Sustainable waste management in the meat processing industry
Presentation by: Robert Kirwan, Group Environmental Manager 8th June 2015
Irish Country Meats – A Member of
Market Leaders in fresh meat processing
Linden Food Group Geographic Locations
Dungannon Newcastle Navan Camolin Bunclody
Liège
Servicing markets direct from locations in Ireland, UK and Belgium
Mission Statement
Our goal is to be recognised as the
Leading Lamb Processor in Europe placing product and process innovation at the heart of our business. We aim to achieve
Supplier of Choice Status with like minded
Retail, Foodservice & Wholesale distributors in all the markets we serve.
Irish Country Meats Company In Brief
ICM is the Largest Processor of Lamb In Ireland 425 Employees
Ireland’s Only Dedicated Single Specie Processor Business Philosophy centres around Specialisation Processing Facilities Value Added / N.P.D. Waste Management / Yields/ Cost Control
Corporate Sustainability Philosophy centres around GreenTrack “Controlling the impacts that our activities, products and services have on the environment”
Approved IPPC Licence compliance Accredited ISO 14001 Environmental Management Systems Origin Green objectives and targets
“GreenTrack is our group strategy for embedding sustainability in all we do. With Agriculture, Integrity, Customers, Environment, and Colleagues & Communities at its heart.” It is our plan, our future…
Renewable Energy
Wind Energy Farms Currently 40 wind turbines installed with a combined energy generation capacity of 83.4 MWs producing a total of 200 GWhs p.a. Eiffel Tower energy consumption – 7.5GWhs p.a!
Tidal Energy Farms Currently involved in developing tidal energy sites in Ireland, U.K., France, Canada & U.S.A.
We Support
Net Energy Supplier Navan Site 1.6 GWhs p.a.
Bunclody Site 11.87 GWhs p.a.
Camolin Site 2.7 GWhs p.a.
Total Energy Consumption 16.17 GWhs p.a.
Total Energy Generation 200 GWhs p.a.
Net Energy Generated 183 GWhs p.a.
Net Carbon Saving 150k Tonnes CO2 p.a.
LINERGY – Waste to Energy Conversion First eco-park in UK and Ireland with all companies using renewable energy. Uses animal by-products and fallen farm animals to produce renewable biomass fuels & tallow oil. Saving over 35k tonnes of CO2 p.a. (equivalent to approx. 11,000 cars). Diverting 500,000 tonnes of waste away from landfill in 10 year period. Phase II – anaerobic digestion & thermal processing for electricity generation.
Why is Sustainability Important to us at ICM?
“Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs” – UN Brundtland Report, 1987
Why is Sustainability Important to us?
We need to play our part in
building a resilient supply chain to ensure long term
security of sustainable food supply...
Billions
World Population 1950 - 2050 10
Demand Challenges
9 8 7 6
6 billion
4
5 billion
3
70% in cities
50% in cities
“changing lifestyles, shifting dietary habits”
4 billion
2 0
8 billion
7 billion
5
1
9 billion
3 billion 30% in cities
Source: UN World Population Prospects; the 2010 revision
1950 1960 1970 1980 1990 2000 2010 2020 2030 2040 2050 “global car fleet to double to 1.7 bn cars by 2030”
By 2050, the planet will need to produce 70% more food, with less land, water and energy while also reducing greenhouse gas emissions
Supply Challenges Climate Change
“The most frequent and significant factor causing volatility is unpredictable weather conditions”. FAO/OECD Agricultural Outlook, 20112020
“By 2025, two-thirds of the world population could be living under water stress conditions”. UN
Food for Fuel: 40% of US corn used for ethanol” Agriculture uses 70% of the world’s freshwater
Growing the success of Irish food & horticulture
Ireland’s Sustainability Advantage through grass Grassland Area Ireland
Europe
80%
40%
Production (t DM/Ha) Ireland
Europe
15
11
* Irish companies need to promote sustainability initiatives to legislatively comply and compete in world markets
Key Pillars in Sustainable Waste Management – Meat Industry
• Efficient wastewater treatment plant operation - New treatment technologies • Product and market innovation to reduce animal by product and packaging product wastes - New sales markets and innovative packaging for increased shelf life • Integrated general waste management - Service provider giving full solutions based on the waste hierarchy to all general waste streams with complete traceability for compliance.
Sustainable Waste Management Initiatives at ICM •
Increased Recycling
•
Zero waste to Landfill Policy – Case Study 5
•
Reduced solids in Waste Water Discharge – Case Study 1
•
Innovative new products reducing rendering waste – Case Study 3
•
Reduced general waste per unit per produced – Case Study 5
•
Paperless Office
•
Reduced tertiary packaging – Case Study 4
•
Composting of Food Waste
Sustainable Waste Management Initiatives at ICM
• ISO 14001 & OHSAS 18001 accreditation • All electricity sources from Renewable Sources • Waste Water Treatment Plant upgrades - Case Study 2 • Cold Chemical Sterilisation • New Compressed Air System • Wexford Green Business Award Winner 2014
Sustainable Wastewater Treatment Management – Case Study 1 • Use of rotary drum screen to reduce solids in effluent wastewater -0.75 mm screen installed removing raw solids before entering WWTP system -20% reduced electricity used by VSD controlled aeration system in Camolin 2014 -25% reduced sludge generation and removal -Issue of annual solids buildup in balance tank eliminated -Reduced pump downtime throughput WWTP -Total Suspended Solids in discharge to local river reduced
Sustainable Wastewater Treatment Management – Case Study 2 • Upgrade of WWTP - Switch to fine bubble diffuse and venturi aeration treatment over surface aeration - 50% decrease in electricity costs with VSD controlled fine bubble diffused aeration upgrade in 2014 over surface aerators -Fine bubble diffused aeration will produce 3.0 kg O2/kWh compared to surface aerators will producing 1.2 kg O2/kWh - Odour emission rate reduction by 400% with fine bubble diffusion compared to surface aeration
Sustainable Animal By Product Waste Management – Case Study 3 • Development of “innovative” products -Increased demand for lamb products in Europe/Africa correlating with growing Muslim populations - Our marketing and sales teams identified demand for lamb products - New process supply commissioned and sales team have secured markets - Positive in terms of increased turnover and reduced animal by product waste -Development of the “fifth quarter” – reduction in animal byproducts
Sustainable Product Waste Management – Case Study 4 • Development of skin packaging - Our marketing and sales teams continue to target and develop new sales markets - Development of our new skin packaging lamb range will give a product shelf life of up to 28 days - Tray and gas preservation packaging gives 8/9 days shelf life - Reduced packaging and gas use in terms of design will give greater added value to our products - Skin packaging products will contribute to sales growth - This reduced product waste shows our commitment to sustainable growth
Sustainable General Waste Management – Case Study 5 • We believe in an “Integrated General Waste Management Approach” - Engaging a competent waste services contractor with solutions to all our waste streams is essential for recovery of wastes and traceability - Develop general waste solutions in line with the waste hierarchy
- Increased our recycling stations for the canteen, office and production areas to help the waste segregation process
Sustainable General Waste Management - Our employees have taken ownership of the recycling effort and are motivated that their efforts through increased baling of plastic and cardboard have resulted in us sending no waste to landfill for the past year - We have a “zero waste to landfill policy” - Recycled a total of 28000kgs of cardboard and composted 1000kgs of food waste in 2014. - 84% of waste generated in 2014 was recycled - Recycled waste increased by 340% in 2014 - 16% of waste generated in 2014 was converted to refuse derived fuel and sent for thermal treatment
Sustainable waste management correlates with Bord Bia’s Origin Green Scheme
April 2013 ICM Origin Green Member Verification Only specialist sheepmeat processor accredited
Origin Green 5 year plan
Target 1 – Reduction in Water Consumption; 25% by 2017 Target 2 – Reduction in Energy Consumption; 10% by 2017
Achieved 31% by year two Reductions to date Electricity 9.1% Gas 48.7% Case Study for EPA
Target 3 - Reduction in Waste & Packaging; 20% by 2017
Waste generated reduced by 7% 2015 “Zero Waste to Landfill” - 2015
Target 4 - Target Env/Social Sustainability ISO14001 & OHSAS18001
Achieved May 2014
Target 5 – Sustainable Supply Chain
500 Farmers through site In 2014
Summary - Key Factors to Successful Sustainable Waste Management - Top level senior management commitment
- Cultural changes amongst management and employees through increased awareness and communication of waste management issues - Redefining waste as a resource at every process opportunity is crucial - Each department in meat processing industry has a role to play - Liaising with new product development, procurement, sales and marketing teams is necessary - Through waste sustainability commitments and the success of those, companies will reduce their costs, improve turnover and achieve legislative compliance
Questions and Thank you???