Midfield Meats EMS


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Matt Boyle, Environment and Sustainability Manager from Midfield Meats Inc., Warrnambool presented to VCE Environmental Science students at Hawkesdale p12 College

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Midfield Meats EMS

  2. 2. One of Australia’s largest red meat producing companies, 100% Locally & Family owned Split into five divisions: - Midfield Meat International (Midfield Meat Processing Site) - Midfield Co-Products (Midfield Rendering Site) - Midfield Transport - Midfield Pastoral (The Union, Ballengeich & Lowlands) - Midfield Wholesalers (The Meat Barn & Gateway Butchers) Full production capacity of 1.6 million head of stock per annum, 6000 head smallstock & 800 head cattle per day Supplying both the domestic and export markets, full Halal certification allows for direct market access into the Middle East Permanent employment of 600 staff on a year round basis
  3. 3. Job Title: Group Environment & Sustainability Manager Time with Midfield: Close to two years 4 Months Production 8 Months Wastewater Treatment 10 Months Environment Education: Bachelor of Environmental Science (Marine and Freshwater) Deakin University, Warrnambool 2004-2007
  4. 4. “ The management of natural resources, utilities and waste/by-products to ensure sustainable business practices & cost savings, while managing a business’s environmental impact” Industrial Environmental Management is not about being a ‘greenie’, but about creation and implementation of plans to bring about cost savings by way of lessened environmental impact.
  5. 5. <ul><li>Odour </li></ul><ul><li>Noise </li></ul><ul><li>Solid Waste </li></ul><ul><li>Recycling </li></ul><ul><li>The Current BIG ISSUES ……. </li></ul><ul><li>Water Consumption </li></ul><ul><li>Liquid Waste Discharge (Wastewater) </li></ul><ul><li>Energy Consumption & Associated Greenhouse Gas Emissions </li></ul>
  6. 6. Environment is the central point around which a business operates Without effective Environmental Management a business will not be able to compete within today's world and is more likely to collapse
  7. 7. <ul><li>The Midfield EMS: </li></ul><ul><li>Environmental Management Review (EMR) undertaken by OTEK in January 2005 </li></ul><ul><li>The EMR recommended that Midfield create an EMS, this would allow The Midfield Group to “ make continual environmental improvements, comply with regulations, set up environmental objectives & targets, document the processes, and communicate the findings” </li></ul><ul><li>Following the EMR, the Midfield EMS was developed in late 2005 </li></ul><ul><li>Structured around ISO 14001 and Based on the Plan-Do-Check-Act methodology </li></ul><ul><li>Formalizes processes for environmental information control and record management </li></ul>
  8. 9. <ul><li>The Midfield EMS cont, </li></ul><ul><li>Purpose: </li></ul><ul><li>Provides alignment of current environmental management policies & procedures </li></ul><ul><li>Implements formal guidelines, processes and directions for continual environmental improvement </li></ul><ul><li>Scope: </li></ul><ul><li>Covers the Midfield Meat International processing site & Midfield Co-Products rendering site. Soon to be updated to cover the full scope of The Midfield Group. </li></ul><ul><li>Applies to all employees, contractors and vistors under the control of Midfield Meat International & Midfield Co-Products. </li></ul>
  9. 10. <ul><li>The Midfield EMS cont , </li></ul><ul><li>What it contains: </li></ul><ul><li>Environmental Policy Statement </li></ul><ul><li>Site information: Maps, Photos, Land Titles etc </li></ul><ul><li>Production flow processes </li></ul><ul><li>Legislative requirements </li></ul><ul><li>Wannon Water Tradewaste agreement </li></ul><ul><li>EPA License </li></ul><ul><li>Procedure & Policy documents </li></ul><ul><li>Yearly utilities & natural resource records </li></ul><ul><li>Yearly waste records </li></ul><ul><li>Yearly production data </li></ul><ul><li>State and Federal environmental programs </li></ul>
  10. 11. <ul><li>1 – 1.5 million litres of potable supply water per day </li></ul><ul><li>1.5 – 2 million litres of wastewater discharged to trade waste per day </li></ul><ul><li>16 million KWH Electricity, enough to power 1800 houses </li></ul><ul><li>200 000+ GJ Natural Gas, enough for 8500 houses </li></ul><ul><li>Spray irrigation of the Midfield Co-Products wastewater </li></ul><ul><li>5500 Tonnes of Paunch material per annum </li></ul><ul><li>Odour from stockyards and rendering processes </li></ul><ul><li>Noise issues associated with 24hr operations </li></ul><ul><li>Onsite solid waste </li></ul>
  11. 12. <ul><li>For a large company such as Midfield the annual bills for natural resource and utilities usage, at the mentioned quantities, will be in the order of: </li></ul><ul><li>$2M for Electricity </li></ul><ul><li>$1M for Natural Gas </li></ul><ul><li>$800 000 for Potable Water </li></ul><ul><li>$600 000 for Wastewater discharge </li></ul><ul><li>Hence why I referred earlier to these as being the big issues! </li></ul>
  12. 13. <ul><li>As an Environmental Manager in Industry this is the procedure I follow when assessing current or future environmental impacts: </li></ul><ul><li>Is the impact likely to be significant environmentally, possibly resulting in either prosecution or extreme environmental degradation? If Yes act immediately to rectify no matter what the cost. If No proceed to next question. </li></ul><ul><li>Is the impact having a negative effect on the bottom line profit of the company? If Yes proceed to next question. If No review impact periodically to assess opportunities for future improvement. </li></ul><ul><li>What are the opportunities for elimination or reduction of the impact? Assess cause of impact followed by opportunities to reduce cause by culture or process change. Identify technologies to help reduce impact if no changes can be made to culture or process. </li></ul><ul><li>Cost-Benefit: Do the associated savings of impact reduction outweigh the costs of implementing the reduction measures, and how long is the payback period? If Yes implementation of the measures is likely to proceed*. If No the impact is to be assessed periodically for future improvement opportunities </li></ul><ul><li>* Unfortunately not all reduction measures will proceed, accountants like to see a payback period of usually less than 3years before they will allocate funds. </li></ul>
  13. 14. “ Where there are threats of serious or irreversible environmental damage, lack of full scientific certainty should not be used as a reason for postponing measures to prevent environmental degradation ” Question 1. of ‘The Checklist’ requires the precautionary principle to be employed. The single most difficult part of using the precautionary principle in industrial environmental management is communicating the reasoning behind having to stop an process due to environmental impact, when that reason is not related to cost, and has limited backing evidence. This requires an understanding of environmental management throughout the whole of the company and more importantly, trust .
  14. 15. <ul><li>Appendix 04 of the Midfield EMS houses the ‘Aspects & Impacts Register’. </li></ul><ul><li>This identifies and assesses all environmental impacts relating the company. </li></ul><ul><li>The aspects and impacts are measured using a simply calculation matrix; where two factors are rated; </li></ul><ul><li>The severity (or consequence) of the impact occuring </li></ul><ul><li>The likelihood of the impact happening </li></ul><ul><li>This allows for an impact significance score for each environmental aspect; where the impact significance is the product of the two figures. </li></ul>
  15. 16. Risk Assessment & Management cont, Risk Assessment Scoring: Severity or consequence of the impact occuring (1-5) Extremely Low……1 Low………………..2 Moderate………….3 High ……………….4 Likelihood of the impact happening (1-8) Very rarely………..1 Rarely…………….2 Infrequently………4 Regularly…………6 Daily………………8
  16. 17. Risk Assessment & Management cont, Impact Significance Register: Severity Extremely low Low Moderate High Severe 1 2 3 4 5 Very rarely 1 1 2 3 4 5 Rarely 2 2 4 6 8 10 3 3 6 9 12 15 Infrequently 4 4 8 12 16 20 5 5 10 15 20 25 Likelihood Regually 6 6 12 18 24 30 7 7 14 21 28 35 Daily 8 8 16 24 32 40 Severity Rating 0 - 3 4 - 6 7 - 13 14 - 24 24 - 40
  17. 18. Risk Assessment & Management cont, Section of Appendix 04 – Aspects, impacts, objectives, risk register Midfield Meat International Pty Ltd Appendix 04 - Aspects, impacts, objectives, risk register Activity Aspect Impact Consequence Likelihood Significance Objective / remedial action Issues that need to be addresses Roles /Authority 246 Plant - General Abattoir Operations                 Stock and yard washing Water consumption Overuse of potable water 2 5 10 Reduce water use/use grey water Water Balance     Wastewater generation Increasing waste loads 2 3 6 Pre-treat drainage water/create on-site ponds   Stock yard manager                                     Sterilising equipment Water consumption Excess use of potable water 2 2 4 Investigate recycling options with Distech       Wastewater generation Increased waste water volume 2 6 12 Look for possible water saving techniques                      
  18. 20. <ul><li>Less than 10% of all solid waste onsite goes to landfill </li></ul><ul><li>Only torn animal skins and comingled waste to landfill </li></ul><ul><li>Every other waste product has a $ value </li></ul><ul><ul><ul><li>Meat By-Products rendered to Meat & Bone Meal, and Tallow </li></ul></ul></ul><ul><ul><ul><li>Blood is separated and dried into Blood Meal </li></ul></ul></ul><ul><ul><ul><li>Torn skins go through a wool recovery process before landfill </li></ul></ul></ul><ul><ul><ul><li>Intact skins sold off for leather goods </li></ul></ul></ul><ul><ul><ul><li>Paunch contents and yard scrapings composted for use as fertilizer </li></ul></ul></ul><ul><ul><ul><li>General rubbish sorted at onsite recycling plant into different fractions </li></ul></ul></ul>
  19. 22. <ul><li>Large user of water, 1 - 1.5 million litres of potable supply per day </li></ul><ul><li>Large percentage goes to boilers for sterilization and hot water demands </li></ul><ul><li>Water reuse options are currently being identified onsite, clean water streams are being reused before discharge. </li></ul><ul><li>The biggest advancement for Midfield is the completion of the Geothermal Bore, which comes on line in about six months time. </li></ul><ul><li>The bore will give Midfield a sustainable water supply separate from the Wannon Water supply. </li></ul><ul><li>Water from the bore is at 43°C and will replace the potable supply (20°C) to the boilers. </li></ul><ul><li>Gas savings in boiler to be around 50% </li></ul><ul><li>Water supplied from bore after treatment will be at a lesser cost than potable supply </li></ul>
  20. 26. <ul><li>Midfield Co-Products: </li></ul><ul><li>Spray irrigation has been recognized as being non-sustainable </li></ul><ul><li>High level of nutrient discharge onto surrounding land </li></ul><ul><li>World first project using Vacuum Distillation to combine water reduction measures with wastewater treatment. </li></ul><ul><li>Wastewater is post a lagoon system. Chemical flocculation assists in ‘sticking’ the solid particles together. </li></ul><ul><li>Solids are screened using a Baleen Filter which replicates the baleen of a whale’s mouth </li></ul><ul><li>Vacuum distillation boils water at 70°C under vacuum to separate concentrate from distilled water </li></ul><ul><li>Distilled water to be used in cooling towers to displace potable water </li></ul><ul><li>Waste concentrate to be investigated for use as liquid fertilizer </li></ul>
  21. 28. <ul><li>07/08 Financial Year </li></ul><ul><li>Midfield Meat International 23 500 tCO 2 e (Carbon Dioxide Equivalent) </li></ul><ul><li>Midfield Co-Products 13 000 tCO 2 e </li></ul><ul><li>Greenhouse Gases are made up of various compounds, as we are unable to accurately quantify these compounds we express all GHG’s as tCO 2 e, Carbon Dioxide Equivalent. </li></ul><ul><li>Black Balloons </li></ul><ul><li>Every Victorian household produces 12 tonnes GHG per year = 240 000 Black Balloons. </li></ul><ul><li>The two Midfield processing sites combined produced around 36 500 tonnes GHG last financial year = 73 000 000 Black Balloons or 304 households. </li></ul>
  22. 29. <ul><li>GHG cont, </li></ul><ul><li>What is The Midfield Group doing to reduce this number? </li></ul><ul><li>Electricity & Natural Gas usage is constantly monitored through a computer system which allows only the bare minimum needed to be used. </li></ul><ul><li>Just like a house we are replacing factory lighting with energy efficient alternatives. </li></ul><ul><li>Geothermal Bore water to replace previously heated town supply will reduce gas consumption in boilers by half. </li></ul><ul><li>Alternative technologies are continually being assessed for more energy efficient options. </li></ul><ul><li>The big one , </li></ul><ul><ul><ul><ul><ul><li>Electricity Co-Generation </li></ul></ul></ul></ul></ul>
  23. 30. <ul><li>Electricity produced from Natural Gas driven turbines onsite </li></ul><ul><li>Investigation started three years ago </li></ul><ul><li>In Victoria Natural Gas produces six times less the amount of GHG per GJ of energy than Electricity. This is due to the fact that Victoria’s power stations are powered by brown coal. </li></ul><ul><li>Would give us the ability to have control over our electricity supply and eliminate problems such as powercuts. </li></ul><ul><li>Added bonus of water heating while cooling turbines. </li></ul><ul><li>Likely to be implemented within the next 18 months. </li></ul>
  24. 31. <ul><li>All SITES who emit more than 25 000 tCO 2 e in a financial year will be involved </li></ul><ul><li>Currently in Australia this is 1000 sites. </li></ul><ul><li>The Midfield Meat International site emitted 23 500 tCO 2 e last financial year, at full production we would trip the threshold. </li></ul><ul><li>The issue: </li></ul><ul><li>If the carbon price is set at $30 tCO 2 e, we would have to buy $750 000 worth of credits to offset our emmisions. </li></ul><ul><li>We will also be faced with higher utilities costs. To offset these costs will would have take a profit cut or increase our prices. Which of these two do you thik is more likely? </li></ul>
  25. 32. <ul><li>Biodiesel production from animal fats - tallow </li></ul><ul><li>Investigation started around four years ago </li></ul><ul><li>Tallow is currently used in the oleic industry for soaps and makeup </li></ul><ul><li>Does not have the same arguments as ethanol based fuels or seed oils as tallow is a by-product of meat production </li></ul><ul><li>Work with Flinders University to solve issues of filter blocking in cold temps </li></ul><ul><li>Midfield could produce 150 000 L of pure B100 biodiesel per month </li></ul><ul><li>A standard blend of B20, or 20% Biodiesel 80% Mineral Diesel would mean production of 700 000 L of blend per month </li></ul><ul><li>Construction of plant likely to start by the end of the year </li></ul>