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ANNUAL ENVIRONMENTAL REPORT 2013
For
Boylan Print Limited,
New Found Well, Termonfeckin Road,
Drogheda, Co. Louth
IPPC Licence Number: P0784-01
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Table of Contents 1. Introduction ..................................................................................................................................... 4
1.1 Company Information ............................................................................................................. 4
1.2 Company Organisation Chart.................................................................................................. 5
2 Site Description ............................................................................................................................... 6
2.1 Company Profile ..................................................................................................................... 6
2.2 Environmental Policy .............................................................................................................. 6
2.3 Manufacturing Process ............................................................................................................ 6
3 Summary of Emissions ................................................................................................................... 8
3.1 Emissions to Atmosphere........................................................................................................ 8
3.1.1 Emissions to Atmosphere – monitoring programme ...................................................... 8
3.1.2 Emissions to atmosphere – Monitoring results ............................................................... 9
3.2 Waste Management ................................................................................................................. 9
3.3 Surface water monitoring emissions ..................................................................................... 10
4 Resource Consumption ................................................................................................................. 11
4.1 Water Consumption .............................................................................................................. 11
4.2 Energy Consumption ............................................................................................................ 11
4.3 Raw Material Consumption .................................................................................................. 11
5 Environmental Incidents and Complaints ..................................................................................... 12
5.1 Reported Incidents Summary ................................................................................................ 12
5.2 Agency Audit/test report Summary ...................................................................................... 12
6 Environmental Management of activity ........................................................................................ 12
6.1 Report on Environmental Objectives and targets for 2013 ................................................... 12
6.2 Environmental Management Programme 2014 .................................................................... 14
7 Licence Specific Reports (IPPC licence P0784-01) ...................................................................... 16
7.1 Noise Monitoring Report 2013 ............................................................................................. 16
7.2 Bund (Printing Inks) ............................................................................................................. 17
7.3 Solvent Management Plan/Fugitive Emissions Programme ................................................. 17
7.4 Residuals Management Plan ................................................................................................. 19
7.5 Environmental Improvements during 2013 and financial provisions ................................... 19
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List of Tables
Table 1 - Company Details ..................................................................................................................... 4
Table 2 - Summary of IPPC Licence and Site History ........................................................................... 4
Table 3 - Air Monitoring Programme (IPPC Licence P0784-01) ........................................................... 8
Table 4 - TOC as C results for Emission points A2-3 and A2-4, 2013 .................................................. 9
Table 5 - Waste Generation 2013 ........................................................................................................... 9
Table 6- Energy Consumption .............................................................................................................. 11
Table 7 - Raw Material Consumption 2013 .......................................................................................... 11
Table 8 - Report on Objectives and targets for 2013 ............................................................................ 13
Table 9 - Summary of Environmental Management Programme for 2014 ........................................... 14
Table 10 - Day Time Noise Monitoring Results 2013 .......................................................................... 16
Table 11 - Night Time Noise Monitoring Results 2013 ....................................................................... 16
Table 12 - Programme for public information ...................................................................................... 19
Table 13 - Environmental Improvements on site .................................................................................. 20
Table of Figures
Figure 1 - Printing Process ......................................................................................................... 7
Figure 2 - Paper Extraction System ........................................................................................... 7
Figure 3- Storm Water Emissions (COD) ................................................................................ 10
Figure 4 - Storm Water Emissions (pH) .................................................................................. 10
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1. Introduction
We at Boylan Print Ltd. have completed our Annual Environmental Report for 2013 to fulfil
our requirements of condition 11.6 of our IPPC Licence (0784-01).
1.1 Company Information
Table 1 - Company Details
Company Boylan Print Limited
Address Newfoundwell,
Termonfeckin Road,
Drogheda.
County/City Co. Louth
Business Production of magazines and leaflets for the
Irish market
Employees 82
Contact Name Courtney O’Reilly
Position EHSQ Officer
Telephone 041 983 9905
Fax 041 983 4827
Email [email protected]
IPPC Registration Number P0784-01
Table 2 - Summary of IPPC Licence and Site History
IPPC Licence Reg:
No.
Licensee Period
P0112 – 01 Thermal Heat Exchangers (Irl)
Ltd. (also known as Advanced
Roofing and Cladding Ltd.)
27/01/1998 – CA. 2001*
(*exact date uncertain)
P0784-01 Boylan Print Ltd. 16th
April 2007 to present
Boylan Print Ltd. holds an IPPC Licence granted by the Environmental Protection Agency
(EPA) (Licence Register Number P0784-01) in 2007. In accordance with condition 11.6 of
this licence Boylan Print Ltd. are required to have a documented Annual Environmental
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Report (AER). Boylan Print Ltd. moved into this property at the start of April 2005. For two
years prior to Boylan Print Ltd. acquiring the premises the site lay derelict. Before the time
the factory was owned by Thermal Heat Exchangers (Ireland) Ltd. who manufactured coil
heat exchangers and were licensed under Class 12.2 ‘The use of coating materials in
processes with a capacity to use at least 10 tonnes per year of organic solvents’.
Thermal Heat Exchangers (Irl) Ltd. had been using perchlorethylene (PCE) (otherwise known
as Tetrachloroethylene) as a degreasing solvent and migration of the solvent into the subsoil’s
from the degreaser had given rise to contamination of the subsoil’s underlying the facility.
According to the EPA inspectors report (September 1997), preliminary attempts to substitute
a less toxic solvent for PCE were not successful. In 1992 there was a diesel spill onsite during
the occupancy of Thermal Heat Exchangers (Irl.) Limited at the site.
1.2 Company Organisation Chart
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2 Site Description
2.1 Company Profile
The primary activity of Boylan Print Ltd. is printing of magazines and leaflets for the Irish
market.
2.2 Environmental Policy
Boylan Print Ltd. has a documented environmental policy in relation to the activities carried
out at the site (Appendix 1).
2.3 Manufacturing Process
The printing process is done via the headset web. Boylan Print Ltd. currently operates a hot
air web offset dryer with the functions of drying, chilling and guiding the web integrated in
one single system and is named emission point A2-4. Machine upgrade works on-site have
included the installation of a new Thermal Oxidiser on the Heildberg Harris M300 printing
press. The model that has been installed on-site is the E105-102. Attached with this document
are the specifications of the subject thermal oxidiser.
The emissions from the M300 printing press were previously emitted through Emission Point
A2-3 which was located externally to the west side of the facility. The process emissions
from the M300 are now diverted through the newly installed thermal oxidiser for destruction.
To clarify, the emissions are from the same process (i.e. M300 printing press) however a new
and improved abatement system has been installed. The upgrading of the M300 abatement
system has necessitated in the relocation of the emission point. A technical Amendment
request has been submitted to the Agency with a final decision pending. For clarity, the
emission point name remains as A2-3 until such time as the Agency recommends otherwise.
Boylan Print Ltd. will ensure that the emissions from the new thermal oxidisers at the M300
meet emission limits for discharge to air as required under the IPPC licence P0784-01.
Flowcharts of the printing process used in the company are shown in Figure 1 and 2 below
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Figure 1 - Printing Process
Figure 2 - Paper Extraction System
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3 Summary of Emissions
The company has the licensed emissions as per Schedule B of P0784-01:
Emissions to atmosphere
Waste emissions
Storm water
3.1 Emissions to Atmosphere
3.1.1 Emissions to Atmosphere – monitoring programme
The monitoring of emissions to atmosphere at Boylan Print Ltd. for emission points A2-3 and
A2-4 was carried during each of the four quarters of 2013.
In accordance with the company’s IPPC Licence, Boylan Print Ltd. monitors air emissions
for total organic carbon compound(s), nitrogen oxides and carbon monoxide. A summary of
emission limit values and allowed flow rates for the stacks and the RTO on site are provided
in the following table.
Table 3 - Air Monitoring Programme (IPPC Licence P0784-01)
Emission point
reference
Parameters Monitoring
Frequency
Volumes &
Concentrations
Licensed Volume
A2-3 (RTO) Flow Rate Quarterly 9,000m3/hr.
Total Organics (as Carbon) 20mg/m3
Nitrogen Oxides (as NO2) 100mg/m3
Carbon Monoxide 100mg/m3
A2-4* Flow Rate Quarterly 2,672m3/hr.
Total Organics (as Carbon) 20mg/m3
Nitrogen Oxides (as NO2) 100mg/m3
Carbon Monoxide 100mg/m3
*Emission limits are based on Schedule B1 of Technical Amendment A to IPPC Licence P0784-01
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3.1.2 Emissions to atmosphere – Monitoring results
Table 4 - TOC as C results for Emission points A2-3 and A2-4, 2013
Emission Point A2-3 A2-4
Period Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
TOC as C
concentration
2013
(mg/Nm3)
ELV
20
0.011 0.001 0.204 0.015 0.001 0.001 0.005 0.001
Nitrogen
Oxides
(mg/Nm3)
ELV
100
0.01 0.43 0.243 0.36 0.0005 0.11 0.3 0.001
Carbon
Monoxide
(mg/Nm3)
ELV
100
0.037 0.01 0.732 1.35 0.052 0.052 0.4 0.001
3.2 Waste Management
The following are the waste types collected from the premises of Boylan Print Ltd. in
2013.
Table 5 - Waste Generation 2013
Waste Type Hazardous Quantity (t) Contractor Permit/Licence
Wooden Packaging
No
0.38 Panda Waste WCP/MH/2001/01D/W0140-
03 /W0060-03-1
Paper and Cardboard No 2391.83 Panda Waste WCP/MH/2001/01D/W0140-
03 /W0060-03-1
Absorbents, filter
materials (including oil
filters not otherwise
specified), wiping
cloths, protective
clothing contaminated
by dangerous
substances
Yes 3.0 Rialta
Environmental
Ltd.
Rialta Environmental
Ltd,W0 192-03
Paper and Cardboard
Packaging
No 37.501 Panda Waste WCP/MH/2001/01D/W0140-
03 /W0060-03-1
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3.3 Surface water monitoring emissions
The following are the storm water emissions for Boylan Print Ltd.
Figure 3- Storm Water Emissions (COD)
Figure 4 - Storm Water Emissions (pH)
Tabulated results for COD and pH can be seen in Appendix 3.
0
50
100
150
200
250
CO
D c
on
cen
trati
on
(m
g/L
)
DATE
COD 2013
COD
6.9
6.95
7
7.05
7.1
7.15
7.2
7.25
7.3
pH
Red
ain
g
DATE
Ph 2013
Ph 2013
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4 Resource Consumption
This section of the Annual Environmental Report details the total annual usage levels of
water and energy at the site.
4.1 Water Consumption
Boylan Print Ltd. does not have a metered water supply form Louth County Council, and
instead pay the council a fixed yearly amount for supply services. Water at Boylan Ltd. is
used for domestic related purposes only i.e. use in the staff kitchen and for sanitary purposes
only. Water is not used in the processing operations at Boylan Print Ltd.
4.2 Energy Consumption
Energy is provided by figure sources at the company namely:
Natural gas
Electricity
Table 6- Energy Consumption
Source
Consumption 2013 Units
2010 2011 2012 2013
Natural Gas 4,552,161 4,707,656 6,819,396 6,118,768 kWh
Electricity 4,958,094 5,602,631 6,189,489 6,370,411 kWh
Forklift Fuel 2,146 3,434 2,924 5,166 kg
4.3 Raw Material Consumption
The following is the list of the raw materials for 2013
Table 7 - Raw Material Consumption 2013
Product Total consumption solvent-based products (kg/Litres)
Inks 236,052.9
Heatset Fount 5,920.00
White Spirit 205.00
Medium Fount 240.00
Blanket Wash 240.00
Silicone Spray 220.00
Wonderstryp 100.00
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Antistatic 1540.00
MRC 375.00
Pro Web Titanium 7,800.00
5 Environmental Incidents and Complaints
5.1 Reported Incidents Summary
Category 2013
Odour Nil
Noise Nil
5.2 Agency Audit/test report Summary
An EPA Site Audit was conducted on 29/01/2013. Five non-conformances were raised during
this audit and three audit observations were made. A response to all observations raised in
this site audit report was undertaken and returned to the Agency. Some issues remain ongoing
at the time of writing and the licensee is in the process of closing out all issues to the
satisfaction of the Agency.
An EPA Test report dated 29/07/2013 noted elevated levels of COD on one occasion.
The licensee undertook a full site investigation into this matter and corrective and
preventative actions to be completed.
6 Environmental Management of activity
6.1 Report on Environmental Objectives and targets for 2013
A report on the implementation of the 2013 EMP is provided in Table 8 and the objectives
and targets for 2014 are outlined in Table 9 below.
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Table 8 - Report on Objectives and targets for 2013
Objective Target Action Timeframe
To keep our emissions as
low as possible
Reduce or eliminate solvent based
compounds
Minimise the use of solvent based
compounds
Maintain ongoing monitoring programme
Ongoing
Reduce combustion gas emissions from
boiler
To monitor air emissions in accordance
with IPPC Licence
To minimise all waste
streams
Maintain a waste register Maintain a hazardous and non-hazardous
waste register
Review current waste production and
implement any improvements identified
Ongoing
Minimise volume of waste produced
To ensure that all water
monitoring requirements
are achieved.
To monitor storm water in accordance
with IPPC Licence
Maintain ongoing monitoring programme
Monitoring completed
in 2013
To monitor ground water in accordance
with IPPC Licence
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6.2 Environmental Management Programme 2014
Table 9 - Summary of Environmental Management Programme for 2014
Objective Method Target completion date
Reduce fugitive emissions by December
2014
Investigate possible sources for the cause of fugitive emissions on
site and reduce emissions to the level stated in condition 5.6 of the
IPPC licence (P0784-01)
Ongoing
Reduce hazardous liquid waste Devise and implement measures to reduce hazardous liquid waste Ongoing
Reduce energy consumption on site Investigate efficiency and suitability of retrofitting lighting system
in facility to replace T5 lightings whilst simultaneously attaining
improved energy efficiency.
Ongoing
Demonstrate compliance with IPPC Licence Carry out emissions monitoring as per IPPC Licence Ongoing
In House Training Ensure training on spill prevention and spill response be
implemented.
Ongoing
Update Accident Prevention
Procedure (APP)
Update the APP in accordance with Item 6 of the EPA
audit observations
November 2014
Bund integrity testing Undertake bund integrity test on all bunds/sumps on
site
October 2014
Cyclone abatement system Replace filters in cyclone June 2014
Groundwater Monitoring Wells Upgrade groundwater monitoring wells heads/caps to prevent
potential contamination
August 2014
Chemical store Complete bunding/sealing of the chemical store area in accordance
with the Guidance Note on Storage and Transfer of Materials for
September 2014
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Scheduled Activities
Site clean-up Remove all waste and any obsolete materials/equipment that will no
longer be required
September 2014
Waste Records Review & upgrade waste recording system September 2014
Waste storage Improve housekeeping with improved waste storage arrangement
onsite e.g. designated waste storage area
October 2014
Staff Environmental Training Complete staff environmental training December 2014
Groundwater monitoring Complete bi-annual monitoring of serviceable boreholes onsite December 2014
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7 Licence Specific Reports (IPPC licence P0784-01)
7.1 Noise Monitoring Report 2013
Environmental Efficiency carried out a noise survey at Boylan Print Ltd. (Doc. No. 919-77)
on the 20TH
December 2013 as required under condition 6.12.2 of their IPPC licence. A
summary of the results are shown in Table 10 and Table 11 below.
Table 10 - Day Time Noise Monitoring Results 2013
Location
Reference
Time Noise Result
LAeq (30 mins) L10 L90
NSL1 10:25 59.2 62.6 52.7
NSL2 12:03 65.5 70.2 53.7
N3 12:10 66.7 67.9 65
N4 10:30 66.3 66.8 65.2
Table 11 - Night Time Noise Monitoring Results 2013
Location
Reference
Time Noise Result
LAeq (30mins) L10 L90
NSL1 23:04 54.4 57.15 45.15
NSL2 23:47 59.25 59.4 51.85
N3 23:54 63.7 64.15 63.4
N4 23:12 56.2 57.2 55.55
There are two noise sensitive locations monitored as part of this report (NSL1 and NSL2) and
two boundary locations (non-NSLs). At both noise sensitive locations external noise
influences were identified as adversely influencing the noise recording results. Where
determined appropriate by the monitoring consultant, the L90 noise result was assumed as the
noise result to offset the adverse influence of external noise sources. Noise levels at NSL1
and NSL2 were considered to be within the ELV when assuming the L90. Boylan Print was
operating during the monitoring period and noise from the site’s operations was audible
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however, the primary noise emissions identified during the course of the monitoring was
traffic and a neighbouring food processing facility.
Night time noise levels at NSL1 and NSL2 exceeded the ELV. However, external noise
emissions were determined to considerably influence the recordings, notably the food
processing plant to the south of the site as refrigerating/chilling units operated continuously
throughout the survey period. In order to establish meaningful representative noise levels
owing solely to the activities of Boylan Print Ltd. a survey would have to take place during a
period when the neighbouring plant, Hilton Foods is not operational (i.e. refrigeration/chilling
units are not in operation) and where the volume of traffic on the Newton road and Drogheda
road is significantly less.
No confirmed tonal attributed to Boylan Print was identified at either NSL during either day
or night time monitoring.
7.2 Bund (Printing Inks)
A correspondence from the agency on the 27th
October 2009, (Ref:P0784-01/ak02ec) in
response to the correspondence submitted by Boylan Print Ltd. on the 7th
October 2009 stated
a water retention test was not required provided appropriate measures are in place so that the
bund is rendered impervious to the inks within. Measures included coating bund walls with
an impermeable epoxy resin; and as such the bund walls are impervious to inks.
7.3 Solvent Management Plan/Fugitive Emissions Programme
The 2013 data is currently under review and a report will be issued to the Agency as soon as
it is completed.
The most up to date fugitive emissions data therefore comprises Fugitive Emissions 2012
which was prepared by EEC on behalf of Boylan Print Ltd. The solvent management plan
carried out took the form of a mass balance plan as shown below. A summary of this report is
included below:
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Determination of F
As previously mentioned, the formula used to calculate the fugitive emissions is:
F = I1 – O1 – O5 – O6 – O7 – O8
F =13,974-354.85-3193.67-428.21-1,397.4= 8,599.87 kg
Fugitive emission value=
The company at present has a 61.5% fugitive emission limit and are therefore in excess of
limits imposed by the solvents regulations. Boylan Labels have been working to reduce their
fugitive emissions so to ensure compliance, and have achieved a reduction of fugitive
emissions.
A number of improvements have been made on-site. These improvements are anticipated to
improve the current level of fugitive emissions.
It is noted that for emission point A2-4, velocity was measured before the thermal oxidizer,
not after as would be normal. This was due to there not being sufficient length of straight duct
after the thermal oxidizer in which to install a velocity port. An emission monitoring port has
been installed post the thermal oxidiser. It must also be noted that the thermal oxidiser
currently in use on-site to treat air emissions has been replaced by an internal after burner unit
on the M850c machine. It is envisaged that these improvements will have a positive impact
on the level of fugitive emissions from the site.
The facility is currently compiling an updated fugitive emissions report for 2013 and will
submit to the Agency accordingly once completed.
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7.4 Residuals Management Plan
A residuals management plan was prepared on behalf of Boylan Print Ltd. by EEC (Doc. No.
919-13). The original initial report is with the Agency. A review of the plan was completed
and there is deemed to be no necessary changes.
Table 12 - Programme for public information
Measures Progress to date
Website
Environmental Policy
Notice/ Bulletin boards
Maintenance of information notice board to
include:
Opening hours
Phone numbers and names of various
relevant personnel: site manager,
environmental/health and safety
manager etc.
Licence reference number
Achieved
Communications programme
Ensure all environmental information is
available on request to public:
Monitoring Results
Pollution Emission Register
Achieved
Public Complaints Procedure
Ensure complaints record form is
available from reception
Achieved
7.5 Environmental Improvements during 2013 and financial provisions
A statement of measures in relation to the prevention of environmental damage and remedial
actions (environmental improvements 2012) is provided in Table 13 below:
Financial provision remains the same as that outlined in the residuals management plan as
previously submitted to the EPA. There are no changes in the amount of financial provision.
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Table 13 - Environmental Improvements on site
Measures Progress to date
Equipment maintenance
All equipment in use is regularly checked in order to identify
and remedy any faults, which may compromise the health and
safety of staff or have a negative impact on the environment.
Ongoing and
continuous
Environmental Monitoring
Emissions to water and emissions to air are monitored
regularly as required by the IPPC license (Reg. No.P0784-01)
Miscellaneous Improvements
Historical waste from the site as highlighted during EPA
audits were removed from site and disposed of correctly.
Where possible waste was recycled.
The company invited expressions of interest to tender for the
Hydrogeological Investigation contract.
A new Environmental Manager has been employed by the
company to oversee all environmental requirements and
ensure compliance.
Ongoing and
continuous
Complete
Complete
Complete
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APPENDIX 1 Environmental Policy
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APPENDIX 2 Specifications
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APPENDIX 3 COD and pH Results 2013
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Date pH COD
23/03/2013 7.02 <15.00
23/03/2013 7.1 <15.00
24/03/2013 7.24 <15.00
29/07/2013 7.12 <15.00
05/09/2013 7.090 206.0
09/09/2013 7.130 61.30
29/09/2013 7.180 31.50
05/10/2013 7.09 <15.00
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APPENDIX 4 AER/PRTR Emissions Data Information
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Releases to Air
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Treatment and Transfer of Waste
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END
