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Attachment D

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INFRASTRUCTURE & OPERATION ru
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Cadbury Ireland Limited


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Rathmore Installation
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IPPC Licence Application


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Project Ref: OES1061_01


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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

Attachment No. D
D1 Operational Information Requirements

Cadbury Ireland Limited, Rathmore Installation is a subsidiary of Cadbury-Schweppes plc, a


global leader in the manufacture of beverages and confectionery products. Cadbury Ireland
Limited was established in 1932, producing three products one of which included Cadbury
Dairy Milk. Cadbury Ireland Limited now has three production plants, comprising of two in Co.
Dublin (Coolock and Tallaght) and one in Co. Kerry (Rathmore). Cadbury Ireland Limited is an
undisputed market leader in the chocolate market with a 48% share of a market worth 473
million annually.

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.

Cadbury Ireland Limited, Rathmore Installation is an international provider of milk chocolate


crumb, this is an intermediate product utilised in the production of milk chocolate in a number
of facilities throughout the World.

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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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storage facilities, a wastewater treatment and utility plants.


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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.

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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

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:

D2.3 Sugar Intake Process

D2.4 Cocoa Mass Intake Process

D2.5 Production of Chocolate Crumb

D 2.6 Storage

D 2.7 Services

D 2.8 Roads and Paving

D 2.9 Laboratory

D2.10 Boiler House

D2.12 Emission Abatement Equipment

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A Plant Flow Diagram of the facility can be seen in Appendix D.1
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D2.1 Milk Intake Process


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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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as quickly and efficiently as is practicable in order to maintain high quality standards of


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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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skimmed milk can be seen in Table 4.1.


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Table 4.1 Typical Composition of Whole and Skimmed Milk

Parameter Whole Milk Skimmed Milk

Fat 3.5% 0.1%


Carbohydrate 4.5% 5%
Protein 3.2% 3.3%
Minerals, Vitamins Trace Trace
Calcium 115 mg 120 mg

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.

On reception, milk is transferred to storage silos prior to incorporation in manufacturing


activities. From storage, milk is distributed on rotation, with oldest milk being used first.

Milk distribution within the plant is through above ground pipelines to the storage silos, and
from there to processing facilities throughout the plant.

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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

The plant produces approximately 65,000 tonnes of Chocolate Crumb per annum.

Raw Material Intake

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

Cleaning in Place (CIP)

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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Cold Post - Rinse


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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:

Parameter Method Frequency Records Control


Log Maximum
Temperature Thermometer Every Delivery
Sheet Limit in place
Free from
Visual Log foreign matter,
Odour/Appearance Every Delivery
Inspection Sheet and abnormal
odours.
Quality Control Log Minimum 4 at
Resazurin Every Delivery
Manual Sheet 10 minutes
Acidity Quality Control Log Maximum
Every Delivery
(Intake Milk) Manual Sheet Limit in place
Quality Control Log
Added Water Every Delivery Limit in place
Manual Sheet
Quality Control Log
Fat Every Delivery N/A
Manual Sheet
If present the
Quality Control Log
Antibiotics Every Delivery milk is not
Manual Sheet
accepted.

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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

Parameter Method Frequency Records Control


Acidity Quality Control Log
Twice Daily Limit in place
(Silo Milk) Manual Sheet
Multi spec Quality Control When Silo is ready Log Limit Ratio’s
Fat SNF Ratio Manual for evaporation Sheet in Place
Maximum
Milk Storage Log
Digital Readout Daily Limit in place
Temperature Sheet

D2.2 Butter Oil Intake Process

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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key process controls are as follows:


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Parameter Method Frequency Records Control


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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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Peroxide value N/A N/A Log Sheet place (0.3 m.


equvi/ kg. max)
Free – Fatty acids N/A N/A Log Sheet < 0.35 % max
Flavour N/A N/A Log Sheet < 0.35 % max
Colour N/A N/A Log Sheet < 0.35 % max
Storage Temperature 2 Year
Read Out Log Sheet < 0.35 % max
on VDU check Digitherm
Supplier Certification N/A Every Load Log Sheet
Supplier visit N/A As Required Log Sheet
Each
APC @ 30° C N/A Log Sheet 10,000g
Consignment
Each
Enteros N/A Log Sheet 10/g
Consignment
Salmonella/Shigella
N/A N/A Log Sheet 0/25g
(Standard Butteroil)
Yeast and Mould
N/A N/A Log Sheet 100/g
(Standard Butteroil)

If butter oil does not satisfy the above quality control standards it is not accepted and returned
back to the manufacturer.

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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

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.

D2.3 Sugar Intake Process

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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Storage As Log Maximum Limit in place


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N/A
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Temperature Required Sheet (15-33 C)


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Certification visit As Covering requirements of


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N/A Log Sheet


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N/A Required specification


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Maximum Limit in place


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Humidity N/A Continuous Log Sheet


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(30-60%)
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D2.4 Cocoa Mass Intake Process


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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:

Parameter Method Frequency Records Control


Each Cert of Maximum Limit in place
Salmonella N/A
Delivery Analysis (0/25g)
Cert of Maximum Limit in place
Fat N/A Daily
Analysis (Max 49-53wb)

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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

Cert of Maximum limit in place


Moisture N/A Daily
Analysis
Storage Maximum Limit in place
N/A N/A Log Sheet O
Temperature (50-60 C)

D2.5 Production of Chocolate Crumb

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:

Parameter Control Records


Calibration

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Recipe Control Load cells on batching tanks
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Records
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Raw Milk Quality Manual Testing Laboratory


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Automatic and manual


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Temperature PLC/Log sheet


Thermometers
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Steam Pressure Automatic and manual PLC/Log Sheet


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Mains Water Pressure In-line pressure gauge PLC


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Water Quality Manual Testing Laboratory


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Temperature in Cooker Continuous monitoring P.L.C./Log Sheet


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Product Quality Manual - laboratory analysis Laboratory


Moisture Manual Testing Laboratory
Fat Manual check Log Sheet
Bacteriological Manual testing Laboratory

Cleaning

Cleaning is an essential element of the chocolate production process, which is dependent


upon high standards of hygiene and cleanliness. Cleaning includes manual as well as CIP
systems.

Cleaning takes place as per cleaning schedules and procedures as outlined in the Quality
Manual.

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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

D 2.6 Storage

3
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 .

Storage is provided for the following:

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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Diesel Oil Stainless Steel (bunded) 22.2


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H.F.O. Stainless Steel (bunded) 380


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Sodium Hypochloride Stainless Steel (bunded) 5


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Caustic Soda Stainless Steel (bunded) 17


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Nitric Acid Stainless Steel (bunded) 9


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Water Stainless Steel 680


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Calor Gas BMS Pressurised 1.5


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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

The services provided on-site are as follows:

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Rathmore Installation
IPPC Licence Application
Attachment D

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.

There are three dryers in use at present:

• one air cooled dryer unit


• three vacuum dryer units

These are connected up to the compressors as appropriate.

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The operation of the compressed air system is variable on demand.
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Wastes and Emissions


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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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effluent treatment plant.


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Air leaks go to the surrounding atmosphere.


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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

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Rathmore Installation
IPPC Licence Application
Attachment D

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.

D 2.8 Roads and Paving

Roads and paving are generally constructed from reinforced concrete and laid to falls. The
car park is surfaced with hard standing asphalt.

Drainage

The drainage at the facility can be categorised as follows:

1. Storm water from roads and other open areas.

2. Wastewater from manufacturing processes and associated utilities, sanitary effluent,


and storm water runoff from hi risk areas.

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:

Product quality Parameter Compositional analysis


Acidity pH
Fat Content Moisture content
Microbiological quality Particle size
Solids content Protein content

D2.10 Boiler House

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

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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

treated to make it more suitable for boiler use using phosphate (scale inhibitor), sodium
sulphate (oxygen scavenger) and caustic soda (pH buffer).

Wastes and Emissions

Condensate is diverted to the effluent treatment plant. Stack emissions go to atmosphere.

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.

Evaporator trays are cleaned regularly.

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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Rigorous cleaning is undertaken in order to maintain a high standard of hygiene. Cleaning


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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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responsible, and the frequency and method in which it should be undertaken.


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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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Waste Water Treatment Plant (WWTP).

Sanitary Effluent
Sanitary effluent is collected and discharges to the wastewater treatment plant at the inlet for
subsequent solids removal and secondary treatment.

Production and Roof areas


Runoff from roof and processing areas are collected via a network of drains which discharge
to the WWTP. Once treated the water subsequently drains to the River Blackwater.

Storm Water Runoff


Storm water run-off from yard areas located to eastern section of the facility drain to the
surface water drains and subsequently to the wastewater treatment plant.

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).

D2.12 Emission Abatement Equipment

Discharges to Surface Waters

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Rathmore Installation
IPPC Licence Application
Attachment D

The drainage at the facility can be categorised as follows:

1. Storm water from roads and other open areas.

2. Wastewater from manufacturing processes and associated utilities, sanitary effluent,


and storm water runoff from hi risk areas.

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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Floor wash down


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Cooling waters from energy centre


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CIP Stations
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Water treatment filter washings


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Caustic soda and acids from cleaning programmes


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Continuous pump and shaft water seals


Oil and chemicals from floor surfaces
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Product residues from pipes, tanks, and machinery e.g. sugar, fats, solids
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Cadbury Ireland Rathmore prioritises implementing waste minimization strategies from


processes. Where practicable targets are set in order to facilitate the reduction of
unnecessary waste.

The waste water treatment plant comprises the following unit operations (Refer to Appendix
D1 for WWTP diagram).

1. Emergency Divert Tanks (2 No.)


2. Tsumuri Bar
3. Balance Tank
4. Dissolved Air Flotation Unit
5. Rough Filter
6. Primary Settlement Tank
7. ADF 1
8. Eastern ADF
9. ADF2
10. Western ADF
11. Thickening Tank
12. Blend Tank
13. Sludge Press
14. Sludge Disposal

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Rathmore Installation
IPPC Licence Application
Attachment D

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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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

Table 4.1 Waste Water Treatment Plant Monitoring Information


Parameter Monitoring Point Frequency Monitoring Target Control
Equipment Result
C.O.D. Inlet Daily on inlet Quality Manual 150 ppm N/A
Balance Tank and N/A
Ex DAF Final N/A
Settling Tank others as N/A
Final required N/A
Surface Water Monthly N/A N/A
B.O.D. Settling Tank Daily Quality Manual
Final 20 ppm 63 ppm
River Before N/A N/A
River After As necessary >2 N/A
Kerry Co – Council Over River < 2 over
Sample before River
< 63 ppm Reading before
Reading
Final < 63 ppm
Temperature Final Daily Thermometer 15 ° C 25 ° C
River before As Required Thermometer N/A N/A
River After As Required Thermometer N/A N/A
pH Inlet Daily Laboratory
Final Daily pH meter 6.0 - 9.0 6.0 – 9.0
Balance Tank Daily pH meter
Inlet Continuous pH meter <13
Final Continuous pH meter 6.0 - 9.0
Total Balance Tank Final and Inlet QSMO3 50 mg/l Final 100
Suspended Final Daily 4 Others N/A mg/l Final

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Solids River In Others as ru Others
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DAF required N/A
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Surface Monthly Quality Manual


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Water
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Flow 1.Inlet Daily N/A N/A N/A


r r rp
ne pu

2. Final
ow ion

Total Nitrogen 1.Inlet 4 Yr N/A N/A N/A


ht ct

2.East/West Surface Water


ig pe

3.Final 3 / year < 5.0 ppm 5.0 ppm


yr ns
op r i

Total 1.Inlet 3 weeks Quality Manual 2 ppm 10ppm


f c Fo

Phosphorous 2.Final
(as P)
to

Ortho 3 weeks Quality Manual < 2 ppm 10 ppm


en

phosphorous
ns
Co

Ammonia 1.Final 3 weeks Quality Manual 1 ppm < 2 ppm


Oils/fat/grease 1.Final 3 / year N/A < 10.0 ppm 10.0 ppm
Nitrate 1.Final 3 / year N/A < 5.0 ppm 5.0 ppm
Ammonia (as 1.Final 3 / year N/A < 1.0 ppm 1.0 ppm
N)
Phosphorous 1.Final 3 / year N/A < 2.0 ppm 10.0ppm
(as P)
Non-ionised 1.Final 3 / year N/A < 0.1 ppm 0.1 ppm
Ammonia
Surfactant 1.Final 3 / year N/A < 1.0 ppm 1.0 ppm
Mineral Oil 1.Final 3 / year N/A

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.

OES Consulting Page 14 of 16

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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

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.

.
se
ru
he
ot
ny
fo y.
d nl
ra
re o
ui es
eq os
r r rp
ne pu
ow ion
ht ct
ig pe
yr ns
op r i
f c Fo
to
en
ns
Co

OES Consulting Page 15 of 16

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Cadbury Ireland Limited February 2007
Rathmore Installation
IPPC Licence Application
Attachment D

D3 Development & Operational History of the Site

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:

Erection of a goods store (1964)


Extension of the chocolate crumb factory (1965)
Construction of a milk processing factory (1965)
Construction of a store adjacent to factory (1965)
Extension to skim milk powder processing plant (1973)
Erection of a water cooling tower (1974)
Extension to stores (1975)
Erection of new entrance to factory (1978)
Erection of single storey offices and canteen (1978)
Alternation of existing entrance and erection of a security hut (1979)
Erection of a milk intake canopy and manifold room (1979)
Construction of a chimney stack (1979)
Construction of a building to house bulk sugar silos (1984)
Construction of a crumb silo structure and covered loading bay (1985)
Construction of a crumb storage silo (1985)

.
Raising level of roof on part of factory (1987)
se
ru
Extension to part of factory roof (1988)
he
ot

Raising of roof level of part of factory (1990)


ny
fo y.
d nl

Erection of a new silo and to raise level of factory (1991)


ra
re o
ui es
eq os
r r rp
ne pu

Capital developments of a number of environmental projects at the site have resulted in


ow ion

improved performance. These have included:


ht ct
ig pe
yr ns
op r i

Ongoing Energy Conservation Projects


f c Fo

Drainage Remediation Projects


Repair and Replacement Projects
to
en
ns
Co

D3.1 Future Developments

The following future developments are proposed for the Cadbury installation:

Drains Remediation Project

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.

OES Consulting Page 16 of 16

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Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.

Process Flow Diagram


Appendix D.1

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Legend

Wells
Weighbridge

Raw Milk Sugar Liquid Cocoa Butter Oil Inputs


(Whole and Skimmed) Mass

Water
intake

Cleaning & Process Controls


Storage Silos (1-6)

.
(Capacity 660m3)

se
ru
he
Storage Silos (1,2,3) Storage Silos (Tank 30-33) Storage Silos

ot
(Capacity 170 Tonnes) (Capacity 210m3) (Capacity 60 m3) Processing and

ny
fo y.
Storage

d nl
ra
Process

re o
Controls

ui es
eq os
r r rp
ne pu
Laboratory

ow ion
ht ct
ig pe
yr ns
op r i
Crumb Production Area Milling Area

f c Fo
to
Buildings and Services en
ns
Administration building,
Co

Engineering Building,
Canteen, toilets, and Storage Area Product and
heating system, (Capacity 400 Tonnes) Associated Outputs

CIP & Process Controls

Issue no. Date By Checked Approved Note Ref. Date


Waste Water Scanned

Treatment Plant

River Blackwater

environmental health and safety engineering project management


© Copyright of OES Consulting, 4 Day Place, Tralee Co. Kerry.
Tel: 353 (0)667128321 Fax: 353 (0)66 7180061 Email: info@oes.ie

Client
Cadbury Ireland Ltd
Title
Plant Flow Diagram
Scale. Project No.
NTS 1061_01
Figure No. Rev.
Drawing No. 4 01

EPA Export 25-07-2013:21:16:05


Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.

Appendix D.2
Site Drainage Plan

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Legend
SW2 Site Boundary
River Blackwater
Oil Interceptors
SW1
Roof areas
Storm water
Effluent water
Surface Water
discharge SW1
Emergency Storage
Eastern ADF
Western ADF
MP-1
Thickening Tank
MP-4 Rough Filter
MP-3

.
se
Balancing Tank

ru
he
Final Effluent Tank

ot
ny
Final Effluent Tank

fo y.
d nl
ra
re o
MP-2 River Room

ui es
eq os
Western Divert Tank

r r rp
ne pu
Sludge Tank

ow ion
Primary Settling Tank

ht ct
ig pe
DAF

yr ns
op r i
De watering Tank

f c Fo
Eastern Divert Tank
to
en
Effluent monitoring
ns
Co

Date
Issue no. Date By Checked Approved Note Ref Scanned

Issue no

environmental health and safety engineering project management


© Copyright of OES Consulting, 4 Day Place, Tralee Co. Kerry.
Tel: 353 (0)667128321 Fax: 353 (0)66 7180061 Email: info@oes.ie

Client Cadbury (Ireland ) Rathmore


Title
Site Drainage Plan
Scale. Project No.
NTS 1061
Figure No. Rev.
Drawing No.5 01A

EPA Export 25-07-2013:21:16:05


Co
ns
en
to
f c Fo
op r i
yr ns
ig pe
ht ct
ow ion
ne pu
r r rp
eq os
ui es
re o
d nl
fo y.
ra
ny
ot
he
ru
se
.

Appendix D.3
WWTP Drainage Plan

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Legend
Emergency Storage Tanks Waste Water Treatment

Sludge Treatment

Waste Water Diversion


Process Sludge Water Diversion
Divert Sump
Wastewater
Aeration Rough
Bar DAF Filter
Screens Tank
Sanitary
Wastewater

Primary
Settlement Tank

.
se
ru
he
ot
ny
fo y.
d nl
Blend Tank Thickening Tank

ra
re o
ui es
eq os
r r rp
Western Primary Eastern

ne pu
ADF Effluent Tank ADF

ow ion
ht ct
ig pe
yr ns
op r i
f c Fo
Belt Press/
to
en
Dewatering Unit
ns
Final Effluent
Co

Recycle
System

Composting/
Landspreading Flow Measurement Issue no. Date By Checked Approved Note Ref. Date
Scanned

Sampling

environmental health and safety engineering project management


© Copyright of OES Consulting, 4 Day Place, Tralee Co. Kerry.
Tel: 353 (0)667128321 Fax: 353 (0)66 7180061 Email: info@oes.ie

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
EPA Export 25-07-2013:21:16:05

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