attachment a.1 non technical summary - … · · 2013-07-25a1 non technical summary ... safety...

Kerry Foods Shillelagh August 2006IPPC ApplicationAttachment A.1

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ATTACHMENT A.1

NON TECHNICAL SUMMARY

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A1 Non Technical Summary

Kerry Foods Shillelagh is a pork processing plant that operates within the KerryGroup. The Shillelagh plant is located in south Wicklow on the outskirts of thevillage of Shillelagh on level ground on the R725, Carlow to Gorey Regional routeand the River Derry (NGR 299 290E, 167 758N). The site was developed from agreen field site in 1991.

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

The site installation comprises of a manufacturing plant, services, wastewatertreatment plant, Microbiological & Chemical Laboratories, storage and carparking and covers an area of approximately 20,000 m2.The Shillelagh plant has developed from a green field site since 1992 and is nowthe flagship food facility in the Kerry Group and one of the largest in the country.

The plant employs approximately 1076 people from the surrounding towns &villages.

Kerry Foods Shillelagh manufactures pork products both cooked & raw for supplyto 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.

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Process Description

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. All cooked and cooled product are held under chilledconditions 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.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 being packed / wrapped and sealed.The packs are then weighed and passed through a freezer. The wrapped productis packed into boxes, placed on pallets or placed into trays and stored in thewarehouse until dispatched to customers.

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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.

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.

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.

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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.

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.

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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 A1.2 for accreditation certificates.

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Appendix A1

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Figure A1.1

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Figure A.1.2

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attachment a.1 non technical summary - … · · 2013-07-25a1 non technical summary ... safety...

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