AER 2009 - Environmental Protection Agency · M. J. Bergin & Sons Ltd._ _AER 2009 2 2: Stunning Animals enter the slaughter hall through a raised door from the race in the

M. J. Bergin & Sons Ltd._____________________________________ _______AER 2009

1

INTRODUCTION

1.1:

NAME & LOCATION OF SITE: M.J. Bergin & Sons Limited

Tanderagee

Broadford

Co. Kildare

LICENCE REGISTER NUMBER: P0192

DESCRIPTION OF ACTIVITY

1.2

M.J. Bergin & Sons Limited operates an abbatoir and boning hall for the processing of

beef and lamb. Slaughtering takes place on average three days a week while boning

takes place on average five days a week. Beef is sold both in carcase form and deboned.

Deboned beef is mainly packed for commercial sale. Lambs are sold in carcase form.

1.3: Cattle Slaughter Line

1: Lairage Yard

Cattle are transported to the lairage yard where a Veterinary Surgeon and Department

of Agricultural Officials inspect the animals for disease. All cattle identification numbers

are entered into the Department of Agricultures computer system (AIMS) for clearance

prior to slaughter. The cattle are held there for approximately 2-3 hours. From here the

cattle are directed through a race towards the stunning area.


2

2: Stunning

Animals enter the slaughter hall through a raised door from the race in the lairage. The

animals are stunned by means of a captive bolt stunner. Stunning is performed by one

captive bolt to the centre of the forehead of the beast. A door is lifted and the animal

falls onto a landing grid, at this point the operator on duty shackles the animal by the

right hind leg, attaches it to the hoist and the animal moves along to the bleed area.

3: Sticking/Bleeding Area

All animals are struck within fifty seconds of stunning. The operator at this station opens

the hide in the neck region and then bleeds the animal. He then cuts out the wizzand for

rodding and inserts a wizzand clip. The animal is bleed over a purpose built bleed table

that collects the blood and transfers it to the storage tanks located outside. The blood

storage tanks are managed by trained staff on site, that are subjected to regular

external and internal inspections.

4: Snout removal:

The operator at this station uses a knife to cut under the skin and around the complete

snout and chin to remove the skin from this area.

5: Front Hoof Removal:

Following the snouting the front hooves are removed using a hock cutter.

6: First Legging:

A strip of hide is cut from the hind leg in order to open the hide. He then inserts a knife

under the hide at the cut area and skins the leg, the cut continues to the elbow joint.

The hock cutter is then used to cut the hock at the joint. A hook is inserted into the

elbow joint and the carcass moves onto the next station.


3

7: Second legging:

The second leg is removed from the shackle and a strip of hide is cut from the hind leg in

order to open the hide. He then inserts the knife under the hide at the cut area and

skins the leg, the cut continues to the elbow joint. The hock cutter is then used to cut

the hock at the joint. A hook is inserted into the elbow joint and the carcass moves

along to the next station.

8: Upper Flanking/De-Horning:

The hide is opened at the flanks in order to prevent the skin/hide been torn during hide

removal. De-horning also occurs at this stage. The operative checks the animal for

horns which if not removed can cause tearing of the skin/hide. If horns are noted then

the operative will remove them with de-horning equipment.

9: Computerised Cattle Identification:

The operative at this station removes the ear tag from each animal and enters the

numbers into the computer system, all relevant information concerning this animal will

be displayed on the screen i.e. herd number, sex, etc. The operator prints five labels for

each animal; two are attached to the head and three to the carcase (after the hide has

been removed).

10: Hide Removal:

A mechanical hide puller controlled by two operatives removes the hide. After the hide

has been removed the breast is spilt using a breast saw.

11: Breast Splitting:

The operator at this station uses an electric saw to open the breast cavity making sure

not to tear the stomach area.

12: Head Removal

The head is labelled with the ear-tag number and is removed from the carcase at the

head removal station.


4

13: Head Wash:

After the head has been removed it is brought into the wash cubicle where the pre-

printed label for that animal is attached to the animals nostrils. The nostrils are then

washed out with the nostril washer. After washing has been completed the head is

placed on the pluck rail for inspection by the veterinary staff on duty and is deboned,

harvesting cheek meat and lips.

14: Bunging:

The operator at this point of slaughter uses a bunging bag (a bag with an inbuilt elastic

band) to seal the bung.

15: Evisceration:

The rectum is pulled out from the carcase and the tissue holding it in place is also

removed; the stomach is cut away from the liver and is transported to the green offal

room via a moving stainless steel table. The liver is removed and placed on a pluck line

for inspection by suitably qualified veterinary staff.

16: Pluck Removal:

The heart, lungs, trachea, spleen and liver are removed for Veterinary inspection.

17: Splitting of Carcase:

The carcase is split in the middle, allowing the spinal cord to be exposed. If not split

correctly, all of the spinal cord may not be exposed.

18: Spinal Cord Removal:

After the carcase has been split an operative removes the spinal cord from the open

channel and all associated fatty tissue and membrane.


5

19: Upper Trim:

The operator at this station cuts the fat from around the bung and kidney area, the fat is

removed to the fat skip via a conveyor.

20: Lower Trim:

At this stand the operator trims the lower half of the carcase, he then cuts two slits in

the carcass to facilitate the attachment of labels. The operator then removes the thin

skirt from the carcass and puts it onto the moving pluck line.

21: Grading:

This operation is carried out by a mechanical grading machine. The machine is calibrated

each morning before the kill starts.

22: Neck Trim:

The operative starts at the top of the last rib and trims the neck muscle clean.

23: Final Inspection, Upper & Lower:

At the lower inspection station the operative inspects the carcase for contamination on

the forequarter and spinal cord residues. The operator at the upper inspection stand

primarily inspects for spinal cord residue in the channel and then for contamination on

the hindquarter. Any spinal cord residue is inked and treated as Category 1 waste.

24: Scales: Weighing:

The eartag number, sex and conformation score are entered into the company

computer system. The computer records the weight and information of each carcase.

Once a final destination has been decided the operative prints a label that allows for full

traceability. The second operator attaches the labels to the carcass, one to the

hindquarter and one to the forequarter.


6

25: Cold Storage

The carcase is stored in a chill between 0 and 4 o C for an average 24 - 48 hours prior to

dispatch or boning. Two inches are left between each carcase to ensure proper cooling

takes place.

26: Boning

Carcases are brought into the boning hall and are deboned into primal cuts and trim.

Product is vacuum packed if being sold chilled or put into lined or wax boxes for freezing

if sold frozen. Deboning usually takes place within two days of slaughter.

Product is despatched by contract haulier.

27: Despatch Carcases are loaded onto refrigerated containers and despatched by contract hauliers. 1.4 Sheep Slaughter Line

1: Lairage Yard

Sheep are delivered to the sheep lairage where they are inspected for disease and all

tags checked. Sheep are retained on average for approximately 3-4 hours with a

maximum retention of 24 hours.

2: Stunning

The sheep once directed to the stunning area are stunned using an electric thong or are

killed by Halal slaughter.

3: Bleeding

The stunned sheep are hung horizontally and bled by slitting their throats with a knife.

4: Head Removal

The head is removed manually


7

5: Skin & Feet Removal

This process involves opening the skin at the breast of the animal. The skin is then

partially removed to the hind feet and then mechanically after which the front hooves

are removed.

6: Evisceration

This part of the process is carried out manually; here the stomach and intestines are

removed. They fall onto a pan and are inspected before being conveyed to the green

offal room.

7: Pluck Removal

The heart, lungs and liver are removed for further processing (Pet food).

8: Washing

After inspection the carcases are washed manually using a high-pressure cold-water

hose.

9: Grading & Weighing

The carcasses are graded according to their age, weight and confirmation.

10: Cold Storage

The carcases are stored in chills between 0 and 5 o C for an average of 24 hours before

dispatch.


8

1.5: ENVIRONMENTAL POLICY

It is the policy of M.J. Bergin & Sons Ltd. to conduct their business of animal slaughtering

(beef and lamb) in such manner that it’s activities minimise and/or eliminate any

potential adverse effects on the environment. Environmental impacts of new

developments are minimised through the use of integrated environmental management

procedures and planning.

M.J. Bergin & Sons are committed to pursing a positive policy on environmental

pollution and waste minimisation. Although the process is environmentally friendly the

company aim in the future is to maximise waste recycling both on site and by using off

site recycling contractors.

M.J. Bergin & Sons Ltd fully intends to be leaders and key drivers in the development of

environmental performance evaluation procedures and associated indicators.

The key objectives are too:

Prevent Pollution

Reduce waste and the consumption of resource i.e. fuel, energy and water

Implement a policy of recovery and recycling as opposed to landfill where

feasible.

M.J. Bergin & Sons ltd is constantly striving towards sustainable development and

recognise the increased concerns of society regarding environmental issues. The

company recognise the necessity for programmes to protect and enhance the

environment. M.J. Bergin & Sons intend to meet all statutory environmental

requirements concerning the company.

M.J. Bergin & Sons Ltd strongly encourages the use of environmental management

systems by both the company suppliers and contractors alike.


9

1.6:

ENVIRONMENTAL ORGANISATIONAL CHART

General Manager

Sean McNamara Responsibilities: Overall decision maker

Communication on Environmental

Issues between departments

Environmental Officer Quality Assurance Personnel:

Liz Quinn Liz Quinn

Responsibilities: IPC Licence, W.W.T.P. Responsibilities: Quality Assurance

Report all environmental issues to Managing Scheme, Report any possible

Director & other members of personnel environmental issues.

Production Supervisors

John Daly / Eamon Prendergast / Joe Bright Responsibilities: Day to day management of the boning hall, abbatoir and despatch.

Also informs the Environmental Officer of environmental issues

which may occur during production i.e. leaking bins, blocked drains, etc.

Maintenance Team

Liam Carter Responsibilities: Overall maintenance of the site including the W.W.T.P.

Will inform the Environmental Officer about issues that may affect the environmental

performance of the site i.e. pumps, screens etc.


10

2.0: SELF-MONITORING DATA

TABLE 1: Emissions to Water (FINAL EFFLUENT) 2009

PARAMETER

AVERAGE EMMISSIONS

(2009)

AVERAGE EMMISSIONS (Kgs)

(2009)

LICENSED

EMMISSIONS

Discharge Period

Whole Year

Discharge Period

Whole Year

pH

7.1

7.1

--

--

6-9

COD

82.0 mg/L

82.0 mg/L

861 Kgs

861 Kgs

100 Mg/l

BOD

18.2 mg/L

18.2 mg/L

224 Kgs

224 Kgs

30 Mg/l

Suspended Solids

8.7 mg/L

8.7 mg/L

101 Kgs

101 Kgs

30 Mg/l

Nitrates (as N)

7.5 mg/L

7.5 mg/L

125 Kgs

125 Kgs

40 Mg/l

Ammonia (as N)

9.2 mg/L

9.2 mg/L

89 Kgs

89 Kgs

10 Mg/l

Total Phosphorus

(as P)

1.3 mg/L

1.3 mg/L

6.8 Kgs

6.8 Kgs

2 Mg/l

Oils, Fats & Greases

10.2 mg/L

10.2 mg/L

111 Kgs

111 Kgs

15 Mg/l

Under the terms of the site IPC Licence (No. P0192) the discharge period extends from

November to February inclusively, for the remainder of the year the effluent is

landspread, weather permitting.

As can be noted from the above table all parameters are within the licence limits set out

by the Agency.


11

3.0: GROUNDWATER MOITORING SUMMARY

There is one borehole on site (115 metres deep) and this provides all the water to the

factory.

As the site is not serviced by any public water scheme it is solely reliant on the site well;

therefore it was proposed that the monitoring of this well gives a representative value

of the general groundwater quality within the area.

Schedule 3 (ii) Groundwater Monitoring (IPC No.P0192) requires that the licensee shall

monitor boreholes on an annual basis, the following tables outline the results obtained

from the groundwater monitoring returns.

TABLE 2: Groundwater Monitoring 2009

PARAMETER

SITE WELL RESULT

UNITS

pH

7.0

PH

COD 6 mg/l

Conductivity 716 us cm-1 @ 25C

Ammonia 0.04 mg/l as N

Nitrate 10.1 mg/l as NO 3

Turbidity 0.01 NTU

Total Coliforms 0 0/100 ml

Faecal Coliforms 0 0/100 ml


12

TABLE 3: Groundwater Monitoring 2009 – Date of analysis 17.06.09

PARAMETER GW Limits RESULTS UNITS

Colour

No abnormal

change

No abnormal change

N/A

Turbidity

4

0.01

FTU

pH

6.5 - 9.5

7.0

pH

Conductivity

1,500

682

us cm-1 @ 25C

Ammonia

0.30

0.05

mg/L as N

Nitrate

50

10.7

mg/L as N

Nitrite

0.1

0.05

mg/L as N

Iron

0.20

0.08

mg/L as Fe

Manganese

0.05

0.03

mg/L as Mn


13

TABLE 4: Water Sample Report 2009 (Department of Agriculture, Fisheries and Food)

DATE Site PARAMETER RESULT

21.04.09

Coliforms <1

E-Coli <1

Sheep line Faecal Enterococci 0

Conductivity 1087 µs

21.04.09

Coliforms <1

Beef line E-Coli <1

Faecal Enterococci 0


14.07.09

Coliforms <1

E-Coli <1

Sheep line Faecal Enterococci 0


14.07.09

Coliforms <1

Beef line E-Coli <1

Faecal Enterococci 0


Tables 4 represents the results of analysis carried out by Department of Agriculture

officials at the Central Meat Control Laboratory, Backweston Campus, Young’s Cross,

Celbridge, Co. Kildare.


14

4.0: EMISSIONS TO ATMOSPHERE

TABLE 5: Results of Flue gas Monitoring

BOILER EMISSIONS

Emission

Point Ref

No.

Temp.

(C)

Pressure

(kPa)

Velocity

(m/s)

SO2

(Mg/Nm3)

Nox as

NO2

(Mg/Nm3)

CO

(Mg/Nm3)

Boiler 1

188

100.58

1.3

110.8

75.0

50.0

Boiler 2

141

101.45

1.6

81.4

91.1

15.0

Boiler 3

219

105.78

1.1

128.3

107

8.9

Boiler 4

154

106.81

2.4

61.7

52.3

2.5

Boiler 5

193

102.64

2.0

99.8

91.1

10.0

Boiler 6

184

198.34

1.9

104.5

83.5

8.7

Emissions to Air Report carried out on 08.05.09

NOTE:

In the absence of limit values for carbon monoxide, nitrogen oxides and sulphur dioxide,

TA Luft (Technical Instructions on Air Quality Control – TA Luft 2002) guideline values

are used. Table 6 outlines the current guideline values.


15

TABLE 6: TA Luft Guideline Values

Parameter Guideline Levels

Carbon Monoxide (CO)

80 mg/ m3

Nitrogen Oxides as (NO2)

180 mg/ m3 to 350 mg/m3

(Depending on operating

Conditions)

Sulphur Dioxide (SO2)

850 mg/ m3

The results of the flue gas analysis illustrate that all boilers monitored for carbon

monoxide, nitrogen oxides as (NO2) and sulphur dioxide levels are within the current

guideline values.


16

5.0: ENVIRONMENTAL COMPLAINTS

TABLE 7: Complaints Received

2002 2003 2004 2005 2006 2007 2008 2009

Complaints

Received

4

1 0

0

0

0

1

0

Complaints

requiring

Corrective Action

2

0

0

0

0

0

0

0

TABLE 8: Complaints

Category of complaint 2002 2003 2004 2005 2006 2007 2008 2009

Odour

1 1 0 0 0 0 0 0

Noise

0 0 0 0 0 0 0 0

Land spreading

2 0 0 0 0 0 0 0

Air

0 0 0 0 0 0 0 0

Other

1 0 0 0 0 0 1 0


17

During 2002 the majority of complaints have been with regard to landspreading issues.

In 2003 there was only one complaint received verbally from the Agency regarding

odour and no corrective action was required. In 2004, 2005, 2006 and 2007 there were

no complaints regarding environmental issues. In 2008, one complaint was received

alleging animal stomachs being spread on land. This complaint was fully investigated in

conjunction with the EPA, and the complaint was found to be invalid. In 2009 no

environmental complaints were received.

6.0: ENVIRONMENTAL INCIDENTS

There was no environmental incident in 2009.

7.0: WATER CONSUMPTION

M.J. Bergin & Sons Ltd has no public water supply available to it therefore the company

relies on the site well for its water needs; the well is approximately 380ft (115 meters)

deep. The water is pumped to an over ground storage tank which has a holding

capacity of approximately 454.6 m 3, prior to storage it is treated with Hypochloride in

order to ensure that the water is potable and is suitable for use in production. The

storage tank is constructed of mass concrete i.e. roof, sides and floor to prevent the

possibility of contamination e.g. birds vermin etc, the wellhead is also kept covered and

locked. There is an on line flow meter that measures the amount of water that is being

consumed. The flow meter is read on a daily basis and the data recorded. The figures in

table 10 for water consumption are based on the daily-recorded consumption records

for the reservoir.


18

TABLE 11: Water Consumption 2007/2008/2009

Water

Consumption

2007

2008

2009

On-site Well

68,714 m³

63,708 m³

51,679 m3

Total Cattle Kill

64,849

61,784

59,870

Total Cattle Units

324,245

308,920

299,350

Total Sheep Kill

86,450

93,809

50,747

Total Sheep Units

86,450

93,809

50,747

Total Units

410,695

402,729

350,097

M³/Unit

0.167

0.158

0.148

The water extracted from the site well during 2009 has decreased by 12,029 m³ on

2008 and 17,035 m3 on 2007. The amount of water used per unit slaughtered has

decreased from 0.158 m³ to 0.148 m³. This decrease can be attributed to the following

factors:

1. A proactive approach to preventing leaks and early detection and repair of

leaks.

2. Analysing the use of water, leading to a change in behaviour. All water sources

turned off at the end of production and all water turned off at source during

weekends.

3. Restriction valves were put on all sterilsers in the factory, restricting the flow of

water to approximately 3m3 per hour.


19

8.0: ENERGY CONSUMPTION

TABLE 12: Energy Consumption 2007 – 2008 - 2009

Energy Consumption

2007

2008

2009

Heavy Fuel Oil

(Light Fuel Oil)

130 M³

1,365 Mw

167 M³

1,753 Mw

165 M3

1,732 Mw

Electricity

2,454 Mw

3,070 Mw

2,585 Mw

Total Units Slaughtered

434,900

402,729

350,097

Total Usage

3,819 Mw

4,823 Mw

4,317 Mw

Energy Used per Unit Slaughtered

8.8

Kw/Unit

11.9

Kw / Unit

12.3

Kw / Unit

Energy Consumption has increased from 11.9 Kw per unit slaughtered in 2008 to 12.03

Kw per unit slaughtered in 2009. However this is largely due to a 13% decrease in

numbers of units slaughtered. The total electricity consumed between 2008 and 2009

has reduced by 52,632Mw.


20

9.0: OBJECTIVES & TARGETS

TABLE 13: Objectives & Targets 2010 - 2014

____________________________________________________________________

Objective 1 – Reduce energy consumption ____________________________________________________________________

Target 1 – Reduce energy consumption by 15% by 2014 based on the baseline electricity consumed per unit in 2008. ____________________________________________________________________

Objective 2 – Reduce water usage on site ____________________________________________________________________

Target 2 - Reduce water usage through recycling and reuse initiatives based on baseline water usage per unit in 2008. ____________________________________________________________________

Objective 3 – Increase recovery, reuse and recycling of waste material ____________________________________________________________________

Target 3 - Recycle 100% of recyclable materials by the end of 2011


21

10.0: ENVIRONMENTAL MANAGEMENT PROGRAMME

The objective and targets are part of the Environmental Management Programme

(EMP); the purpose of the EMP is to ensure that licensee’s schedule of environmental

objectives and a realistic programme of works supports targets.

Over the past twelve months several projects have been undertaken as part fulfilment

of the EMP and on-going improvement programme.

Environmental Management Programme (Report)

____________________________________________________________________

REPORT 1

____________________________________________________________________

Target: Pave the remaining surrounds

Objective: Complete the paving from the Lairage around to rear of factory

Completion Date: July 2010

____________________________________________________________________

Reasons For Undertaking Project

The first phase of paving the surrounds of the abattoir was completed in October 2004.

The first phase included the entrance to the factory as far as the wall of the existing

sheep lairage. There is also a car park to facilitate all staff to the left of the driveway.

This accommodates 65 cars. This area is only accessible to cars and so is treated as an

uncontaminated surface. This whole area has been paved using hot rolled asphalt.


22

The second phase included the area in front of the lairage and extended as far as the

Waste-water Treatment Plant. The area was graded to fine-tune an existing fall towards

the lairage. There is a layer of compacted 804, 100mm dense base macadam and 40mm

hot-rolled asphalt.

This area carries cattle trucks and is designated as a contaminated area and all washings

are diverted to the Waste water Treatment Plant.

Any areas that do not carry vehicles have been designated as green areas and are

landscaped appropriately.

A gate has been installed along side the lairage, limiting the movement of traffic to the

back of the factory.

Details on Completion of Project

Phase three has begun.

Three areas have been laid immediately outside the despatch area.

The target completion date for the remainder of the yard is July 2010.


23

_________________________________________________________________

REPORT 2

____________________________________________________________________

Target: Investigate Electricity Usage

Objective: Reduce the amount of energy used per unit slaughtered

Completion Date: Continuous

___________________________________________________________________

Reasons for Undertaking Project

This project was undertaken to identify all opportunities for energy use reduction and

efficiency.

To do this, the company undertook to examine:

1. All electricity consuming machinery, their efficiency and effectiveness.

2. If machines can be used in a more efficient manner.

3. If chills could be run more efficiently

4. If any lights can be changed to energy saving or eliminated.

5. If sterilisers can be altered to be more efficient


24

Table: 14 Energy Consumption 2004/2005/2006/2007/2008/2009

Energy

Consumption

2004

2005 2006

2007

2008

2009

Heavy Fuel Oil

(Light fuel oil)

126 M³

1323 Mw

119M³

1249 Mw

120 M³

1285 Mw

130M³

1365 Mw

167 M³

1753Mw

165 M3

1732 Mw

Electricity

2209 Mw

2151 Mw

2391 Mw

2454 Mw

3070Mw

2,585 Mw

Total Units Slaughtered

436,815

396,921

448,031

434,900

402,729

350,097

Total Usage

3669 Mw

3400 Mw

3676 Mw

3819 Mw

4823 Mw

4317 Mw

Energy Used per

Unit

Slaughtered

8.4

Kw/Unit

8.7

Kw/Unit

8.2

Kw/Unit

8.8

Kw/Unit

11.9

Kw / Unit

12.3

Kw / Unit

Energy Consumption has increased from 11.9 Kw per unit slaughtered in 2008 to 12.3

Kw per unit slaughtered in 2009.

This increase in electricity consumption may be attributable to the following factors:

1. The refrigeration capacity was increased with the addition of a tripe chill as a

requirement of the production of edible tripe.

2. The number of units slaughtered in 2009 was down on 2008 yet the overhead

costs for the factory remained the same.

________________________________________________________________


25

REPORT 3

____________________________________________________________________

Target: Investigate Water Usage

Objective: Reduce the amount of water used per unit slaughtered

Completion Date: Continuous

___________________________________________________________________


This project was undertaken to identify all opportunities for water use reduction.

Water usage in recent years has remained relatively static per unit slaughtered.

M. J. Bergin & Sons undertook to examine:

1. All areas of water usage and quantities used.

2. If any process can be altered to reduce the quantity of water used

3. If sterilisers can be altered to reduce water usage

4. If recycled water can be used in any areas currently on clean water.

M.J. Bergin & Sons Ltd has no public water supply available to it therefore the company

relies on the site well for its water needs; the well is approximately 380ft (115 meters)

deep. The water is pumped to an over ground storage tank which has a holding

capacity of approximately 454.6 m 3, prior to storage it is treated with Hypochloride in

order to ensure that no Coliforms or E-Coli are present in the water being used for

production purposes. The storage tank is constructed of mass concrete i.e. roof, sides

and floor to prevent the possibility of contamination e.g. birds vermin etc, the wellhead

is also kept covered and locked. There is an on line flow meter that measures the

amount of water that is being consumed. Through out the factory a reading is taken


26

from the flow meter on a daily basis and recorded. The figures in Table 1 for water

consumption are based on the daily-recorded consumption records.

TABLE 15: Water Consumption 2004/2005/2006/2007/2008/2009

Water

Consumption

2004

2005

2006

2007

2008

2009

On-site Well

75,983 m³

70,145 m³

73,029 m³

68,714 m³

63,708m3

51,679 m3

Total Cattle Kill

70,397

67,071

69,690

64,849

61,784

59,870

Total Cattle

Units

351,985

335,305

348,450

324,245

308,920

299,350

Total Sheep Kill

84,830

61,616

99,581

86,450

93,809

50,747

Total Sheep

Units

84,830

61,616

99,581

86,450

93,809

50,747

Total Units

436,815

396,921

448,031

410,695

402,729

350,097

M³/Unit

0.173

0.176

0.163

0.167

0.158

0.148

The water extracted from the site well during 2009 has decreased by 12,029 m³ on

2008. The amount of water used per unit slaughtered decreased from 0.158 to

0.148m³.


27

________________________________________________________________

REPORT 4

____________________________________________________________________

Target: Designate Fridge Storage Area

Objective: Create a designated area for fridges to be stored

Target Completion Date: June 2010

____________________________________________________________________


Refrigerated containers are stored in one location at the back of the site.

Details of Job Completion

A designated fridge area has been put in place although a structural barrier has not

been erected. This will be erected when all ground work in the back yard has been

completed and the yard is paved. Target completion date July 2010.

____________________________________________________________________


28

REPORT 5

____________________________________________________________________

Target: Erect security fencing around the site

Objective: Restrict the movement of traffic around the site from surroundings areas

Target Completion Date: Completed

____________________________________________________________________


The site at M. J. Bergin & Sons Ltd. is surrounded by green fields. A security fence has

been erected around the site boundaries. A laurel hedge has been planted inside the

security fence.


Completed 2009


29

___________________________________________________________________

REPORT 6

____________________________________________________________________

Target: Install a 6mm screen in back yard to pre-screen all waste going to the Waste

Water Treatment Plant

Objective: To minimise the amount of solid waste going to the Waste Water Treatment

Plant

Target Completion Date: Completed 2009

____________________________________________________________________


To reduce the amount of solid waste going into the Waste Treatment Plant and thus

reducing the load going into the treatment plant.


The screen has been installed, commissioned and is fully operational. The installation of the screen has been an improvement in performance of the treatment plant.


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11.0 PROPOSED OBJECTIVES AND TARGETS 2010

The objectives and targets for 2010 are outlined in three main phases. The first phase

include continuous improvements to ensure maximum efficiency, the second is

improvements to existing areas of the factory and the third is structural changes to the

factory and surrounds.

PHASE ONE

“A”

The objective of phase one “A” will be to investigate the electricity usage on site and

examine possible ways of reducing the amount of energy used.

While energy consumption has increased from 11.9 Kw per unit slaughtered in 2008 to

12.3 Kw per unit slaughtered in 2009, the total energy consumption has reduced from

2008 to 2009. M.J. Bergin & Sons will strive to reduce this in 2010.

It is planned to install inverter speed controllers on all high consumption equipment.

Where new equipment is being installed, it is planned to install the most energy

efficient versions available within budget.

Work commencement date: Continued

Proposed Completion Date: Continuous

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦


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PHASE ONE

“B”

The main objective of phase one “B” will be to reduce the amount of water used. Water

usage in recent years has remained relatively static however consumption per unit

dropped from 0.158 in 2008 to 0.148 in 2009.

Table 16: Water Consumption per unit Slaughtered

Water

Consumption

2004

2005

2006

2007

2008

2009

On-site Well

75,983 m³

70,145 m³

73,029 m³

68,714 m³

63,708

51,679 m3

Total Units

436,815

396,921

448,031

410,695

402,729

350,097

M³/Unit

0.173

0.176

0.163

0.167

0.158

0.148

Bergin & Sons will strive to continue to reduce water consumption per unit further in

2010.

We will continue to be proactive in relation to leaks and water wastage.

Work commencement date: Continued

Proposed Completion Date: Continuous

♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦


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PHASE TWO “A” The main objective of phase two “A” will be to reduce the amount of solids entering the

biological plant from the lairage / truck wash area and tripe preparation area.

At present waste from the lairage and truck wash goes straight to the primary screen.

This waste has a high loading and adds greatly to the ingoing COD of the effluent plant.

Likewise waste from the tripe preparation room goes to the main screen. This waste

consists of a large amount of solids.

It is expected that this will reduce the biological load on the wastewater treatment plant

and so make it more efficient.

Work commencement date: June 2010

Proposed Completion Date: August 2010

Total Cost of Phase Two “A”: €10,000


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PHASE THREE “A” Phase three “A” will consist of completing the paving of the surrounds of the factory.

The process of paving the area surrounding the factory was completed in three phases.

This is the third and final phase of this project.

Work commencement date: June 2009 Proposed Completion Date: July 2010 Total cost of Phase Three A: €80,000 approximately M. J. Bergin & Sons propose to pave all necessary zones of the site in order to

completely comply with all regulations. The company propose to accomplish this by

means of a number of phases. The first and second phases are complete and the third

phase is underway.

The first phase of paving the surrounds of the abattoir was completed in October 2004.

The first phase included the entrance to the factory as far as the wall of the existing

sheep lairage. There is also a car park to facilitate all staff to the left of the driveway.

This accommodates 65 cars. This area is only accessible to cars and so is treated as an

uncontaminated surface. This whole area has been paved using hot rolled asphalt.

The second phase included the area in front of the Lairage and extends as far as the

Waste-water Treatment Plant. This area has been graded to fine-tune an existing fall

towards the Lairage. This area carries cattle trucks and is designated as a contaminated

area and all washings are diverted to the Waste water Treatment Plant.

Any areas that do not carry vehicles are designated as green areas and are landscaped

appropriately.


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Phase 3 will consist of completing this project to fully pave the surrounds. The remaining

area is predominately for refrigerated trucks and the run off will be designated clean.

12.0: ORGANIC WASTE

TABLE 17: Organic Waste (Pressed Paunch/De-watered Sludge) 2009

Nutrient Content of pressed Paunch / Sludge material Test Parameter

Result

Units

pH 7.0 pH

% Dry matter 20.34 %

Total N 4.9 %

Total P 0.83 %

Total K 1.01 %

Condition 7.6.7 states, “Organic waste produced at the site shall be analysed in

accordance with schedule 2 (iii) waste analysis of this licence” Table 13 outlines the

results of the actual analysis.


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TABLE 18: Average Nutrients Land spread in Effluent

Average Nutrient Content of Final Effluent Test Parameter Result Units pH 7.0 pH

Total Phosphate 1.01 Mg/L

Nitrate 7.30 Mg/L

TABLE 19: Total Nutrients Land Spread in Effluent

Parameter

2008 Land spread

2008 Discharged

2009 Land spread

2009 Discharged

Total N

0.069

Tonnes

0.046

Tonnes

0.064 Tonnes

0.075 Tonnes

Total P

0.007

Tonnes

0.013

Tonnes

0.008 Tonnes

0.010 Tonnes

Volume Land spread

10,852 M³

8,636M³

Volume Discharged to River

6994 M³

10,270 M³

TOTAL (Landspread/Discharged)

17,846 M³

18,906 M³


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13.0 INFORMATION ON WASTE STREAMS TABLE 20: Waste Disposal 2009

European

Waste Catalogue Code

Hazardous (Yes/No)

Description of

Waste

Quantity

(Ton/year)

Disposal/ Recovery

Code

Location of

Disposal/Recovery

Name of Waste Disposal Recovery Contractor

02 02 03

No

Category 1

(SRM)

3728

D10

Ferrybank, Co.

Waterford

(b) Waterford Proteins

02 02 02

No

Fat & Bone

1398

R1

Cahir, Co. Tipperary

(b) Munster Proteins

02 02 02

No

Fat

2871

R1

Ballyhaunis,

Co. Mayo

(b) Western Proteins

02 02 02

No

Blood

830

D8

Craigavon Co. Armagh N. Ireland

(c) APC Technologies Ltd.

02 02 02

No

Blood

240

D8

Nobber, Co. Meath.

(b) College Proteins

20 00 00

No

Refuse

7.90

D1

Oxigen Environmental

Limited

(b) Oxigen Environmental Limited

20 00 00

No

Recyclables

5.90

D1

Oxigen Environmental

Limited

(b) Oxigen Environmental Limited

NOTE: (b) Disposal Off Site Ireland (c) Off-Site (abroad) (a) Disposal On Site


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14.0 PRTR

Releases to Air

Releases to air were calculated from the most recent flue gas monitoring which was carried out by Euro Environmental Services. Flue

gas monitoring was carried out on five boilers. Flue gas measurements were carried out in accordance with the standard method

(Flue Gas Analyser) using TCR Tecora Isostack Basic & Impinger system and IMR 2000.

The results were as follows:

Table 21

Bolier No: NOx kg/hr NOx kg/year CO kg/hr CO kg/year SO2 kg/hr SO2 kg/year

1 0.0081 18.954 0.00054 1.2636 0.0012 2.808

2 0.0013 3.0420 0.00021 0.4914 0.0012 2.808

3 0.0009 2.106 0.00008 0.1872 0.0012 2.808

4 0.00005 0.117 0.00006 0.1404 0.0015 3.510

5 0.0015 3.5100 0.00016 0.3744 0.0017 3.978

6 0.0007 1.638 0.00014 0.3276 0.0013 3.042

0.0119 27.846 0.00105 2.457 0.0068 15.912

Releases to Water

Releases to water were estimated using the daily, weekly, monthly and annual test results.

Documents

AER 2009 - Environmental Protection Agency · M. J. Bergin & Sons Ltd._____ _____AER 2009 2 2: Stunning Animals enter the slaughter hall through a raised door from the race in the

AER 2009 - Environmental Protection Agency · M. J. Bergin & Sons Ltd._ _AER 2009 2 2: Stunning Animals enter the slaughter hall through a raised door from the race in the