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RAW MATERIALS REVIEW

March 2019

(BALLYMENA)

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Contents 1.0 Scope ................................................................................................................................................. 2

2.0 Purpose ............................................................................................................................................. 2

3.0 Executive Summary .......................................................................................................................... 2

4.0 Raw Material Consumption per tonne of production .................................................................... 3

Table 1. ................................................................................................................................................ 3

Table 2. ................................................................................................................................................ 3

5.0 Gas .................................................................................................................................................... 4

Graph 1................................................................................................................................................ 4

Graph 2................................................................................................................................................ 4

6.0 Electricity .......................................................................................................................................... 5

Graph 3................................................................................................................................................ 5

7.0 Gas oil ............................................................................................................................................... 6

Graph 4................................................................................................................................................ 6

8.0 Chemicals - Cleaning......................................................................................................................... 7

Table 3. ................................................................................................................................................ 7

Graph 5................................................................................................................................................ 8

Table 4. ................................................................................................................................................ 9

Graph 6................................................................................................................................................ 9

Graph 7................................................................................................................................................ 9

9.0 Chemicals – Effluent Treatment .................................................................................................... 10

Table 5. .............................................................................................................................................. 10

Graph 8.............................................................................................................................................. 10

Current and Future Improvements on site .......................................................................................... 13

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1.0 Scope The review covers raw materials that have entered the Cranswick site to be used for production and hygiene operations and effluent treatment in terms of fuels, chemicals and electricity.

2.0 Purpose As part of IPPC Permit Requirements raw materials must be reviewed at least every 3 years. The review also encapsulates commitment with Cranswick PLC targets for improved efficiency in the use of raw materials.

3.0 Executive Summary The site is currently improving efficiency and the use of raw materials year on year. The site is on track to meet the group target of reducing raw material/energy consumption by 50% by 2020 (base line year 2009). Some further improvements have been made on the site to reduce chemical usage.

There is no correlation between pig numbers and gas usage and the time of year pigs are slaughtered, however there is a downward trend in gas usage suggesting improved efficiency on site. There appears to be a correlation between electricity usage and the time of year, where the warmer months of the year have increased usage (July-August). There is no correlation with electricity usage and pig numbers. Gas oil efficiency is increasing when comparing with pig numbers as there is a downward trend in gas oil usage and upward trend in pig numbers.

Cleaning chemical usage is dependent on the types of cleaning occurring within the factory (e.g. deep cleaning) and also dependent on weekend cleaning. It is expected that the usage of Topaz CL4 will decrease in 2019 as a result of the installation of a dolav washer, however introduces a new raw material (MIP SC), usage of this chemical will be monitored. When comparing a full year’s usage, there is a slight decrease in the levels of chemicals procured and used to clean machinery and the factory (when comparing Topaz CL4 and CL1 usage). With the increase in production from 2016-2018 it displays that the substitution of CL1 for the introduction of CL4 was positive and reduced overall usage of a chemical the factory is highly dependent on.

Better understanding of the purpose and quantity of chemicals required for effluent treatment has reduced the procurement and wastage of effluent treatment chemicals on site.

CO2 usage is in direct correlation with the pig numbers, as pig numbers increase so does the CO2 usage. The use of CO2 is production dependant and therefore usage cannot decrease.

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4.0 Raw Material Consumption per tonne of production

Using billed raw material consumption/procurement, see below table of gas, electricity and oil consumed per tonne of production in the last 2 calendar years:

Energy Consumption

Unit 2017 % 2018 %

% Difference 2017/2018

% Improvement

Site Tonnage Produced

Tonnes 91,829 N/A 98,941.34 N/A +7.19 N/A

Electricity MWh 3,691.74 4.02 3,964.63 4.31 +7.39 +2.95 Gas MWh 5,486.70 5.97 5,527.97 6.01 +0.75 +4.96 Oil MWh 1,396.20 1.52 2,588.70 2.81 +85.41 -0.33

Table 1. Table displaying site usage of raw materials and % improvement

Table 1 explains that Cranswick Country Foods Ballymena production (product killed and then boned out) has increased by 7,112.34t with an increase in raw material/usage efficiency compared with the previous year.

The below table (Table 2) describes the reduction in total consumption of raw materials – gas, electricity and oil and displays an improvement in efficiency year on year.

Parameter 2016 2017 2018 Total Energy Consumption (MWh/tonne of production)

0.121 0.115 0.114

Table 2. Table displaying total energy consumption MWh/tonne of production 2016-2018

The Cranswick Group have committed to the below target:

• To reduce energy consumption per tonne of production at Cranswick (Ballymena) by 50% by 2020 using 2009 as a base year.

Total energy consumption per tonne of production decreased by 47.88% between 2009 and 2018. This is working towards the Group Target of 5% reduction YOY to achieve a 50% reduction by 2020. The target is on track as being achieved.

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5.0 Gas Gas is used throughout the site to process carcasses e.g. hand flaming and automatic singeing.

Graph 1. Gas usage 2018

Graph 2. Gas usage vs pigs killed

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40421 43237 50175 40703 40677 51032 37888 41989 52656 43190 43762 50480

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Gas Usage vs Pig Killed 2018

Pigs Killed Gas Usage (kWh) Linear (Gas Usage (kWh))

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Graph 1 displays that there is no correlation between the time of year and the gas usage; gas usage remains relatively stable throughout the year. There is a slight downward linear trend in relation to gas usage. Graph 2 also displays that there is no correlation with pig numbers and gas usage with varying gas usage throughout the year. There is however a downward trend in the gas usage displaying an increase in efficiency throughout the year (2018).

6.0 Electricity

Graph 3. Graph displaying electricity usage in comparison with pigs killed

Graph 3 displays no direct correlation with pig numbers and usage of electricity, however a slight positive trend is observed in the use of electricity. This upward trend appears to be related to external temperatures during the warmer months of the year June-August where mean temperatures are higher than that throughout the year. Chills and Dawson units must be ran more frequently and at lower temperatures to ensure that they are reaching their desired temperature causing more electricity to be used.

40421 43237 50175 40703 40677 51032 37888 41989 52656 43190 43762 50480

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Electricity Usage vs Pigs Killed 2018

Electricity Consumed Pigs killed Linear (Electricity Consumed)

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7.0 Gas oil

Graph 4. Graph displaying gas oil usage vs pigs killed

There appears to be an increase in efficiency when observing the gas oil usage and pigs killed. There is a small downward trend in gas oil usage where there is a positive linear trend in the number of pigs killed. Gas oil is used for the running of some external chills (Dawson Units) and the boilers related to heating the factory.

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Gas Oil Usage vs Pigs Killed

Gas Oil Usage Pigs killed Linear (Gas Oil Usage) Linear (Pigs killed)

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8.0 Chemicals - Cleaning On site there are a number of chemicals used, they have many different purposes, however are predominantly for cleaning purposes. See below table (Table 3.). The information below will focus on the most highly used chemical on site (Topaz CL4 and Topaz CL1 – foam cleaner).

Jan-18 Feb-18 Mar-18 Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18 Oct-18 Nov-18 Dec-18 TOTAL Product Description Amount Amount Amount Amount Amount Amount Amount Amount Amount Amount Amount Amount Amount

INSPEXX 210 (CONNEXX) 210KG 420 420 420 840 420 420 630 420 630 630 630 5,880 MIP MX 24KG 144 240 288 144 360 168 216 288 168 384 240 216 2,856

P3-ANSEP CIP 24KG 600 480 480 816 768 768 672 1,488 816 1,728 1,992 1,560 12,168 TOPAZ CL4 1175KG 4,700 3,525 3,525 4,700 4,700 3,525 3,525 5,875 2,350 5,875 4,700 3,525 50,525 P3-CLINT GP 230KG 690 230 690 1,150 920 920 690 1,150 690 1,610 1,150 690 10,580

P3-TRIQUART AM 21KG 336 273 420 504 252 189 357 525 336 504 378 273 4,347 P3-MANODES LI 2X5L 35 35 69 104 130 60 95 147 78 138 147 130 1,166 P3-TOPAX 91 975KG 975 975 975 975 3,900

TAXAT EXTRA CLASSIC 20KG 80 40 100 60 40 40 40 40 40 60 60 40 640 POLIX CHLORANT 24KG 96 48 192 96 96 216 72 144 48 168 96 1,272

TOPAZ AC3 23KG 46 69 69 46 46 92 69 437 TOPAZ HD3 25KG 125 175 125 250 100 50 125 125 1,075 INCIDIN AL 19KG 38 95 76 38 247

TOPACTIVE 200 23KG 92 92 DRYSAN OXY 12X1L 12 12 12 36

DRYSAN OXY WIPES 1X700PCS 4 4 AIRSPEXX 20KG 20 20

20 LITRE CLEAR DRUM UN 15 15 *P3-OXONIA ACTIVE 21KG 42 42

OXONIA ACTIVE 21KG 42 42 COMPONENTA FG 25KG 25 25

7,147 6,335 6,347 8,776 7,899 7,149 6,207 11,404 5,042 11,310 9,401 8,354 95,370 Table 3. Table displaying overview of cleaning chemicals purchased in 2018 (kgs)

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Table 3 displays that the chemical most commonly used throughout the factory is Topaz CL4 (61% of the total chemical delivered to site in 2018). This chemical is used for the cleaning of machinery and the factory floor during the evenings. Also, during 2018 Topaz CL4 was used for the cleaning of dolavs, the installation of the dolav washer will aim to decrease the usage of CL4 over time as a different chemical is used in this installation (MIP SC) (note details of MIP SC purchase/delivery are not included within the review).

Graph 5. Graph displaying trends in the procurement of Topaz CL4 for cleaning purposes

Graph 5 displays no specific trend, with a number of peaks and troughs throughout the year. This may be dependent on the procurement of large quantities of CL4 at one time (August and Oct). This would explain the largely reduced quantity of CL4 purchased in September 2018; it may also be correlated with an increase in the number of deep cleans and weekend cleaning. The time frame of large purchases of CL4 is in conjunction with an increase in cleaning regime throughout the factory to combat microbiological issues that were observed during routine Technical compliance testing for microbiological organisms - October 2018. Procurement of CL4 reduced significantly thereafter as the increased cleaning schedule combatted the microbiological issues.

4,700

3,525 3,525

4,700 4,700

3,525 3,525

5,875

2,350

5,875

4,700

3,525

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TOPAZ CL4 1175KG - Delivery to Site

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Year and Chemical Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total

Sum Total

2016 - CL1 4,400 3,300 4,400 5,500 4,400 4,400 4,400 4,400 4,400 4,400 4,400 4,400 52,800 70,400 2017 - CL1 4,400 3,300 5,500 3,300 1,100 0 17,600 2017 - CL4 0 0 0 0 3,525 4,700 3,525 3,525 4,700 3,525 4,700 3,525 31,725 82,250 2018 - CL4 4,700 3,525 3,525 4,700 4,700 3,525 3,525 5,875 2,350 5,875 4,700 3,525 50,525

Table 4. Table displaying largest quantity raw material (chemical) delivered to site

Graph 6. Topaz CL4 usage Graph 7. Topaz CL1 usage

Graphs 6&7 display the chemical used most frequently between 2016 & 2018; Topaz CL1 was substituted for Topaz CL4 in May 2017. Usage of CL1 appeared to be more consistent when comparing with CL4. When comparing 2016 and 2018 where a full 12 months usage can be observed, the usage of CL4 is less than CL1 (reduction of 2275kgs). This suggests that CL4 is more effective where less chemical is used.

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Topaz CL4 - 2017 & 2018

2017 - CL4 2018 - CL4

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9.0 Chemicals – Effluent Treatment

A sample period from 2017 and 2018 was taken for the review of effluent treatment chemicals procured and used for the treatment of effluent water. The sample period is from Jan-Oct in 2017 and 2018, respectively. The main chemicals procured are:

• Cellfloc A11 - coagulant. It releases solids from solution into tiny particles. It is the main factor in achieving clarity in the final water.

• Cellfloc C19B - cross linked polymer. It pulls together all the particles created by the A11 and bonds them together leaving it possible for the white water in the DAF to float flocs to the surface.

• Caustic Soda - pH correction. The flocs would not form unless the pH was neutral.

Comparison 2017-2018 Jan-Oct 2017 2018 Chemical Quantity purchased L Quantity purchased L Cellfloc A11 52,000 28,000 Cellfloc C19B 8,000 9,000 Caustic Soda 11,000 7,000

Table 5. Table displaying effluent chemicals purchased for effluent treatment 2017-2018

Graph 8. Graph displaying effluent chemical procurement 2017-2018

Effluent chemical purchased has decreased significantly in total, with the major difference being a large reduction in the procurement of Cellfloc A11 (coagulant). The usage of chemicals was reviewed to ensure that disparity in the use of chemicals does not occur. Therefore dependency on effluent chemicals has reduced. Better knowledge of the chemicals, dosage rates and function of

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the chemicals was also sought which in turn reduced waste of chemicals in comparison with 2017 procurement.

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10. Carbon Dioxide

Carbon dioxide is used on site to stun pigs before slaughter. See below usage graph in comparison with pig numbers:

Graph 9. CO2 usage vs pig numbers (Financial Year)

The use of carbon dioxide is directly related to pig numbers, the higher the pig number the more CO2 that is in use. Some anomalies may be within Graph 9, some retention of CO2 within the system was completed due to the shortage of CO2 during the summer months.

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C02 Usage 2018/2019 Pig Number 2018/2019 Linear (C02 Usage 2018/2019) Linear (Pig Number 2018/2019)

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Current and Future Improvements on site A new dolav washer has been purchased on site to reduce to accurately dose chemicals when washing dolavs (MIP SC is used for this process). The employment of a new even shift Hygiene manager will aim to improve cleaning practices and better control the use of chemicals during hygiene operations (December 2018). A new automatic singeing machine is being sought to enable more efficient processing of carcasses to reduce raw material usage reducing the dependency on LPG procured for use when hand singeing.

The effluent treatment process is being assessed, investigations into how the effluent is being treated are ongoing. Any method of reducing chemical usage in this process is being assessed.