Professional Documents
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INFRASTRUCTURE & OPERATION ru
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Rathmore Installation
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Attachment No. D
D1 Operational Information Requirements
Cadbury Ireland Limited manufactures and distributes over 25 products within the Irish Market
and exports a number of key lines. Cadburys has core operations in Rathmore, the UK, and
Europe, serving local and global markets. Cadbury Ireland Limited uses local ingredients and
is one of the largest users of indigenous Irish materials. Using local produce is a major factor
in creating the legendary taste of Cadbury Ireland Limited products.
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Cadbury Ireland Limited Rathmore Installation comprises of a crumb processing centre,
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laboratory, administration and engineering buildings. In addition the plant also contains
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Chocolate crumb is produced 24 hours per day and owing to efficient processing operations,
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the plant operates for 50 weeks within the year. Although the majority of unit operations are
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automated, Cadbury Ireland Limited retains approximately 115 permanent employees at the
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installation.
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Control of the processes undertaken in each of the plant areas and the transfer of liquid
feedstock between unit operations is highly automated. In addition to the sophisticated
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Programmable Logic Controller (PLC) systems, product quality is ensured through a regime
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of frequent, routine sampling and analysis and is regulated under a strict Quality Management
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System.
In addition to down time associated with feedstock availability, each plant area has a
scheduled regime of plant outages. These enable cleaning in order to observe strict hygiene
requirements.
Cleaning operations utilise dilute acid and caustic solutions. The frequency and cleaning
solution specification is governed by the requirement of each unit operation.
In situ cleaning of pipelines, vessels and other plant items is termed here ‘clean in place’
(CIP). Process control of the CIP sequence of cleaning and flushing is highly automated.
D2 List of Processes
The Cadbury Rathmore installation exclusively produces chocolate crumb for the domestic
market. The following processes are carried out at the Rathmore installation:
D 2.6 Storage
D 2.7 Services
D 2.9 Laboratory
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A Plant Flow Diagram of the facility can be seen in Appendix D.1
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Whole milk is received by road tanker at the intake area at a rate of approximately 33,000 m
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per year. There is an overfill alarm system present within the milk intake area.
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The milk intake operator off-loads fresh milk for storage and distribution throughout the plant
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freshness and quality. Whole milk is primarily used throughout the production process and
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skimmed milk is used according to requirements. Typical compositions of both whole and
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There are three milk receptions numbered 1, 2 and 3 which connect the milk tank outlets to
the intake pump. Samples are taken from each compartment and analysed in the laboratory
for clearance prior to being pumped to the silos. In the event of rejection by the laboratory, the
milk load is not accepted.
Milk distribution within the plant is through above ground pipelines to the storage silos, and
from there to processing facilities throughout the plant.
The plant produces approximately 65,000 tonnes of Chocolate Crumb per annum.
There are a series of liquid intake areas associated with the main processing plant, including
a primary milk intake area comprising:
1. 1 weighbridge
2. 3 reception bays
3. 2 CIP stations for washing
Milk trucks are also washed at the end of each days run. The quality control manual contains
details of the cleaning schedule for the milk intake area.
The CIP process is controlled according to methods detailed in the Quality manual. The key
process controls are as follows:
The milk intake lines and road tankers are cleaned using a detergent - Lactrin. The quantity
and strength at which the detergent is applied varies depending on the equipment being
cleaned.
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Hot Water Pre - Rinse
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Any build up, deposits, wastes etc. are removed during this process.
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Circulation Wash
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Lactrin based solution is used on surfaces and pipelines to soften any leftover residue to
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ensure complete removal when rinsing. The detergent is subsequently drained and
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recovered.
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This removes all previously applied detergent and leaves all surfaces visually clean.
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Process Controls
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The intake process is controlled under the Milk Intake Procedure. The milk quality is tested
manually everyday within the laboratory. The key process controls are as follows:
Butter oil is received by road tanker at the intake area at a rate of approximately 35 tonnes
per year. The butter oil is distributed within the plant though above ground pipelines from the
storage silos, and from there to processing facilities throughout the plant. There is an overfill
alarm system present within the butter oil intake area.
The composition of the butter oil is a 99.9% fat based product produced from cream via a
multi stage separation process. The butter oil intake process occurs within the main intake
area of the main processing plant which comprises:
1. Weighbridge
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2. Storage Silos ru
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3. CIP
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Process Controls
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The intake process is controlled under the procedures detailed in the Quality Manual. The
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Maximum Limit in
Moisture N/A N/A Log Sheet
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place (0.3%)
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Maximum Limit in
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If butter oil does not satisfy the above quality control standards it is not accepted and returned
back to the manufacturer.
Cleaning is an essential element of the butter oil intake process which is dependent upon high
standards of hygiene and cleanliness. Cleaning takes place as required. During CIP all
process intake lines and other equipment are cleaned as are all floor areas within the
manufacturing plant.
Sugar is received by road tanker at the intake area at a rate of approximately 37,000 tonnes
per year. There is an overfill alarm system present within the sugar intake area.
The sugar is distributed to processing facilities within the plant though above ground pipelines
from the storage silos. The sugar intake process occurs within the main intake area of the
main processing plant which comprises:
1. Weighbridge
2. Storage Silos
Process Controls
The intake process is controlled according to procedures detailed in the Quality Manual.
Humidity is monitored continuously and a maximum control limit (30-60%) is in place.
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Parameter Method Frequency Records Control
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N/A
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(30-60%)
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Cocoa Mass is received by road tanker at the intake area at a rate of approximately 9,000
tonnes per year. There is an overfill alarm system present within the cocoa mass intake area.
The cocoa mass is distributed to processing facilities within the plant though above ground
pipelines. The silos are heated in order to maintain the cocoa mass in a continuous liquid
state. Cocoa mass intake process occurs within the main intake area of the main processing
plant which comprises:
1. Weighbridge
2. Storage Silos
Process Controls
The intake process is controlled under the cocoa mass intake Process Manual. The key
process controls are as follows:
A written description of the production process for chocolate crumb can be seen in Section
A1.1. of Attachment A. In addition, a diagram of the process is shown in Appendix A1.3 of
Attachment A.
Process Controls
The chocolate crumb manufacturing process is controlled under a series of procedures within
the Quality manual, which cover Chocolate Crumb Production and Packaging.
The intake procedures and process controls for the inputs (sugar, milk, butter oil, and cocoa
mass) have been illustrated in the previous sections.
The key process controls in the manufacture of chocolate crumb are as follows:
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Recipe Control Load cells on batching tanks
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Production
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Records
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Cleaning
Cleaning takes place as per cleaning schedules and procedures as outlined in the Quality
Manual.
D 2.6 Storage
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There is approximately 1,205 m and 570 tonnes of storage provided on-site for raw material,
intermediate and finished product.
Bulk storage comprises stainless steel silos, which are located throughout the three main
production areas in tank farms. The capacity of storage silos on site varies from
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approximately 1 m to 400 m .
Approximate Storage
Material Tank Type 3
Capacity (m )
Milk Stainless Steel 660
Cocoa Mass Stainless Steel 210
SCM Stainless Steel 275
Butteroil Stainless Steel 60
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Lactrin Stainless Steel (bunded) ru 5
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Arising from the way in which development has taken place at the site over the past 58 years,
the degree of local bunding on individual tanks and for tank farms is limited.
The tanks themselves are stainless steel and no serious tank failure has occurred at the site
in the past 58 years, although minor pinhole leaks have been detected along weld seams on
some tanks. The risk of serious tank rupture is considered to be low.
A number of the storage tanks within the production areas receive a degree of containment
through the routing of adjacent surface water drains to the wastewater treatment plant.
Storage arrangements for fuels and cleaning chemicals differ from dairy storage in that all fuel
oil storage tanks and cleaning (CIP) chemical storage tanks are bunded.
Palletised storage is provided for vacuum dried processed chocolate crumb, which is packed
in 1150 kg tote bags. Air dried crumb is stored in one of two bulk silos, from where it can be
packed in containers in kibbled form or milled and stored in 750 kg. tote bags. All tote bags
are then transported to one of six finished goods storerooms.
D 2.7 Services
Compressed Air
Water Treatment
Heat System
Compressed Air
The compressed air plant provides an adequate quantity of dry air free of oil and other
contamination at a pressure of 12 bar.
The air compressors in use are two stage air cooled machines, which deliver oil free air for all
requirements. The compressors are connected to the air inlet, the electricity and the cooling
air supply.
Compressed air after leaving the cooler and going into the air inlet is 100% saturated with
water vapour and dried.
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The operation of the compressed air system is variable on demand.
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Discharge from dryers consisting of water goes to a drain and is diverted from there to the
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In the event of an oil leak suitable absorbent material is used to absorb the oil, which would
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be disposed of appropriately.
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Water Supply
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The water treatment plant provides an adequate quantity of potable water to the quality
standards S.I. No. 439 of 2000 for the entire site.
Well water is supplied from two principal boreholes located to the southeast of the factory in
the car park. The two boreholes supply the borehole reservoir, which in turn supplies the
water treatment plant. In addition, there is a top up borehole located to the south of the
factory, adjacent to the administration building.
Chlorination
Chlorine is added to the well water. The purpose of this is to provide disinfection of the water
leaving it free from disease causing organisms.
Filtration
Filtration of the well water occurs in sand filter beds to remove impurities in the water.
The water flows down through the filter bed and out under drains to the clean water storage
Silo.
Storage
Water is pumped from the clean water sump to the storage reservoir, which has a capacity of
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570m . One quarter of the water from the reservoir is utilised for processing and cleaning, and
the remaining three quarters is reserved as fire water.
Roads and paving are generally constructed from reinforced concrete and laid to falls. The
car park is surfaced with hard standing asphalt.
Drainage
There are two storm water drainage catchments and associated collection systems at the site.
The storm water runoff from the western section of the facility flows to a drainage channel
located to the west of the facility and subsequently to the River Blackwater.
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The eastern parts of the site currently drain to the wastewater treatment plant for treatment
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prior to discharge.
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The waste water drainage system collects process waste water, domestic sewage from the
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production plant, administration areas for treatment at the waste water treatment plant.
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Surface water from the milk and intake areas also discharges to the WWTP.
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D 2.9 Laboratory
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There is a laboratory on-site, which carries out a range of microbiological, chemical tests on
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raw materials, intermediates and end products. The tests undertaken include:
The boiler system has been operational since 1966 when two boilers were installed, in 1978 a
third boiler was installed. The primary function of the heat system at the plant is steam
generation to meet the demand from process areas. In addition, the system provides hot
water (65°C) for processing areas.
The base steam load at the plant is met by one of two operational HFO (Heavy Fuel Oil)
boilers (duty and stand-by). A third boiler is partly decommissioned and unavailable for use.
Boiler feed water is made up from condensate, evaporate form the processing plant and raw
water (potable water from on-site storage) where required. Boiler feed water is chemically
treated to make it more suitable for boiler use using phosphate (scale inhibitor), sodium
sulphate (oxygen scavenger) and caustic soda (pH buffer).
Debris, dust, etc. accumulates in the boiler house over a period of time. This is swept up, put
into rubbish bags and sent to landfill.
Waste oil, which has been drained, is put into bunded tanks, identified and sent for recycling
by a number of licenced waste contractors.
Wash water goes to drain and is diverted to the effluent treatment plant.
Solid Waste
The sources of solid waste at the Rathmore facility predominantly consist of debris from
clean-up activities together with minor quantities of chocolate crumb as dust and organic
waste (sludges) from the waste water treatment plant.
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D2.11 Process Waste Water Treatment
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The main sources of process waste water arising from production activities at the plant are as
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follows:
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Cleaning Operations
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operations are undertaken at scheduled periods as specified within the Quality Manual. The
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Quality Manual contains details of the plant equipment which is to be cleaned, the personnel
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Floor Washings
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Floor washings, which are generated in all process and services areas, are diverted to the
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Sanitary Effluent
Sanitary effluent is collected and discharges to the wastewater treatment plant at the inlet for
subsequent solids removal and secondary treatment.
Surface water arising from the western section of the building including the car park flows into
a stream which runs to the River Blackwater (SW2).
There are two storm water drainage catchments and associated collection systems at the site.
The storm water runoff from the western section of the facility flows to a drainage channel
located to the west of the facility and subsequently to the River Blackwater.
The eastern parts of the site currently drain to the wastewater treatment plant for treatment
prior to discharge.
The waste water drainage system collects process waste water, domestic sewage from the
production plant, administration areas for treatment at the waste water treatment plant.
Surface water from the milk and intake areas also discharges to the WWTP.
A diagram depicting the site drainage plan can be seen in Appendix D.2. The drainage plan
for the Waste Water Treatment Plant (WWTP) can be seen in Appendix D.3.
The process waste water from the facility is treated to a high level utilizing chemical, biological
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and physical separation processes within the Waste Water Treatment Plant WWTP to remove
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organic and inorganic substances and render the water safe prior to discharge to the River
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Blackwater. Some of the typical contributions to process wastewater include the following:
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CIP Stations
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Product residues from pipes, tanks, and machinery e.g. sugar, fats, solids
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The waste water treatment plant comprises the following unit operations (Refer to Appendix
D1 for WWTP diagram).
The water quality of the effluent from the WWTP is analysed in the onsite laboratory, in
addition to permanent monitoring devices at the treatment plant itself i.e. flow and pH meters.
Table 4.1 illustrates the parameters monitored at each location, the frequency at which this is
undertaken, and the target result for each parameter. The accuracy of the temperature and
pH probes in addition to solids instruments are checked on a regular basis, and if necessary
re-calibrated using standard solution to ensure that they are operating correctly.
Waste minimisation plans are implemented at the site to target an overall reduction of
effluents discharged. This gives immediate benefits of reduced water consumption, less
effluent treatment demand and reduced impact on the environment.
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Solids River In Others as ru Others
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DAF required N/A
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Water
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2. Final
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Phosphorous 2.Final
(as P)
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phosphorous
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In addition there is a cut off level in operation at the WWTP which operated on a high high
(HH), high low (HL), and low low (LL) alarm system to prevent any of the tanks from
overflowing, and conversely from drying up. If the effluent surpasses the low low level it will
activate a pump, and if this surpasses the high low level it will activate a second pump. In the
event of one pump failing a second pump will be activated. All readings from the monitoring
probes and alarm systems are registered at both the WWTP, and the processing plant.
In the event of pH, and suspended solid values exceeding threshold limits an alarm will
activated and divert the wastewater to one of he two emergency holding tanks, where it is
aerated and gradually feed back into the balance tank.
Solid Wastes
The plant is designed to incorporate settlement tanks where the waste products and excess
organisms fall to the bottom and settle out forming a thick sludge requiring disposal. Solid
waste is removed post biological treatment. Sludge from the Dissolved Air Flotation (DAF)
Plant is mixed with the microbiological sludge before it is compressed and further liquid is
removed in the Belt Press. The sludge is then stored in a metal skip for subsequent
composting.
A licensed waste disposal contractor removes the sludge and solid waste arising form the
process are collected and disposes of them at a licenced facility. A report detailing the
quantities of sludge produced, the location of composting and the quantities subsequently
recovered is submitted to the EPA.
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The Cadbury Ireland Limited Rathmore installation has been subject to continuing upgrade
and modernisation over the past 58 years to reflect changing production practices, new
technologies and improved environmental controls.
Developments at the site since construction of the original installation have included:
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Raising level of roof on part of factory (1987)
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Extension to part of factory roof (1988)
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The following future developments are proposed for the Cadbury installation:
The Drains Remediation Project is being undertaken on a phased basis. Currently some of
the drainage from the facility to the waste water treatment plant (WWTP) has been replaced.
To date, three phases of the project have been completed and an additional phase is planned
to complete the replacement of all drains leading to the WWTP. The purpose of this project is
to reduce the potential threat of effluent leakage to surface and groundwater.
The new pipelines are of stainless steel construction, with integrated stainless steel
manholes. The entire system will be pressure tested as part of its commissioning.
As part of the remediation project, the eastern stormwater drainage catchment will be
reviewed in order to allow for the discharge of uncontaminated stormwater directly to the river.
This stormwater is currently discharging to the wastewater treatment plant.
Wells
Weighbridge
Water
intake
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(Capacity 660m3)
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Storage Silos (1,2,3) Storage Silos (Tank 30-33) Storage Silos
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(Capacity 170 Tonnes) (Capacity 210m3) (Capacity 60 m3) Processing and
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Storage
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Controls
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Laboratory
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Crumb Production Area Milling Area
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Buildings and Services en
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Administration building,
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Engineering Building,
Canteen, toilets, and Storage Area Product and
heating system, (Capacity 400 Tonnes) Associated Outputs
Treatment Plant
River Blackwater
Client
Cadbury Ireland Ltd
Title
Plant Flow Diagram
Scale. Project No.
NTS 1061_01
Figure No. Rev.
Drawing No. 4 01
Appendix D.2
Site Drainage Plan
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Balancing Tank
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Final Effluent Tank
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Final Effluent Tank
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MP-2 River Room
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Western Divert Tank
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Sludge Tank
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Primary Settling Tank
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DAF
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De watering Tank
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Eastern Divert Tank
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Effluent monitoring
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Date
Issue no. Date By Checked Approved Note Ref Scanned
Issue no
Appendix D.3
WWTP Drainage Plan
Sludge Treatment
Primary
Settlement Tank
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Blend Tank Thickening Tank
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Western Primary Eastern
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ADF Effluent Tank ADF
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Belt Press/
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Dewatering Unit
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Final Effluent
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Recycle
System
Composting/
Landspreading Flow Measurement Issue no. Date By Checked Approved Note Ref. Date
Scanned
Sampling
To River Client
Cadbury Ireland Rathmore
Blackwater Title
Waste Water Treatment Process Flow
Scale. Project No.
NTS 1061
Figure No. Rev.
Drawing No.6 01
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