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Attachment-4-8-1-Operational Report
IEL REVIEW APPLICATION
DAIRYGOLD CO-OPERATIVE SOCIETY LIMITED
DFI Mogeely, Co. Cork
APPLICATION ID: LA001622
F
or in
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IEL Review Application – DFI Mogeely Application ID:
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Attachment-4-8-1-Operational Report
Table of Contents 1. INTRODUCTION
.......................................................................................................................
1
2. SITE DEVELOPMENT & OPERATIONAL HISTORY
........................................................................
1
2.1. Existing Licensed Facility
............................................................................................................
1
2.2. Proposed Changes
......................................................................................................................
2
2.3. No. Of Employees
.......................................................................................................................
3
2.4. Hours of Operation
....................................................................................................................
3
2.5. Products
.....................................................................................................................................
3
3. DFI PLANT PRODUCTION PROCESSES AND UNIT OPERATIONS
................................................... 5
3.1. MILK PROCESSING
......................................................................................................................
6
3.1.1. Unit Operations
..................................................................................................................
6
3.1.2. Capacity and Throughput
...................................................................................................
7
3.1.3. Process Emissions
..............................................................................................................
7
3.1.4. Process Control Systems
....................................................................................................
7
3.2. CHEESE-MAKING
........................................................................................................................
9
3.2.1. Unit Operations
..................................................................................................................
9
3.2.2. Capacity and Throughput
.................................................................................................
10
3.2.3. Process Emissions
............................................................................................................
10
3.2.4. Process Control Systems
..................................................................................................
10
3.3. WHEY PROCESSING
..................................................................................................................
12
3.3.1. Unit Operations
................................................................................................................
12
3.3.2. Capacity and Throughput
.................................................................................................
12
3.3.3. Process Emissions
............................................................................................................
12
3.3.4. Process Control Systems
..................................................................................................
12
4. NEW JARLSBERG® CHEESE PLANT PRODUCTION PROCESSES AND UNIT
OPERATIONS .............. 14
4.1. Process Description
..................................................................................................................
15
4.1.1. Milk Supply to TINE
..........................................................................................................
17
4.1.2. Milk Processing
................................................................................................................
17
4.1.3. Starter Make up
...............................................................................................................
17
4.1.4. Cheese Vats
......................................................................................................................
17
4.1.5. Curd Buffer tanks
.............................................................................................................
17
4.1.6. Curd Forming / Moulding / Pressing
................................................................................
18
4.1.7. De-moulding
.....................................................................................................................
18
4.1.8. Brining
..............................................................................................................................
18
4.1.9. Drying
...............................................................................................................................
18
4.1.10. Block Packaging & Wheel Treatment
...............................................................................
18
4.1.11. Block Final Packaging
.......................................................................................................
18
4.1.12. Wheel Final Packaging
.....................................................................................................
18
4.1.13. Storage
.............................................................................................................................
19
5. UTILITY PROCESSES
................................................................................................................
20
5.1. Cleaning and disinfection
.........................................................................................................
20
5.1.1. DFI Production Plant
........................................................................................................
20
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IEL Review Application – DFI Mogeely Application ID:
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Attachment-4-8-1-Operational Report
5.1.2. New Jarlsberg® Cheese plant
...........................................................................................
20
5.2. Energy generation
....................................................................................................................
21
5.3. Process Water Treatment
........................................................................................................
22
5.4. Wastewater Management and Treatment
.............................................................................
22
5.4.1. Process wastewaters
........................................................................................................
22
5.4.2. Wastewater Treatment
....................................................................................................
22
5.4.3. Hydraulic design
...............................................................................................................
23
5.4.4. Discharge controls
............................................................................................................
24
5.5. Surface Water / Stormwater Treatment/Management
.......................................................... 24
5.6. Fire controls and firewater treatment/management
..............................................................
25
5.7. Sewerage Management
...........................................................................................................
27
5.8. Cooling water treatment/management
..................................................................................
27
5.9. Boiler feed-water treatment/management
.............................................................................
27
5.10. Refrigeration
........................................................................................................................
28
5.11. Compressed air generation
..................................................................................................
28
5.12. Laboratory Facilities
.............................................................................................................
29
6. ABATEMENT SYSTEMS
...........................................................................................................
29
7. MATERIALS HANDLING AND STORAGE FACILITIES
...................................................................
29
8. ALTERNATIVES
.......................................................................................................................
31
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1. INTRODUCTION Dairygold Co-operative Society Ltd was granted
planning permission by An Bord Pleanála on 24th April
2018 (Planning Ref PL04.249108) for development comprising works
at its existing licenced Dairygold
Food Ingredients (DFI) speciality cheese manufacturing facility
at Mogeely, Co. Cork and also works on
neighbouring unlicenced greenfield lands which provide for the
expansion of the existing DFI facility
and the development of a new cheese production plant for the
manufacture of Jarlsberg® cheese.
This Operational Report describes the plant, methods, processes,
ancillary processes, abatement,
recovery and treatment systems, and operating procedures for all
activities to be carried out at the
upgraded Dairygold Food Ingredients (DFI) cheese manufacturing
facility and the new Jarlsberg®
cheese manufacturing plant at Mogeely, Co. Cork.
2. SITE DEVELOPMENT & OPERATIONAL HISTORY
2.1. Existing Licensed Facility
The Dairygold Co-operative Society Ltd DFI facility at Mogeely
is a milk processing installation for the
production of speciality cheeses for the niche branded market.
The DFI Mogeely installation has been
producing speciality cheeses since 1974 serving both the branded
retail and cheese ingredients
markets in the UK, US and mainland Europe.
The DFI facility at Mogeely is a licensable activity regulated
by the EPA and currently operates under
Industrial Emissions Licence P0817-01. The facility was first
granted an Integrated Pollution Prevention
Control (IPPC) Licence (Reg No. P0817-01) on 21st April 2011.
The licence was subsequently amended
on 16th December 2013 under Section S82A(11) of the
Environmental Protection Agency Act 1992 to
bring the licence into conformity with the Industrial Emissions
Directive (2010/75/EU). A Technical
Amendment (Technical Amendment A) to the licence was approved in
June 2018.
The licensed activities are as follows:
Class 7.2.1 The treatment and processing of milk, the quantity
of milk received being
greater than 200 tonnes per day (averaged value on a yearly
basis)
The existing milk processing plant is located in the north
western section of the site and comprises
milk intake, pasteurisation / separation facilities, Whey
Storage, Cream Storage, CIP, water treatment
and refrigeration. South of the milk processing area is the main
cheese manufacture plant. Further
south is the WWTP with access gained by an unpaved roadway.
The facility has the capacity to processes in excess of 120,000
tonnes (approx 120 million litres) of raw
milk per annum (224,657 litres of raw milk per day) producing
12,000 tonnes of cheese products
annually. The current Dairygold Cheese Plant has 3 production
lines. The types of cheese made
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include Jarlsberg (an internationally renowned Norwegian brand
swiss style cheese), Imokilly Regato
PDO (a premium Italian style hard cheese, Regato Light (a
reduced fat cheese), Monterey Jack (a semi
hard white cheese), Gran Alto (Mallo) (a parmesan type cheese).
The process also produces surplus
whey and cream, which are removed from the site.
The layout of the existing facility is illustrated in Drawing
No. 3 (Site Plan Existing).
2.2. Proposed Changes
Dairygold Co-operative Society Ltd was recently granted planning
permission by An Bord Pleanála
(Planning Ref PL04.249108) for following proposed development at
Mogeely, Co. Cork:
Modification and re-organising of the existing on-site cheese
facility including new relocated milk intake/reception area and raw
milk storage tanks and Demolition of existing “Dairy” building,
i.e. milk intake, raw milk storage, bulk cream storage.
Construction of a new cheese production building on a Greenfield
site east of the existing
Dairygold cheese facility.
Upgrading of the on-site facility WWTP.
Installation of an underground discharge pipeline from the
facility WWTP to the public
discharge outfall at Rathcoursey.
New and modified vehicle site access arrangement.
New and modified internal vehicle circulation routes and
pedestrian walkways
Revised parking areas.
New plant (including reverse osmosis plant) and overground
distribution pipe network.
New and modified storm water, process water and foul water
drainage and run-off
control systems.
New additional storage tanks and silos including new HCL bulk
tank.
additional 15m boiler stack associated with the existing
boilers.
New external lighting provisions.
Boundary landscaping.
The additional key items of plant to be installed as part of the
proposed overall changes include:
New additional whey separators,
New additional whey clarifier
New whey thermisers
New Whey cream thermisers
New whey concentration plants
New additional transformer
New emergency diesel generator/motors (firepumps and WWTP)
New electrical switch room.
Construction works are currently underway at the site and it is
intended that new developments will
be operational by the final quarter of 2019.
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http://www.dairygoldfoodingredients.com/Imokilly-Regato-PDOhttp://www.dairygoldfoodingredients.com/Imokilly-Regato-PDO
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IEL Review Application – DFI Mogeely Application ID:
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The layout of the future overall site is illustrated in Drawing
No. 4 (Site Plan Proposed).
Land and building ownership details are illustrated in Drawing
No. 8 (Site and Building Ownership).
The new cheese plant will be owned and operated by TINE Ireland
Ltd. to produce Jarlsberg® for the
exports market. Figure 2-1 shows a simple flow diagram of the
exchange of key goods and services to
be undertaken between the DFI plant and the new Jarlsberg®
cheese plant. The DFI facility will also
provide process hot water and bulk storage facilities for water
and Clean-in–place (CIP) chemicals to
be used at the new Jarlsberg® cheese plant.
Dairygold and TINE Ireland Ltd will put an operational business
agreement in place to underpin the
licencing arrangement. The scope of the Business Agreement
between TINE Ireland Ltd with the
Licencee (Dairygold) will be sufficiently wide to permit the
applicant to maintain control of the
licensed activities and intermediary activities and permit
access to regulatory authorities.
2.3. No. Of Employees
Approximately 161 permanent staff will be employed across both
plants once fully operational.
2.4. Hours of Operation
The plant will operate 52 weeks per year. Operating hours are 24
hour per day, across 7 days.
2.5. Products
The products to be manufactured will continue to comprise
speciality cheese products. Liquid Whey
and Cream will also continue to be produced on site and will be
dispatched as a saleable by-product.
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Figure 2-1 OVERVIEW OF EXCHANGE OF GOODS AND SERVICES BETWEEN
DAIRYGOLD
AND NEW JARLSBERG® CHEESE PLANT
RAW MILK
Cool storage Silos
DAIRYGOLD PROCESSING PLANT NEW JARLSBERG® CHEESE PLANT
MILK
TREATMENT
MILK
TREATMENT
CHEESE
MANUFACTURING
CHEESE
MANUFACTURING
PACKAGING &
STORAGE
PACKAGING &
STORAGE
Dairygold Whey
Processing Plant
Whey Whey
Wastewater
Wastewater
WASTEWATER
TREATMENT PLANT
Wastewater
Wastewater
= Dairygold Activity
= New Jarlsberg® cheese plant Activity
cream cream Cream
silo
Warm energy water
Cool energy water
CIP chemicals
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3. DFI PLANT PRODUCTION PROCESSES AND UNIT OPERATIONS The
principal current and future activities carried out at the DFI
plant are raw milk processing and
cheese making. The processes and unit operations (existing and
future) associated with these
activities are set out in Table 3.1 and described in Sections
3.1 to 3.3 below.
Table 3.1 DFI Installation Processes and Unit Operations
ACTIVITIES /PROCESSES UNIT OPERATIONS
1. Milk Processing Milk intake and storage
Separation (Centrifugation)
Standardisation
2. Cheese-making Pasteurisation
Coagulation
Forming/moulding and extruding
Brining/salting
3. Post processing operations Packing
Storage and Ripening
4. Liquid Whey Processing Filtration (Clarification)
Separation
Thermisation
RO Concentration
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3.1. MILK PROCESSING
3.1.1. Unit Operations
Milk Intake
Raw whole milk is delivered to the facility by milk tankers. On
arrival at the factory, all tankers are
directed to the weighbridge where details such as vehicle
registration, weight etc are recorded in a
centralised computer system. The raw milk is then rapid tested
for antibiotics. On acceptance, the
milk tankers are directed to the milk reception bays where the
milk is pumped from the tankers into
the raw milk silo storage tanks through a plate cooler and held
at temperatures below 40C. Each raw
milk silo tank is fitted with high level electrodes to prevent
overfilling. Milk is usually processed within
24 hours of receipt.
Separation and Standardisation
When running the Casomatic/ Jarlsberg line milk is pumped from
the silo to the cheese plant where it
is pre-heated and separated into skim milk and cream. The skim
portion is then routed to the
Bactocatch, where spores, if present, are removed by micro
filtration. The cream portion and the
retentate from the Bactocatch are sent to a HTT unit (High
Temperature Treatment) where it
undergoes a high heat treatment (> 122°C) to ensure all
bacteria and spores are inactivated.
The skim permeate from the Bactocatch and cream from the HTT
section are then transferred to a
standardising unit called a Compomaster. The skim and cream are
recombined in the Compomaster to
give the desired % fat in the milk for processing. The surplus
cream is sent to a cream holding tank.
The standardised milk for cheese making is pumped to the
Pasteuriser and pasteurised at > 72°C for 15
seconds.
When running the Regato and Mallo/ Block lines the following
process applies to achieve the desired
fat levels in the final product. Depending on the type of cheese
product to be manufactured, this
involves blending known volumes of skim milk and/or cream
generated from the separation of the
whole raw milk, with whole milk. The resulting standardised milk
is plate cooled and stored in
dedicated 30,000 gallon standardised milk silos. The milk for
cheese making is standardised the
previous day for use early the following morning. However in the
future Regato milk will be separated
and standardised as it is being pasteurised. This will be on a
replacement pasteuriser. Mallo milk will
undergo a similar process on existing equipment. This means that
raw milk is pumped from a silo
through a pasteuriser & separator arrangement and on to a
cheese vat). Excess cream is pasteurised
in an existing (relocated) dedicated cream pasteuriser and
transferred to a storage tank).
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3.1.2. Capacity and Throughput
There will be 6 No. raw milk storage silos on site (4 no. 300m3
raw milk silos and 2 no. 137m3 raw milk
silos) giving an internal capacity for milk reception of 1,474m3
(1,474,000 litres)
There will be 2 no. milk separators at the facility each sized
at 25,000Ltrs/hr. Each system separates
milk for 16 hours per day giving an overall internal throughput
for milk separation of 400,000litres per
day.
3.1.3. Process Emissions
The main emissions from the milk processing operations during
normal operation is the wastewater
generated during the CIP of the milk intake lines and separation
plant. The wastewater is collected
and conveyed via process effluent drains on the site to the
Wastewater Treatment Plant.
3.1.4. Process Control Systems
Process Controls installed at the milk intake include:
Level indicators and/ or High Level Alarms on raw milk intake
silos to prevent overfilling
Milk intake reception bays remotely bunded via process
drains
All milk storage tanks and silo suitably bunded to prevent
pollution risks of any spills/leakages.
The bulk milk storage tanks will also be provided with remote
secondary bunding via the
wastewater treatment plant.
Process Controls at the milk processing plant include:
Flow controller
Flow transmitter
Constant pressure valve on milk clarification and separation
processes
Regulating valve
Shut-off valve
Plc control for safe hold points and shutdown.
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Figure 3-1 RAW MILK TREATMENT /PROCESSING FLOW DIAGRAM
RAW MILK
Cool storage Silos
SEPARATION
CREAM SKIM MILK
Standardised Milk
PASTEURISATION
Cream storage
Silos
DISPATCH In line standardisation
Microfiltration
To new Jarlsberg®
cheese plant
PRE-HEATING
Casomatic Cheese Making
Raw milk
HTT (>121°C)
PRE-HEATING
SEPARATION
Pasteurisation SKIM MILK CREAM
In line standardisation
Standardised Milk
PASTEURISATION
Regato & Block Cheese
Making
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3.2. CHEESE-MAKING
3.2.1. Unit Operations
There are a range of cheese varieties made at the Dairygold
Cheese plant with some slight differences
in processing. In general the following steps apply.
Pasteurisation
The initial step of the cheese making process involves
filtration and pasteurisation of the standardised
milk. This is a process to improve the bacterial quality of the
milk by heating milk to a specific
temperature for a defined length of time to ensure that any
pathogenic micro-organisms which may
be present are destroyed and then cooling it immediately. To
ensure that pasteurisation temperatures
are achieved the pasteuriser is fitted with a flow diversion
value system.
Coagulation
Following pasteurisation, the milk is then pumped to cheese vats
where starter cultures and other
ingredients are added during filling. These cultures produce
acid and determine the flavour, body and
texture of the cheese. This is followed by the addition of
Rennet, an enzyme which causes the
coagulation of the milk proteins to lead to the formation of a
coagulum.
Cutting
The coagulum is then cut, resulting in the formation of curd
particles and whey which are stirred and
heated.
Draining/Pre-pressing
Following cutting the contents of the cheese vat is pumped to a
buffer tank and from there to a pre-
press draining belt. The pre-press stage involves draining off
of whey leading to the formation of a
curd slab. The drained whey is pumped to the whey plant.
Cutting/Moulding/Pressing
The curd slab is cut into cubes of uniform size by a guillotine.
The curd cubes fall on the second belt
and conveyed to the pre washed moulds. The moulds are then
transferred to the pressing tunnels
where final mould shape is determined.
Salting
Depending of the type of cheese product, salt addition can be
carried out by direct salting of the curd
slab prior to moulding or by brining following moulding. Brining
involves transferring the pressed
cheese moulds to the brine system where they are submerged in
brine pools.
Packaging
Following final moulding and pressing, cheese is transferred to
the packing room where it is labelled,
vacuum packed, metal detected, weighed and finally
boxed/cartoned.
Storage and Ripening
The package cheese is transferred to stores and held until it
has ripened and matured.
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3.2.2. Capacity and Throughput
The following table sets out the processing rates for each of
the DFI cheese production lines:
Line Milk Flow/Hr Hrs per day
typically
Tons/hr Tons per day
typically
Regato 25000L 16 2.2 35
Casomatic 15000L 16 1.4 22
Mallo 32000L 19 2.5 48
3.2.3. Process Emissions
The main emissions from the cheese making operations during
normal operation is the wastewater
generated during the CIP of the various systems, brining
solution wastewater, heat from
pasteurisation systems and noise.
3.2.4. Process Control Systems
Plc control for safe hold points and shutdown.
Process held in VAT
Localised emergency stop in place.
Shut off values.
The wastewater is collected and conveyed via process effluent
drains on the site to the
Wastewater Treatment Plant.
The heat is recovered for use in other pre-heating
operations.
For i
nspe
ction
purp
oses
only.
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Figure 3-2 CHEESE-MAKING FLOWING DIAGRAM
PASTEURISATION
CHEESE VATS
Draining/Pre-Pressing
Additives
(starter cultures,
Rennet, enzymes)
curds whey
Salting/brining
Moulding
COAGULATION
CUTTING
Cutting Whey processing
plant
Storage & Ripening
Pressing
Packaging
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3.3. WHEY PROCESSING
3.3.1. Unit Operations
During the cheese making process when rennet is added to milk,
it causes coagulation of the milk
proteins to form curd and whey. They curd is made into cheeses
and the whey is pumped to the whey
plant.
The incoming whey is pumped into fresh whey silos. Whey is then
pumped from the fresh whey silos
into clarifiers (which act like filters to removed particles
including curd, etc). The filtered whey is then
preheated and then pumped to separators where it is separated
into whey cream and low fat whey.
The separated streams of whey cream and low fat whey are then
thermised, cooled and transferred to
chilled storage.
Chilled, separated low fat whey will undergo Reverse Osmosis
(RO) filtration to concentrate the whey
by removing water. Hydrochloric acid (HCL) will be added if
required to reduce the pH of the whey to
get more efficient RO processing and meet the specification
requirements for further processing off-
site. The concentrated whey is then chilled and pumped to
chilled product silos and held while
awaiting dispatched off-site for further processing.
3.3.2. Capacity and Throughput
2 x 25,000 l/hr whey separation & thermisation lines
1 x 55,000 l/hr whey separation & thermisation line
2 x 50,000 kg/hr whey concentration (RO) lines.
2 x 400 kg/hr whey cream thermisation lines.
3.3.3. Process Emissions
The main emissions from the whey processing operations during
normal operation is the wastewater
generated during the CIP of the plant systems, heat from
pasteurisation and cooling systems and
noise.
3.3.4. Process Control Systems
Plc control for safe hold points and shutdown.
Localised emergency stop in place.
Shut off values.
Waste heat from whey pasteurisation and cooling recovered to
pre-heat incoming raw milk
The wastewater is collected and conveyed via process effluent
drains on the site to the
Wastewater Treatment Plant.
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Figure 3-3 WHEY PROCESSING FLOW DIAGRAM
Cheese Whey
Filtration
Separation
Chilled Storage tank
Whey cream Low fat whey
filtered particles
RO
Filtration
Storage tank
water
Chilled Storage tank
WWTP
Recovered Warm water
to milk processing plant
Cooling
Recovered energy water from raw-milk pre-heating
Cooling
Preheating
Cooling
From DFI Plant From New Jarlsberg®
cheese plant
Thermisation Thermisation
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4. NEW JARLSBERG® CHEESE PLANT PRODUCTION PROCESSES AND UNIT
OPERATIONS
The new Jarlsberg® Cheese production building is being developed
on an area of land that was
previously a ‘green field’ site, east of the existing Dairygold
facility. While the proposed facility will
share utilities and milk reception facilities with the Dairygold
facility, it will be an independently
owned and operated manufacturing plant and will include its own
raw milk processing facilities,
production and packing equipment, stores and CIP
(Clean-in-place) system.
The proposed new facility is a 10,700 m2 development,
approximately 153 m long and 77 m wide. This
will be predominantly a single storey building with a
three-storey central corridor and will also include
a two storey administration block at the southern end providing
offices, meeting rooms, canteen and
sanitary facilities. Floor areas of the new Jarlsberg® Cheese
building are given below.
The layout adopted allows for a production capacity of 20,300
tonnes annually. The production area
consists of a large ground floor area (circa 7,687 m2)
containing milk treatment, starter tanks, cheese
vats, pressing and brining, cheese handling equipment,
maturation stores, warm rooms, cold stores,
final packaging and dispatch (see Figure 4-1). The first floor
consists of a visitors’ corridor which runs in
a north / south direction for the entire length of the
production building. Second floor area consists of
plant space above the visitors’ corridor.
The administration block consists of a two storey building
accommodating canteen, office, meeting
room and gowning facilities to be occupied by TINE staff.
Department Area (m2)
Ground Floor (Factory) 7,687
First Floor (Factory) 827
Second Floor (Factory) 865
Sub-Total (Factory) 9,379
Ground Floor (Admin) 714
First Floor (Admin) 616
Sub-Total (Admin) 1,330
Total 10,709
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Figure 4-1 New Jarlsberg® Cheese Production Area Layout
4.1. Process Description
The new Jarlsberg® Cheese processing facility has been designed
to produce circa. 20,300 tonnes of
cheese per annum. The primary ingredients in the cheese are
standardised, pasteurised fresh milk,
rennet and cheese making cultures. The by-product of the cheese,
whey will be transferred directly to
the adjacent Dairygold facility and processed in their whey
processing plants.
These unit operations are described in the following subsections
and their sequence is illustrated in the
basic process schematic contained in Figure 4-2.
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Figure 4-2 New Jarlsberg® Cheese Plant Process Flow
Schematic
Raw Milk ex Dairygold
Milk Treatment – Separation
>Microfiltration>Pasteurisation
Cheese Vats
Starter Cultures Rennet
Hot Water
Curd Buffer Tanks
Curd Forming / Moulding / Pressing
Brining
Wheel TreatmentBlock Packing
Warm Room
Final Packing / Despatch
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4.1.1. Milk Supply to TINE
Raw milk will be supplied from the adjacent Dairygold facility
based on volumes required per
production cycle.
4.1.2. Milk Processing
Flow rate between 26,700 l/hr. to 35,000 l/hr;
Milk Standardisation;
Anaerobic Spore removal;
Production Time 20 hrs/day;
Cleaning in Place 3 hrs/day;
Planned downtime 1 hrs/day;
Min pre-treatment run time 20 hrs. without any quality
issues
The cheese milk will be standardised to achieve the desired Fat
to Protein ratio by the removal of
varying amounts of excess cream. Excess cream will be
pasteurised to achieve the required level of
treatment prior to being cooled for dispatch to Dairygold.
Skimmed milk from the separator will be passed through a system
to achieve reduction in anaerobic
spore count.
The milk processing equipment will be washed using the Raw Milk
CIP centre.
4.1.3. Starter Make up
Starter will be grown from cultures in six stainless steel
tanks.
4.1.4. Cheese Vats
There will be 5 vats at the facility;
The vats have cooking water, starter and rennet addition
capabilities;
Rennet will be manually added via a rennet pot to the vat when
prompted;
Vats have both stirring and curd cutting capabilities;
The whey from the vat will be pumped to the whey storage
tanks;
Vat stirring and cutting will have the required torque and
robust knife design to handle short stoppages (
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4.1.6. Curd Forming / Moulding / Pressing
Curd forming will be via a cheese press capable of curd forming
and moulding the cheese into 10 kg
wheels and / or 10 kg blocks and pressing the cheese into its
final weight. Whey will be recovered to
whey storage tanks.
4.1.7. De-moulding
Here the cheese is removed from the mould and then x-rayed.
4.1.8. Brining
Cheese will be conveyed from the de-moulding section of the
cheese press to an automatic cheese
brine rack loading system. Salt will be added daily to the brine
which will be taken up by the cheese in
the brining process. The brine will be continuously treated
through an ozone system and a filtration
system.
4.1.9. Drying
Wheels and Blocks exiting from the brine will pass through an
Air Knife type dryer situated on the exit
conveyor.
4.1.10. Block Packaging & Wheel Treatment
Wheels from the brine system will be placed on racks for a
series turning and coating with plastic
(Figure 4-3). It will then be transferred into a warm room to
allow maturation to take place. It will then
be transferred to final cooling. Block will be packaged into
plastic vacuum pouches.
Figure 4-3 Wheel Treatment
4.1.11. Block Final Packaging
Blocks having been removed from the trays will be packed into
boxes.
4.1.12. Wheel Final Packaging
Wheels will be conveyed through an X-Ray machine prior to final
packing (Figure 4-4).
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Figure 4-4 Wheel Final Packaging
4.1.13. Storage
A pallet manifest will be provided for each pallet. Packed
cheese will be stored centrally prior to
dispatch.
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5. UTILITY PROCESSES The production activities are supported by
associated ancillary processes, i.e. cleaning and
disinfection, energy generation, water supply and treatment,
wastewater treatment, refrigeration,
and compressed air generation.
5.1. Cleaning and disinfection
5.1.1. DFI Production Plant
The DFI CIP plant will incorporate a pre rinse tank, caustic
tank, nitric acid tank and a recovery tank.
Typically there is a supply pump to send the CIP solution to the
area to be cleaned and return pump to
bring the solution back to the CIP station. The RO plant will
have its own CIP system on skids.
Cleaning-In-Place (CIP) is a system designed for automatic
cleaning and disinfecting without major
disassembly and assembly work. The upgraded CIP systems will
result in savings in CIP liquid (by
recycling cleaning solutions), reduced load on waste water
treatment facility, water saving (the system
is designed to use the optimum quantity of water) and
man-hours.
The cleaning can be carried out with automated or manual
systems. Other benefits of CIP plant
includes: operator safety (operators are not required to enter
tanks and vessels to clean them and
potent cleaning materials do not need to be handled by
operators), and downtime (if any) between
product runs / product changeover is minimized.
Under normal operating conditions the primary emissions
associated with cleaning and disinfection
processes are wastewater emission.
The wastewater is collected and conveyed via process effluent
drains on the site to the Wastewater
Treatment Plant for treatment prior to discharge.
Process controls include:
Bulk chemical storage tanks will be bunded and fitted with level
gauges and alarms to prevent
overfilling.
Bunds have been designed to provide containment to a volume not
less than the greater of
the following:
(i) 110% of the capacity of the largest tank or drum within the
bunded area; or
(ii) 25% of the total volume of substance that could be stored
within the bunded area.
All CIP storage areas are impervious, hardstanding areas which
connect into the process
wastewater drainage system
5.1.2. New Jarlsberg® Cheese plant
CIP Mixing Phase Control will ensure that excess water is not
used to "push-out" product during start-
up and shut-down, thus reducing the amount of water used and
sent to the effluent plant.
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The CIP system will be configured to enable the recovery of heat
from the final flush to preheat the
incoming water to the hot water tank. The final rinse water will
be returning at 80°C; there is potential
to use this to heat the incoming water to 75°C, cooling the
final rinse water to 30°C. This has been
chosen in lieu of allowing the hot water to go to the DFI WWTP
and heating the incoming water with
the hot water system. The method means that there will be less
energy used and reduced load going
to the waste water treatment plant. Additional heat exchangers,
pumps and controls will be installed
for this heat recovery.
The CIP system will be designed to recover the intermediate and
final rinses during a CIP recipe. This
has been chosen in lieu of allowing the water to go to the floor
drains thus reducing the amount of
water being used and reducing the hydraulic load on the effluent
plant. Additional tankage and
pumping will be installed in order to re-use this water.
5.2. Energy generation
There are 2 hot-water boilers (Boiler No.1 and Boiler No. 2)
burning natural gas at the DFI facility. The
generating capacity of Boiler No 1 is 6.5MW and 7.5MW for Boiler
No 2. Only one boiler is required to
provide sufficient quantities of hot-water for the cheese
manufacturing process, with the other in
standby mode. A small steam boiler with a maximum rating of 0.2
MW, with a steam generating
capacity of 320 kg/h, is also used for heating cream in the
cheese production process. There is
sufficient boiler capacity on-site to meet future process heat
demand of both the Dairygold facility and
to supply hot water requirements at the adjacent new Jarlsberg®
Cheese plant. The new Jarlsberg®
Cheese plant facility will also include a 1,000 kW gas boiler
for the generation of steam. The primary
pollutants from these boilers are oxides of nitrogen (NOx).
There is a requirement for a new emergency diesel generator to
be located at the WWTP to keep the
WWTP operational in the event of a power outage or in
recirculation mode in the event of an accident
or emergency situation. There is also to be an additional new
emergency diesel generator to operate
the firewater pumps in the event of fire. The new Jarlsberg®
Cheese plant will also its own dedicated
emergency diesel generator to keep the plant operational in the
event of a power outage.
The primary pollutants from these generators are oxides of
nitrogen (NOx), sulphur dioxide (SO2) and
particulates (PM). The emergency generator diesel tanks will be
double skinned and have leak
detection.
Process Controls for energy generation to control and minimise
emissions include:
Oxygen, temperature meters to monitor and ensure optimum
operation
The services of suitability qualified external professional are
employed as required to ensure
efficient operation, eg systems auditing, equipment calibration,
boiler maintenance
Gas leaks will trigger alarms and shut off valves within the
site and along the Bord Gáis Network.
Emergency shut-down valves on the internal gas pipeline will
ensure complete shut-down of gas
supply within 60 seconds of leak detection
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5.3. Process Water Treatment
The process water requirement is supplied by 1 No. deep bore
well (GW1). Water from the supply well
is pumped to the on-site process water tanks and undergoes soft
water treatment and chlorination
prior to being used as process water in the cheese manufacturing
plant. Treated process water will
also be supplied to the new Jarlsberg® Cheese plant.
Process Controls include:
automated dosing system controlled by pH and conductivity
meters
PLC system controls the sequencing and speed of chlorination
dosing system.
Metered supply to new Jarlsberg® Cheese plant.
5.4. Wastewater Management and Treatment
5.4.1. Process wastewaters
Process wastewater is mainly generated during cleaning
operations (tank, truck and storage tank
washing, pipe line washing and sanitizing) during the
manufacturing process. It contains milk solids,
detergents, sanitizers and milk wastes. All process wastewaters
generated by the both production
plants will be directed to the DFI facility’s wastewater
treatment plant (WWTP) prior to discharging. It
is proposed that process wastewater from the new Jarlsberg®
Cheese manufacturing plant will be
conveyed to the DFI WWTP at an agreed volume and concentration
implemented under a Service
Level Agreement (SLA) between the two businesses, to the DFI
WWTP for treatment. The proposed
standard for receipt of Wastewater from new Jarlsberg® Cheese
manufacturing plant is set out below.
In coming wastewater from the new Jarlsberg® Cheese
manufacturing plant will be monitored by the
plant operator prior to connecting to the DFI process wastewater
drainage system.
Parameter Receiving Standard
Flow 625m3/day
BOD 1,400kg/BOD
5.4.2. Wastewater Treatment
The Permission granted by An Bord Pleanála on 24th April 2018
(Planning Ref PL04.249108) includes for
upgrading of the on-site on DFI wastewater treatment plant
(WWTP) site. The upgraded WWTP will
consist of the following elements: -
1. Preliminary Treatment
a. Automatic Fine Screen with Manual screen by-pass and
Firewater overflow (new)
b. Proportional sampling and TOC, TN & TP Monitoring by
Biotector
c. Flow measurement (in-line)
d. Inlet Pumping Station with overflow to Firewater Pumps
(new)
e. Above ground Balancing Tank using duty/stand-by recirculation
pumps (to include a dedicated
1,000 m3 for firewater) (new)
f. Proportional sampling point (new)
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2. Secondary Treatment
a. 2 no. Dissolved Air Flotation (DAF) units (pH/chemical
adjustment and flocculated as well as
mechanical scraping)
b. 2 No. fixed bed anaerobic reactors. (Also Anoxic tanks)
c. 2 No. Nitrification/Denitrification extended aeration (fine
bubble diffused air) Activated Sludge
tanks (new)
d. 2 No. Final Clarifiers
e. Final Effluent Tidal Balancing Tank. Existing 2 aeration
basins to be modified for tidal holding
tanks
3. Sludge Management
a. Sludge Holding/ DAF sludge /Picket Fence Thickening Tank
(new)
b. Dewatering House (new to include MCC Room)
c. GEA Westfalia UCD 345 Decanter (Existing machine to be
relocated)
4. Odour Scrubbing
“Shell” type Biofilter (or similar) for odour scrubbing
(new).
5. New Control building containing
a. Office & SCADA
b. MCC Room
c. Sludge Dewatering
5.4.3. Hydraulic design
The incoming design hydraulic load (DFI facility and new
Jarlsberg® Cheese manufacturing plant) is
2,700 m3/d of which 1,000 m3/d is whey permeate. The whey
permeate will normally be discharged
directly to the Final Effluent Holding tank but provision is
made to divert it to the Activated Sludge (AS)
Plant.
The normal WWTP throughput will be 1,700m3/d. The WWTP, post
Balancing tank and high-rate
treatment, will be designed to process this flow in 20 hours
(120% of average), plus permeate at a rate
of 50 m3/hr to allow room to catch up in the event of an
interruption i.e.
In addition to the foregoing flows, it is proposed to provide
additional storage at the WWTP to cater
for Fire Water Retention in accordance with EPA Guidelines
(please see the Firewater Risk Assessment
included in Appendix A to this report). This requires provision
of an additional 1,000 m3 of storage
capacity reserved exclusively for Firewater retention. In the
event of a fire at either of the Process
Facilities, production will stop and the storm water drains will
be diverted to the WWTP.
Peak fire flow rate is 735 m3/hr. At the inlet to the
Preliminary Treatment flows in excess of the 425
m3/h capacity will be diverted to a separate pump sump for
lifting into the Balance/Retention Tank.
The Fire Pump Sump will have Duty/Assist storm pumps each rated
155 m3/h.
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5.4.4. Discharge controls
The discharge point has been agreed with Irish Water and is the
existing Midleton Main Drainage Outfall at Rathcoursey. The
discharge is to take place on the ebb tide only as required by the
Midleton WWDA. Each ebb tide is approximately 6hrs 15 mins. This
means that, an Outfall Holding tank is required to store treated
effluent and permeate from the RO system for a total of 6.25 hours
on each tide. Pumping to outfall is to be over 6.25 hours (the ebb)
per tide means that 25 hours of effluent (including permeate) must
be discharged in 12.5 hours. The outfall Holding Tank is sized as
follows: -
(4,000/24)*6.25 = 1,085 m3
This volume will be provided by upgrading the existing Aeration
basins and raising the height of the
walls by a further metre.
Prior to discharging to the outfall holding tanks, effluent will
pass into a effluent monitoring chamber
complete with a divert system, based on turbidity, to the inlet
Balancing Tank.
Outfall pumping Rate = (4,000/24)*25= 4,167 m3 = 333.4 m3/hr
(Initial Outfall pumping Rate (2,700 m3/d in 25 hours of
effluent = 225 m3/hr)
5.5. Surface Water / Stormwater Treatment/Management
It is proposed to upgrade the on-site stormwater drainage
network. The proposed on-site storm water
drainage system is designed so that the new extended facility
will have three (3) independent surface
water networks/catchments within the development site. The three
distinct storm water catchments
are outlined under;
Catchment 1(a) (Milk Intake/Yard Area, HGV turning areas,
Weighbridge Units, staff/visitor car
parking areas),
Catchment 1(b) (new Jarlsberg® Cheese Plant)
Catchment 2 (existing Dairygold facility),
Each of these independent storm water sewer network will be
designed to collect storm (surface)
water through roof drains and road gullies. The storm water
networks will discharge into a storm
water monitoring/divert chamber, via full retention petrol
interceptors. The storm water monitoring
chamber will analyse the storm water for pH, Conductivity and
Temperature. Also prior to discharging
into the Kiltha River there will be a sampling point/chamber on
the storm water networks. These
sampling locations are indicted on the storm water drainage
drawings.
The storm water from Catchment 1(a) and 1(b) will be connected
to a storm water attenuation tank,
before discharging into the Kiltha River via a flow regulating
valve. The allowable outflow from these
catchments will be equivalent to the development site Greenfield
Runoff (Qbar). The storm
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attenuation tank is designed to store on site surface water for
a 1 in 100 Year Return Period storm
event.
The storm water networks will discharge to Kiltha River through
Class 1 full retention hydrocarbon
(petrol) interceptors. These petrol interceptors will be located
upstream of the storm water
monitoring tank. Locating the petrol interceptors upstream of
the pH/Conductivity monitors reduces
the possibility of the pH/Conductivity Analysers being tripped
and also reduces the amount of silt etc.
that can settle at the head of the monitoring probes at the
sampling location.
Surface water Catchment 2 (existing Dairygold facility) is an
existing storm drainage network and is
currently discharging directly into the Kiltha River with no
storm water attenuation on-site. This storm
water drainage network will continue to discharge directly into
the river without storm water
attenuation as part of the new development.
5.6. Fire controls and firewater treatment/management
The new Jarlsberg® Cheese Plant will have a sprinkler system and
fire hose reels strategically located
around the plant. A new fire water ring main will supply water
to fire hydrants strategically located on
the DFI site. The fire water ring main network and the
Jarlsberg® Cheese Sprinkler System will be
supplied by a dedicated fire water storage tank to ensure there
is sufficient water available in the
event of a fire in compliance with FM Global requirements.
The redesigned storm water system is such that in the event of a
fire/spill on site, the relevant
affected independent storm water network will be diverted into
the site process drainage network for
treatment/storage at the upgraded WWTP.
The retained fire water will remain in the Inlet Balance/Fire
Water Retention Tank until such time as it
can be transferred to Dairygold’s WWTP for treatment.
The combined Inlet Balance/Fire Water Retention Tank will be
designed such that the required fire
water retention volume is available at all times (prior to a
fire event) to ensure that the appropriate
fire water retention capacity for a fire event is
maintained.
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Figure 5-1 Wastewater Treatment Plant
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5.7. Sewerage Management
The on-site sanitary wastewater drainage system will be
redesigned. It is proposed that sanitary
wastewater will, subject to agreement/approval from Irish Water
(IW), be collected and conveyed
separately from the site to the Mogeely Village WWTP via a
connection into the existing public foul
sewer on the Castlemartyr Road. It is anticipated that the
volume of domestic wastewater to be
generated by future site activities will be in the order of
9.6m3 per day. Communication with Irish
Water has indicated that there is capacity in the existing
public sewer network and municipal WWTP
to accept this wastewater stream.
The proposed new foul sewer is 225mm dia. uPVC sewer laid at a
minimum gradient of (1/150). This
foul sewer has a flow capacity of 41 L/sec. at a velocity of 1.0
m/sec.
5.8. Cooling water treatment/management
The DFI site employs the following for the management and
treatment of cooling water:
Cooling control unit on each system that bleeds water off the
systems to control the level of solids
in the condenser. This is related to the cycling of conductivity
in the water and is a pre-calculated
number based on raw water conductivity.
Corrosion Inhibitor. This protects the Chillers and related
Pipework from Corrosion. This is dosed
via water meter pulse and dosed as a percentage of incoming
water. Failure to add inhibitor can
lead to corrosion in pipework and asset damage to
condensers.
Biocide to control Bacteria in the condenser systems. Dosing is
via timed dosing on a daily basis.
This controls bacteria in the systems and protects condensers
from Legionella Bacteria and other
related bacteria that are harmful to both asset and health
5.9. Boiler feed-water treatment/management
The site employs the following for the management and treatment
of boiler feed water:
Caustic is used as an alkalinity builder in the boilers to
ensure correct pH control in Boilers. This is
dosed via dosing pump in boiler house. The pH in the boiler is
between 10.5 and 12.0 as per boiler
specification. Failure to do this will lead to low pH control
and corrosion of boiler Tubes.
The site uses a Phosphate based solution to control scaling in
boiler. Failure to keep reserve at 20 to
70ppm may result in scaling of tubes making boilers inefficient,
and may lead to tubes blowing in the
boiler. This also protects the boilers if there is slippage in
softeners. This is dosed via dosing pump in
boiler house.
The site uses a boiler solution Bi-sulphite based to control
oxygen in boiler. Failure to keep reserve at
30 to 70ppm will result in oxygen entering system through the
supply of water. This will lead to oxygen
pitting and corrosion taking place in Boiler, hot well and
related pipework. This will result in extensive
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damage to boilers and related pipework that can lead to
catastrophic damage to systems. This is
dosed via prominent dosing pump in boiler house.
The site uses automatic blowdown units to blowdown the hot water
boilers to remove solids and keep
Total Dissolved Solids (TDS) within specification and keep
boilers clean and clear. The steam boiler is
blown down manually.
5.10. Refrigeration
The refrigeration plant is an ammonia R717 plant and includes
the following key operational and
control systems to ensure efficient performance and promote
energy efficiency, water conservation
and waste minimisation:
The refrigeration system and automation are designed to ensure
that the refrigeration system
load will track closely the cooling load required in the
factory.
Fixed refrigerant leak detectors to give early warning of a
dangerous concentration of
refrigerant vapour in the surrounding air of a refrigerating
system and of pollution of the
environment.
MCC & control panel. The Ammonia alarm is linked backed to
the fire panel.
Motor efficiency will be upgraded to IE3 minimum where
appropriate.
Condenser fans will be upgraded to have variable speed control
for good control and
efficiency.
5.11. Compressed air generation
Compressed air is used extensively at the site for the operation
of pneumatic valves and motors.
The compressors are fully automated and use line pressure
control systems to monitor demand.
Typically, a drop in pressure signals an increase in demand,
which is corrected by increased
compressor output. Rising pressure, indicating a drop in demand,
causes a reduction in compressor
output. The automated system will monitor these changes in
pressure and adapt the air supply to the
changing air demand.
Multi-pressure system in place to meet differing generating and
user requirements.
Increased filtering at points of uses
Pipe diameter appropriately designed to Reduce frictional
pressure losses
VSD on Main air compressor supplying the plant
external cool air used as intake air
Compressors use line pressure control systems to monitor demand.
Typically, a drop in pressure
signals an increase in demand, which is corrected by increased
compressor output. Rising pressure,
indicating a drop in demand, causes a reduction in compressor
output. system monitors changes in
pressure and adapt the air supply to the changing air
demand.
Maintenance programmed to manage leaks and routine filter
replacement
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5.12. Laboratory Facilities
The laboratory facilities at Mogeely are involved in product
quality assurance testing and final product
testing and grading. The laboratory facilities also undertake
chemical analysis of process effluent and
stormwater emission environmental testing.
6. ABATEMENT SYSTEMS The only abatement systems employed at the
installation is the on-site Wastewater Treatment Plant.
Refer to section 3.4.4.2 above.
7. MATERIALS HANDLING AND STORAGE FACILITIES The range of
materials onsite can be categorised as follows:
Food Grade Raw materials
Intermediates and Finished Products
Chemicals
Fuels
The handling, storage and internal distribution of each category
of material is described in the
following sections.
Food Grade Raw Materials
Food Grade Raw Materials handled on onsite comprise both liquid
and dry materials. All raw liquid
and bulk dry food grade materials will be stored in a number of
dedicated silos and tanks.
The transfer of materials from the storage silos and tanks to
processing will be conveyed by
overground piping systems. Cross contamination between the
environment and the conveyed
material is eliminated since the conveying systems are
closed.
Other dry food grade material inputs are typically delivered in
bagged packaging and these will be
stored on pallets in dedicated material storage areas and
manually transferred to the production
processes as required.
All liquid storage tanks and silo will be suitably bunded to
prevent pollution risks of any spills/leakages.
This is a redevelopment of an existing facility with all bunding
and containment structures to be
constructed in line with the EPA’s Guidance Note for Storage and
Transfer of Materials for Scheduled
Activities. Bunds will be 110% of largest tank or 25% of total
volume of silos. All such newly installed
silos and tanks, constructed containment structures, and
material transfer systems will be tested in
accordance with EPA Guidance. This will include routine visual
inspection of bunds and overground
pipelines and bund and tank integrity testing to be undertaken
every three years.
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Intermediates and Finished Products
All intermediate products will be stored in a number of
dedicated tanks. The transfer of intermediates
for processing will be conveyed via a network of above ground
pipelines.
All intermediates storage tanks and silos will be suitably
bunded to prevent pollution risks of any
spills/leakages. This is a new redevelopment of an existing
facility with all bunding and containment
structures being constructed in line with the EPA’s Guidance
Note for Storage and Transfer of
Materials for Scheduled Activities. Bunds will be 110% of
largest tank or 25% of total volume of silos.
All such newly installed silos and tanks, constructed
containment structures, and material transfer
systems will be tested in accordance with EPA Guidance. This
will include routine visual inspection of
bunds and overground pipelines and bund and tank integrity
testing to be undertaken every three
years.
Finished cheese products will be stored internally in the
dedicated storage building prior to dispatch
(Building No. 02).
Chemicals
All chemicals and chemical cleaning mixtures held on site will
be stored in dedicated containers or
storage tanks which will be suitably bunded to retain the
contents in the event of a spill/leak.
All chemicals will be segregated according to their individual
properties and stored appropriately.
Large volumes of incoming chemicals will be stored in a
dedicated bulk chemical storage bund
(Storage bund 40). A number of individual cleaning in place
(CIP) storage tanks will be stored in bunds
located adjacent to their associated processes. Refer to Drawing
No. 4.
Transfers from the bulk chemical storage tanks to the CIP tanks
will be via a network of above ground
pipelines.
This is a new redevelopment of an existing facility with all
bunding and containment structures being
constructed in line with the EPA’s Guidance Note for Storage and
Transfer of Materials for Scheduled
Activities. Bunds will be 110% of largest tank or 25% of total
volume of silos. All such newly installed
tanks, constructed containment structures, and material transfer
systems will be tested in accordance
with EPA Guidance. This will include routine visual inspection
of bunds and overground pipelines and
bund and tank integrity testing to be undertaken every three
years.
Any smaller quantities of chemicals to be used on site will be
stored in close to their points of uses.
These chemicals will be stored on suitable self contained bunds
or spill trays.
WWTP chemicals will be stored at the WWTP. These chemicals will
be stored on suitable self
contained bunds.
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Laboratory reagents will be stored in the Lab/Admin
Building.
Empty chemical drums or IBCs requiring disposal will be stored
within a designated area of the site
suitable for the storage of these containers. Refer to Drawing
No. 15.
Fuels
The primary fuel in use the installation is natural gas which is
piped to the site gas compound. The
location of the gas compound is shown on Drawing No.4.
Diesel is held on site as a back-up fuel for the emergency
generator/firewater pumps. This will be
stored in a dedicated diesel storage tanks and will be suitably
bunded in line with the EPA’s Guidance
Note for Storage and Transfer of Materials for Scheduled
Activities.
8. ALTERNATIVES The expansion of the Dairygold Food Ingredients
installation at Mogeely is based on scaling up the already existing
process and technology on site. The main alternatives considered
relate to disposal options of the treated process wastewater.
A number of alternatives to the option chosen for the disposal
of treated effluent were considered,
none of which was feasible. These local options included:
Discharging further down the R. Kiltha or R. Womanagh
catchments, both of which were excluded from further consideration
on environmental grounds due to insufficient capacity to
accommodate the discharge volumes.
Infiltration to groundwater which was excluded from further
consideration on feasibility grounds as the surrounding lands are
liable to flooding.
disposal by means of constructed wetland with final discharge to
surface waters would not
only be impractical with regard to the extent of lands that
would be required for such a
proposal and the ability of the Developer to acquire these
lands, but would also be
unworkable due to lands being within floodplains.
alternative disposal route to coastal waters at Ballycotton was
not a viable alternative option.
Currently the necessary outfall infrastructure is not in place
at this location, or at any other
location along this section of coast, and there is substantial
uncertainty of a realistic prospect
of the Developer acquiring the necessary consents in order to
deliver this proposal. There are
a number of environmental considerations relevant to this option
as set out below.
- While a Foreshore Licence has been issued for a proposed
treated effluent outfall at
Ballycotton, into Ballycotton Bay (not the open sea) pursuant to
the White Young Green
designed Sewerage Scheme for Castlemartyr, Saleens, Cloyne and
Ballycotton, the Wastewater
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Discharge Authorisation (WWDA) application, and WWDA issued, was
for Ballycotton only
(strictly domestic) and for the treated effluent from 1,420 p.e.
This outfall has not been
constructed nor is it on the Irish Water Capital Investment
Programme.
- the Hydrometric assessment of the outfall options for
Ballycotton focused on bacteriological
quality in relation to Bathing Waters and did not address
nutrients. The area of the coastline
between Garryvoe and Ballycotton is designated as an SPA. For
the Dairygold discharge to be
accommodated as part of the proposed Ballycotton outfall both
the Foreshore License and the
WWDA would have to be revised to accommodate the possible
twelvefold increase in flows to
the Ballycotton site.
The current proposal to discharge treated wastewaters to the
Midleton main drainage sewer at
Rathcoursey is considered the best viable option.
Appropriate management and separation of wastewater streams will
be undertaken. The proposal
includes a Whey Permeate RO Plant which effectively separates
whey permeate into collectable solids
and clean water thus is a Best Available Technology (BAT) for
treatment of wastewater at source. CIP
systems will be in accordance with Best Available industry
standards (BAT) and reduces potential
additional wastewater loads by recycling where feasible and
managing the number of CIP washes.
The proposal includes a bespoke biological activated sludge
plant particularly suited to the treatment
of dairy wastewaters. This will provide the necessary treatment
to ensure the final wastewater will
comply with statutory limits for Industrial discharges.
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APPENDIX A
FIRE WATER RISK ASSESSMENT
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