Derek Doherty Operations Director. Rich Sauces was founded in 1987 by Trevor Kells The business is privately owned We manufacture a broad range of the.

Derek DohertyOperations Director

• Rich Sauces was founded in 1987 by Trevor Kells

• The business is privately owned

• We manufacture a broad range of the highest quality mayonnaise, sauces, dressings and bouillons

• Our factory is located in Newtownards

• We supply customers in UK, Ireland, USA, Middle East & Europe

Company Background

• Create our team• Roles and responsibilities• Monitor, measure, and save – Energy, resource & money• Create environmental policies for the business• Set short, medium and long term goals:

Short – understand our waste (3 -6 months)

Medium – create an EMS for the business (6-9 months)

Long-term – work towards accreditation for our EMS (ISO 14001)

This was achieved in 9 months against objective target of 12-18 months

Environmental Management System

We assessed our energy and waste streams:

• Water – mains water

• Electricity – lighting / refrigeration / machinery

• Dry Waste – paper / cardboard / plastic / wood

• Wet Waste – wash water / waste product / effluent

• Train Staff – buy in and accountability / signage / team meetings

Key Factors in our Policy

• Meter and measure water volumes, check your bill is correct• Reduce hose dimensions / attach guns to hoses,

for example a hose left running all night wastes the following:

1” hose = 60lpm x 12hrs = 43,200L

¾” hose = 40lpm x 12hrs = 28,800L

½” hose = 25lpm x 12hrs =18,800L

• The operatives complained about reduced water pressure and increased wash down time. We stated to operatives that this was our new policy and it will take longer

• Reduce rinse cycles for CIP system (was there any subsequent impact on hygiene results)

• Staff awareness - turn off taps / never leave hoses running / attach guns to hoses at all times /signage / team meetings

Water

• Measure where the electricity is going• Explore market tariffs – are we on the right tariff/CCL rebates• Staff training: turn off lights, installation of PIR sensors for offices and factory,

and make people responsible for checking• Power factor correction

• Refrigeration – update to inverter pack system• Inverters for motors over 2.2kw• Change lighting to energy efficient were practical – we have adopted a

‘change as they blow’ policy (50% less lighting required, 100w now 50w)

Electricity

Electricity

ExampleOutside security lights 22 x 400w x 10hours = £4818 per annumChange to 125w led 22 x 125w x 10hours = £1505 Saving £276 per monthPAYBACK: 30 months

• We decided this year to install solar panels• Amber Green solar were chosen for the installation• We chose to start with a 12KW system to lock us into the

ROC’s with a view to increasing to 50KW system in thenew financial year .

• We also secured an interest free loan from the carbon trust• Payback is 4 years • Eventual savings of 11% per annum of our total electricity

costs

Electricity

How do we separate our waste which is currently going to compactor/landfill?

• Cardboard – 11.5 tonne per annum

• Plastic – 3 tonne p.a.

• Metal – 1 tonne p.a.

The benefit from separating this waste is that we now have an income fromthis waste stream, we have diverted 15.5 tonnes per annum from landfill.

A cost of £2,500 per year to the business is now cost neutral

Dry Waste

• Meter the WWTP and assess overall volume

• What can we take out at source – start up and final production 300-500lpw - this is recycled by a 3rd party for bio-diesel

• We contacted a local company who were setting up an Anaerobic Digester. They agreed to take away our wet waste for a nominal fee – this has saved the company £7,000 this year and the waste product no longer has to be further processed before going to landfill (approx 129 tonnes per annum)

• Aim / Target – cost neutral

Wet Waste / Effluent

Wet Waste / Effluent

• We have benefited from their experience and networking forums which has allowed us to explore other revenue streams

• Networking – we were introduced to Parwork Solutions, Amber Green Solar and NCH waste water who we have done business with

How Stem Continue to Add Value

• Gerard Enright -(Stem project officer) guided us through our accreditation and reminded us to include the small things we had implemented eg:

Reps cars – Blue motion vehicles with a tax and fuel benefit to company and employee

Pallets – purchase of recycled pallets and agreement to exchange damaged pallets

Sustainable suppliers Electricity - % of wind to replace fossil fuels Packaging – transfer of business to local supplier to reduce carbon

footprint CCL rebate on energy bills

How Stem Continue to Add Value