IPPC License Application
Glanbia Consumer Foods Drogheda
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Attachment D:
Glanbia Consumer Foods Drogheda
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IPPC License Application
Glanbia Consumer Foods Drogheda
INTRODUCTION
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Glanbia Foods Society Ltd. (Glanbia) is an international food company based primarily in Ireland, the UK and USA which serves markets for dairy and meat products across the world. Glanbia ranks as one of Europe's largest dairy companies and one of the world's largest cheese manufacturers. It is quoted on the Dublin and London Stock Exchanges and had a turnover in 2002 of over €2.6 billion. The company employs over 7,500 staff worldwide. The Glanbia Group has three main business divisions: • Consumer Foods • Food Ingredients • Agribusiness Glanbia’s site at Drogheda serves as part of the Consumer Foods Division. The total area of the site is ca. 1.705 hectares of which all is currently developed. Glanbia Dairies Ireland is part of the Consumer Foods Division and is the Irish liquid milk division of Glanbia plc. It is the leading supplier of fresh and value added milk beverages to Irish consumers through its market leading brands, Avonmore, Premier and Snowcream from its three liquid milk processing facilities at Drogheda, Waterford and Ballitore. Glanbia Dairies, Drogheda comprises a liquid milk processing, packing and primary dispatch facility and has the capacity to contribute 30 million gallons per annum to the liquid milk division. Founded in 1957 as the Ryan Dairies, the plant started producing the Avonmore brand in 1986. It now processes fresh and light milk for the Avonmore and Premier brands as well as flavoured milks and Supermilk, Slimline and Cream under the Avonmore label, for the Dublin markets and the Eastern part of the country. The dairy facility employs a total of 128 staff and operates on a 20-hour basis processing milk six days a week and dispatching milk seven days a week.
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History • Ryan Dairies formed on this site in 1957
Formed Drogheda and Dundalk Dairies in 1959
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Acquired by Avonmore in 1986
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Accredited with ISO 9000 1993
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Merged with Waterford to form Glanbia in 1997
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Accredited with BRC 2004
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Accredited with ISO 14000 2004
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Accredited with CLAS 2005
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Existing Dairy Plant and Operations General Glanbia Dairies Drogheda processes fresh and light milk for the Avonmore and Premier brands as well as flavoured milks, Supermilk, Slimline and Cream under the Avonmore label. The existing dairy is designed to process a maximum of 30 million gallons
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IPPC License Application
Glanbia Consumer Foods Drogheda
(136,380m3) per annum. This equates to an average throughput of 100,000 gallons (455m3) per day based on 300 days per annum processing. The process operations in the dairy plant currently operate 24hours/day and six days per week (Monday – Saturday) with the following shift pattern: 6.00am to 2.00pm Shift 1 Processing and packing 2.00pm to 10.00pm Shift 2 Processing and packing 10:00pm to 06:00am as required. Dispatch operations to market are on a 24-hour basis, seven days per week. Deliveries of milk (milk intake) to the plant take place seven days a week which includes a limited period on Sundays (8:00 am to 4:00 pm). The factory operates a 3-shift 24 hour /7 day processing and packing system at peak periods – i.e. Christmas, Easter and some bank holiday weekends The plant currently has a total workforce of 130 persons.
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Process Raw milk is unloaded from road tankers at a milk intake bay and transferred directly to a raw milk storage silo. Prior to being unloaded a QA (Quality Assurance) sample is taken from the road tanker and tested in the on-site laboratory. A total of about 15 tankers per day each carrying about 5000 gallons. Milk temperature in the intake line is monitored with two setpoints, one to start cooling the milk and the other to reject the milk. The raw milk silos are agitated once a pre-set volume is achieved in the silo, primarily to prevent the separation of cream and milk. From the raw milk storage silos milk is processed through a milk pasteurising line which has three main operations: 1. To pasteurise the milk. This is achieved by heating the milk to 71.6oC and holding at that temperature for 16 seconds. 2. To adjust the amount of fat in the milk, firstly the cream is separated from the milk in a separator. A portion of the cream is then recombined with the milk to give a fixed fat content in the milk (0.1% for “skim”, 1.5% for “semi-skim” and 3.5% for “whole” milk) 3. After adjusting, the cream and milk mix are homogenised which ensures that they do not separate at a later stage. Pasteurised milk is stored in the finished milk silos until a filling line is available to receive and package it. Finished milk silos are dedicated to hold milk with different fat contents. From these silos the milk is piped to filling machines where it is packed into a range of containers including 2 litre plastic bottles, 0.5 litre and 1 litre cardboard containers etc. A portion of the milk throughput is diverted through a mixing system where additives such as vitamins and flavours are added to create “speciality” milks. The resulting mix must only be pasteurised again. After been pasteurised it is held in a fortified milk silo until a filling line is available to receive and package it. Surplus cream from the standardising operation is transferred to a raw cream storage silo. This cream is processed in a dedicated cream pasteurising line, however it is not standardised or homogenised. After been pasteurised it is held in a fresh cream vessel until a filling line is available to receive and package it. All packed milk and cream is then shrinkwrapped or placed in trollies (depending on the packaging size and type) and transferred to the chill store, where it is temporarily held at a temperature of 40C before being loaded onto refrigerated trailers and transported to the marketplace. The returns area of the plant takes in any out of date packaged milk which is
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IPPC License Application
Glanbia Consumer Foods Drogheda
returned to Glanbia and empties the milk from the packaging before transferring the milk to the returns milk silos. Any waste milk from the plant process is also transferred to the returns milk silos. The returns milk is then used for animal consumption and waste milk from the plant processes is stored for further processing. The process plant and lines are cleaned in place (CIP). This is achieved by pumping CIP solutions from a central CIP station at pre-set flowrate, chemical concentration and temperature to the tank, piping system or process plant to be cleaned and then returning the solutions to the same CIP station. There are two typical CIP cleans, the first is a caustic wash (Lactol – sodium hydroxide solution ), which is a caustic wash preceded and followed by a water flush. The second CIP clean is an acid (nitric acid solution) and caustic wash. The sequence for this clean is water flush, caustic wash, water flush, acid wash & water flush.
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Plant and Utilities The dairy plant comprises the following principal areas: • Administration block comprising reception area, offices, and staff welfare facilities (changing rooms, toilets) • Staff Canteen (Temporary prefabricated portakabin facility) • Laboratory (Quality Assurance) • Tanker Unloading Milk Intake Area • Raw Material Store (Additives, Milk Flavours) • Process Area • Returns Area • Carton Store • Filling Hall • Chill Store • Milk and cream storage silos located external to the dairy plant comprising 4 No. Raw Milk Silos, 5 No. Finished (pasteurised) Milk Silos, 3 No. Buttermilk silos, 3No. Pasteurised Cream Silos and 2 No. Returns Milk Silos. Areas around the milk silo storage areas drain to the balance tank. • Dispatch / Truck Loading Area (8 No. Loading Bays) There are also a number of ancillary buildings and utilities on the site which support the dairy process and operations and are outlined as follows: • 2 No. Steam Boilers (total capacity of 3500 kg/hr steam) located in the Boiler House. • MCC (Motor Control Centre) Room • 1 No. Groundwater Wells and well water storage tank • Well Water Treatment Plant (Softening and Chlorination System) • Cleaning in Place (CIP) System • Chilled Water System comprising 3 No. Chillers and 1 No. Chilled Water Tank. • Compressed Air System with 2 No. Air Compressors. • Bunded area for chemical IBCs and drums (e.g. caustic and acid used in CIP system) • Truck Wash Area • 2 No. Waste Compactor
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Glanbia Consumer Foods Drogheda
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IPPC License Application
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IPPC License Application
Glanbia Consumer Foods Drogheda
4
1
2
3
2 5 ,0 0 0 g a l.
2 5 ,0 0 0 g a l.
2 5 ,0 0 0 g a l.
5 0 ,0 0 0 g a l. P 1 3 0 ,0 0 0 L t
H om o g 4 K
R a w C re a m 9
E s k ov a t
1 ,8 0 0 g a l.
1 ,5 0 0 g a l.
3 ,2 0 0 G a l
B le n d
S u p e r m ilk
P 2 8 / 1 3 ,0 0 0 L itre s
H o m o g 8 /1 3 K
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C re a m 2 0 0 0 L t/h r
C re a m
B u tte r m ilk 11
12
4 ,0 0 0 G a l
4 ,0 0 0 G a l
13
14 1 ,5 0 0 g a l.
h ot w ater
7
15
5
6
2 ,2 0 0 g a l.
7 ,0 0 0 g a l.
7 ,0 0 0 g a l.
5 0 0 g a l.
1 0 ,0 0 0 g a l.
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2 ,2 0 0 g a l.
P a s te u r is e d
1 Lt
2 Lt
3 Lt
6000 lt/h r
6000 lt/h r
6000 lt/h r
4 Lt 6000 lt/h r
Load O ut
5 0 .5 l 6000 lt/h r
6 P o ly
7 P o ly
1 3 .5 & 2 0 L t 1 0 / M in u te
Load O ut
8 189 ml
9 189 ml
10 250 ml
4500 u n it/h r
3600 u n it/h r
3600 u n it/h r
4 Lt
P o ts
100 u n it/h r
2500 u n it/h r
11 2 Lt 9000 u n it/h r 6000 u n it/h r S h rin k
Load O ut
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