e e Schedule of Attachments Attachment no A.1- Attachment no B.2- Attachment no B.5- Attachment no B.8- Attachment no C- Attachment no D- Attachment no E- Attachment no E.2- Non Technical Summary Mogeely ordinance Survey location Site Location Plan Grid Reference for the centre of the site. Planning Permissions WP (W) 490 WP (W) 403 Index of Inclusions Letter to local authority. Site notice Mogeely Site notice Location Newspaper advertisement Dairygold Organisation Structure Calibration system Quality Control System Quality Control Policy Statement Mogeely Organisational Structure Waste control system. Flow charts and process descriptions Schematic of site WWTP A Development and operational history at the site Air Emission points Labelling of air emission points Meteorological data for Mogeely Storm water Discharge points Treated effluent discharge point Drainage Site plan Proposed SW3 Elv’s Attachment no E.4.B- Nutrient management plan. Attachment no E.5- Environmental Noise Survey 2006 Noise emissions at Mogeely Attachment no F.1- Layout and equipment of Effluent Treatment Plant For inspection purposes only. Consent of copyright owner required for any other use. EPA Export 25-07-2013:21:08:35
Transcript
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Schedule of Attachments
Attachment no A.1-
Attachment no B.2-
Attachment no B.5-
Attachment no B.8-
Attachment no C-
Attachment no D-
Attachment no E-
Attachment no E.2-
Non Technical Summary
Mogeely ordinance Survey location Site Location Plan Grid Reference for the centre of the site.
Planning Permissions WP (W) 490 WP (W) 403 Index of Inclusions
Letter to local authority. Site notice Mogeely Site notice Location Newspaper advertisement
Dairygold Organisation Structure Calibration system Quality Control System Quality Control Policy Statement Mogeely Organisational Structure Waste control system.
Flow charts and process descriptions Schematic of site WWTP A Development and operational history at the site
Air Emission points Labelling of air emission points
Meteorological data for Mogeely Storm water Discharge points Treated effluent discharge point Drainage Site plan Proposed SW3 Elv’s
Attachment no E.4.B- Nutrient management plan.
Attachment no E.5- Environmental Noise Survey 2006 Noise emissions at Mogeely
Attachment no F.1- Layout and equipment of Effluent Treatment Plant
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Attachment no. F.2- Monitoring location for on site wells Effluent Plant Layout Abatement at ETP
Attachment no. H.l- Storage Locations of waste Waste Permits
Non- technical summary of IPPC licence application.
This application is for an IPPC licence at the Dairygold plant in Mogeely Co.. Cork. It is being undertaken to take account of proposed expansion in production and to incorporate the requirements of the Protection of the Environment Act, 2003. This application (reference no. pending) will supersede Cork County Council existing licence at the site W.P. (W) 4/03. The scope of the application covers the following class of activity as specified in the First Schedule of the 2003 Act: Class 7.2.1: The treatment and processing of milk, the quantity of milk received being greater that 200 tonnes per day (average value on a yearly basis).
Dairygold is Irelands largest farmer owned business with over 10,000 shareholders. The Co-op is governed by the board of directors (1 0 members and 2 co-opted external directors), the CEO reports to the board. Dairygold was established in 1990 on the merger of Ballyclough Co-op creamery ltd and Mitchelstown Co-op Agricultural society Limited. Dairygold is Irelands second largest milk purchaser, processing approx. 860 million litres annually, producing 120,000 tonnes of product, employing in excess of 500 people and generating a revenue of approx. €360million through providing top quality Cheeses, dairy commodities and Dairy based ingredients to selected customers and markets. Dairygold Food Ingredients (DFI) is a wholly owned subsidiary of Dairygold, in the milk processing and ingredients marketing division of the group. Since 2003 the society has gone through a radical re-organisation to maximise returns and to provide cost effective goods and services to its members. DFI’s important speciality cheese facility is located at Mogeely, east county Cork. The Mogeely facility processed in 2006 l8,940,000gals, this volume is planned to increase by 15.8% in 2007.
The site produces high specification niche branded products to the top end of the quality market. The types of cheese made include Jarlsberg: an internationally renowned Norwegian brand, Mallo, Regato:an Italian hard cheese , Manchego: a semi hard Spanish style cheese. Consumption of speciality cheeses is growing as they fulfil the customers need for indulgence particularly flavour and texture.
The main raw materials include milk and milk products, cultures, process chemicals such as detergents and salt and water. Natural gas, gas oil and electricity are used as energy inputs. Compliance with air quality standards is the pre-requisite to burning all fuels under licensing. However, the recent increases in fuel costs have placed considerable pressure on the operating costs of the manufacturing sector.
Traditional and modern processes are employed including pasteurisation, coagulation to produce cheese curd and whey, separation of the curd, salting and ripening of the cheese. The whey is collected and sent off site for further processing.
Process wastewaters are directed to the site’s wastewater treatment plant. The abatement process includes balancing, pH correction, fat removal, high rate biofiltration, activated
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sludge, phosphate removal, final clarification, sand filters and sludge thickening. Sludge is spread in accordance with the County Council approved nutrient management plan.
The main sources of emissions from the Mogeely site are losses of milk solids and plant washings arising from cheese processing operations and flue gases from the boilers. There are 3 boilers on site two for hot water generation and 1 for steam generation. 2 boilers run on natural gas with the oldest operating as a standby on gas oil. There is provision being allowed in this application for a third new standby boiler. There is also a generator which runs during the winter months on marked gas oil to partake in the ESB's Winter Peak Demand Reduction Scheme. The nature and quantities of current and foreseeable emissions from the licensable activities are detailed in this application. The ongoing rationalisation, 'development and expansion of operations present continuing challenges for the control and management of emissions. Environmental considerations therefore form an integral part of the planning and development of hture manufacturing operations. The prevention, elimination or minimisation of emissions is a key consideration in rationalisation or new project planning. Among the process changes already put in place or planned to optimise the use of energy and water resources are:
0
0
0
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Water reduction per tonne of product Energy recovery by means of whey/water/milk heat exchange system. Automatic doors in cold store areas Replacement of fixed speed drives to motors with variable speed drives.
Normal operating hours of the plant are proposed to be 24hrs for 6 days during peak processing lessening to a 5 day operation off peak. In 2007 production is planned to run for 49 weeks of the year, by better utilisation of the highly seasonal milk supply, using off peak milk volumes to deliver higher margins and reduce the cost base. The five year plan for the site will involve year round production.
Natural gas as the main fuel for the site has reduced emissions to atmosphere. In relation to noise, the sites first noise survey was carried out in 2006. While no noise complaints have been received to date, the survey highlights areas that need attention.
Future
The dairy Industry has been the recipient of a restructuring grant from the Department of Agriculture and Food. This fund, for which grant application was due by November 23rd,2006 should result in a change of output for many current operators. Dairygold Mogeely have applied for the Enterprise Ireland dairy restructuring grant under the headings of
0 Increasing capacity 0
0
Increased flexibility on product options/ formats Improving efficiency - Labour, product yields, energy costs, reduction of solids lost
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0 Replace some outdated technologies 0
Delivering higher hygiene standards and increased process and product integrity.
Meeting customer and regulatory standards and requirements.
The future plan for the site is to extend the existing Jarlsberg line to accommodate Manchego product and the entire replacement of the existing Regato line. The replacement of existing cheese vats, upgrading of milk intake and pre- treatment systems, whey concentration, effluent plant upgrade and product flexibility.
Production tonnes 2005 2006 7515 7664
The aim being to balanced product mix which is insulated against major fluctuati market price or in demand over a medium time frame. The five year strategy for the site is to increase production output of speciality cheese by 50%.
s in 8
These changes in operational practices are in line with recommendations from the Dairy Prospectus report 2003 (Prospectus Promar Strategic Development Plan for the Irish Dairy Processing sector, 2003). This major review of the Irish Dairy Industry highlighted some fundamental changes required to ensure the sustainability of the industry namely; manufacturing higher value/ nutritional type products and shifting away from the bulk commodity products. Consolidation and rationalisation at producer and processor levels to achieve competitiveness in international markets was strongly recommended
Dairygold is being proactive in the restructuring required, increasing in scale of operations, entering into joint ventures with other milk processors and continuously analysing energy and resource efficiencies.
Monitoring arrangements for emissions are already in place under the current County Council licence. Dairygold surface water emissions from the site are for most parameters lower than guidelines in the Bref document for the industry. Best available techniques are employed to achieve this. An accident prevention and emergency plan is in place. The plan is designed to prevent or limit the consequences of any environmental incident. Appropriate measures will be put in place in the event of a definitive cessation of activities to avoid pollution risk and return the site to a satisfactory state.
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Attachment no B.2
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Attachment no B.5
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.-.‘
C O R K C O U N T Y C O U N C I L
Local Government (Planning & Development) Act 2000
TO: DAIRYGOLD CO-OP SOCIE’N LTD. C/o Murphy McCarthy Unit D, Marina Commercial Park, Centre Park Rd
Planning Register No: 5/02/5694
Application by DAIRYGOLD CO-OP SOCIETY LTD.
C/o Murphy McCarthy Unit D, Marina Commercial Park, Centre Park Rd
Of
@ On 19/12/02
f o r Boundary ,fence and gate
at MOGEELY,
Further to Notice dated 14/02/03. the Cork County Council hereby conveys a grant of PERMISSION’ for the application described above subject to the conditions set out in the schedule (if any) attached to the said Notice dated 14/02/03 of its intention to grant PERMISSION
Signed on behalf of Cork County Council
Planning Dept., Model Business Park, Model Farm Road, Cork.
/r. &wJJj. Date: 24/03/03
NOTE FOR GUIDANCE OF DEVELOPERS
A grant of Planning Permission or Permission Consequent on the grant of Outline Permission does NOT of itself empower a person to carry out a development unless that person is otherwise legally entitled to do so. Unless otherwise stated or unless it 4s .revoked a Permission is valid for a period of five years.
Any development which takes place prior to the payment of a financial contribution required by any of the.conditions attached to a permission or Permission Consequent on the grant of Out-line Permission will be unauthorised until compliance with the condition or conditions.
,
Please note that there is an onus on developers to ensure that there is no danger to the public as a result of the proposed development.
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C O R K C O U N T Y C O U N C I L
. LOCAL GOVERNMENT (PLANNING & DEVELOPMENT) ACT 2'000
NOTIFICATION OF DECISION TO GRANT PERMISSION (with conditions)
Reference No. in Planning Register S/02/5694
DAIRYGOLD CO-OP SOCIETY LTD. C/o Murphy McCarthy Unit D, Marina Commercial Park, Centre Park Rd
In pursuance of the powers conferred upon them by the abobe mentioned Act and for the reason set out in the First schedule hereto,
the Council of the County of Cork have by Order dated
decided to GRANT PERMISSION for the developmentof land namely;
Boundary fence and gate
#
AT: MOGEELY,
in accordance with the plans and particulars submitted by the applicant
On: 19/12/02
and subject to the conditions- ( 3 No.) set out in column 1 of the Second Schedule attached hereto. of the said conditions are set out in column 2 of the Schedule.
@ An appeal against a decision of the Planning Authority may be made to & Bord P l e a n a l a by any authorised person before the EXPIRATION of the period of FOUR WEEKS beginning on the day of the giving (i.e. Date of Order) of the decision of the Planning Authority.
The reasons for the imposition
(SEE NOTES ATTACHED)
If there is no appeal against the said decision, a grant of PERMISSION in accordence with the decision will be issued after the expiration of the period within which an appeal may be made to An Bord Pleanala.
It should be noted that until a grant of PERMISSION has been issued the development in qudstion is NOT AUTHORISED.
It is considered that, subject to compliance with the conditions set out int he second schedule, the. proposed development would not seriously injure the amenities of the area, would not be prejudicial to public health and would be in accordance with the proper planning and sustainable development of the area.
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Reference No. in Planning Register: 02/5694
The proposed development shall be carried out in accordance with plans and particulars lodged with.the Planning Authority 'on 19/12/02, save where amended by the conditions herein.
To clarify the documents to which this permission relates in the interests of the proper development of the site.
(2) The proposed fence shall be P.V.C. coated chain-link fencing coloured green.
The proposed hedging shall be of evergreen variety.
In the interests of visual amenity .
In the interests of visual amenity .
.
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? I
C O R K C O U N T Y C O U N C I L
Local Government (Planning & Development) Acts, 1963 - 1993
TO: DAIRYGOLD CO-OP SOCIETY LTD c/o .Murphy McCarthy Ltd. , Unit D, Marina Comm. Pk., Centre Park Road, Cork
Planning Register No: S/00/1615
Application by DAIRYGOLD CO-OP SOCIETY LTD
of c/o Murphy McCarthy Ltd., Unit D, Mar ina Comm. Pk.,
On 23/03/00 And as amended by Drawings on 07/06/00
f o r Erection of 6 no. grain s i l o s , grain dryer, dust house, new
Centre Park Road, Cork . @
boundary walls & re-roof stores
at MOGEELY, A
Further to Notice dated 03/08/00 the Cork County Council hereby conveys a grant of PERMISSION for the application described above subject to the conditions set out in the schedule (if any) attached to the said Notice dated 03/08/00 of its intention to grant PERMISSION.
NOTE FOR GUIDANCE OF DEVELOPERS
A grant of Planning Permission or Approval does NOT of itself empower a person to carry out a development unless that person is otherwise legally entitled to do so. Unless otherwise stated or unless it is revoked a Permission is valid for a period of five years. Approval is valid only for the period of the Outline Permission t o which it relates.
Any development which takes place prior to the payment of a financial contribution required by any of the conditions attached to a permission or approval will be unauthorised until compliance with the condition or conditions.
Please note that there is an onus on developers to ensure that there is no danger to t h e public as a result of the proposed development.
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. In
C O R K C O U N T Y C O U N C I L
LOCAL GOVERNMENT (PLANNING Et DEVELOPMENT) ACTS, 1963-1993
NOTIFICATION OF DECISION TO GRANT PERMISSION (with conditions)
Reference No. in Planning Register S/00/1615 I
DAIRYGOLD CO-OP SOCIETY LTD c/o Murphy McCarthy Ltd., Unit D, Marina Comm. Pk., Centre P’ark Road, Cork
pursuance of the powers conferred upon them by the above mentioned
+3 AUG 2000 Acts, the Council of the County of Cork have by Order dated
decided to GRANT PERMISSION for the development of land namely; Q Erection of 6 no. grain silos, grain dryer, dust house, new
boundary walls & re-roof stores
AT :’ MOGEELY,
in accordance with the plans and particulars submitted by the applicant . .
On: 23/03/00
and subject to the conditions ( 13 No.) set out in column 1 of the Schedule attached hereto. said conditions are set out in column 2 of the Schedule.
An appeal against a decision of the Planning Authority may be made to An Bord Pleanala by any person before the EXPIRATION of the period of ONE MONTH beginning on the day of the giving (i.e. Date of Order) of
If there is no appeal against the said decision, a grant of PERMISSION in accordance w i t h the decision will be issued after the expiration of the period within which an appeal may be made to An Bord Pleanala.
It should be noted that until a grant of PERMISSION has been issued, development in question is NOT AUTHORISED.
Planning Department ,
And as amended by Drawings on 07/06/00
- The reasons for the imposition of the
@ the decision of the Planning Authority. (SEE NOTES ATTACHED)
the
Signed on behalf of t h e said Council
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. ... . . .. . . . . . . .. .. ~ ~~
--...._ ._ , . . .
The cladding of the proposed silos shall be coloured to match existing silos on site.
(2) The roof and side.’cladding of all other proposed structures shall be coloured to match existing structures on site.
( 3 ) Notwithstanding the exempted development provisions of the Local Government (Planning and Development) Regulations 1994, as amended, signs, symbols, emblems, nameplates or other advertising devices shall not be erected or displayed externally on the site/ structures, save with a prior grant of Planning Permission/ Approval.
(4 1 Ancillary structures other than those shown on plans shall not be constructed on site without the prior Approval of ‘the Planning Authority, notwithstanding the Exempted Development provisions of the Local Government (Planning & Development) Regulations, 1994, as amended.
(5) Precise details in relation to the proposed on site car park shall be agreed on site with the Area‘ Engineer, prior to the commencement of development.
( 6 ) Road boundary wall to proposed
‘.
- - - - Rea
- - - -
In the interests of visual amenity.
In the interests”of visual ameni ty .
To safeguard the amenities of the area and because it is consTdered that the erection of signs, emblems etc. warrant the making of an application for and the grant of a Planning Permission/ Approval.
Loading or unloading shall not take place on the adjoining public road.
SCHEDULE -----I--
In the interests of safety.
road
( 8 ) All solid wastes arising on the site shall be recycled as health . far as possible. Materials
In the interest of public
exported from the site for recovery, recycling or disposal shall be managed at an approved facility and in such a manner as is agreed with the Planning Authority. In any case no such wastes shall be stored on the site except within the,confines of the buildings on site. Adequate on site arrangements shall be made to the satisfaction of the Planning Authority for the storage of recyclable materials prior to collection.
e
( 9 ) Noise levels emanating from the proposed development when
boundaries shall not exceed 5 5 dBa (15 minute Leq) between 08-00 hours and 20.00 hours, Monday to Saturday inclusive and shall not exceed 45 &a (15 minute Leq) at any other time. Measurements shall be made in acc dance with I.S.O. Recommendat ns R.1996/1 "Acoustics - Description and Measurement of Environmental Noise, Part 1: Basic quantities and procedures".
To safeguard the amenities of the area.
@ measured at the site
At no time shall the noise,, generated on site result in an increase in noise level of more than lOdBA above
daries of adjoining ises. Background noise shall be interpreted as ean minimum sound level
at the relevant place and time .in the absence of noise from the premises the subject of the application.
4)
If the noise contains a discrete, continuous note (whine, hiss, screech, hum, etc.), or if there are distinct impulses in the noise (bangs, clicks, clatters or thumps), of if the noise is irregular enough in character to attract attention, a penalty of +S dBA should be applied to the measured noise level and this increased level shall be used in assessing compliance with the specified levels.
(10) All operations on-site shall . be carried out in such a manner as to ensure that no odour or dust nuisance occurs beyond the site boundary because of such operations.
The developer shall i d e n t i f y items of plant critical to the proper operation of a l l atmospheric emission abatement plant in the place at the site. These items of plant shall be serviced and maintained in accordance with a preventative maintenance programme.
(12) All water contaminated with hydrocarbons discharging to the public stream shall discharge via a grit trap and
hydrocarbon interceptor. An inspection chamber with a sump shall be constructed between the interceptor and the sewer/ stream. The sump shall be of a minimum size of 5OOmm square and 400mm 'deep. The interceptor and sump shall be installed and operated to the satisfaction of the Planning Authority. The applicant shall undertake an inspection of the interceptor traps monthly and shall mdintain a register of the outcome of such inspections.
e . ( I31 All over ground tanks containing l i q u i d fuels shall be contained in a waterproof bunded area of suff,icient volume to hold 110% of the value of the largest tank within the bund. A l l valves on the tank shall be contained . '
within the bunded area.. The bunded area shall be fitted with a pentstock valve which shall be opened only to discharge storm water to the interceptor. The developer shall ensure that this valve is locked at all times.
To provide safe storage of liquid fuels and to ensure that no water pollution occurs.
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C O R K C O U N T Y C O U N C I L
LOCAL GOVERNMENT (PLANNING & DEVELOPMENT) ACTS, 1963-1993
NOTIFICATION OF DECISION TO GRANT PERMISSION (with conditions)
Reference No. in Planning Register S/99/2115
CO-OP SUPERSTORES c/o Murphy Mc Carthy, Unit D,Marina Corn. Park, Centre Park Road, Cork
. In pursuance of t h e powers conferred upon them by the above mentioned
Acts the Council of the County of Cork have by Order dated2 5 BUG 1999 @ decided to GRANT PERMISSION f o r t h e development of land namely;
Alterations to shop front &.forecourt
AT: MOGEELY,
in accordance with the plans and particulars submitted by the applicant -. On: 28/04/99 . .
And as amended by revised documentation on 28/06/99
and subject to the conditions ( 12 No.) set out in column 1 of the Schedule attached hereto. said conditions are set out in column 2 of the Schedule.
The reasons for the imposition of the
An appeal against a decision of the Planning Authority may be made to A n Bord Pleanala by any person before the EXPIRATION of the period of ONE MONTH beginning on the day of the giving (i.e. Date of Order) of the decision of the Planning Authority. (SEE NOTES ATTACHED)
If there is no appeal against the said decision, a grant of PERMISSION in accordance with the decision w i l l be issued after the expiration of the period within which an appeal may be made to An Bord Pleanala.
It should be noted that until a grant of PERMISSION has been issued, development in question is NOT AUTHORISED.
Planning Department,
County Hall,
Cork.
the
'. . . . .
SEE NOTES ATTACHED
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(1) The proposed development shall be carried out in accordance with plans and particulars lodged with the Planning Authority on 28/04/99 save where amended by the conditions herein,
(2 ) The external finish and roof shall be consistent with that of t h e existing building 4B (3 1 Footpath shall be re-instated at developer's expense to the satisfaction of the Councilfs Area Engineer.
(4) A l l proposed works shall be carried out to the satisfaction of the Council's Environment Officer.
(5) Notwithstanding t h e exempted development provisions of the Local Government (Planning and Development) Regulations 1994, as amended, signs, symbols, emblems, nameplates or other advertising devices shall not be erected or displayed externally on the site/ structures, save with a prior grant of Planning Permission/ Approval.
(6) A sample of the proposed brick paviour and its colour shall be submitted to and agreed ~
with the Planning Authority: before development commences.
( 7 ) The removal of petrol pump and
In the interests of the proper development of the site.
In the interests of visual amenity .
In the interests of safety.
..
In the interests of Environmental protection and public health.
To safeguard the amenities of the area and because it is considered that the erection of signs, emblems etc. warrant the making of an application for and the grant of a Planning Permission/ Approval.
i '
In the interests of.visua1 5
amenity .
In the interests of orderly I
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( 8 ) No fuel dispensing facilities or fuel storage shall be retained on site.
. (9) Any future plans to install fuel dispensing facilities and fuel storage shall be the subject of a separate planning application. Q
In the interests of orderly development.
In the interests of orderly development.
(10) All solid wastes arising on the site shall be recycled as far as possible. Materials exported from the site f o r recovery, recycling or disposal shall be managed at an approved facility and in such a m a n n e r to be agreed with t h e -Planning Authority. In any case no such wastes shall be stored on the site except within t h e confines of the buildings on site. Adequate on site arrangements shall be made to the satisfaction of the Planning Authority fok the storage of recyclable materials prior to collection.
In the interests of orderly development.
. .
(11) Noise levels emanating from the proposed development when measured at the site boundaries shall not exceed 55 dBa (15 minute Leq) between 08.00 hours and 20.00 hours
' Mondays to Fridays inclusive and shall not exceed 45 &a (15 minute Leq) at any other +. time. Measurements shall be made in accordance with I.S.O. Recommendations R.1996/1
To safeguard the amenities of the area.
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If the noise contains a discrete, continuous note (whine, hiss, s c r e e c h , hum, etc.), o r if there are !I I distinct impulses in the noise (bangs, clicks, clatters or thumps), of if the noise is irregular enough in character ( I '
11' to attract attention, a penalty of +5 dBA should be applied to the measured noise
, level and this increased level I shall be used in assessing 1 compliance with the specified
levels. (Ref. BS 4142 Section I 7 . 2 )
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(12 1 All operations on-site shall be carried out in such a manner as t o ensure that no odour or dust nuisance occurs beyond the site boundary because of such operations.
I
To safeguard the amenities of the area.
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C O R K C O U N T Y C O U N C I L
Local Government (Planning & Development) Acts, 1963 - 1993
TO: DAIRYGOLD CO-OP SOCIETY LTD c/o Murphy Mc Carthy, The Marketing Centre, Ballinlough Road, Cork .
Planning Register No: 5/96/4032
application by DAIRYGOLD CO-OP SOCIETY LTD
Of c/o Murphy M c Carthy, The Marketing Centre,
on 08/11/96 And as amended by revised documentation on 25/11/96
for Up-grading of existing milk processing facilities and
Ballinlough Road, Cork
relocation of existing equipment and holding s i l o s
at . MOGEELY, KILLAMUCKY ,
Further to Notice dated 20/12/96 the Cork County Council hereby conveys a grant of PERMISSION for the application described above subject to tlie conditions set out in the schedule (if any) attached to the said Notice dated 20/12/96 of its intention to grant PERMISSION.
signed on behalf of Cork County Council
Planning Dept., County Hall, Cork.
4322/3 Date: 23/01/97
NOTE FOR GUIDANCE OF DEVELOPERS r --------------------_____^_____
A grant of Planning Permission or Approval does NOT of itself empower a person to carry out a development unless that person is otherwise legally entitled to do so. Unless otherwise stated or unless it is revoked a Permission is valid for a period of five years. Approval is valid only for the period of the Outline Permission to which it relates.
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C O ' R K C O U N T Y C O U N C I L
r LOCAL GOVERNNENT (PLANNING & DEVELOPMENT) ACTS, 1963-1993
NOTIFICATION OF DECISION TO GRANT PERMISSION (with conditions)
Reference No. in Planning Register 5/96/4032
DAIRYGOLD CO-OP SOCIETY LTD c/o Murphy Mc Carthy, The Marketing Centre, Ballinlough Road, Cork
In pursuance of the powers conferred upon them by the above mentioned
Acts the Council of the County of Cork have by Order dated 20 DEC I996 @ decided to GRANT PERMISSION f o r the development of land namely;
Up-grading of existing milk processing facilities and relocation of existing equipment and holding silos
AT: MOGEELY,KILLAMUCKY,
in accordance with the plans and particulars submitted by the applicant
On: 08/11/96
and subject to the conditions ( 7 No.) set out in column 1 of the Schedule attached hereto. The reasons for the imposition of t h e said conditions are set out in column 2 of the Schedule.
And as amended by revised documentation on 25/11/96
An appeal against a decision of the Planning Authority may be made to An Bord Pleanala by any person before the EXPIRATION of the period of
the decision of the Planning Authority.
If there is no appeal against the said decision, a grant of PERMISSION in accordance with the decision w i l l be issued after the expiration of t h e period within which an appeal may be made to An Bord Pleanala.
@ ONE MONTH beginning on the day of the giving (i.e. Date of Order) of (SEE NOTES ATTACHED)
I
It should be noted that until a gran development in question is NOT AUTHO
Planning Department, Sig
'County Hall,
Cork. DATE :
20 DEL' 1996
SEE NOTES ATTACHED
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Q
SCHEDULE -------- Reference No. in Planning Register: 96/4032
. (1) A l l solid wastes arising on the site shall be disposed of a t a location and in such a manner as is agreed with the Planning Authority: In any case no such wastes shall be stored on the site except within the confines of the buildings on site.
To safeguard the amenities of the area.
( 2 ) Noise levels emanating from the proposed development when measured at the site boundaries shall not exceed 50 dEa (15 minute Leq) between 08.00 hours and 20.00 hours and s h a l l not exceed 4 5 dBa (15 minute Leq) a t any other time. Measurements shall be made in accordance with I .S .O. Recommendations R.1996/1 tlAcoustics - Description and Measurement of Environmental
quantities and procedures”. Noise, Part 1: Basic . .
If the noise c o n t a i n s a discrete, continuous note (whine, hiss, screech, hum, etc) or if there are distinct impulses in the noise (bangs, clicks, clatters, or thumps), or if the noise is irregular enough in character to attract a t t e n t i o n , a penalty of +dBA should be applied to the measured noise level and t h i s increased level shall be used in assessing compliance with the specified levels. (Ref. BS 4 1 4 2 Section 7 . 2 )
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(3) A l l operations on-site shall be carried out in such a manner as to ensure that no odour or dust n u i s a n c e occurs beyond the site boundary because of such operations.
(4 ) All liquid chemicals shall be
To safeguard the amenities of the area.
*To safeguard the amenities of t h e area.
To safeguard the amenities of i
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(5) All inflammable substances to be stored in accordance with the area. Fire Officers requirements.
To safeguard the amenities of
16) All over ground tanks containing liquids other than water shall be contained in a waterproof bunded areas of sufficient volume to hold 110% of the value of t h e largest tank within the bund.
To safeguard the amenities of t h e area.
( 7 ) Any surf ace water drainage contaminated with hydrocarbons shall be directed to an oil interceptor trap.
To safeguard the amenities of the area.
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U5/0'.l "07 16: 01 FAX 0214667109 MOGBELEY MPI 4 I . . 1 ( I . I
7 . J . . . , . , ' I ) . I
The Council of thc County of Cork, excercise of the pavers conferred OII it by the Lo& Government ( Water Pollution ).Acts, 1977 a Licence, Reference Number W . P . 0 4/03 Rcfcrence Number W.P. (W) 42/78
~ nmended,
in substitution for Licence
To Discharge dl'hmat &sinrr from cleaaioe o&ationa nssociated with all muduction lines at the ~tdnt
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From Located at To Al Rivcr Withs subjccl to die Conditions set out in the schedqe attached hereto. It should be noted that a person sllali not be entitled soIely by r&on oFa licence to make, =use or permit a discharge to a sewer.
ENVIRONMENT DEPART'MENT, ROOM 708,
CORK. COUNTYHAU,
DR MARY STACK
I2m3 &L Dated thir.(..a_aly of
- NOTE: An appeal against a decision made by a Sanitary Authority under b x i o n 16 and Section 17 of the Act of 1977, may be made to An Bord Pleanala under Section 20 of the Act, as insened by Seclion 15 of Ute Local Government (Water Pollution) (Amendment) Act, 1990
Q '4
Appeals should be addressed to THE SECRETARY, AN BORD PLEANALA, Floor 3, Irish Lifc Centre, Lower Abbey Street, Dublin 1, and wil l be invalid unless accommnied bv an additional fee of €126.00 A request for an oral h&g slw be accompanied by an addbonal fee of E83.00
A party to an appeal sltall give to An Bord Pl-a any document, information or
for die purpose of determining the appeal, evidence in Ius possession or pmcuremenl which An B o d Pleanala consider necessary
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, Effluent discharges shall fdce place only as specified in the licence application. .MP(W) v-vwv (R) as modified and/or cbntrolled by this licence. and subject to the requkernmts of law , Any changes in the nature or quanti9 of any &sion shall.requke the. k m c e to noti@ the Licensing Authority and in the case of any material chws fbr thc licensee to request a review or obtain a new licence as may be d&emined by the Lictncing Authority prior to any such
The Licensing Authority shaU hterpret whethe+ A y change is material or not .
This licence supercedes all previous licences &d correspondence issued in respect of the facility under the tenns of the Water'PolIution Acts (1977 / 1990).
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change being made. 7 . 1 ,
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ScheduIe 1. EFFLUENT MANAGEMENT.
1 . 1 The Licensee shall employ the best available technology not entailing exckssive cost in the avoidance, minimisation, treatment and disposal of effluent produced on site.
2.2 The Licensee shall prepare an effluent management progrannne which s h d assess operations which produce effluent on site. The review shall consider the use of clearner technologies and production which could avoid and minimise washe water quantities arising on site. The review should also document any such measures which have already km assessed or implemented by the licensee. A report shall be submitted to the Licensing Authority detailing the results of this study within twelve months of the issue of this licence. l%e report skid address the following topics as a minbnum:
4BL
a) Process modifications and conti.01 b) Clean procedures and r&erials used e) Reuse, recovery and recycle of waste waters
Following the completion of this repc , .-o-- .yl -" ,- terms of volume andor organic load1 shall be3 nimarprl h r
1.3 Comprehensive written operating instructions and procedures shall be prepared m resper:t of effluent ._control. and::treatment systems to assist personnel with responsibilities for the operation of such systems and plant. These procedures shall be made available to the Licmh g Authority on request.
The licensee shall prepare and agree with the Licensing Authority, not later than the 1 st cf December 2003, a manual on contmgeacy plans the event of an incident with the potentiill for significant environmeptaf consequences due to breakdown or rnalfUnction of the efflwlt treatment plant. The applicant shall noninate a responsible person or persons for all periocls the effluent treatment plant is op+ting and shall notify the Licensing Authority tliaeof. '
1.4 Employees with respmibilities h'the effluent control' and treatment .weji -. )" shall - receive training adequate to enable them to executetheir tasks in relation to pallution cc$rol.
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I use of low& q&& wat& (effluent discharge) which may be recycled for use +aher than fi&, .
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i 2.1 All contaminated waste:water shall be treatedin the on-site biological treatmen; plant. *
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2.2 Contaminated waste water shall comprise those arismg ftom the sources on the list belovr and shall include in particular the following, having regard to the recluirements of I:ondition 1.1 ofthis licence :
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(a) Process waste water
(b) Boiler blowdown and condensates (c) AqueQus wastes and contamhated runoff &om'the bunded areas (d) Contaminated wastes fiom the truck unloading and storage areas (e) Contaminated storm water (0 Itloor washings and wash water
2.3 All treated effluent shall be directed to river Rilta at Castelmartyr, Co. Cork. 'The outflow pipe shall be .fitted with a fIow meter oftlie continuous recording and integrating type and with a-composite sampler of a flow proportionjite type at locations agreed with the
Licensing Authority. 2 . . ... ,
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The sampler shall be opmted so as to take samples at a frequency to be agreed with the Licensing Authority making up to a composite sample once every 24 hours . This composite samples shall be collected at 1200 noon each day or as otherwise agreed with
oses shall be defined as an^ the licensing authority. . A composite sample .for testing purp
sample extracted fkom tfie samphb appeatus between 8.00'am and 12.00 noofl, I
In addition, a continuous pH monitor with. chart; recorder shall .be' installed on the influent pipe
line to the biological plant and on the final ernu& discharge line. Monitoring of these stre :m sihall'Eje c3nductes cliulrig-dl -wce% opmtions: This r;@nplhg &d monitoring systmshall be M y operational and in use at al1'tim.i~ during which effluent is being discharged.
2.4 The t o t d m of treated effluent 'shall not exceed.
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r ; 3 566 litrdmin or 34m3kour or 700 m3 / dav 1 2.5 Composite samples obtained in acwrdance with condition.2.4 above s h d be tested @,, the licensee for the parameters indicated in the following table and no such sample or grab sznple taken at the point of sampling in the effluent discharge line 9hh;la exceed the following condidon limits from the date ofissue o f the licence.
Temperature : The receiving of all,,eflluent should be such that the temperature of the receiving v,*ater downstream o f the outfbll shall not be artificially increased above the following limits:
May - October , I November - April @
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21 degrees centigrade 10 degrees centigrade
Subject to the above the ambient temperature of the receiving waters shaU not. beaincreaswd by more than 1.5 degrees centigrade.
PH 6.5 - 8.5
B.O.D. s m g / l C.O.D. 30 @
Total Suspended Solids . I I ' i s : mg/i I : I
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05/01 '07 1 6 : O Z FAX 0214667109 NOGEELEY MPI .* 2y
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Total Nitrrogen (as N) 12 mgfl
Ammonia(as N) I * * . - ' 0.2 If&I ! 11
Total PhospHojrus (as P) IiourIy average / 1.2 mg;'/i da$%vtjriige ' .- I- '- 5 mgfl Detergents (A LAS)
The Licensing Authority reserves the right to,reduce the discharge flow in pen'ad of severe low
flow in the river Kilta if a threat to fish Iifii exists. . . .
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The frequency of testing ofthe above parameters shall be as follows, p H continuo.m, .-',A B.0.D S S ammonia shall be tested daily, total phosphorus MY h m May to July and weekly outside this perio&-total nitioien'TortniEhtly &id: all other-Paramet&'s shall be tested irionj;h& except 02 f&s and grease and rm'neral'oils which shall be tested qilarterly.
In the event that satisfhctorv correlatiod can be established between C.'O.D ancl B.O.D. lev!& then with the agreement of the licehsing 'authority the C.O.D. results may he wed to the B.O.D. loading, subject to the fonowing :
v
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Quarterly B.O.D.(5 day) tests being carried out. , I I ,
re-evaluation of the C.O.D. / B.O.D. mtio.
Dangerous substances. This licence does not p d the discharge of compounds listed
(appendix 1) on Water Q q (Dangerous Substances Regulations ) S.I. 12, 2001 6-om I any operation arising on this site. I
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2.6 The toxicity of the treated etEIuent as expressed by the number of toxic units shall be determined with reference to a representative aquatic orgdsm on the basis 19 a twenty .lour hour flow propodonate composite sample of treated efnuent.
The determination shall be cm-ed out by a competent independent body using methods agxeed with the Licmmg Authority. The number of toxic.units in the treated efnuent ps discharged shall not exceed 5 Toxic Units
The number of toxic units in the treated effluent is to be calculated as hllows : ! I
8 ; 0 .
. .
Ji Number of toxic units = 100% fie.undiluted sample)
96 how LCso in %
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The toXiGity of the treated kffl determined withih 6 months fi-om the date of isiue of licence,, at a time when maximwm discharge is -ccurrbig and on request of the Licens:ng Authority thereafter.
2.7 The licensee shall pw$de a S&k a&.. 09 the. treateh effluent dis use of any, gatutoq body h a h g resp for water pohtion contro~. also ensurk'that direCt'&cks io h e sampling point is available at dl times .
2.8 In the event of malfimction o eakdown of the effluent control system, inC,luding, fi-actme or blockage of any eauent &e'-:t$e Licensee shall immediately report the incident to the Licensing .Authp&y by telephqn4 ck telefax and shall confirm the commm~cation in wriling within tw&+ fob hours. The Licensee shall take all possible steps to ensure that discharges not in accordance with the provisions of this Iicence do not occur and shall consult with &e Licensing Authority on the
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best practicable means of rectification. ' , e
2.9 The Licensee s h d agree with the Licensing Authority with a View to ens ofge collection S$&m g d b f the undergiound ahd oGirg36und.pipelines on
2.10 The Licensee shall submit an updated map of the pipework on the production site and effluent treatment plant site and o u m within five yeam %om date of issue tjf.the licenci: or immediately followmg alternations on site which would impact on the site distiibution systein
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2.11 The Licensee shall cany out a daily visual inspection of the effluent aid surface water discharge points daily and any abnormalities in. water qualay shall be noted. 'If it appears that the abnormalities m y be 'occmrhg as a Tesult of the Licamee's discharges then the Liceilsee shall immediately noti@ the Licensing Authority and hitiate an investigation into the pos!;ible cause of the abnormalities.
2.12 The company shall ensure that a flow recordm is installed and operational below the discharge pomt downstream Kilts river. This infomation shaIl be submittedm request 01: the Licensing Authority. I
2.13 The river up and down stream of the discharge'pomt shall be monitored €orthnil$tly between May to September inclusive, at sites agreed with the Licensing Authority for the following parameters, dissolved oxygen, biochemical oxygen demand, remperature and ammonia and monthly for orthophosphate and nitrates.
3 STORMWATERS
3.1 A11 uncontaminated storm water shall be directed to the river Kilta adjoining the site Not withstanding the above no composite or grab sample from the storm water discharge pipes shall exceed the following limits:-
PH 6 9
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BOD . 5w Suspended solids, 1 0 4 . Ammonia(asN) , ,. : 0.5rngO I t
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r .
Temperature 15 oc , ,.., . . . : :'i ;!! ; , .: . . - i .- .
The frequency of testing for thi ab0 armeteq shall weekiy for pH, temperature and BOD
e, the Licensee shall tmve in place a
and monthly for suspended . . so * - . . + J { I ! . ! . . . . . . .
3.2 .Within 'six months of management .control programme addressing the risk and control of fire wat event of a fi;e indicate ad&Qd nkasurps smoun&i +iteii ii&& posi%je po 3 1/07/12004.
.&t+, F O ~ O . oft& progmvne, the Lic ,be tken by the Licerisee in ion from such an event. This programme shall be: by
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4 STORAGE FACILITIES I
4.1 All storage tank areas and ,& storage are& shall be rendered'hpenio& to the &<ei-ials stored therein. In addition, s t o k e tank areas shall be bunded, either locally oi remotely, to a volume of 110% of the largest tank within ea& individual bunded area. DNun storage axeas shall be bmded to .a volume eqhl to 0% of the sum of the volumes of the largest ten dz-urns likely to be stored therein. The height of the bund for any drum storage. are; s h d be not less than 300 millimetres. The balancing tank shall be bunded to a volume equal to, 1 1 0 % cjf its volume.
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4.2 The integrity and watertightness of all the bqded'structurw' and the@ resistancl: to penetration by water or other inateri& stored therein shall be tested and denionstrated kjl the licensee to the satisfixtion of the Lkming Authority. The results of these tests shall be certified by a Chartered Enqineer.
5 SOLIDWASTES
5.1 All treatment plant sludges shall be stabilised and mechanically thickened prior to disposal off-site. Any liquid extracted shall be pumped back to the effluent treatment unit.
5.2 All .solid waste which ca5 be regarded as neither tokic nor dangerous including treatment plant sludges and. general r e h e shall be dispdsed to landfill ' or .by othq meam as may be agreed with the Licerising Authority.
5.3 While awaiting disposal, dl wastes and by-pfoducts shall be collected and. stored in , designated areas protected against spillage and leachate run-of€
5.4 The licensee shall keep records of all wastes disuosed of off-site and shall retain ych records for a minimum period of ten years. These records shall be sutnrritted to the Licensing AuthonW quarterly.
05/01 ' 0 7 18:04 FAX 0214667109, MOGEELEY BIPI @ U l U , .* - . _ I ; I Y- s - L J - t . .y - .I 3
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5. 5 Within two months of issue of this licence, the Licensee shall submit results of soil q@&s carsied out on the lands into which it is proposed to inject s1udgeJprior to any disposal taking place}. These t e g dertakm .--. _-_- .- bya.~mmt independent technical body approved by Cork cil. Nutrient levels and heavy metals concentrations shall be measured. The number of tests required shall be determined by the 'Licensing Authority (one per 5 hectares unless otherwise determined). A representative sample of the sludge shdl be similarly tested and the results submitted to the Licensing Authority. These tests shall be remated annually. The Testing Body shall recommend the maximum rate of spread of sludge. Upon receipt of these results, the Licensing Authority shdl determine the maKimurn . rate of spread of sludge allowable ( as recommended by the Testing body unless otherwise determined) . r .
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ed shall be based on the nutrient requirements of the soil md,the o waters. The Licensee sliall indicate whether the ,d&&ated
lands will be used for the disposal o€sludge. If it appears to the Licensing A~hor i ty~ that .the-.concentrations of ckrtain substances is'kcreasina.to undesirable levels as a.. -
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The preferred methodlof sludge disposal on land is soil mjec%on. The' Licensing Authority may insist that only this method be used i
A sludge holding tank of capacity to accommodate 12 days production of excess : sludge shall be available €or storage prior to landspreading. . f
The lands designated for landspreading shall be indicated on a map to a scale of not less than 1/10,560 and submitted to the Licensing Authority prior to any disposal taking place. %e Licensee shall maintain a record, of the q d t i e s -- of sIudge deposited and the approximate locations of applications on aigrid mg.'
Landspreading shall not be carried out following periods of heavy rain or when the ground is saturated or frozen. Landspreading shall not be carried out within 10 metres of any watercourse, stream or river or in any circumstances when water pdhtion L
might QCCUT.
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MOGEELEY NPI . .
6 MONITORING < . 2 1 ' . . . ..
6.1 The licensee shall grant immediate and unhindered access to the site'and effluent treatment plant, including sewki.s.and pipes, to any authorised personi~el represenliing any' statutoj body having responsibility for water pollution control, at all tinies to carry Dut
such inspections, monitoring a,nd.myesbgations . I . ! , , . as the body deems necessary.. 4 , . . , , I I
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authorised paomel rqrtisenting q y statutory body involved in water pollution control a:t all reasonable times. The licensee shall submit to the LicensinP AuthoritV before the tenth d a : j f each calendar month the results of al l rnonitorina relating to the urevious monf:h,?i&ha with any other records relating to pollution controi which may be required by the Licen:sing Authority. ,The format of t h s e regults shall include minimum, maXirrmm and average v-dueir for each of the parameters teste9 Anv.non-compliance with the of the licence shaH .- be hifiphted and the reason why this occwed shall be stated. The measures taken to e n : ~ non-recurrencel shall &o .be outlined. The percentage compliance with licence tvalues for r:ach parameter shall also be hdicat8d. I I
6.3 Before January 15th. of each calender year, the Licensee shall submit a summary repa-rt of allqonitorinp carried out in the previous yeg, This report shall evaluate the operation of the facilities available on site to treat the effluent produced m the light of the results achieved til the previous year. The report shall also outline the intentions of the Licensee with regard tc, the upgrading o f treatment facilities or operations should these results not llly cornply with the terms of this licence. All monthly and annual repom shall be cat3it:d accurate and representative by the Licensee's plant manager or other senior officer designated by him.
7 . RESPONSIBLE PERSON
7.1 The licensee shall ensure that a person or persons is/are available at all times to give relevant i n f o d o n on emissions to the Licensing Authority. The licensee shdl identify ti, the Licensing Authority each such person.
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8. BF"LUENT CONTROL FACILITIES
8.1 The integrity of the system shall be demonstrated to the satishtion of tlie Licemmg Authority prior to the, commencement of any discharge, if required. All liquid retaining units shall be rested for watertightness. The results of all such tests shall be certified correct by a Chartered Engineer.
e for all mechanical and 8.2 The Licensee shalI initiate an approved maintenance p r o m electrical plant in use m the treatment process or m pollution control. -&er shall b c : b t of all maintenance work carried out on such units and this information shdn be made aveiilable to the Licensing Authonty on request.
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BlOGEELEY MPI
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8.3 I All pump sumps or other keattnent .plant chambers from which spillages night OCCUT shall be fitted with high liquid level alarms. The a l a m i condition shall be signified by an audible signal on site. Duty and standby pumps and other duplicate plant equipment shall be interchanged weekly in order to allow each unit equal running h e in duty mode. Cont:-ol panels shall incorporate hours run meters €or each individual unit.
9 CONTRlBUTIONS
9.1 The licensee shall pay to the Licensing Authority such m u d contributions towards the cost of monitoring. tho dischhge as the Licensing Authority considers necessary for tbe pertbrmance of its duties under this Act as follows: I ,
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(a) Not lata than 30th September 2003 the licensee shall pay to the Licensing contribution of-42 4500,.
(b) k subsequent years <he not less than € 4500 updated,in ac
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@ , .J' , fo. the LkeGiing Authority an amud aih~uzl.: of with the Consumer Price Index &om the datu of
the grant ;of thk I;ic&cei contriiutidn (This &no&&
e @bkl pertaining at the time of pawtinti, of each mrmd payible befhd 30th September each year).,'
(c) Notwithstanding the foregoing, the rate of contriiution each year shall take account of the actual costs of monitoring as incurred by the Licensing Authority in the preiiok year and as estimated €or the next ye&.
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Planning Permissions and Trade effluent discharge Licences Dairygold CO- Operative Society Mogeely
Number Year Planning permissions
5/96/4032 s/99/2 1 1 5 SlOOll615
S/O2/5694
1996 Upgrading of Existing Milk Processing Facilities and Relocation of Existing Equipment and Holding Silos 1999 Alterations to Shop front and Fore court. (this relates to the trading shop- not included in the IPPC site boundary). 2000 Erection of 6 no. Grain Silos, Grain dryer, dust house, New boundary walls and Re-roof Stores.
2002 Boundary fense and Gate. This relates to to work ajoining the public roadway on the south side. (This relates to work on the north side of the public roadway- most of which is outside the IPPC site boundary)
A new boundary rence and gateway would be required to secure the site.
I refer to the review of Licence Reg. No. W.P. (W) 41/78 undertaken by Cork County Council arld enclose herewith for your attention Revised Licence Reg. No. W(W) 4/90.
Yours fa i th fu l ly ,
PLANNING DEPARTPENT
* DB/EL
Encl/ 1.
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. .
L i c e n c e t o d i s c h a r g e T r a d e o r S e w a g e E f E l u e n t t o W a t e r s .
TO/ ImokillyCo.Op Creamery R e f e r e n c e No. i n R e g i e t e r
MogelY Co. CORK ' .
t
W.P. (W)
4 /90
T h e C o u n c i l o f t h e C o u n t y o f Cork, i n e x e r c i s e o f t h e powers c o n f e r r e d
o f a l i c e n c e t o m a k e , c a u s e o r p e r m i t t h e d i s c h a r g e o f T r a d e or S e w a g e
E f f l u e n t t o W a t e r s .
WATER POLLUTION D E P T . , COUN-TP. HALL, -. I
..
I
... S u b m i s s i o ' n s or o b s e r v a t i o n s made t o the B o a r d by o r on behalf of a p e r s o n ( o t h e r t h a n t h e a p p l i c a n t ) in r e l a t i o n t o a n ' a p p e a l made by a n o t h e r p e r s o n m u s t b e a c c o m p a n i e d by a f e e o f €10 .
r d P l e a n a l a a n y d o c u m e n t , s p o s s e s s i o n or p r o c u r e m e n r w h i c h An B o r d
s e o f d e t e r m i n i n g the appea l .
1 - __ 1
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i i i fiilk Spillages. t .
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1.3 A l l t r e a t e d ed+luent s h h l l be discharged t o the River k i l t h a . t i t Killamucky. The outflow pipe s h a l l be t ' i t ted w i t h a flow meter o i the continuous recording and in tegra t ing type. In addition the oirtflow pipe s h a l l be f i t t e d w i t h a composite samp1er.od h f low proportionate tvpe.
Ihe sampler s h a l l . b e operated so as t o take samples at a frequency t o be agreed w i t h the Licensina Authority making up t o a composite sample once every 24 hours.
T h i s carnciorite sample s h a l l be collected at 12:QQ noon each day or 3s otherwise bgr-eod w i t h the Licensing A u t h o r i t v .
- Ihe' +iow meter and saapler s h a l l be ins ta i led i n the eQtlcrent d i c - cnarqe p i p e a t a 1c)cation aqrr-ed w i t h the Licensing Authority.
Ci7ntinuous pH monitors complete w i t h chttril recorders s h a i i be in- s t a l l e d on t h e Int'i?ient oipe i i n e t o -;ne b i o l q i c a ? trestment p l a t .
8
The pH a+ the in-Fluent s h a l l be control led sum that n 5 adverse ai . fect is ca?!r;ed t o the b i o l u g i c a : treattnent system.
T h i s sampling and monitoring system s h a l l be i u l l y operational and i n cise a t al.l@imes d u r i n g which eif lc :ent is being dischar-aed.
The Licensing Authority reserves the t - i ~ h t t o control acce5r l o t n i s sampling and monitoring equipmenr.
.p '. 1
1.4 The t o t a l volume o-t: t rea ted e f f luent sha l l n o t exceed SO0 cubic metresiday or 500 litresimio.
-_ -
1.5 Composite sample obrained i n accordance w i t h condition 1 . 1 above s h a l l be tes ted by the l i censee +or the parameters indicated i n the -following table and no such sample or qrab sample taken af the p o i n t o f sampling i n the eCiluent discharue line s h a l l exceed t h e followina condition limits:-
. . sat i c i e t i ion .:?+ i j? E t i ten g ir? Q Aut hot- 1 'L y *.
. t i
c J . 2 The licEnsee s h a i l g!'ant immediate and wni.ndered acce s s t o
the s i t e acd any po r t i on OS: the efiluent trektment i n c l u d i n g sewers and p ipe s , t o any author ised
6 \
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- - _. - - ^^ - 6 RESPONSIBLE FERSON ..
.- 3 . i T i i z l ir2nzs2 S ! i > . A i encitre that 3 persan nr persons i 5 j a t - e ~ . . v r . . i l a ~ i e X - E ~ ~ E at ali t i w s t o g i v e relevant in+ornat ion m 2mlf.sions t o the Licensing Authority. Tils licensee s h a l l ic..intiSy t o t h e L i c e n c i n g Author i tv m c h such Person.
7
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il
1 %
- * +
censee shall i n i t i a t e an approved kintenance pro t .
i c a l and e l e c t r i c a l plant i n use i n the treatmgnt i n pollution control. A r e g i s t e r shall be kept of a l l mainFenance work carried out on such u n i t s and this information shal l be made available t o the Licensing quthority on request.
Duty and standby pumps and’other such duplicated plant / I I
interchanged weekly i n order t a allow each u n i t equal t mode. Control panels shal l incorporate hours r u n meters rridividual u n i t .
7 . 2 A l l pump sumps’or other treatment plant chambers irom which spi l laaes m i g h t occur shal l be i i t t e d w i t h h i g h l i q u i d level alarms. The alarm condition shall be s iqnif ied by an audiblr signal on s i t e a t timen when maintenance stafi. are present an s i t e and shal l be connected t o an autgdiallina communicaiion and messaae system at ali other times.
8 CONTRIBUTIONS .
8.1 ee khall ‘pay t o ‘the Li’censin t ? i b u t i o n s towards the cost e
aischarge as the Licensina Authority consider: necessary‘ f o r erfarmance o f i t s duties under t h Act 35 S o l law& -
(a) Not l a t e r than 30th. September 1991 the l icensee shal l pay t o the licensing riuthority a contribution o f not l e s s than f 1,000.
- -
(b) In subsequent years the l icensee shal l p a y t o the Licensing fiuthority an annual amount o f not l e s s than fi,000 updated i n accordance w i t h the Consumer Price Index from the date o f the grant of this l icence t o the value pertaining at the time at: payment o f each annus1 ccntr i b u t ic?n .
@
’ i c j Not withstanding the foregoinq, the r a t e of ~ contribution each year- shall -take -account od.-the.actual
costs of monitoring a5 incurred b y the licensing authority i n the previous year and as estimated for the
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J
Attachment no B.8
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Unit 4600 Cork Airport Busineb> Park Cork, Ireland
PHONE f353 (0121 4917800
SHEET 1 OF 3
0733-D-CE-002
8
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APPLICATION TO THE ENVIRONMENTAL PROTECTION AGENCY FOR A LICENCE
Transfer of Application for a licence, to the Environmental Protection Agency.
Name of Applicant: Dairygold CO- Operative Society Limited.
~ Address: Mogeely, Co. Cork
Class of activity in accordance with the First Schedule of the Act:
Schedule 1, Class 7.2.1. The treatment and Processing of milk, the quantity of milk received being greater than 200 tonnes per day (average value on a yearly basis).
Site Location: Mogeely, Co. Cork.
A copy of the application for the licence may be inspected at or obtained from the headquarters of the Agency as soon as is practicable after the receipt by the Agency of the application for the licence. 8
The Secretary, Cork County Council, County Hall, Carrigrohane Road, Cork.
11 December 2006
Re Application to EPA for IPPC licence
Dear Sir/Madam,
This letter is to notify you in accordance with the requirements of Section 87(l)(a) of the EPA Acts 1992 and 2003 that Dairygold Co-operative Society is applying to the EPA for an Integrated Pollution Control Licence replacing Cork County Council licence register Number W.P.(W) 4/03,for its activities at Mogeely Co. Cork.
Yours Sincerely, e
1 Karen Kennedy
Group Environmental Manager
Address for Correspondence
Dairygold
Mitchelstown CO Cork
, Castlefarm
Dairygold Food Ingredients Limited Regostered Office: Unit 5100, Cork Airport Business Park, Kinsale Road, County Cork. Registered No. 19852. A subsiduary of Dairygold Co-operative Society Limited.
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I
Q Attachment no C
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,
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Structures in place for the Management and Responsibility of the Operation
The Manufacturing Manager has overall responsibility for the operation of the site including environmental issues. The manufacturing manager prepares reports on environmental performance as required under the existing County Council license. The site Environmental manager looks after Laboratory testing, sample collection and results reporting. The Maintenance Supervisor looks after the planned maintenance and repairs of abatement equipment in the effluent treatment plant. The Group Environmental Manager assists in ensuring the site is achieving all e nvi ro n m e n ta I q u a I i ty stand a rd s.
Training and Qualifications of the personnel involved
Manufacturing Manager- Christy 0 Sullivan: BSc Dairying, Diploma in CO Op management, various management courses, experience in dairy industry 35years.
QNEnvironmental Manager - Beatrice Walsh: Diploma in Food Science and Technology, Various management courses, 28 years dairy experience.
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Production manager : William Slattery, BSc Food Science and Technology, various management courses, 8 years dairy industry experience.
Maintenance Supervisor: Percy Peddar, qualified fitterlturner, various management courses, electronics course (Grade1 ), Pneumatic and Hydraulic course. 30 years experience in the dairy industry.
t Dairygold Food ingredients Environmental manager: Karen Kennedy, BSc Environmental Science, various management courses. 8 years experience in the dairy industry.
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IPPC Application Attachment C
Waste Control Systems operating at Dairygold Mogeely.
Dairygold Food Ingredients is committed to eliminating waste generation at its processing facilities. Where this is not possible minimisation of generation, reuse and recycling are the favoured options.
Munster Waste is the company contracted to handle waste at the site in Mogeely. Munster Waste subcontract to Glenanore Cartons Permit no. CK WMC 75/01, who remove all recyclable packaging materials, cardboard and plastics and segregate it at their premises at Castletownroche, CO Cork permit no. CK (N) 23 1/05. Any non recyclable material gets taken by Greenstar to their transfer station at Sarsfield Industrial Estate, Glanmire, Co. Cork permit no. 136/2, to KTC landfill at Kilcullen, Co. Kildare, IPC licence no. 8 1/2. The Mogeely site is a Repak certified site.
41D
Milk processing losses are monitored daily by production, and a continuous improvement policy is encouraged. The wastewater treatment plant on site breaks down all the Biological Oxygen Demand of the waste stream and removes nutrients as per County Council discharge license number W.P. (W) 4/03.
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1
IIIPPC Agplication Attach. d
!CONTROL OF MEASURING & MONITORING DEVICESII
o Calibration of measuring and monitoring devices on site is contracted to an outside specialist company.
o Calibration of such devices is carried out on the site bi-annually.
o The devices in question include all temperature indicators and weighing scales, where necessary.
o Some calibrations and checks are performed by the Quality Assurance Laboratory e.g. pH meters, temperature indicators etc.
o Calibration by the Quality Assurance Laboratory as carried out bi-annually.
o QA Calibrations are carried out in compliance with the written site SOP.
o All calibrations records are maintained on file in the Quality Assurance Laboratory.
o Annual planned maintenance of the WWTP is carried out by an external contractor, all spares are held on site. Day to day maintenance is carried out by Dairygold maintenance staff.
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QUALITY CONTROL SYSTEM
The Quality Control System complies with the Site Quality Policy, BRC Global Standard and IS0 9001 2000 Standards i.e.:
Deliver product to customer specifications and achieve product quality targets. Maintain Food Safety and Hygiene Standards as per customer and Regulatory requirements. Ensure that all Health & Safety and Environmental requirements meet all Regulatory and Legislative Standards. Ensure adequate training is provided to satisfy all operational and Health & Safety requirements. Non-conforming product applies to product outside specification, encountered at intake, process and finished product. All significant incidences of non-conforming product, as soon as they arise, are brought to the attention of the relevant personnel. The status of non-conforming product encountered at in-process and finished product stages may be established by consulting Quality Records or by use of labels. The following physical labelling systems may be used: Failed Metal Detection Hold Pallet - Under Test Experimental Vat Process Curd Production issues are recorded in the Plant Incident Book. Quality issues are reviewed daily and communicated to the relevant operators verbally or by means of a written Operator Notice Form. In the area of finished products, all produds are graded when micro and chemical results are completed. These are entered live on the main frame system by the QA Manager. The system prevents the release of non- conforming products. Corrective Action / Preventative Action on site is initiated and driven by Quality Assurance Management.
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Mogeely
Quality Policy Milk Processing Ireland
It is the objective of Dairygold Milk Processing Ireland Division to market profitably products that are safe, meet customer expectations and legal requirements.
To meet this objective it is our policy to:
Develop and implement a Quality Management System that supports the needs of the business and strives for continuous improvement
- Maintain a customer focus ensuring - -
Customer needs and expectations are understood throughout the business Customer requirements are defined and fulfilled
Implement best hygiene practices and standards to ensure facilities and operations meet customer expectations and legal requirements
- Implement a Food Safety System based on the principles of HACCP incorporating a traceability system that allows tracing at all stages of procurement, processing and product dispatch
Continually train and develop employees on the manufacture and supply of quality products that are safe for use
Purchase materials, ingredients, packaging and products from suppliers that operate to a recognised Quality Management System.
Tim Healy, / Head of Milk Processing Ireland Division.
A Development and Operational History at the Dairvgold Mogeely Site.
Dairygold is Irelands largest farmer owned business with over 10,000 shareholders. The Co-op is governed by the board of directors (1 0 members and 2 co-opted external directors, the CEO reports to the board. Dairygold was established in 1990 on the merger of Ballyclough Co-op creamery ltd and Mitchelstown Co-op Agricultural society Limited. Dairygold is Irelands second largest milk purchaser, processing approx. 860 million litres annually, producing 120,000 tonnes of product, employing in excess of 500 people and generating a revenue of approx. €360million through providing top quality Cheeses, dairy commodities and Dairy based ingredients to selected customers and markets. Dairygold Food Ingredients (DFI) is a wholly owned subsidiary of Dairygold, in the milk processing and ingredients marketing division of the group. Since 2003 the society has gone through a radical re-organisation to maximise returns and to provide cost effective goods and services to its members. DFI’s important speciality cheese facility is located at Mogeely, east Co. Cork. The Mogeely facility processed 2006 18,940,000gals of milk, planned to increase by 15.8% in 2007.
The types of cheese made include Jarlsberg, Mallo, Regato , Manchego, Parmesan style cheeses. Consumption of speciality cheese’s is growing and this plant supplies specialist cheese of the highest specification to the top end of the quality market
The main raw materials include milk and milk products, cultures process chemicals such as detergents and salt and water. Natural gas, gas oil and electricity are used as energy inputs. Milk arrives on site by tanker where it is pumped into the whole milk silos. The wholemilk is then diverted to the various process outlined in the attached flowchart depending on the type of product being manufactured. Traditional and modern processes are employed including pasteurisation, coagulation to produce cheese curd and whey, separation of the curd, salting and ripening of the cheese. The whey is collected and sent off site for hrther processing. Process water is supplied by way of 2 on site boreholes.
, Process wastewaters are directed to the site’s wastewater treatment plant. The treatment process include balancing, pH correction, fat removal, high rate biofiltration, activated sludge, phosphate removal, final clarification, sand filters and sludge thickening. Sludge is spread in accordance with the County Council approved nutrient management plan.
The main sources of emissions from the Mogeely site are losses of milk solids and plant washings arising from cheese processing operations and flue gases from the boilers. There are 3 boilers on site two for hot water generation and 1 for steam generation. 2 boilers run on natural gas with the oldest operating as a standby on gas oil. There is also a generator which runs during the winter months on marked gas oil to partake in the ESB’s Winter Peak Demand Reduction Scheme. The nature and quantities of current and foreseeable emissions from the licensable activities are detailed in this application. The prevention, elimination or minimisation of emissions is a key consideration in rationalisation or new project planning.
1
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Natural gas as the main fuel for the site has reduced emissions to atmosphere.
The Mogeely plant has been producing speciality cheese since 1974 serving both the branded retail and cheese ingredients markets in the UK, US and mainland Europe. The facility and product range have been extended over the years with the most recent development being the installation of new technology in 2005 to produce the growing Jarlsberg cheese product under licence from a Norwegian dairy.
The dairy Industry has been the recipient of a restructuring grant from the Department of Agriculture and Food. This fund, for which grant application was due by November 23rd,2006 should result in a change of output for many current operators. With the aid of this restructuring grant it is hoped to increase the internal capacity of the site by 50- 60%.
In the event of a malfunction ie power loss on the grid, the local standby generator would be powered up to complete production and minimise losses. In the unlikely event that the power outage was to be longterm in the Mogeely area, the milk could be diverted to other Dairygold milk processors in the Cork area.
The laboratory facilities at Mogeely are involved in environmental analysis ie. surface water emissions testing. The laboratory is also involved,in quality assurance testing, process intermediate testing and final product testing and grading.
2
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DISCHARGE POINT N0.3. E = 59616 N = 60836
I 0
I
IPPC APPLICATION. PARIONI NoTK+: THE DR*wwo W NOT BED( WUJSIW. IT 12 WE -'' ff DAIRYGOLD UMITED*IID IS ~RIIWEO m W
PARSONS ENGINEERING LIMITED Unit 4600. Cork Airport Business Park
-FOR coI(NIMIuL U S E W Y . THE RmRDlT PRMU MOGEELY, CO. CORK.
ol-mwsE asposED oc CmEClLY OR DawzcnY. Nai usm FOR MNonER RlRposEonER THul W R R mwn C O IUmImm.
XOEHTl
l o ~ m To RH mls ~ u w w o u r n mum UID
SITE PLAN -TH*TIT WU Nar 8E RWRaWSD. COROD. W O M) 'ITLE'
s u L E : 5 u E : DRAW M E
IRAWING WlBES SHm: m
SHEET 3 OF 3. DNRYGOLD GROUP
I 0733-D-CE-004
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Mogeely
During the cheese making process when rennet is added to milk, it causes coagulation of the milk proteins to form curd and whey. The curd is made into cheese and the whey is pumped to the whey plant. The fresh whey is pumped alternatively into two fresh whey silos i.e. TlOl and T102.
From here the whey is pumped through a Rotex Sieve containing a cermia filter which removes any curd particles suspended in the whey. The particles are moved and placed in cartons and labelled ‘Russel Curd’ which is transferred to cold storage.
Q
The whey is then pumped from a balance tank to separators where it is separated into whey cream and low fat whey. The whey cream is then transferred to the silo T 103. The separated low fat whey is chilled and pumped to the chilled product silos - T110 and TI 1 1. The whey is held here until despatched to the Group Whey Powder Plant or in some cases as animal feed.
The plant is located in an entirely separate building at the rear of the cheese plant. All silos and CIP tanks are situated in a bunded area attached.
All operations from intake to despatch are completely automated with a computer programme for each stage. Q
Authorised by:Beatrice Walsh Status: CURRENT Version: 1 .O Page 1 of 1 Date:01/06/2006
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Mogeely
Block Cheese Process Overview. Approx 4,000 tonnes of Block Type Cheeses are manufactured at the Mogeely site on an
annual basis. Block cheese is sold in the market place under the trade name of “Mallo”
Cheese, Black Abbey, Monteray Jack, 3 % Cheddar, Red Leister , in the form of 20 kg
blocks. The cheese is manufactured mainly for the Uk, Italian and US market.
The manufacturing process can be summarised as follows; milk is collected at farm level
and brought to the milk intake area. On arrival, the milk is pumped into two whole milk
silos. . On a daily basis, a portion of the whole milk is separated to generate skim for
standardisation purposes. The standardised milk is plate cooled & held in silos 3,4, 5 & 6
for cheese production.
The initial step of the process involves pasteurisation of the standardised milk. This step
ensures that any pathogenic micro - organisms which may be present, are destroyed. To
ensure correct pasteurisation, a flow diversion valve is in place. The milk is then pumped
to the vats, where starter cultures & other ingredients are added, during filling. This is
followed by the addition of an enzyme called Rennet which causes the coagulation of the
milk proteins and hence leads to the formation of a coagulum. The coagulum is then cut,
stirred and heated during which acidification and whey expulsion take place. The starter
cultures along with the rennet determine the flavour, body and texture of the cheese.
The next stage of the process is referred to as “running”. This is where the contents of the
cheese vat i.e. curd and whey is pumped to a buffer tank and from there to a draining belt.
The whey is drained and pumped to the whey plant. The curd is stirred as it moves along
the first belt, then allowed to set and is cut into cubes by a guillotine. The curd cubes fall
on to the second belt where it is continuously stirred as it moves along this belt. The curd
particles at this stage are conveyed to a salting machine and from there to belt 3 -
mellowing belt. Finally the particles are conveyed to an automatic weighing/mould filling
unit. Lids are then placed on the moulds which are then. transferred by conveyor to
pressing lanes. After pressing, the cheese blocks are taken from the moulds, vacuum
packed, metal detected, boxed and finally placed in stores where maturation takes place.
Authorised by:Beatrice Walsh Status:CURRENT Version:1.2 Page 1 of 1 Date:31/03/2006
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Mogeely
ll Jarlsberg Cheese Process Description All milk loads are tested for antibiotics on arrival. When tested negative, the milk is pumped to a silo through a plate cooler and held overnight at < 4°C. The milk is routed to the Cheese Plant balance tank (hopper) of the Jarlsberg Pasteurizer where it is passed through the heating section of the pasteurizer. From there, the heated milk is pumped to the separator where is converted into skim and cream.
The skim portion is then routed to the Bactocatch, where spores are removed by micro filtration. The retentate from the filters is returned to a HTT unit (High Temperature Treatment) where it undergoes further heat treatment (> 124°C) along with the cream generated from separation.
The skim permeate from the Bactocatch and cream from the HTT section is then transferred to a standardising unit called a Compomaster. The skim and cream are re-mixed in the Compomaster to give the desired % fat in the milk for processing. The surplus cream is sent to a cream holding tank.
The standardised milk for cheese making is routed to the Pasteurizer and pasteurized @ > 72°C for 15 seconds. To ensure pasteurisation temperatures are reached and maintained, the pasteurizer is fitted with a flow diversion valve system. The milk leaves the pasteurizer through the cooling section and is pumped to the vats at 30- 32°C. In the event of milk being required for starter make up, the plant is pre programmed to route milk 2000 litres to the starter room where it is heated and cooled to 21°C prior to starter inoculation.
At the vats, 1 - 1.5% of bulk starter culture is pumped to the vat, 1 - 3 minutes after the start of vat filling. This is followed by the addition of propionic culture
Rennet is added to the vat. Depending on clot formation, a rennet setting time of 30 - 40 minutes is allowed. When ready the curd is cut automatically using the vat program steps.
Approx. 45 % of whey is drawn off and this is followed by further cutting and stirring. To allow further moisture expulsion and washing out of lactose to improve pH control, approx 25% of the cooking water is added back to the vat. Again, this is followed by further cutting and stirring. Then the vat contents are transferred to the buffer tanks located in the casematic room.
Within the buffer tanks, ingredients are added to control eye formation. Following this, the contents of the buffer tank are transferred to the casomatic tunnels where pre pressing of curd occurs. The curd is transferred into pre washed moulds and cut by a guillotine. Automatically, lids are placed on the moulds and final pressing takes place in the sanipress for 40 minutes approx. Authorized by:Beatrice Walsh Status: CURRENT Version: 1 .O Page 1 of 2 Date: 15/04/2006
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Following pressing, the cheese is removed automatically from the moulds and is transferred to a brine system which is treated to control microbial growth, for 24 hours. The cheese units are then removed from the brine system, dipped in delvocid, vacuum packed, metal detected, labelled and palletized on trays.
The product is then transferred to stores@ 6 - 9°C k!"C for 7 - 9 days and then it is transferred to the warm room @ 21 "C +I "C for 14 - 21 days.
Following incubation in the warm room, the cheese is checked for eye formation, texture and flavour and is then transferred to cold storage @ <4"C
Final grading takes place after 12 - 14 weeks and product is released to the market place in accordance with customer requirements.
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Mogeely
Packaging Delvocid Water Resm Salt
F're Cooler
Warm Room
Authorised by:Beatrice Walsh Status:CURRENT Version:l.i Page 1 of 1 Date:31/03/2006
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