NON-TECHNICAL SUMMARY

Transcription

1 Attachment A.1 NON-TECHNICAL SUMMARY Cadbury Ireland Limited Rathmore Installation Project Ref: OES1061_01

2 Cadbury Ireland Limited, July 2006 Rathmore Installation. Attachment A.1 A.1 Non - Technical Summary Cadbury Ireland Limited is subsidiary of Cadbury-Schweppes plc, a global manufacturer of confectionery and beverage products which has operations in Ireland, the U.K. and throughout Europe. Cadbury Ireland Limited manufactures and distributes over 25 product types within the Irish market. In addition to its home base market it also exports to a number of key lines to Cadbury Limited U.K. and global markets. Cadbury Ireland Limited, Rathmore Installation, is responsible for the manufacturing of chocolate crumb since The facility is located in Rathmore Co. Kerry. The plant is located adjacent to the River Blackwater, approximately 2 Km from the village of Rathmore and 20Km east of Killarney. The total area of the site is 5.4 hectares, of which 1 hectare is under roof. Approximately 34% if the total area is comprised of hard standing areas. The facility is serviced by the R582, which connects Rathmore to Millstreet, and the N72 (National Primary Route), located to the north of the plant. A railway line runs through a portion of the facility. Initially used to transport the product, this operation ceased in the early 1980s as a result of its unreliability and expense. The site is flanked to the east and west by agricultural farmland, to the north by the River Blackwater, and to the south by the R582. The topography of the area consists of gently undulating farmland which has a gradual decrease in elevation towards the Blackwater River. The plant employs a total of 115 people and is operated 24 hours per day 50 weeks per year. The working shifts are allocated on a cyclical basis, comprising three as follows: 8am-4pm 4pm-12pm 12pm-8am The working population density within 2 Km radius of the site boundary is less than 50 and the residential population is approximately 200. There is a security office located at the entrance to the plant and site security is provided on a continuous basis. Chocolate crumb is made in accordance with customer specifications from milk, sugar, and cocoa mass, butteroil, and rework. The purpose of producing chocolate crumb is to provide a stable means of storing milk and to manufacture a product that is easily handled and transported. The Rathmore Installation was established to export crumb to the U.K. as well as Dublin but with the expansion of the plant in 1952 the export crumb to the U.K. increased considerably. Cadbury Ireland Limited, Rathmore Installation, now manufactures chocolate crumb for the following markets: Cadbury Ireland Limited (Coolock), Dublin. U.K. North America Japan Spain The total production for 2004 was 41,000 tonnes. The production figure for 2005 increased to 46,000 tonnes. Owing to recent upgrade in processing capacity the production throughput is of the order of 65,000 tonnes per annum. There are three main activity centres involved in production of the crumb. These include milk intake/storage, sugar intake/storage, crumb production facilities, and packaging store rooms. OES Consulting Page 1 of 6

3 Cadbury Ireland Limited, July 2006 Rathmore Installation. Attachment A.1 In addition to the production areas, there is an administration block, engineering building, laboratory building, powder store, boiler house. The waste water treatment plant for the facility is located to the north of the facility (Appendix A.1.1.). The facility is currently operating under a discharge licence from Kerry County Council. Trade and sanitary effluent from the facility is diverted to the Cadbury Ireland Limited, Rathmore Installation, wastewater treatment plant located to the north of the facility. Storm water runoff from the yard areas drains to the Cadbury Ireland Limited, Rathmore Installation, soak away, which is located to the north east of the site, and subsequently into a land drain. Storm water from the employee car park flows to the west of the manufacturing plant and discharges to the River Blackwater at a point upstream of the Waste Water Treatment Plant (WWTP). A.1.1 Process Description Cadbury Ireland Limited, Rathmore Installation, manufactures milk chocolate crumb which is an intermediate product utilised in the production of milk chocolate in a number of facilities throughout the world as specified in Section A.1. A range of quality assurance procedures and audits are used to ensure the quality of materials used is optimal. As part of the application, Cadbury Ireland Limited, Rathmore Installation, is committed to reviewing raw material to ensure that environmentally preferable materials are selected, as far as possible. The crumb is prepared under stringent hygienic by processes of concentration, cooking, and vacuum drying. Table 1.1 provides a description of the inputs and outputs involved in the production process. Table 1.1 Inputs and Outputs involved in the production of Chocolate Crumb at the Cadbury Ireland Limited, Rathmore Installation Inputs Milk, Sugar, Cocoa Mass, Butteroil, Rework, Water Outputs Chocolate Crumb The crumb processing facility may be further divided by activity type into unit operations which include: Milk intake Pasteurisation Evaporation 120 million litres of milk are received annually by road tanker from a number of co-ops. This is unloaded at one of three reception bays. The process involves the intake of both whole and skimmed milk. The milk undergoes quality testing for acceptability and, once approved, it is pumped to storage silos. The total storage capacity of the silos is 540,000 litres. Both the whole and skimmed milk are stored independently. The skimmed milk is used in periods when the fat content in the milk is high. Conversely, the butteroil is added in periods when the fat content is low. Both whole and skimmed undergo an evaporation process to reduce the moisture content. OES Consulting Page 2 of 6

4 Cadbury Ireland Limited, July 2006 Rathmore Installation. Attachment A.1 Production of Sweetened Concentrated Milk (SCM) Sugar is stored in three silos with a storage capacity of 55 tonnes. The milk and the sugar are combined to produce Sweetened Concentrated Milk (SCM). Batches of SCM are held in storage tanks until required for production. The total storage capacity is 227,125 litres. Addition of Liquid Cocoa Mass The cocoa bean is imported from Ghana, West Africa, to Dublin where it is processed to produce liquid cocoa mass. The liquid cocoa mass is transported by road from Dublin to the Rathmore Installation in tankers. Each tanker has a 22 Tonne storage capacity. Once at the Rathmore Installation, the liquid cocoa mass is stored in three storage tanks, numbered 30, 31 and 32. Each tank has a storage capacity of 65 Tonne. A fourth tank, numbered 33, is used to store the liquid cocoa mass prior to its incorporation to the production process. The quantity of liquid cocoa mass is monitored by a level control system and increased when necessary. Batching Process The SCM is mixed with liquid cocoa mass to form a paste. Butteroil is added depending on the recipe and required fat concentrations. Three tanks, numbered 6, 7 and 8, are controlled by load cells. These ensure the correct concentration of ingredients is added according to recipe set point. The recalled material which, through means of quality control is deemed unsuitable for release, is also reworked into the production process at this stage of production. The concentrations are checked and controlled by computer controlled system. Cooking Phase The batches are transported by means of a variable speed pump to undergo a cooking phase. There is an established quality control temperature required for this process. Any deviation from the required temperature results in batches being recalled back into storage tanks until the cooker has reached the optimum temperature. Production of Final Crumb The Kibbled crumb is fed to an air drier or one of three vacuum driers, numbered 1, 2, and 3, and cooled. The crumb is then weighed and packed into polypropylene Mini-Bulk Bags which have a holding capacity of 1,100kg. Alternatively, it is sent to the two bulk storage silos to the North West of the facility The factory produces two types of crumb which include: Milled Crumb Kibbled Crumb The Milled Crumb is produced when the Kibbled Crumb is processed in the Alpine Mill. This is used to reduce the particle size by means of a milling process. The Milled and Kibbled Crumb is then packed in accordance with customer requirements. A schematic illustrating the production process can be seen in Appendix A.1.3. The total projected production of chocolate crumb for has been estimated at approximately 65,000 tonnes per annum. The projected throughputs for each material utilised in the production process at the Cadbury Ireland Limited, Rathmore Installation, for the period have been estimated. These estimations can be seen in Table 1.2. OES Consulting Page 3 of 6

5 Cadbury Ireland Limited, July 2006 Rathmore Installation. Attachment A.1 Table 1.2 Projected throughputs at the installation over 2006/7 Material Volume m 3 Whole and Skimmed Milk 33,000 Material Tonnes Sugar 37,000 Cocoa Mass 9,000 Butter Oil 35 The control of the processes undertaken in each of the plant areas and the transfer of liquid feedstock between unit operations is highly automated. In addition to sophisticated programmable logic controller (PLC) systems, product quality is ensured through a regime of frequent, routine sampling and analysis. Although the majority of unit operations are highly automated, Cadbury Ireland Limited, Rathmore Installation, retains approximately 115 employees at Rathmore. In addition to down time associated with feedstock availability, each plant area has a scheduled regime of plant outages to enable cleaning in order to observe strict hygiene requirements. Cleaning processes utilise dilute acid and caustic solutions. The frequency of cleaning and the cleaning solution specification is governed by the requirement of each unit operation. In situ cleaning of pipelines, vessels and other plant items is termed here clean in place (CIP). Process control of the CIP sequence of cleaning and only. flushing is highly automated. purposes A.1.2 Economic Contribution inspection Cadbury Ireland Limited, Rathmore Installation, is a significant employer in East Kerry, For directly employing approximately 115 people. Using an accepted multiplier of 1:2, the plant would contribute to downstream employment of the order of 230 people in the transport and services supply sectors. In addition to salaries and local economic contribution through purchase of supplies and services, significant expenditure has been made at the plant in terms of new processes and modernisation. Expenditure on Environmental Protection As a result of the commitment of Cadbury Ireland Limited, Rathmore Installation, to environmental protection at the site, significant expenditure has been incurred in the upgrade of existing environmental controls in addition to energy conservation measures and structural remediation work. An approximation of the environmental expenditure incurred over the past five years can be seen in Table 1.3. OES Consulting Page 4 of 6

6 Cadbury Ireland Limited, July 2006 Rathmore Installation. Attachment A.1 Table 1.3 Expenditure on Environmental Protection Item Capital Expenditure Approximate Cost ( ) o Site repair and upgrade Projects 320,000 o Energy Conservation Projects 220,000 o Drains Remediation Project 210,000 Total Environmental Capital Expenditure 750,000 Operational Expenditure o o o o Total operational spend Effluent Plant Non-Hazardous Waste Recycling and Disposal Hazardous Waste Disposal IPPC Application Costs Total Environmental Operational Expenditure Total Environmental Protection Expenditure 400,000 75,000 10,000 80, ,000 1,315,000 In addition to the costs outlined above, there will be environmental expenditure associated with the provision of reports as part of the IPPC Licence process. A.1.3 Additional Activities Although the factory leases two warehousing units, no additional processes or activities are undertaken outside the facility. A.1.4 Management Structure Cadbury Ireland Limited, Rathmore Installation, has a structured management approach to the operation of the business in terms of product quality, process control, environment, safety, training and analytical capability. Training of personnel is a key function in the successful operation of the plant. The Quality, Environment, Health and Safety (QEHS) Manager, as designated Environmental Representative, has responsibility for day-to-day environmental management at the Rathmore Installation, ensuring that the requirements of ISO14001 are implemented and maintained. The QEHS Manager is supported in the role by a number of laboratory staff, WWTP staff and security staff. He reports directly to the Head of Manufacturing (Appendix A.1.2). Generally, procedural control is implemented by operators, crafts persons and area managers on a daily basis, to ensure the efficient and compliant running of the plant. The Environmental Management System at Cadbury Ireland Limited, Rathmore Installation, is outlined in the Environmental Manual. This references the applicable procedures (contained in the Plant Process Manuals and the Environmental Procedures Manual) and Registers, which include environmental legislation, and Effects/Aspects. OES Consulting Page 5 of 6

7 Cadbury Ireland Limited, July 2006 Rathmore Installation. Attachment A.1 ISO14001 Accreditation was gained in November controlled documents in accordance with the standard. Relevant Registers are also The company has obtained OSHAS 18001:1999 and ISO 9001:2000 Accreditations. As a result of this, Cadbury Ireland Limited, Rathmore Installation, has established, documented, implemented and maintains a quality management, and health and safety management system and continually improves its effectiveness in accordance with the requirements of the International Standard ISO 9001:2000, and OSHAS 18001:1999. Table 1.4 provides a summary of the accreditations obtained by Cadbury Ireland Limited, Rathmore Installation, to date. Table 1.4 Management Systems at Cadbury Ireland Limited, Rathmore Installation Year of first certification Standard Certification Body 1993 ISO9001: 2000 QMS NSAI 2004 ISO14001: 2004 EMS NSAI 2005 OHSAS 18001:1999 SMS NSAI Environmental, Health and Safety and Quality management systems are audited by personnel who successfully completed a Registered Assessor Training course/or ISO 9002 training course. Audits are undertaken on an ongoing basis by a combination of internal audits and external certification surveillance audits. The QEHS Manager is the designated management representative. He has the necessary qualifications, authority and responsibility for: Ensuring that the requirements of the standard are established implemented and maintained. Reporting on the performance of the Environmental Management system to top Management for review and to improve the Environmental Management system. The Shift-Area Managers are responsible and accountable for environmental tasks and duties within their own work area. All employees received environmental training in The induction programme contains a section on Environmental Awareness Issues and an overview of the Environmental Management System in place. Staff assigned environmental duties are provided with ongoing training in environmental issues. All new employees at the installation receive an environmental induction and, depending on requirements, external and internal training courses are given as needs arise. The environmental performance objectives and consequent targets are set on an annual basis with the objective of minimising and, wherever possible, eliminating adverse effects and meeting policy requirements. Increasingly stringent targets are established each year. The programme is reviewed and changed as required. OES Consulting Page 6 of 6

8 Appendix A.1.1 Site Location Map

9 Appendix A.1.2 Environmental Management Structure

10 Cadbury Ireland Limited, Rathmore Installation Environmental Management Structure Head Head of of Manufacturing Steve Flello Shift Manager Willie Gleeson Shift Manger Con Lynch Shift Manager Liam Warren Shift Manager Mike O'Connor Physical Logistics Manager Andy Kiely Office Support Production Engineer Liam O'Flynn (Site Engineer accountabiilties) Engineering Manager Jim McSweeney Day Based Trades QEHS Manager Frank Hickey Effluent Plant Team (1 Operator and 1 relief Operator) Laboratory Team (6 Technicians) Milk intake Team 1 Operator and 1 relief Operator) CSMS Coordinator David O'Sullivan Shift Manager Joe O'Riordan Security Two Operators Shift Trades Production Teams

11 Appendix A.1.3 Process Flow Diagram

12 Cadbury (Ireland) Rathmore Process Flow Diagram Storage Silos (Stored in 1 of 6 Silo s) Raw Milk Whole and Skimmed Standardisation Evaporation KEY Process Storage Area Ingredient Final Product Storage Silos 1, 2, 3 Sugar Batching and Mixing Butter Oil Storage Tanks 11, 12, 13. Storage Tank 33 Liquid Cocoa Mass Storage Tanks 30,31,32 Sweetened Evaporated Milk (SCM) Rework Batching Process Cooking Temperature (Cookers 1-8) Dependent Crystallisation Drying Drier (0,1-3) Cooling Cookers Tanks 1,2,3 T9 4,5 T70 6,7 T80 8 T90 Final Crumb Milling Kibbled Crumb Milled Crumb Packaging Crumb Storage and Distribution