Western Proteins, Hazel Hill, Ballyhaunis, Co. Mayo. Review of IPC Licence. (l&g No. 48);

(T) 094 963 1232 (F) 094 9630127

Attachment N”D

DeveloDment and ODeratio& Historv of the site

The Dawn Meats Group purchased the fixed assets of Irish Country Meats beef and sheep plants and rendering plant at Ballyhaunis, Co. Mayo ftom Glanbia plc in July 1999.

Western Proteins is engaged in the rendering of animal by-products to produce tallow oil, and meat and bone meal at a modern rendering facility at Ballyhaunis, Co. Mayo.

Dawn Ballyhaunis is a modern and efficient beef and lamb slaughtering and processing facility, supplying meat, in fkesh and frozen form to the Irish market, EU

l and third country markets. The plant operates to meet the highest customer standards of hygiene and quality.

In 1997 the company received their first JPC licence from the Environmental Protection Agency. Since the grant of the Jl?C Licence Reg No. 48 Western Proteins has been committed to achieving high environmental standards.

Currently there are approximately 20 people employed till time at Western Proteins and approximately 160 employed at Dawn Ballyhaunis.

Phnt Descrbtion:

Dawn BaUyhaunis

Dawn Ballyhaums slaughter cattle and sheep to produce meat cuts to meet customer requirements. In addition to slaughtering, there are also facilities for cutting, boning, chilling and freezing of beef and lamb products.

a Beef and lamb slaughtering and processing takes place normally Monday to Friday depending on the number of animals to be slaughtered. Peak slaughtering season occurs for cattle between September and November and for sheep from June on- wards. The nature of the beef industry in Ireland is such that there is a tendency towards seasonal&y, with the peak time normally being in the autumn and early winter months.

Western Proteins

Western Proteins renders animal by-products and produces tallow and meat-and- bone-meal. Western Proteins also operate the WWTP which functions to biologically treat process waste waters from both the rendering operations and Dawn Ballyhaunis.

Plant production hours are directly proportional to the amount of by-products delivered for rendering. Western Proteins produces approximately 30 tonnes of meat

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Western Proteins, Hazel Hill, BaIlybaunis, Co. Mayo. Review of PC Licence. (Reg. No. 48)

(T) 094 9631232 (F) 094 9630127

and bone meal, and approximately 16 tonnes of tallow oil per 100 tonnes raw material processed. The plant operates 24 hours per day, and five to seven days per week.

Developments / Upgrades at Western Proteins

A detailed assessment of the odour abatement systems was carried out in 2000 and 2001 and modifications and upgrades of existing systems were also carried out. The net result of all works carried out was an improvement in the e&iency and effectiveness of odour control. The upgrade involved m Increasing the volume of the biofilter being utilised l Modification of scrubbing system - increasing the efficiency of extraction fi-om

key production areas and following best available practices and procedures. l A cover was fitted to the balance tank and then an air extraction and treatment

system was installed. b The roof area of the process building was completely replaced.

Production Process Description:

The purpose of the rendering facility is to process animal by products (i.e. offals in the form of meat, bone and fat f?om meat factories and butcher shops after the required edible meat is removed fi-om the carcass for sale for human consumption). These wastes products from the meat industry is converted into two separate products namely tallow oil and meat and bone meal.

Raw materials are delivered to raw material reception areas in covered delivery vehicles. The raw materials are emptied into intake pits to be transported to the process plant area by conveyors. The process equipment includes crushers, where material is crushed prior to entry into the cooker. In the cooker, heat in the form of indirect steam is applied to the material. Water is evaporated from the materials in the form of steam vapour, and a mixture of meat and bone meal and tallow oil is left behind in the cooker. The meat and bone meal and tallow oil mixture is then conveyed through enclosed conveyors to tht: presses where the prows of separat& the oil from the meal takes place. The tallow oil is then fk-ther purified in the separators prior to being sterilised and pumped to a designated heated storage facility.

Meat and bone meal is then milled, sterilised and Ioaded for dispatch.

All equipment through raw materials, intermediates or products pass in contained within designated buildings. Potentially odorous air t?om the buildings and process equipment is extracted for treatment in the water scrubber and in the biotilter prior to being discharged to the atmosphere. The process area includes the use of conveyors, crushers, cookers, pumps, presses, separators, sterilisers, condensers, extraction equipment and associated control equipment, to process the raw materials and provide appropriate environmental controls, Large quantities of steam are required to facilitate processing of the raw materials. Steam is supplied from two on-site boilers burning tallow oil or meI oil.

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Western Proteins, Hazel HiJ.l, BaIlyhatis, Co. Mayo. Review of LET Licence. (Reg. No. 48);

(T-J 094 9631232 0 094 9630127

The raw material is processed to produce a high-grade tallow oil and protein meal. Tallow oil is used as an energy additive in animal feeds in Ireland. It is also used in the manufacture of soap products and cosmetics in the U.K. and Europe.

Processine of Raw Materials:

A basic process flow diagram, showing the flow of raw materials through the process areas is shown below:

Basic Process Flow Diagram for the Western Proteins Site

Intake of Raw Materials

*

Crushing

v Processing

Tallow Production Meal Production

v Tallow Sterilisation

v Meal Sterilisation

v Storage Tanks

v Storage

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Western Proteins, Hazel Hill, Ballyhaunis, Co. Mayo. Review of PC Licence. (Reg. No. 48)

(T) 094 963 1232 (F) 094 9630127

Processes Waste Water Treatment Plant

The existing wastewater treatment plant at Western Proteins comprises of the following unit processes. 1. Raw Effluent Collection 2. Screening 3. Dissolved Air Flotation 4. Raw Effluent Balancing 5. Activated Sludge 6. Nutrient Removal 7. Final Clarification 8. Sludge Thickening and Dewatering

The Environmental Manager and the laboratory technician have the responsibility for the operation of the wastewater treatment plant and its monitoring.

1. Raw Effluent Collection

Rainwater, wash waters and contaminated surface waters are drained to a designated collection sump in Dawn Ballyhaunis and pumped to a Meva screen in Western Proteins. Contaminated waters and wash waters fiom Western Proteins flow to a designated sump and are also pumped to a brush screen. All effluent then enters a combined sump. Condensate from the cooker and wash water from the presses is also pumped to this sump.

The Western Proteins sump is located in the yard between the two DAF’s. The volume of raw effluent entering the sump is dependent on rainfall but operating experience shows the maximum hydraulic load to be about 1250 m3/day. The collection sump is also operated as a primary fat removal facility and fats collected in this sump are recovered and returned to the process area.

2. Screening

Wastewater from the sumps is delivered to the screens where all floating debris is removed. There is one brush screen located on site, for waste entering from Western Proteins. Wastewater received from the inlet sump passes over a large holed sieve. Debris is removed from the sieve by a number of brushes. The debris falls down a chute to a skip located at the base of the brush screen.

There is one Meva screen located on site, for waste entering from Dawn Ballyhaunis. Wastewater is pumped from the Dawn sump to the screen. The meva screen is a step screen that filters the effluent and removes particle of size greater then lmm. Debris is removed from the screen by a continuous step motion. The debris falls down a chute to a skip located at the base of the screen.

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(T’) 094 9631232 (F) 094 9630127

After the effluent has been screened it then flows to the Dissolved Air Flotation @An

3. Dissolved Air Flotation

The Dissolved Air Flotation removes fat, grease and particulates fi-om the wastewater. The removed matter floats to the surface of the tank where it is skimmed off the surface by a scraper.

The removal of matter from the wastewater reduces the BOD and COD loading into the activated sludge system. This in effect reduces the amount of food entering the system. This allows for a decreased level of bacteria in the system, therefore giving greater control/management of the activated sludge system.

Two DAF units are contained on site; 1) Western Proteins DAF 2) Dawn Ballyhaunis DAF

Incoming effluent flows fi-om the screen into the impeller unit. Air is introduced into the wastewater by the impeller; it then flows into the DAF tank.

Wastewater is recycled from the downstream end of the DAF unit. This recycled flow is retained in a pressure vessel where mixing and saturation with air occurs. This recycled wastewater is added at the start of the DAF unit by means of jet nozzles with the incoming wastewater from the impeller unit. As the pressurised water returns to atmospheric pressure, the dissolved air comes out of solution, forming fine bubbles, which rise to surface bringing matter with them. The matter is then removed by a steel scraper with rubber tips to the DAF sludge tank.

Overflow from the 2 DAF’s flows to an underground combined sump where all the wastewater streams mix together. Condensate arising corn the cooking process does not contain any fat or grease and therefore does not require treatment in the DAF so it is also directed to the combined sump where it mixes with the DCM waste stream and the WP stream before being pumped to the Balancing Tank.

4. Raw Effluent Balancing

The mixed effluent corn the combined sump is pumped to the Balance Tank where it is continuously mixed and aerated. The balance tank has a total holding capacity of 1450 m3 and is fitted with two 22 kW submersible aerators- The aerators are used to mix the contents of the tank and to prevent anaerobic conditions from developing in the balance tank. The balance tank is also used to allow the forward feed to the biological treatment system to be controlled at a constant rate. The balanced raw effluent has an average COD of 3,850 mgL and a corresponding BOD of 2,000 mg/L. The daily volume pumped from the balance tank depends on the

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Western Proteins, Hazel Hill, Ballyhaunis, Co. Mayo. Review of IPC Licence. (Reg. No. 48)

(T) 094 9631232 (F) 094 9630127

time of year, rainfall etc. but the average is approximately 1000 m3, thus giving an average BOD load of approximately 2000 kg BOD /day entering AT 1 for treatment.

The balance tank is f?tted with a cover, and is vented to the biofilter system to minimise the risk of potentially odorous fugitive emissions from this source.

5. Activated Slu&e

Biological treatment is provided by activated sludge. A total aeration tank capacity of 5780m3 is provided in five separate tanks. These tanks are piped to operate in series. Each aeration tank can be operated at a mixed liquor suspended solids (MLSS) level designed to provide an operating F: M in the ratio 0.08 to 0.12 kg BOD/kg MISS/day. Aeration/mixing in aeration tank 1 is provided by three 55 kW surface aerators, in AT2 by a 45 kW aquaturbo aerator. Aeration in AT3 is provided by a 15 kW surface aerator, AT4 contains a 45 kW aquaturbo aerator and AT5 contains a 22 kW surface aerator. The sludge-loading rate is designed to ensure a suitable sludge age to sustain a viable population of nitrifying bacteria. A sludge age in the range of 20 to 30 days is normal at the plant. The % BOD removal in the system is approximately 99.2%.

6. Nutrient Removal and DH Control

AT1 is used as an anoxic zone to encourage denitrification to occur. During this process nitrates are converted to nitrite which is in turn converted to nitrogen gas. Denitrification occurs in this tank under low oxygen conditions. pH is closely monitored in this tank and is maintained above 7.5 to provide optimum conditions for denitrification to occur.

A Phosphorous removal facility, using chemical precipitation of Phosphorous by Aluminium Sulphate addition is also provided at the plant. The chemical addition is made into the sump which contains the owdkm from the two ~e~lement t&s. The mixed wastewater and Aluminium Sulphate are then pumped to flocculation tanks where it is gently mixed to encourage floes to form.

Addition of Ahtminium Sulphate can sometimes result in unacceptably low pH values in the treated effluent discharge. A separate pH controller and dosing pump are used for the addition of Sodium Hydroxide where appropriate.

7. Final Clarifkation

A final effluent clarifier with a capacity of 175 M3 is provided at the treatment plant. All treated effluent Tom the activated sludge aeration tanks passes through the clarifier prior to discharge. The clarifier is fitted with a bridge scraper to encourage solids to settle. The tank is also fitted with a bottom sludge removal facility. Sludge settles in the bottom of the tank and is returned to the sludge holding tank.

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Western Proteins, Hazel Hill, Ballyhaunis, Co. Mayo. Review of IPC Licence. (Reg. No. 48)

(T) 094 9631232 (F) 094 9630127

8. Sludpe Thickenine and Dewatering

During peak processing periods excess biological sludge, amounting to an average of about 7 - 10 tonnes of solids / day, must be removed from the biological system on a continuous basis. Sludge is continuously returned to AT1 from the bottom of ST2 and ST3 to reinnoculate the system with bacteria. To waste, the sludge is prevented fi-om going back to AT1 and is instead diverted to one of two tanks to feed to the presses.

The two tanks to waste into are l Sludge Holding Tank l Blue Decanter Tank

There are two belt presses on site for de-watering sludge. The sludge presses allow

a the sludge to be chemically conditioned and de-watered as it arises or to be thickened prior to conditioning and de-watering. The sludge can be thickened by removing the pockets of water fiom the settled sludge prior to de-watering which results in fewer chemicals being used and reduced cost of de-watering.

Wash and filtrate waters from the presses are returned to the wastewater treatment plant for re-processing.

Sludge from the DAF’s is continuously skimmed from the flotation cell as it arises. This sludge is collected separately in designated bins and is returned for reprocessing in the factory.

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Western Proteins, Hazel Hill, Ballyhaunis, Co. Mayo. Review of PC Licence. (Reg. No. 48)

(T) 094 9631232 (F) 094 9630127

Descrimion of Process Control Svstem Indicating the kev Control EauiDment

Once the raw materials have been delivered to the facility and placed into the hopper, all the mechanical handling of raw materials is a continuous operation. Automatic control is provided on critical items of equipment and any failure is automatically detected and the system is designed to interrupt the complete process in the event of any such failure in plant or equipment.

Critical items of the plant are identified and described separately.

FAT & BONE PROCESSING:

Raw Material Intake:

The raw material is placed in the two pits in the intake. These pits have a capacity for 130 tonnes.

The material is transferred to the intake hopper by track-machine. The hopper holds the raw material prior to being fed into the crusher. The hopper has a capacity of 40 tonnes and it is emptied by means of rotating screws that are controlled by intake personnel.

The rough and fine crushers process raw material at a rate of 20 tonnes/ hr. It is manually operated.

If the crusher blocks it has to be manually cleaned. Full ranges of spares are held in the stores for the crusher.

Pum~iw System:

The raw material pumping system has capacity to deliver material from the feed vessel to the cooker at a rate of 15 tonnes / hr. Personnel controls the pumping rate.

continuous cooker:

The material is pumped into the cooker and exits after approximately 1.5 to 2 hours. The temperature varies from 90-140 degrees Celsius during the cooking process and the cooker is heated by indirect steam. The foul gases Tom the cooker enter the odour control system.

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Western Proteins, Hazel Hill, Ballyhaunis, Co. Mayo. Review of PC Licence. (Reg. No. 48)

(T) 094 963 1232 (F) 094 9630127

TALLOW OIL PROCESSING:

Details of critical controls on equipment in the tallow processing area are presented here.

Decanter:

The decanter is a centrifugal machine that separates the smaller solids from the filtered liquid / tallow &action. This machine will shutdown automatically if overloaded with tallow.

Semtators:

Separators are used to remove water and fine particles from the tallow oil. The separators have a self- cleaning system built-in. This cleaning system discharges sludge, which has been separated from the tallow 12 times /hr. Sludge from the separators is returned to the cooker for reprocessing. Wastewater arising from the separators is returned to the main wastewater sump for pumping to the wastewater treatment plant.

Storafze:

There are 4 tanks used for storage. Each of the tanks are lagged and have capacity of approximately 60 tonnes. They are heated by a coil, which uses indirect steam.

PROCESSING OF MEAT & BONE MEAL:

Pressinrr:

Greaves, i.e. the mixture of cooked meat and bone meal and tallow oil, are discharged and transported to the presses at a rate of approximately 5 tonne/hour.

The greaves are compressed to extract tallow oil. The press feed rate is controlled by an ammeter, which shuts off the incoming material if the amps rise above the threshold limit for the motor. This system ensures the presses do not become overloaded.

Condenser:

There are 4 condenser fans, which are controlled Tom a dedicated electrical panel. The choice of 2 speeds is available for each condenser. The temperature probes in the condenser detect both condensate and ambient temperatures- The Supervisory personnel can select condenser speed according to temperature conditions and requirements. There are also two non-condensable fans which are electrically controlled.

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Western Proteins, Hazel Hill, Ballyhaunis, Co. Mayo. Review of IPC Licence. (Reg. No. 48)

(T) 094 9631232 (F) 094 9630127

Biofilter:

A variable inverter controls the extraction fan on the biofilter plant. This allows fan speed to be adjusted depending on the required conditions.

Boiler & Steam Distribution:

The temperature of the fuel oil in the main storage tank is controlled by a thermocouple linked to an automatic steam valve on the heating coil. The fuel oil temperature is allowed to fluctuate between 80 degrees Celsius and 90 degrees Celsius. A ballcock controls the level of water in the condensate tank (hotwell). All water going to the hotwell passes through a de-alk / softening plant. Water is fed from the hotwell to the boilers with a variable speed controlled water Pump.

The two steam boilers have water level probes built in to maintain a correct water level in the boiler. This ensures that the boilers will shut down if the water level falls below the low-level probe.

Safety release valves are fitted to all the boilers. In the event of failure of the in-built pressure sensors in the boiler, the pressure relief valve will open when an internal pressure is reached.

Condensate check valves are fitted to all steam lines. Water in steam lines can be dangerous because it cannot be compressed and it can cause breaks in steam lines if a weakness occurs in the pipe or delivery system.

Milliw Plant:

Overheating of the main motors in the milling plant is prevented by elect&d thermocouples.

The frequency inverter controls the speed of the screw conveyor feeding the mill. This can be varied by the operator. The buffer bin provides a continuous feed to the mill and is fitted with a Ievelling screw to maintain an equal distribution of meal in the bin.

Tallow Storwe:

l

The tallow oil storage tanks are fitted with steam coils to prevent materials from solidifying in the storage tanks. These controllers draw steam from the boiler as the temperature of the oil falls, so a correct temperature is maintained.

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Western Proteins, Hazel Hill, Ballyhaunis, Co. Mayo. Review of IPC! Licence. (Reg. No. 48)

(T) 094 9631232 (F) 094 9630127

Loss of Dower to the Waste Water Treatment Svstem

If electrical power to the wastewater treatment plant fails, all tanks in the treatment plant run to gravity and aeration stops.

If the problem appears to be of a persistent nature, the hire of generators for the effluent treatment plant may be necessary. A contract for the hire of the generators is in place with an external generator hire company.

Details of the Activities carried on in Laboratorv Facilities Associated with the ACtiVim

Dawn Country Meats, t/a Western Proteins operates on the Western Proteins site, a laboratory that carries out all the environmental monitoring and also carries out on- site quality control duties.

The Laboratory has an Environmental Manager and an Environmental Offker working till-time. Environmental and quality control is an essential part of the process and a number of critical aspects of the overall activity are carried out in the laboratory. The test procedures used in the laboratory are either those specified in Standard Methods for the Examination of Water and Wastewater or a standard test procedure specifically developed for control in the rendering industry.

Details of the quality control test procedures are described below:

Boiler Water Feed:

The quality of being fed to the boiler is monitored daily. The water is sampled for hardness, total dissolved solids and PH. There is no significant excess sample volume arising from these test procedures. Results are recorded on a daily report sheet.

Meat & Bone Meal:

Quality control on the meat and bone meal is also an essential aspect of the daily course in the Laboratory. Samples of meat and bone meal are collected and analysed daily for the following parameters: (A) Protein Content (B) Oil Content Of Meal (C) Moisture Content (D) Ash Content.

The meal samples are analysed via a Foss Meal Analyser and results are all stored in the program database.

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Western Proteins, Hazel JAill, Ballyhaunis, Co. Mayo. Review of IPC Licence. (Reg. No. 48)

(T) 094 9631232 0 094 9630127

The results obtained from these tests are also recorded on a daily report sheet. Samples of meat and bone meal are also sent to an independent outside Laboratory for microbiological testing.

Any excess of sample material is returned to the raw material section of the factory for reprocessing.

Analvsis of Tdlow Oil:

The two separate grades of tallow are analysed for the following parameters: (A) Free Fatty Acids (B) Moisture Content (C) Soap Content.

Excess sample material is collected in a designated container in the Laboratory and is returned to the plant for reprocessing at the end of the week.

Analvsis of Waste Water Treatment Plant:

Successful operation of the Wastewater Treatment Plant requires that a significant amount of process control data be generated and interpreted each day. All the necessary monitoring of the wastewater treatment plant is also carried out in the laboratory.

This includes analysis of the materials being fed to the balance tank, analysis of materials passing through the D.A.F unit, analysis of material being delivered to the biological treatment process, monitoring of operating conditions in the five aeration tanks, and analysis of the treated wastewater.

Analvsis of Atmosuheric Emissions:

&)a\~@ of emis&ms to iitiwsphere includes the monitoring of en-&km from the two-biofilter units. Drager tubes and designated Drager test equipment, are used to define the Ammonia, Mercaptans, Hydrogen Sulphides and Amines content of the discharge from the biofilter

The company also has its own Anemometer on site. This allows the Laboratory staff to monitor wind speed and direction on the site on a daily basis.

Waste Arising: from Laboratory Test&

a

Procedures for treatment or disposal of wastes arising from Laboratory test procedures are described below:

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Western Proteins, Hazel Hill, Ballyhaunis, Co. Mayo. Review of IPC Licence. (Reg. No. 48)

(T) 094 9631232 (F) 094 9630127

Water and Waste Water Testim:

Any excess of water or wastewater samples arising fi-om the Laboratory test procedures are returned to the wastewater treatment plant.

An approved contractor currently collects pre-filled test vials used in the Chemical Oxygen Demand test procedure for disposal.

All other aqueous samples arising in the Laboratory are disposed of to the effluent treatment plant. The load arising for the treatment process is insignificant.

Product Analvsis:

The meat and bone meal samples after analysis are returned to the mill area in the plant. Excess tahow oil arising from the free fatty acid analysis and the soap content analysis are recovered for reprocessing.

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Attachment Na D Flow Diagram Of Process At Western Proteins

Goods In (1) +

Intake (2)

+ Hop er (3)

4 Rou

8” Crusher (4)

Metal Detector (5)~Bin

4 Fine Crusher (6)

+ Feed Vessel (7)

4

J.““:“’ @) -1

Meal Component (9) i Tallow (20)

4 1 Recycle + A Sweco Screen (21)

Magnetic Stage (10) b +

+ i Line T - Screen (22)

+ Prefs (11) + T&W i

Recycle - Gough Screen (23)

Line + Decanter (24) +

Hofdmg Bins (12) +

20,OOOL Tank (25) It Sterilisers (13)

4 Cooling Bin (14)

4 Holding Bin (15)

4 Metal Detector (16) +Bb

4 Milling Process (17)

4 Magnet - Bin

Loading Bin (18)

1 Trailer (19)

1 Stick water 4 i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.......... Clafifier (26)

+ Holding Tank (27)

4 Steriliser (28)

4 Storage Tanks 1 8z 2 (29)

4 Basket Filters (30)

4 Loading Tanks 3 & 4 (31)

4 IS0 663 Test (32)

+ Tankers (33)

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Attachment N” D

GENERAL PROCESS DESCRIPTION

The principal process carried out at Western Proteins is the rendering of category 3 animal by-products. The associated processes are the treatment plant for wastewater and odorous gases from the production process.

The raw material for the production plant consists of category 3 material as specified in our C3 licence issued by the Department Of Agriculture. All raw materials are transported to the plant in covered skips or cover articulated trailers. The end products manufactured are tallow and meat and bone meal.

The raw material is tipped into the intake pit and transferred to the intake hopper. The material is crushed and checked for metal. The mixture is stored in a feed vessel and transferred through an enclosed pipe to a continuous cooker. The cooker is heated by indirect steam where the steam condensate is recovered and re- used in the boiler feed water system. The foul gases Tom the cooking process enter the odour control system. The cooked material is conveyed at a steady rate to two presses. These greaves are recycled through the presses. The presses mechanically squeeze the tallow from the meal. The meal is then stored in a holding bin. From the holding bin the meal is transferred to the sterilisers where it is sterilised. It is then milled in a pulvisier and sieved to the desired particle size and conveyed to a storage room. Meal is stored in the storage bin and loaded into articulated trailers.

Tallow is collected fi-om the cooker outlet screw and the two presses and pumped from a holding tank through a screen. Solids are separated fi-om the tallow in a decanter. The tallow is stored in 20,000~litre tank before further refining in a clarifier. Tallow is pumped back at a continuous rate to the cooker. The separated tallow is pumped to a tallow holding tank where it is maintained on stand- by for sterilisation. The steriliser is fed from this tank and after the sterilisation process the product is pumped to storage tanks 1 and 2. From storage tanks 1 and 2, the tallow is separated or is further refined through 2 basket filters. The resultant product is stored in the feed grade tanks from which it is dispatched.

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Attachment W D Odour Treatment System at Western Proteins Process Flow Diawam (February 20051

Condensors Raw Material

Effluent

Press 1 I Press 2

meEiz:=q 1

+g+

Hopper

I

Woodchip Woodchip Biofilter Biofilter

(Treated gases to atmosphere)

(Treated gases to atmosphere)

Main Extraction Duct

+ Raw material (2) b heater

Separator (2)

4-j Clarifier (6) 1

4-l Stickwater Trough I

4 Sterilised cooler bin )

Main Extraction fan

water in

drain off to WWTP (1 - 1.5 M/s)

W&Z-l-

Pressure . wy Ozone in

7

+ Drain off to effluent plant

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Attachment W D

Odour Treatment System at Western Proteins

The air extraction duct begins in the intake area where all the foul odours are sucked to the duct due to the negative pressure which is maintained in the building.

The odour treatment system at Western Proteins consists of one main air extraction duct to which all the equipment in the production area are vented. All the primary odour sources e.g. sterilisers and presses are extracted to the main duct. Steam from the cooker / dryer is the strongest source and this is led separately to an external air-cooled condenser. Non - condensable material is returned to the main ventilation flow.

The main extraction fan which draws all the potentially odorous air through the duct is located adjacent to the biofilters.

The extracted air first passes through a water scrubber tank / humidifier which consists of rows of jet nozzles which gives greater contact surface area compared to a conventional system Ozone is dissolved in the irrigation water as an additional degree of treatment.

The scrubbed air stream is then split between two biofilters. The walls and slats of the biofilters consist of reinforced concrete to ensure no leak occurs of untreated gases. Wood chips are used as a medium as they do not become compacted and therefore enhance treatment efficiency. An automated sprikling system is installed on both biofilters which ensures optimum moisture levels are maintained. The biofilters have open tops, and treated air is dfised to the atmosphere

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Attachment N” D Summary Table Of Beef Line In Dawn Ballyhaunis 2005

Cattle Intake Cattle Slurry Landspreading

I Kill Box I

Blood

+- 1st Legging

Hides Hide Pulling 4

4 Further Processing

Rodding

Further Processing

Brisket Saw and Evisceration

+ Spinal Cord Removal

I Cl Rendering

I + , I I I

Skirts and Tail removal I

I Grading Machine I

‘It Weighing

Labelling.@ading

&

I Carcase Wash I I-G-l

$A+- I Transfer to chilling Deboning & Packaging

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Attachment No D Sheep Plant at DCM Ballyhaunis Process Flow Diagram (March 2005)

1. Sheep Intake f Lairage siurly

Slurry Tank

3. Sticking & Bleeding

lL -b Blood

Storage Tank . I

I

1 4. Ear tag/tailremoval 1 (

Cl / C3 Rendering

1 6. Opening Leg Region 1

I 7. Front Opening I

It 10. Evisceration C11/ C3 Rendering

11. Stomach / Rmnen Removal l Paunch Contents Storage

+ and Landsureadiw

1 12. Grading I

1 15. Final Carcase Chilling 1

1 17. Packaging I

23 18. Sale

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Attachment P D

Description of the Beef Line In Dawn Ballyhaunis

Cattle are unloaded into the cattle intake area where they are penned and have their eartags read. The subsequent cattle slurry waste collected in this area is stored during the winter months and is landspread during the summer period. The cattle are then loaded into the stun box / kill box where they are stunned and shackled. The animal is stuck and allowed to bleed. This blood is processed further in Category 1 and Category 3 Rendering plants. Following the sticking and bleeding, the animal’s snout is removed, as is the fore leg and any horns, which may be present. Flaying of first hind leg and second leg occurs and also hock is removed. The opening of the midline and flaying of the flanks occurs then. All the parts removed from the animal in the above processes are fin-ther processed in Category 1 and Category 3 Rendering plants.

The animal’s hide is now attached to the hide puller and is removed for f&her processing. The oesophagus is clipped to seal it and the head is removed and sent for further processing. Splitting of the brisket and removal of viscera occurs, as does the splitting of the carcass into sides. At this stage the spinal cord is removed and this SRM is sent to Category 1 Rendering plant. The skirts and tail are then removed and sent for f&her processing. The carcasses are now graded by the grading machine and are weighted and labelled. Carcasses are washed to remove bone dust and are then transferred to the chills. From chills they are deboned and packaged and are thus ready for sales.

Description of the Sheep Line In Dawn Ballvhaunis

Sheep arrive at the plant and are booked in and unloaded. They are then put into a restainer and stunned. The throat is cut and the animal is then allowed to bleed. Eartags are then removed and read. The hides and hind legs are then removed. The stomach is opened and the viscera is removed. The carcass is then graded, weighed and labelled. The carcass is then transferred to the chills and then to the boning halls for deboning. Cuts of meat are packaged and sold.

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has been extracted fkom this location in the document and has been stored in a separate file.

(This is due to file size issues.)

The extracted content can be found in the following electronic pdf file:

Application Form-Drawing-4

Licence: POO48-02

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The extracted content can be found in the electronic pdf file:

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Licence: POO48-02

,

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