11/2016 0.09 28 135 10 2 7.3 61 12
24/11/2016 2.3 24 170 12 5.9 7.2 80 9.8
01/12/2016 0.51 15 125 7.8 8 7.4 31 11
08/12/2016 46 81 327 17 3 7.5 73 21
15/12/2016 21 19 174 15 < 2 7.5 50 18
22/12/2016 < 0.08 36 135 14 4 7.1 29 18
*The Arrow Groups results of split samples taken by Agency personnel on various dates in 2016

In addition to the above monitoring schedule, the EPA also sampled the effluent discharge
from WEP2 on the 26th January 2016 and the 12th May 2016. Results can be seen in Table
4.1.2 below. Split samples were taken on these dates and analysed by both the EPA and T.E.
Laboratories on behalf of the Arrow Group.

Table 4.1.2: Results of Foul Sewer Monitoring carried out by the EPA in 2016
ELV's as
per IPPC
Licence
70 400 760 15 10 6 - 9 600 20
mg/l (from
1st June
2009)
Ammonia Orthophosphat Oils, Fats & Suspended Total
Date BOD COD
as (N) e Greases pH Solids Phosphorous
Sampled (mg/l) (mg/l)
(mg/l) (mg/l) (mg/l) (mg/l) (mg/l)
Results
26/01/2016 1.0 5 40 4.3 6 7.4 8 6.3 from Tel
Labs
Results
26/01/2016 3.0 <4 69.0 7.8 NS 7.3 <5 9.1 from
EPA
Results
12/05/2016 < 0.08 5 52 9.8 < 2 7.1 12 11 from Tel
Labs
Results
No
12/05/2016 0.038 31.0 3.5 NS 7.64 14 4.4 from
Reading
EPA

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Arrow Group Annual Environmental Report 2016
4.2 Storm Water Emissions
The licence requires storm water emissions to be monitored on a weekly basis for a number
of parameters. Please refer to Table 4.2.1 below for weekly monitoring results for storm
water emissions. The samples are analysed by T.E. Laboratories in Carlow.

Table 4.2.1 Results of SEP1 Monitoring carried out by the Arrow Group in 2016

Ammonia as NH4 COD BOD Conductivity pH
ELV < 2 mg/l 10 mg/l 1000µs/cm 6 - 9
Warning Limit 1.6 50 8 950 7 & 8.4
Action Limit 1.8 80 9 980 6.7 & 8.8
07/01/2016 0.29 8 < 2 667 7.5
14/01/2016 0.56 9 < 2 966 7.7
21/01/2016 0.51 16 6 781 7.9
26/01/2016 < 0.10 58 29 315 7.5
*26/01/2016 0.34 70 32 352 7.5
04/02/2016 0.13 17 5 747 7.7
11/02/2016 < 0.10 22 7 707 7.0
18/02/2016 0.63 19 4 700 7.7
25/02/2016 0.91 18 7 728 7.6
03/03/2016 0.42 < 4 < 2 559 7.6
10/03/2016 0.64 7 657 7.2

16/03/2016 < 0.10 19 670 7.7
24/03/2016 1.4 24 410 7.4

31/03/2016 0.66 43 714 7.6

07/04/2016 0.80 14 5 697 7.8
15/04/2016 0.81 19 288 7.0

21/04/2016 1.0 7 690 7.8

28/04/2016 <0.10 48 462 7.6

05/05/2016 <0.10 17 4 775 7.5
12/05/2016 0.93 18 550 7.5

*12/05/2016 0.92 < 20 607 7.8

19/05/2016 0.34 29 141 7.4

26/05/2016 1.2 42 690 7.7

02/06/2016 1.4 19 11 814 7.6
09/06/2016 0.5 19 797 7.7

14/06/2016 0.68 12 279 7.6

23/06/2016 1.2 19 678 7.9

30/06/2016 1.0 14 305 7.6

07/07/2016 1.3 44 13 407 7.3
14/07/2016 <0.10 10 608 7.7

21/07/2016 1.2 31 671 7.6

28/07/2016 0.48 28 511 7.4

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