ABP Food Group Animal By-Product Valorisation · ABP Food Group • Olleco is one of the UK’s...

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ABP Food Group

26th April 2018 Fergal Maguire NDA, BSc (Hons)

ABP Food Group Animal By-Product Valorisation



ABP Food Group

Introduction Company Overview

€3 bn Turnover

10,000 Employees

46 Production Sites

1 Million Cattle

Ireland - 6 operational sites; Processing c400,000 cattle per annum. Recent EU approval of JV with Slaney Foods. Poland - 3 operational sites; Processing >200,000 cattle. UK - 14 operational sites; Processing >500,000 cattle & 1m sheep per annum; Retail packing >2,000t per week.

One of Europe’s leading manufacturers of private label pet food, producing 570,000 tonnes every year from 9 facilities including pouch, alutray, canned & dry formats.

The largest collector of used cooking oil in the UK and Ireland. Our efficient and traceable waste management service converts waste streams from over 50,000 customer premises into renewable energy.

Processing the by-products from ABP’s beef processing business into functional ingredients, organic fertilizer, pet food proteins, alternative fuel and a range of other products.



ABP Food Group

Our Presence We export our award winning beef to premium Retailers, Foodservice Operators & Manufacturers

across 4 Continents…

… all with a keen focus on Sustainability – ABP Food Group is the first food company in the world to achieve quadruple Carbon Trust Certification Standards.



ABP Food Group

BIG PICTURE : UN Sustainable Development Goals (SDG’s)- 163 Nations all signing up – Less Harm – More Good

• Each SDG underpinned by targets and Objectives.

• Each Nation to deploy strategies and policies around, taxation, investment, legislative, environmental, etc to deliver targets and goals.



ABP Food Group

Big Picture: Paris COP 21 – Agreements Reached

• To limit rise in global temps – To max 2’C – target 1.5’C – COP Pledges limit to 2.7’C – Current trajectory 3.6’C

• Phase out Fossil fuels by 2050

• Sources and Sinks of GHG in balance by

2100

• $100Bn donated to emerging countries by 2020 and reviewed thereafter.



ABP Food Group

ABP Food Group Corporate Targets



ABP Food Group

20.05%

42.54%

23.21%

92.92%

Such has been the success of our DoingMoreWithLess campaign, we’ve revised our targets 5 years ahead of our original 2020 deadline!

So how is ABP Food Group facing into this context? Then – Our operational 2020 targets

30% CARBON FOOTPRINT REDUCTION

ZERO WASTE TO LANDFILL

50% WATER

CONSUMPTION REDUCTION

40% ENERGY

CONSUMPTION REDUCTION

Our 2020 targets

(All vs 2008 base levels)

Cumulative Progress to 2016

199,918 Tonnes

85,632 Tonnes

7,386,667 Metres3

1,100 Giga Watt Hours.

Cumulative Net Reduction to 2016



ABP Food Group

Abattoir Process Product Hierarchy

1. Meat for human consumption – develop products and markets

2. Convert to edible co-products, Oleochemical and Pharmaceutical

3. Pet foods 4. Category 3 Animal By-products (Offal/Bone) 5. Category 2 Animal By-products – manure, digestive tract

content (Paunch) 6. Category 1 Incineration



ABP Food Group

Abattoir Process Waste Streams

• Category 2 Animal by-products- Stomach contents of animals also known as (Paunch)

• Lairage and truck wash materials

• Activated sludge

• Dissolved Air Flotation unit sludge

• CAT 3 Animal by-products (offal/Bone)

• Blood



ABP Food Group

Abattoir Process Waste Streams

These waste streams:

• Acceptable raw materials for Anaerobic Digestion

• Easily transported to site

• Don’t require additional treatment prior to addition.

• Mainly liquid in format for Anaerobic Digestion but can be semisolid in nature

• Gas yields considerable

• Digestate nutrient content is good



ABP Food Group

• ABP Lurgan – Low Temperature Anaerobic Digester

• Olleco - Anaerobic Digestion Facility

ABP Food Group Projects and Case Studies



ABP Food Group Innovate UK Sustainable Technologies Showcase

ABP Food Group

300 m³ wastewater per day per moduleEasily expandable with additional modules11 m height, 3.5 m diameterInfluent 500-5000 mg/L90% removal rateInfluent < 1000 mg/L50% removal rate

Sludge 90% organic sludge removedPassive pumped systemNo heating or aeration required>85% methane content biogas100% available for useCloses carbon loopOff-site manufactured moduleContainerised M&ESmall footprint on siteSmart HMI controls system with remote monitoring

Treatment Capacity

Module Dimensions

Wastewater Pollutant Removal

COD

TSS

Low OPEX

Energy Positive

Modular

Control System

Carbon Neutral

Biogas

Treated Wastewater

Influent Wastewater

ABP Lurgan – Low Temperature Anaerobic Digestor



ABP Food Group

Low Temperature Anaerobic Digestion

Non Temperature Dependent (unique) (As low as 4oC to 400C)

Removes Wastewater Pollutants (>80% COD removal)

High Quality Biogas (100% available to end user) (>85% CH4 content)

Modular Design, off site manufactured & Small Footprint

Scalable – Multiple Modular system can treat any volume of wastewater

Energy Positive & Carbon Neutral



ABP Food Group

Wastewater Treatment Performance – Pollutant Removal >18 months of consistent operational performance

90% average COD removal following commissioning

Robust performance despite variable influent COD



ABP Food Group

Biogas Performance

Steady production despite variable influent COD

>85% CH4 (methane) content

Low H2S (hydrogen sulphide) content, averaging < 80 ppm

Biogas suitable for on-site boilers without scrubbing



ABP Food Group

Experience to Date

• LTAD is a successful treatment technology, • Removal of COD is good, • Robust piece of technology, • Cheap wastewater treatment in terms of COD, • Pre-treatment is essential prior to LTAD, • Sludge production is negligible, • Energy input insignificant, • Consistent results,



ABP Food Group

PROJECTS & CASE STUDIES

Olleco – delivering carbon neutrality for Arla Aylesbury Mega-Dairy

Background Our sustainability division, Olleco have linked up with Arla to build a large anaerobic digestion facility on their site. This will assist in Arla’s ‘zero carbon’ proposals as the facility would provide enough electricity to power the Arla mega dairy next door. How it works: Olleco will collect waste food from catering and food factory customers which can then be processed at its new Anaerobic Digestion facility in Aylesbury. The food waste is converted into a ‘soup’ and digested in large tanks by millions of microscopic organisms which produce methane gas from digesting the food waste particles under anaerobic conditions. The gas is collected and either used to run an engine which in turn generates electricity and heat or is refined and injected directly into the gas network. The project is a great example of Olleco’s ability to turn waste from the food industry into a useful resource. In addition to the energy produced, the AD plant also produces a liquid compost which is rich in NPK and can be returned to the land to replace fertilisers.

OPERATIONS



ABP Food Group

WHY? This was a natural extension of our renewable energy division to utilise the waste feedstocks it collects to generate gas & electricity to run our Liverpool operation inclusive of biodiesel refinery. HOW? Let’s consider the example of going out for a meal. Have you ever wondered what happened to the left-overs on the plate? Or what is done with the cooking oil that was used to prepare your meal? Well traditionally much of the waste food would have gone into a bin, and the used cooking oil poured into drains, causing damaging ‘fat-bergs’ in our water system. We estimate that almost 3 billion kilograms of waste food is thrown into the general waste bins of commercial kitchens. At Olleco, we work with over 50,000 customers spread throughout the UK ranging from fine-dining restaurants to fish & chip shops to make this waste a thing of the past. At these 50,000 outlets, their food waste is collected by Olleco in one of our colourful vehicles you might have seen on the roads and taken to our organic recycling centre in Liverpool. Once it arrives there it is fed into the anaerobic digester where microorganisms ‘eat’ and ‘digest’ the wasted food and convert it into biogas, clean water and a rich compost. The biogas which is natural and rich in methane is burned in an engine to produce renewable electricity. We even harvest the heat generated by this engine and use it in production of biodiesel at our site next door. The compost we generate is sold to farmers who plough it back into the land replacing man-made fertilisers. The used cooking oil we collect is then put through a multi-stage process to product biodiesel that can safely be used in car & lorry engines converted to run on biodiesel. All of our biodiesel meets EU specification EN 14214. Even our process is sustainable and environmentally friendly! In the first step of the process the used oils and fats are de-packed and any plastic or tin containers are sent for recycling. Secondly, any moisture and impurities are removed from the used cooking oils to ensure they can be fully converted into biodiesel. All impurities from this cleaning step are mixed and processed with de packaged waste food and sent as feed to the Anaerobic Digester. The oil itself is then sent to be chemically converted in a three step process that produces the biodiesel and two other by-products. The first by-product is a bio-heating oil that is used in boilers and the second is glycerol that can either be sent to the Anaerobic Digester or sold into the cosmetic industry to produce natural cosmetics. In this way we ensure 100% recycling through our process to ensure nothing is ever wasted. Leading edge technology and innovations have been smartly brought together to achieve a transport fuel that reaches heights of greenhouse gas savings most businesses dream of. Using ISO 14064 methodology Olleco has shown GHG savings of over 95%, encouraging household names to work with Olleco to run their distribution fleets on the same oil they fried their chips in.

Olleco Anaerobic Digestion Facility

90,000 customers

1MWh Electricity produced for the national grid

16 million litres

Bio-diesel produced

Quick stats…

100,000t Organic Waste

recycled

OPERATIONS

Anaerobic Digestion Facility Olleco Liverpool

Anaerobic Digestion Facility Olleco Liverpool



ABP Food Group

• Olleco is one of the UK’s largest distributors of fresh cooking oil to the catering industry and is the largest collector of used cooking oil, serving over 90,000 catering establishments. It also has a bespoke food waste collection business, ensuring that food waste never goes to landfill

• https://www.youtube.com/watch?v=jXJFR46RFxQ

PROJECTS & CASE STUDIES

Olleco – delivering carbon neutrality for Arla Aylesbury Mega-Dairy

https://www.youtube.com/watch?v=jXJFR46RFxQ





ABP Food Group

Thank you Any Questions? Fergal Maguire, NDA, BSc (Hons).

John Durkan ABP Food Group Environmental and Sustainability Manager [email protected] 00 353 862565129

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ABP Food Group Animal By-Product Valorisation · ABP Food Group • Olleco is one of the UK’s...

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