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Tel: 353 1 276 1428 Fax: 353 1 276 1561 Email: [email protected]
www.enviro-consult.com
Registered Office as above. Registered Number 243 412
ANNUAL ENVIRONMENTAL
REPORT
2009
For
Flight Group Ltd. (Sleever International)
IPC Licence No. P0674-01
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 2 of 36 Document No.: 1216-01 v3.00
QF 1. v2 Document Lead Sheet
Document Title AER 2009
Project No. 1216
Document No. 1216-01
Client Flight Group Ltd (Sleever International)
Address 65 Heather Road, Sandyford Industrial Estate, Dublin
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
1.00 Approved 30/03/2010 AR
2.00 Approved 06/04/2010 AR
3.00 Approved 09/04/2010 AR
Where it is a requirement that this report be issued to a regulatory or other authority,
then the client should sign the appropriate place in the above table and, unless
specifically agreed in writing to the contrary, forward copies to the appropriate
authority (e.g. EPA).
EEC Project Manager: Bob Sutcliffe, CEng, MIMechE
EEC Document Author: Agnès Ricoux, Diplôme d’Ingénieur, Industrial
Processes
Conditions relating to the issue of this report:
1. No alteration to this report by third parties is permitted
2. Where this report is reproduced, it shall only be reproduced in full.
3. Reports remain the property of Environmental & Efficiency Consultants
(Ireland) Limited until paid for in full.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 3 of 36 Document No.: 1216-01 v3.00
Table of Contents
1 Introduction ....................................................................................................... 5 1.1 Company Details........................................................................................ 5
2 Environmental Policy ........................................................................................ 6 3 Company Description ........................................................................................ 8
3.1 Previous site history................................................................................... 8 3.2 Company background ................................................................................ 8 3.3 Description of equipment ........................................................................... 8 3.4 Manufacturing process ............................................................................... 8 3.5 Company Organization chart...................................................................... 9
4 Emissions Summary .........................................................................................10 4.1 Emissions to sewer summary ....................................................................10 4.2 Surface water monitoring summary...........................................................10 4.3 Emissions to Atmosphere summary...........................................................11
4.3.1 Results: TOC as C.............................................................................12 4.3.2 Results: Volume Flow Rate ...............................................................13
4.4 Fugitive Emissions to Atmosphere summary.............................................14 4.5 Environmental Noise summary .................................................................15
5 Waste Management Report ...............................................................................16 6 Agency Monitoring and enforcement................................................................18 7 Resource Consumption .....................................................................................19
7.1 Energy ......................................................................................................19 7.2 Water Usage .............................................................................................19 7.3 Raw materials ...........................................................................................20
8 Bund integrity report.........................................................................................21 9 Environmental Incidences & Complaints ..........................................................22
9.1 Environmental Incidences .........................................................................22 9.2 Environmental Complaints Summary........................................................22
10 Management of the Activity..........................................................................22 10.1 Environmental Management Programme (report and proposal) .................22
11 Pollution Emission Register ..........................................................................26 12 Pollution Register and Transfer (PRTR)........................................................27
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 4 of 36 Document No.: 1216-01 v3.00
List of Tables
Table 1 Company details ........................................................................................... 5 Table 2: Results of Surface Water Analysis 2009 .....................................................10 Table 3 TOC as C results for A2-01 .........................................................................12 Table 4 TOC as C results for A2-02 .........................................................................12 Table 5 Volume flow rate for A2-01.........................................................................13 Table 6 Volume flow rate for A2-02.........................................................................13 Table 7: Details of Waste Disposal 2009 ..................................................................16 Table 8: Details of EPA Correspondence and Enforcement 2009..............................18 Table 9: Details of energy consumption 2009 ...........................................................19 Table 10: Details of water usage 2009 ......................................................................19 Table 11 Hazardous raw materials used in 2009 .......................................................20 Table 12 Summary of bund integrity test results .......................................................21 Table 13: Schedule of Environmental Objectives and Targets...................................23 Table 14 Pollution Emissions Register (all quantities in kilograms)..........................26
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 5 of 36 Document No.: 1216-01 v3.00
1 Introduction
1.1 Company Details
Table 1 Company details
Company Flight Group Ltd
Trading Name Flight Flexible
Address 65 Heather Road, Sandyford Industrial
Estate, Dublin
IPC Registration Number 674
IPPC Class of Activity (Schedule 1 of the
EPA Act 1992 as amended by PoE Act
2003)
12.2.2 The manufacturing or use of coating
materials in processes with a capacity to
make or use at least 10 tonnes per year of
organic solvent not included in paragraph
12.2.1
NACE Code*1
DE – manufacture of pulp, paper and paper
products, publishing and printing
Number of full-time staff equivalents 25
Contact Name Sydney Oosthuizen
Position QSE Manager
Telephone (01) 295 5133
Fax (0)1 295 7673
Email Email: [email protected]
*1 As according to NACE codes referenced from Commission Regulation EC No 29/2002 amending
Council Regulation (EEC) No 3037/90 on the statistical classification of economic activates in the
European Community
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 6 of 36 Document No.: 1216-01 v3.00
2 Environmental Policy
Flight Group Ltd (Sleever International) regards environmental protection as an
essential requirement of its operations. The company will undertake to conduct its
business in a manner which protects the environment in which it operates. The
company’s objective is to balance the need to achieve its business aims with the need
to protect the environment.
To achieve this goal the company will adhere to the following guiding principles:
Guiding Principles:
� Ensure continued compliance with all Irish and EU legislative environmental
requirements.
� Continually assess activities with the specific goal of preventing pollution,
minimising and reducing the environmental impact.
� Ensure that Environmental Policy objectives and targets have equality with
other business interests.
� Maintain a programme of Environmental awareness training (train staff to act in
an environmentally responsible manner).
� Communicate its Environmental Policy to employees, suppliers, visitors and
interested parties.
� Maintain an open information policy towards all parties affected, interested and
involved in its activities and to issues, which concern the environment.
� Ensure that its employees have the knowledge, resources and authority to
implement these guiding principles.
In particular, Flight Group Ltd (Sleever International) will:
� Establish and comply with an Environmental Management System.
� Meet environmental objectives and targets set in the Environmental
Management Programme and review within each management review meeting
for their continuing suitability and effectiveness in achieving the aims of the
Environmental Policy.
� Ensure all hazardous materials are stored in an environmentally safe manner
� Reduce wherever practicable the level of effluent, air and noise emissions
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 7 of 36 Document No.: 1216-01 v3.00
� Ensure good Waste Management practices e.g. reuse rather than dispose
whenever possible, promote recycling and used licensed waste contractors
The objectives of this policy are achieved through the implementation of the
Environmental Management System documented in the Environmental Manual,
Environmental Procedures and Environmental Forms. This Environmental Policy
covers all activities at Flight Group Ltd (Sleever International) site, and has the full
commitment and support of Management. Commitment to this policy involves almost
every aspect of the company’s business and its employees and resources shall be
made available to implement these guiding principles.
Signed: _____________________ Date: __________________
(Company Director)
Signed: _____________________ Date: __________________
(Environmental Manager)
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 8 of 36 Document No.: 1216-01 v3.00
3 Company Description
3.1 Previous site history
Flight Group Ltd (Sleever International) was set up in 1991. No environmental issues
are associated with the previous nature of the site.
3.2 Company background
Flight Group Ltd (Sleever International) primarily manufactures gravure printed
shrink sleeves for various companies but has also facilities to produce flexo and plain
printed sleeves as well as tamper evident sleeves. The company primarily provides
product to Irish and UK markets.
The company was awarded ISO 9002 in 1992 and re-assessed and accredited for ISO
9001:2008 in 2009. The company has only required and received an IPC licence since
May 2004. The company employs approximately 25 staff and during times of high
demand operates on a two-shift basis Monday to Friday.
3.3 Description of equipment
The main energy consuming equipment is:
� Flexographic Printing Press
� Rotogravure Printing Press
3.4 Manufacturing process
Sleeves are mainly printed on PET, OPS or PVC and range in micronage from 40 mic
to 75 mic
Gravure printed sleeves are produced on the 8 colour Rotogravure printer while flexo
printed sleeves are produced on the 6 colour press and are generally supplied to
contract packers who specialize in their application onto the product. Lead times on
flexo sleeves are quicker than gravure because of the use of plates rather than
engraved cylinders. Tear tape may be added to produce tamper evident packaging.
Flight Flexible currently use water based inks and solvent based inks with the
objective of eliminating solvent based inks.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 9 of 36 Document No.: 1216-01 v3.00
3.5 Company Organization chart
Chairman/Owner
Eric Fresnel (Sleever)
Plant Manager
Jason Dingle
QSE Manager:
Sydney Oosthuizen
Purchasing and Production co-ordinator
Brian Byrne
Sales and Customer service:
Kevin Cleary
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 10 of 36 Document No.: 1216-01 v3.00
4 Emissions Summary
4.1 Emissions to sewer summary
Condition 6.2 and Schedule 2ii of the company's IPC licence dictate that the company
must conduct quarterly monitoring of emissions to SE-01. The company ceased
discharging any trade emissions to sewer in June 2003 on the advice of their suppliers
who informed them that the inks that were being used are not suitable for discharge to
sewer. It was therefore not necessary to collect any sewer samples during 2008. A
report was sent to the EPA out-lining this decision (Environmental Efficiency
Document No: 593-01 and 593-02)
4.2 Surface water monitoring summary
According to Condition 9.1.2 and Schedule 4i, surface water monitoring is to occur
bimonthly and the results are to be submitted to the EPA bi-annually. The IPC licence
does not define any limits for the parameters that are monitored at Flight Group Ltd
(Sleever International) Following high BOD and COD results in September 2008, the
Agency requested that warning levels be defined. Above these thresholds, an
investigation will be carried out to investigate the origin of the high results. The table
below shows the analysis results of all surface water samples collected by
Environmental Efficiency Consultants Ltd in 2009 along with the warning levels.
Table 2: Results of Surface Water Analysis 2009
Sample
Number 593/44 593/45 593/46 593/47 593/48 593/49 Proposed
Period Jan/Feb Mar/Apr May/June Jul/Aug Sep/Oct Nov/Dec Warning
Levels
BOD mg/L 17.0 26 24 21 3 26 20
COD mg/L 31.8 <15 115 <15 16.7 19.6 100
Conductivity µS/cm 352.0 136.8 298.0 235 271 298 N/A
pH pH Units
7.80 7.48 7.39 8.49 7.94 7.06 N/A
Temperature ˚C _ 11.3 16.6 16.4 13.8 7.4 N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 11 of 36 Document No.: 1216-01 v3.00
4.3 Emissions to Atmosphere summary
Condition 5.6 and Schedule 1ii of Flight Group Ltd (Sleever International)’s IPC
licence requires air emission monitoring of TOC as C and volume flow rates be
carried out at the Rotogravure Printer (A2-01) on a quarterly basis and the
Flexographic Printer (A2-02) on an annual basis.
With the water-based ink programme, the company was able to reduce their solvent
consumption under 15 tonnes per year. A Technical Amendment was issued on the 20
January 2010 to reflect this and the limits for the TOC as C were changed as follows:
Please note that on the 20 January 2010, the limits for TOC as C were changed as to:
Emission Point New Limit
A2-01 When annual solvent consumption <15tonnes : 630mg/Nm3
When annual solvent consumption ≥15tonnes: 100mg/Nm3
A2-02 When annual solvent consumption <15tonnes : 150mg/Nm3
When annual solvent consumption ≥15tonnes: 100mg/Nm3
A summary of the air monitoring results is given in the following tables.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 12 of 36 Document No.: 1216-01 v3.00
4.3.1 Results: TOC as C
Table 3 TOC as C results for A2-01
Period Q1 2009 Q1 2009 Q2 2009 Annual
2009 Units
Date 19/03/2009 19/03/2009 23/06/2009 01/02/2010 N/A
TOC as C (mg/Nm3) 166.5 151.8 114.9 85.5 mg/Nm3
Compliance with ELV
(100mg/Nm3)
Non-
Compliant
Non-
Compliant
Non-
Compliant Compliant N/A
Table 4 TOC as C results for A2-02
Period 2009 EPA
Monitoring 2009 Units
Date 19/03/2009 01/10/2008 01/02/2010 N/A
TOC as C (mg/Nm3) 89.9 37.15 37.3 mg/Nm3
Compliance with ELV
(100mg/Nm3)
Compliant Compliant Compliant N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 13 of 36 Document No.: 1216-01 v3.00
4.3.2 Results: Volume Flow Rate
Table 5 Volume flow rate for A2-01
Period Q1 2009 Q1 2009 Q2 2009 Annual
2009 Units
Date 19/03/2009 19/03/2009 23/06/2009 01/02/2010 N/A
Volume Flow (Nm3/hr) 4,915 6,405 6,399 6,633 mg/Nm3
Compliance with ELV
(11,000 Nm3/hr)
Compliant Compliant Compliant Compliant N/A
Table 6 Volume flow rate for A2-02
Period 2009 EPA
Monitoring
Annual
2009 Units
Date 19/03/2009 01/10/2008 01/02/2010 N/A
Volume Flow rate 691 Not reported 1,780 Nm3/hr
Compliance with ELV
(1,800Nm3/hr)
Compliant Compliant Compliant N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 14 of 36 Document No.: 1216-01 v3.00
4.4 Fugitive Emissions to Atmosphere summary
Condition 5.10 of the IPC licence states that:
“fugitive emission (including venting from the ink store) to air of volatile organic
compounds shall be reduced to meet the following limit subject to Condition 3 of this
licence: 25% of the total solvent input, where solvent consumption is 15-25 tonnes per
year or 20% of solvent input where solvent consumption is greater than 25 tonnes per
year”.
The annual solvent input for the year 2009 was calculated at 5,773.7kg (TOC as C)
and thus the limit for the fugitive emission percentage is 25% of the solvent input.
The fugitive emissions represent 10.5% and thus the company is in compliance.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 15 of 36 Document No.: 1216-01 v3.00
4.5 Environmental Noise summary
On the 23/02/2009, the company sent a letter to the EPA to request that noise
monitoring be removed from their regular monitoring. The reason for this request is
that the company is located in an industrial estate and also very close to the M50 (less
than 150m) and that therefore the readings for the noise surveys do not reflect the
noise emissions generated by the company alone. The company is still awaiting the
response from the Agency on this matter.
It should be noted that the company has never received any complaint with regards to
the noise emissions from the site.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 16 of 36 Document No.: 1216-01 v3.00
5 Waste Management Report
Schedule 3i and 3ii of Flight Group's IPC licence details the disposal/recovery methods for specified wastes. All wastes are managed so as to
minimise their impact on the environment and appropriately licensed contractors are used in all cases.
Table 7: Details of Waste Disposal 2009
European
Waste
Code
Quantity
T/Yr Description of Waste
Name and
Licence / Permit
No. of Recoverer
/ Disposer /
Broker
Address of Recoverer /
Disposer / Broker
Name and Address of
Final Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
Licence / Permit
No. of Final
Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
08 03 14 6.8 Waste Sludge Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
15 02 02 0.043 Used cleaning rags Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
08 03 12 0.036 Waste solvent (rationalisation) Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
20 03 01 1.620 General and canteen waste
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 17 of 36 Document No.: 1216-01 v3.00
European
Waste
Code
Quantity
T/Yr Description of Waste
Name and
Licence / Permit
No. of Recoverer
/ Disposer /
Broker
Address of Recoverer /
Disposer / Broker
Name and Address of
Final Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
Licence / Permit
No. of Final
Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
15 01 01 4.16 Paper and cardboard packaging waste
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
15 01 02 49.920 Reels of backing/ Offcuts (PVC/PET) and Plastic wrapping
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
15 01 10 1.128
Empty 200L steel drums (solvent-based inks) and empty 20kg steel pails (solvent-based inks)
Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Environmental Efficiency Page 18 of 36 Document No.: 1216-01 v3.00
6 Agency Monitoring and enforcement
The following table details documentation regarding EPA monitoring and
enforcement in 2009.
Table 8: Details of EPA Correspondence and Enforcement 2009
Date Content
23/02/2009 Letter to EPA re. Noise monitoring
Early July 2009 Meeting with the EPA to discuss the
company’s emissions status
15/07/2009
Letter to EPA requesting a licence technical
amendment as the annual solvent
consumption is now below 15t.
31/07/2009 EPA Letter re. Enforcement Category
19/10/2009 Site Inspection Report
09/11/2009 Response letter to EPA’s Site Inspection
Report
Environmental Efficiency Page 19 of 36 Document No.: 1216-01 v3.00
7 Resource Consumption
7.1 Energy
Table 9: Details of energy consumption 2009
Source Energy Consumption
Electricity 304,571 kWh
Gas 188,294 kWh
7.2 Water Usage
The following table details water use by the company.
Table 10: Details of water usage 2009
Water Source Volume
On-site groundwater N/A
On-site surface water N/A
Municipal Supply 548,000L
N/A - Not applicable, not used by the company
Environmental Efficiency Page 20 of 36 Document No.: 1216-01 v3.00
7.3 Raw materials
The total quantities of solvents and solvent-based inks consumed during 2009 are
summarised in the table below. The detailed figures for each product are provided in
Appendix 2 and Appendix 3.
Table 11 Hazardous raw materials used in 2009
Quantity
consumed
in 2008,
kg
Quantity
consumed
in 2009,
kg
Equivalent
TOC as C
2009
Totals Inks 22,082 5,607 1,557.5
Totals Solvents 15,138 7,835 4,216.2
Total 37,220 13,442 5,773.7
Environmental Efficiency Page 21 of 36 Document No.: 1216-01 v3.00
8 Bund integrity report
The integrity test of all the bunds was carried out on the 07/09/2007.
Table 12 Summary of bund integrity test results
Bund No. Pallet Type/Application Location Pass/Fail
44229 Bunded pallet – Solvent storage Stores Pass
47137 Bunded pallet – Solvent storage Stores Pass
53439 Bunded pallet – Solvent storage Stores Pass
44228 Bunded pallet – Solvent storage Stores Pass
52159 Bunded pallet – Ink storage Press Room Pass
48163 Bunded pallet – Ink storage Press Room Pass
48875 Bunded pallet – Ink storage Press Room Pass
48164 Bunded pallet – Temp storage Press Room Pass
48193 Bunded pallet – Solvent storage Chesnut Pass
53962 Bunded pallet – THF & Sludge Press Room Pass
5632 Bunded pallet – Ink storage Ink Room Pass
5633 Bunded pallet – Ink storage Ink Room Pass
4946 Barrel station (4 x solvent barrel storage) Press Room Pass
66051 Bunded pallet – Empty barrel storage Container Pass
01 Press-side spill tray – Inks & Solvents Aquaflex Pass
02 Press-side spill tray – Inks & Solvents Aquaflex Pass
03 Press-side spill tray – Inks & Solvents Aquaflex Pass
04 Press-side spill tray – Inks & Solvents Chesnut Pass
05 Press-side spill tray – Inks & Solvents Chesnut Pass
06 Press-side spill tray – Inks & Solvents Chesnut Pass
07 Press-side spill tray – Inks & Solvents Chesnut Pass
08 Ink trolley spill trays Press Room Pass
09 Ink trolley spill trays Press Room Pass
10 Toner trolley spill trays Press Room Pass
11 Shelving spill trays (under grated shelves) Ink Room Pass
12 Shelving spill trays (under grated shelves) Ink Room Pass
13 Solvent bath spill tray Ink Room Pass
14 Catchment tray Chesnut Pass
As can be seen in the previous table, all the bunds passed the integrity test.
Environmental Efficiency Page 22 of 36 Document No.: 1216-01 v3.00
9 Environmental Incidences & Complaints
9.1 Environmental Incidences
There were no environmental incidences on site during the course of 2009.
9.2 Environmental Complaints Summary
There were no environmental complaints associated with the site during the course of
2009.
10 Management of the Activity
10.1 Environmental Management Programme (report and proposal)
The table below summarises the objectives (set out in the AER 2005) achieved to date
and sets out a Schedule of Environmental Objectives and Targets for 2010.
Environmental Efficiency Page 23 of 36 Document No.: 1216-01 v3.00
Table 13: Schedule of Environmental Objectives and Targets
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT1 13-Dec-04 Ensure that spill incidents are minimised
and managed N/A Ongoing
This is an ongoing objective. Flight is constantly
striving to minimize spills. Our Environmental
procedures ensure minimal spills but we are always
improving on them. No spills were reported for 2009.
OT2 13-Dec-04
Implement a rationalisation programme to
minimise the storage of redundant solvents
on site
N/A Ongoing
Numerous ink rationalisations have taken place during
the year 2008. Our stock of solvent based inks have
begun to diminish during this period as we have
developed our water-based inks program to a stage
where most orders are produced on water based inks.
With the successful transfer from solvent inks to water
based inks a substantial amount of solvent based inks
were disposed of through the company’s hazardous
waste contractor (GSL). This initiative will be ongoing
in 2010.
Environmental Efficiency Page 24 of 36 Document No.: 1216-01 v3.00
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT4 13-Dec-04 Ensure that all hazardous materials are
managed and stored correctly N/A Ongoing
Flights procedures dictate that all solvents and inks are
managed and stored in the correct manner. These
procedures are ISO14001 based and are policed by day-
to-day inspections and a monthly site inspection, which
is discussed at monthly environmental meetings. As a
result of the water based programme less ink is stored
on site. This has resulted in 3 bunded pallets being made
obsolete and placed into storage. This initiative will
continue on in 2010.
OT5 13-Dec-04 Ensure the protection of surface water N/A Ongoing
This is an ongoing objective. Flight monitor surface
water every two months and submit a report bi-
annually. No unusual activity regarding surface water
monitoring for 2009. Monitoring to continue in 2010.
OT7 13-Dec-04 Minimise the generation of fugitive
emissions N/A Ongoing
Through investigation we have realised new methods of
reducing fugitive emissions and the fugitive emission
level for 2009 was found to be 6.9%, which is a further
reduction.
Environmental Efficiency Page 25 of 36 Document No.: 1216-01 v3.00
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT8 13-Dec-04 Ensure appropriate management of waste
generated by company N/A Ongoing
This is an ongoing objective. Our waste is segregated
and disposed of according to our environmental
procedures, which dictate that all wastes are stored and
disposed of in the correct manner and the correct
documentation is present. In late 2009 the company
employed the services of Greyhound waste contractors.
OT12 21-Aug-06 Investigate compliance with 2007 Toc as C
emissions limits N/A Closed
During 2008 Flight conducted quarterly monitoring.
Through this monitoring and in conjunction with their
water based inks program, the company was able to
analyse their processes and how best to achieve
compliant emissions results. Both monitoring and water
based program implementation to continue in 2009 to
comply with our IPC licence. As the annual solvent
consumption was below 15 tonne in 2009 and
application was made and approved by the EPA to
increase the ELVs, the company is now compliant.
Environmental Efficiency Page 26 of 36 Document No.: 1216-01 v3.00
11 Pollution Emission Register
Table 14 Pollution Emissions Register (all quantities in kilograms)
POLLUTANTS SUMMARY
Outputs
Pollutant Name CAS
Number Input
Note 1 Gross Usage Air MOM
Liquid Effluent
MOM Waste MOM Product MOM Recovered MOM Treated MOM Unaccounted
2-methoxy-1-methylethyl acetate 31.36 31.36 16.2 M, E 0.0 O 11.6 E 0.0 M, E 0.0 E 0.0 O 3.6
4-Methyl-pentane-2-one 41.40 41.40 21.4 M, E 0.0 O 15.3 E 0.0 M, E 0.0 E 0.0 O 4.7
Ethanol 2,115.98 2,115.98 1,094.7 M, E 0.0 O 780.6 E 0.0 M, E 0.0 E 0.0 O 240.7
Ethyl Acetate 1,221.01 1,221.01 631.7 M, E 0.0 O 450.4 E 0.0 M, E 0.0 E 0.0 O 138.9
Methyl Ethyl Ketone 107.33 107.33 55.5 M, E 0.0 O 39.6 E 0.0 M, E 0.0 E 0.0 O 12.2
N-Propyl Acetate 1,011.27 1,011.27 523.2 M, E 0.0 O 373.1 E 0.0 M, E 0.0 E 0.0 O 115.0
Propan-1-ol 86.33 86.33 44.7 M, E 0.0 O 31.8 E 0.0 M, E 0.0 E 0.0 O 9.8
Propan-2-ol 106.69 106.69 55.2 M, E 0.0 O 39.4 E 0.0 M, E 0.0 E 0.0 O 12.1
Ethoxypropanol 228.46 228.46 118.2 M, E 0.0 O 84.3 E 0.0 M, E 0.0 E 0.0 O 26.0
N-Propanol 877.95 877.95 454.2 M, E 0.0 O 323.9 E 0.0 M, E 0.0 E 0.0 O 99.9
Tetrahydrofuran 0.00 0.00 0.0 M, E 0.0 O 0.0 E 0.0 M, E 0.0 E 0.0 O 0.0
TOTAL (kg) 5,827.8 5,827.8 3,015.0 0.0 2,149.9 0.0 0.0 0.0 662.9
MOM = Method of Measurement, Codes taken from the EPA Guidance Note for AER: M = Direct Measurement B = Material Balance E = Engineering Estimates O = Other
Note 1: The purchased quantities were used for the PRTR as the stocks for the individual substances are not known.
Environmental Efficiency Page 27 of 36 Document No.: 1216-01 v3.00
12 Pollution Register and Transfer (PRTR)
| PRTR# : P0674 | Facility Name : Sleever International LTD | Filename :
P0674_2009.xls | Return Year : 2009 |
Version 1.1.10
REFERENCE YEAR 2009
1. FACILITY IDENTIFICATION
Parent Company Name Sleever International LTD
Facility Name Sleever International LTD
PRTR Identification Number P0674
Licence Number P0674-01
Waste or IPPC Classes of Activity
No. class_name
12.2
The manufacture or use of coating materials in processes with a
capacity to make or use at least 10 tonnes per year of organic
solvents, and powder coating manufacture with a capacity to produce
at least 50 tonnes per year.
Address 1 65 Heather Road
Address 2 Sandyford Industrial Estate
Address 3 Dublin 18
Address 4
Country Ireland
Coordinates of Location -6.21314 53.272
River Basin District IEEA
NACE Code 2030
Main Economic Activity
Manufacture of paints, varnishes and similar coatings, printing ink
and mastics
AER Returns Contact Name Sydney Oosthuizen
AER Returns Contact Email Address [email protected]
AER Returns Contact Position Quality/Environment Manager
AER Returns Contact Telephone Number 01-2957588
AER Returns Contact Mobile Phone Number
AER Returns Contact Fax Number 01-2957674
Production Volume 0.0
Production Volume Units
Number of Installations 0
Number of Operating Hours in Year 0
Number of Employees 0
User Feedback/Comments
Web Address
2. PRTR CLASS ACTIVITIES
Activity Number Activity Name
50.1 General
3. SOLVENTS REGULATIONS (S.I. No. 543 of 2002)
Is it applicable? Yes
Have you been granted an exemption ? No
If applicable which activity class applies (as per
Schedule 2 of the regulations) ?
Is the reduction scheme compliance route being
used ? No
AER Returns Worksheet
Environmental Efficiency Page 28 of 36 Document No.: 1216-01 v3.00
4.1 RELEASES TO AIR | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 01/04/2010 18:49
8 8 16 16 24 24 6 6 6
SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
07 Non-methane volatile organic compounds (NMVOC) M ISEN13526-2002 FID 3015.0 3623.8 0.0 608.8
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
Additional Data Requested from Landfill operators
Landfill: Sleever International LTDPlease enter summary data on the
quantities of methane flared and / or
utilised
additional_pollutant_no T (Total) kg/Year M/C/E Method Code
Designation or
Description
Facility Total Capacity m3
per hour
Total estimated methane generation (as per
site model) 0.0 N/A
Methane flared 0.0 0.0 (Total Flaring Capacity)
Methane utilised in engine/s 0.0 0.0 (Total Utilising Capacity)
Net methane emission (as reported in Section
A above) 0.0 N/A
POLLUTANT METHOD
Method Used
For the purposes of the National Inventory on Greenhouse Gases, landfill operators are requested to provide summary data on landfill gas (Methane)
flared or utilised on their facilities to accompany the figures for total methane generated. Operators should only report their Net methane (CH4)
emission to the environment under T(total) KG/yr for Section A: Sector specific PRTR pollutants above. Please complete the table below:
Method Used
Method Used
RELEASES TO AIR
POLLUTANT METHOD
Method Used
POLLUTANT
RELEASES TO AIR
RELEASES TO AIR
METHOD
Environmental Efficiency Page 29 of 36 Document No.: 1216-01 v3.00
4.2 RELEASES TO WATERS | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
8 8 16 16 24 24 6 6 6
SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this onl
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
RELEASES TO WATERS
Method Used
RELEASES TO WATERS
RELEASES TO WATERS
Method Used
POLLUTANT
Method Used
POLLUTANT
POLLUTANT
4.3 RELEASES TO WASTEWATER OR SEWER | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 |30/03/2010 13:27
8 8 16 16 6 6 6 6
SECTION A : PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER
OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER
Method Used
Method Used
POLLUTANT METHOD
POLLUTANT METHOD
Environmental Efficiency Page 30 of 36 Document No.: 1216-01 v3.00
4.4 RELEASES TO LAND | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
8 8 16 16 6 6 6 6
SECTION A : PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year
0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year
0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
POLLUTANT METHOD
Method Used
RELEASES TO LAND
RELEASES TO LAND
POLLUTANT METHOD
Method Used
5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
5 11 3
Quantity
(Tonnes per
Year)
Haz Waste : Name and
Licence/Permit No of Next
Destination Facility Non
Haz Waste: Name and
Licence/Permit No of
Recover/Disposer
Haz Waste : Address of Next
Destination Facility
Non Haz Waste: Address of
Recover/Disposer
Name and License / Permit No. and
Address of Final Recoverer /
Disposer (HAZARDOUS WASTE
ONLY)
Actual Address of Final Destination
i.e. Final Recovery / Disposal Site
(HAZARDOUS WASTE ONLY)
Transfer Destination
European Waste
Code Hazardous Quantity T/Year Description of Waste
Waste
Treatment
Operation M/C/E Method Used
Location of
Treatment Name and Licence / Per mit No. of Recoverer / Disposer / Br oker Addr ess of Recoverer / Disposer / Br oker Name and Address of F inal Destination i.e. F inal Recovery / Disposal Site (HAZARDOUS WAST E ONLY) Licence / Permit No. of Final Destination i.e. Final Recover y / Disposal Site ( HAZ ARDOUS WASTE ONLY)
To Other Countries 08 03 14 Yes 6.8 Ink sludge D10 M Weighed Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
To Other Countries 15 02 02 Yes 0.043 Used cleaning rags D10 M Volume Calculation Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
To Other Countries 08 03 12 Yes 0.036 Waste Solvent (Rationalisation) D10 M Weighed Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
Within the Country 20 03 01 No 1.62 General and canteen waste D1 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 01 No 4.16 Paper and cardboard packaging waste R3 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 02 No 49.92
Reels of backing/ Offcuts (PVC/PET) and
Plastic wrapping R5 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 10 Yes 1.128
Empty 200L steel drums (solvent-based
inks) and empty 20kg steel pails (solvent-
based inks) R4 M Weighed Onsite in Ireland
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Method Used
Environmental Efficiency Page 31 of 36 Document No.: 1216-01 v3.00
Appendix 1 Contact details for waste contractors
Company Contact Details
Guardian Silver Lining Unit 61,
Cookstown Industrial Estate,
Belgard Road,
Tallaght,
Dublin 24
01-4587270
OZO Jamestown Road,
Inchicore,
Dublin 8,
Ireland
01 616 0610
Environmental Efficiency Page 32 of 36 Document No.: 1216-01 v3.00
Appendix 2 Details of solvent based inks consumed in 2009
Ink description Qty (kg)
component % kg TOC as C
INK CAP SHRINK WHITE 1360 Ethanol 50 680 354.78
Propan-2-ol 5 68 40.80
P/R FINELAP NT 710 WHITE 920 Ethyl Acetate 37.5 345 188.18
Methyl Ethyl Ketone 17.5 161 107.33
Propan-2-ol 6.25 57.5 34.50
4-Methyl-pentane-2-one 6.25 57.5 41.4
2-methoxy-1-methylethyl acetate 6.25 57.5 31.36
PVC SHRINK 072 BLUE /20KG 20 Ethanol 50 10 5.22
Propan-2-ol 5 1 0.60
PVC SHRINK 872C GOLD /20KG 20 Ethanol 50 10 5.22
Propan-2-ol 5 1 0.60
PVC SHRINK BLACK/20KG 600 Ethanol 50 300 156.52
Propan-2-ol 5 30 18.00
PVC SHRINK GREEN /20KG 30 Ethanol 50 15 7.83
Propan-2-ol 5 1.5 0.90
SOLVENT PRIMER 995 Unknown
STILETTO BLACK TONER /20KG 100 Ethanol 37.5 37.5 19.57
Ethyl Acetate 12.5 12.5 6.82
N-Propyl Acetate 12.5 12.5 7.35
Propan-1-ol 12.5 12.5 7.50
STILETTO BLACKTHORN GOLD 10 Ethanol 37.5 3.75 1.96
Ethyl Acetate 12.5 1.25 0.68
N-Propyl Acetate 12.5 1.25 0.74
Propan-1-ol 12.5 1.25 0.75
STILETTO BLUE TONER 10 Ethanol 37.5 3.75 1.96
Environmental Efficiency Page 33 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
Ethyl Acetate 12.5 1.25 0.68
N-Propyl Acetate 12.5 1.25 0.74
Propan-1-ol 12.5 1.25 0.75
STILETTO CYAN TONER 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO MEDIUM /170-90KG 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO MEDIUM /20KG 220 Ethanol 37.5 82.5 43.04
Ethyl Acetate 12.5 27.5 15.00
N-Propyl Acetate 12.5 27.5 16.18
Propan-1-ol 12.5 27.5 16.50
STILETTO ORANGE TONER /20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO PROCESS BLACK/20KG 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO PROCESS MAGENTA /20KG 100 Ethanol 37.5 37.5 19.57
Ethyl Acetate 12.5 12.5 6.82
N-Propyl Acetate 12.5 12.5 7.35
Propan-1-ol 12.5 12.5 7.50
STILETTO PROCESS YELLOW 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
Environmental Efficiency Page 34 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO RED TONER/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO REFLEX BLUE/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO REFLEX BLUETONER/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO RUBINE RED/20KG 40 Ethanol 37.5 15 7.83
Ethyl Acetate 12.5 5 2.73
N-Propyl Acetate 12.5 5 2.94
Propan-1-ol 12.5 5 3.00
STILLETTO RUBINE RED TON/20KG 60 Ethanol 37.5 22.5 11.74
Ethyl Acetate 12.5 7.5 4.09
N-Propyl Acetate 12.5 7.5 4.41
Propan-1-ol 12.5 7.5 4.50
STILETTO SILVER 15 Ethanol 37.5 5.625 2.93
Ethyl Acetate 12.5 1.875 1.02
N-Propyl Acetate 12.5 1.875 1.10
Propan-1-ol 12.5 1.875 1.13
STILETTO VIOLET /20KG 15 Ethanol 37.5 5.625 2.93
Ethyl Acetate 12.5 1.875 1.02
N-Propyl Acetate 12.5 1.875 1.10
Environmental Efficiency Page 35 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
Propan-1-ol 12.5 1.875 1.13
STILETTO WARM RED/20KG 21 Ethanol 37.5 7.875 4.11
Ethyl Acetate 12.5 2.625 1.43
N-Propyl Acetate 12.5 2.625 1.54
Propan-1-ol 12.5 2.625 1.58
STILETTO WARM RED TONER/20KG 30 Ethanol 37.5 11.25 5.87
Ethyl Acetate 12.5 3.75 2.05
N-Propyl Acetate 12.5 3.75 2.21
Propan-1-ol 12.5 3.75 2.25
STILETTO YELLOW TONER 130 Ethanol 37.5 48.75 25.43
Ethyl Acetate 12.5 16.25 8.86
N-Propyl Acetate 12.5 16.25 9.56
Propan-1-ol 12.5 16.25 9.75
ENERGY WHITE 200 Unknown
Total Purchased 5,296 1,467.87
Stock 01/01/2009 3,012 867.59
Stock 31/12/2009 2,701 778.01
Total Consumption 5,607 1,557.5
average TOC as C proportion 0.28804
Environmental Efficiency Page 36 of 36 Document No.: 1216-01 v3.00
Appendix 3 Details of solvent consumed in 2009
Quantity
purchased (kg) Composition
concentration %
Weight (kg)
Equivalent TOC as C
(kg)
EP 400 Ethoxypropanol 99 396 228.46
MIX 25/m22 1,951 N-Propanol 75 1463.25 877.95
N-propyl acetate 25 487.75 286.915
MIX 03/M16 2,508 Ethyl Acetate 25 627 342
Isopropanol 0.75 18.81 11.29
Ethanol 75 1881 981.39
NPA 1,093 NPA 99.5 1087.535 639.73
EA 1,110 Ethyl Acetate 99.5 1104.45 602.43
NIMROD REDUCER 1,040 Ethanol 70 728 379.84
Ethyl Acetate 1.75 18.2 9.93
Total Purchased 8,102 4,359.91
Taking into account the stocks:
Overall
(kg) TOC as C
(kg)
Total Purchases 8,102 4,359.9
Stock 01/01/2009 3,012 743.2
Stock 31/12/2009 2,701 886.8
Total Consumption 7,835 4,216.2
Tel: 353 1 276 1428 Fax: 353 1 276 1561 Email: [email protected]
www.enviro-consult.com
Registered Office as above. Registered Number 243 412
ANNUAL ENVIRONMENTAL
REPORT
2009
For
Flight Group Ltd. (Sleever International)
IPC Licence No. P0674-01
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 2 of 36 Document No.: 1216-01 v3.00
QF 1. v2 Document Lead Sheet
Document Title AER 2009
Project No. 1216
Document No. 1216-01
Client Flight Group Ltd (Sleever International)
Address 65 Heather Road, Sandyford Industrial Estate, Dublin
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
1.00 Approved 30/03/2010 AR
2.00 Approved 06/04/2010 AR
3.00 Approved 09/04/2010 AR
Where it is a requirement that this report be issued to a regulatory or other authority,
then the client should sign the appropriate place in the above table and, unless
specifically agreed in writing to the contrary, forward copies to the appropriate
authority (e.g. EPA).
EEC Project Manager: Bob Sutcliffe, CEng, MIMechE
EEC Document Author: Agnès Ricoux, Diplôme d’Ingénieur, Industrial
Processes
Conditions relating to the issue of this report:
1. No alteration to this report by third parties is permitted
2. Where this report is reproduced, it shall only be reproduced in full.
3. Reports remain the property of Environmental & Efficiency Consultants
(Ireland) Limited until paid for in full.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 3 of 36 Document No.: 1216-01 v3.00
Table of Contents
1 Introduction ....................................................................................................... 5 1.1 Company Details........................................................................................ 5
2 Environmental Policy ........................................................................................ 6 3 Company Description ........................................................................................ 8
3.1 Previous site history................................................................................... 8 3.2 Company background ................................................................................ 8 3.3 Description of equipment ........................................................................... 8 3.4 Manufacturing process ............................................................................... 8 3.5 Company Organization chart...................................................................... 9
4 Emissions Summary .........................................................................................10 4.1 Emissions to sewer summary ....................................................................10 4.2 Surface water monitoring summary...........................................................10 4.3 Emissions to Atmosphere summary...........................................................11
4.3.1 Results: TOC as C.............................................................................12 4.3.2 Results: Volume Flow Rate ...............................................................13
4.4 Fugitive Emissions to Atmosphere summary.............................................14 4.5 Environmental Noise summary .................................................................15
5 Waste Management Report ...............................................................................16 6 Agency Monitoring and enforcement................................................................18 7 Resource Consumption .....................................................................................19
7.1 Energy ......................................................................................................19 7.2 Water Usage .............................................................................................19 7.3 Raw materials ...........................................................................................20
8 Bund integrity report.........................................................................................21 9 Environmental Incidences & Complaints ..........................................................22
9.1 Environmental Incidences .........................................................................22 9.2 Environmental Complaints Summary........................................................22
10 Management of the Activity..........................................................................22 10.1 Environmental Management Programme (report and proposal) .................22
11 Pollution Emission Register ..........................................................................26 12 Pollution Register and Transfer (PRTR)........................................................27
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 4 of 36 Document No.: 1216-01 v3.00
List of Tables
Table 1 Company details ........................................................................................... 5 Table 2: Results of Surface Water Analysis 2009 .....................................................10 Table 3 TOC as C results for A2-01 .........................................................................12 Table 4 TOC as C results for A2-02 .........................................................................12 Table 5 Volume flow rate for A2-01.........................................................................13 Table 6 Volume flow rate for A2-02.........................................................................13 Table 7: Details of Waste Disposal 2009 ..................................................................16 Table 8: Details of EPA Correspondence and Enforcement 2009..............................18 Table 9: Details of energy consumption 2009 ...........................................................19 Table 10: Details of water usage 2009 ......................................................................19 Table 11 Hazardous raw materials used in 2009 .......................................................20 Table 12 Summary of bund integrity test results .......................................................21 Table 13: Schedule of Environmental Objectives and Targets...................................23 Table 14 Pollution Emissions Register (all quantities in kilograms)..........................26
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 5 of 36 Document No.: 1216-01 v3.00
1 Introduction
1.1 Company Details
Table 1 Company details
Company Flight Group Ltd
Trading Name Flight Flexible
Address 65 Heather Road, Sandyford Industrial
Estate, Dublin
IPC Registration Number 674
IPPC Class of Activity (Schedule 1 of the
EPA Act 1992 as amended by PoE Act
2003)
12.2.2 The manufacturing or use of coating
materials in processes with a capacity to
make or use at least 10 tonnes per year of
organic solvent not included in paragraph
12.2.1
NACE Code*1
DE – manufacture of pulp, paper and paper
products, publishing and printing
Number of full-time staff equivalents 25
Contact Name Sydney Oosthuizen
Position QSE Manager
Telephone (01) 295 5133
Fax (0)1 295 7673
Email Email: [email protected]
*1 As according to NACE codes referenced from Commission Regulation EC No 29/2002 amending
Council Regulation (EEC) No 3037/90 on the statistical classification of economic activates in the
European Community
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 6 of 36 Document No.: 1216-01 v3.00
2 Environmental Policy
Flight Group Ltd (Sleever International) regards environmental protection as an
essential requirement of its operations. The company will undertake to conduct its
business in a manner which protects the environment in which it operates. The
company’s objective is to balance the need to achieve its business aims with the need
to protect the environment.
To achieve this goal the company will adhere to the following guiding principles:
Guiding Principles:
� Ensure continued compliance with all Irish and EU legislative environmental
requirements.
� Continually assess activities with the specific goal of preventing pollution,
minimising and reducing the environmental impact.
� Ensure that Environmental Policy objectives and targets have equality with
other business interests.
� Maintain a programme of Environmental awareness training (train staff to act in
an environmentally responsible manner).
� Communicate its Environmental Policy to employees, suppliers, visitors and
interested parties.
� Maintain an open information policy towards all parties affected, interested and
involved in its activities and to issues, which concern the environment.
� Ensure that its employees have the knowledge, resources and authority to
implement these guiding principles.
In particular, Flight Group Ltd (Sleever International) will:
� Establish and comply with an Environmental Management System.
� Meet environmental objectives and targets set in the Environmental
Management Programme and review within each management review meeting
for their continuing suitability and effectiveness in achieving the aims of the
Environmental Policy.
� Ensure all hazardous materials are stored in an environmentally safe manner
� Reduce wherever practicable the level of effluent, air and noise emissions
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 7 of 36 Document No.: 1216-01 v3.00
� Ensure good Waste Management practices e.g. reuse rather than dispose
whenever possible, promote recycling and used licensed waste contractors
The objectives of this policy are achieved through the implementation of the
Environmental Management System documented in the Environmental Manual,
Environmental Procedures and Environmental Forms. This Environmental Policy
covers all activities at Flight Group Ltd (Sleever International) site, and has the full
commitment and support of Management. Commitment to this policy involves almost
every aspect of the company’s business and its employees and resources shall be
made available to implement these guiding principles.
Signed: _____________________ Date: __________________
(Company Director)
Signed: _____________________ Date: __________________
(Environmental Manager)
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 8 of 36 Document No.: 1216-01 v3.00
3 Company Description
3.1 Previous site history
Flight Group Ltd (Sleever International) was set up in 1991. No environmental issues
are associated with the previous nature of the site.
3.2 Company background
Flight Group Ltd (Sleever International) primarily manufactures gravure printed
shrink sleeves for various companies but has also facilities to produce flexo and plain
printed sleeves as well as tamper evident sleeves. The company primarily provides
product to Irish and UK markets.
The company was awarded ISO 9002 in 1992 and re-assessed and accredited for ISO
9001:2008 in 2009. The company has only required and received an IPC licence since
May 2004. The company employs approximately 25 staff and during times of high
demand operates on a two-shift basis Monday to Friday.
3.3 Description of equipment
The main energy consuming equipment is:
� Flexographic Printing Press
� Rotogravure Printing Press
3.4 Manufacturing process
Sleeves are mainly printed on PET, OPS or PVC and range in micronage from 40 mic
to 75 mic
Gravure printed sleeves are produced on the 8 colour Rotogravure printer while flexo
printed sleeves are produced on the 6 colour press and are generally supplied to
contract packers who specialize in their application onto the product. Lead times on
flexo sleeves are quicker than gravure because of the use of plates rather than
engraved cylinders. Tear tape may be added to produce tamper evident packaging.
Flight Flexible currently use water based inks and solvent based inks with the
objective of eliminating solvent based inks.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 9 of 36 Document No.: 1216-01 v3.00
3.5 Company Organization chart
Chairman/Owner
Eric Fresnel (Sleever)
Plant Manager
Jason Dingle
QSE Manager:
Sydney Oosthuizen
Purchasing and Production co-ordinator
Brian Byrne
Sales and Customer service:
Kevin Cleary
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 10 of 36 Document No.: 1216-01 v3.00
4 Emissions Summary
4.1 Emissions to sewer summary
Condition 6.2 and Schedule 2ii of the company's IPC licence dictate that the company
must conduct quarterly monitoring of emissions to SE-01. The company ceased
discharging any trade emissions to sewer in June 2003 on the advice of their suppliers
who informed them that the inks that were being used are not suitable for discharge to
sewer. It was therefore not necessary to collect any sewer samples during 2008. A
report was sent to the EPA out-lining this decision (Environmental Efficiency
Document No: 593-01 and 593-02)
4.2 Surface water monitoring summary
According to Condition 9.1.2 and Schedule 4i, surface water monitoring is to occur
bimonthly and the results are to be submitted to the EPA bi-annually. The IPC licence
does not define any limits for the parameters that are monitored at Flight Group Ltd
(Sleever International) Following high BOD and COD results in September 2008, the
Agency requested that warning levels be defined. Above these thresholds, an
investigation will be carried out to investigate the origin of the high results. The table
below shows the analysis results of all surface water samples collected by
Environmental Efficiency Consultants Ltd in 2009 along with the warning levels.
Table 2: Results of Surface Water Analysis 2009
Sample
Number 593/44 593/45 593/46 593/47 593/48 593/49 Proposed
Period Jan/Feb Mar/Apr May/June Jul/Aug Sep/Oct Nov/Dec Warning
Levels
BOD mg/L 17.0 26 24 21 3 26 20
COD mg/L 31.8 <15 115 <15 16.7 19.6 100
Conductivity µS/cm 352.0 136.8 298.0 235 271 298 N/A
pH pH Units
7.80 7.48 7.39 8.49 7.94 7.06 N/A
Temperature ˚C _ 11.3 16.6 16.4 13.8 7.4 N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 11 of 36 Document No.: 1216-01 v3.00
4.3 Emissions to Atmosphere summary
Condition 5.6 and Schedule 1ii of Flight Group Ltd (Sleever International)’s IPC
licence requires air emission monitoring of TOC as C and volume flow rates be
carried out at the Rotogravure Printer (A2-01) on a quarterly basis and the
Flexographic Printer (A2-02) on an annual basis.
With the water-based ink programme, the company was able to reduce their solvent
consumption under 15 tonnes per year. A Technical Amendment was issued on the 20
January 2010 to reflect this and the limits for the TOC as C were changed as follows:
Please note that on the 20 January 2010, the limits for TOC as C were changed as to:
Emission Point New Limit
A2-01 When annual solvent consumption <15tonnes : 630mg/Nm3
When annual solvent consumption ≥15tonnes: 100mg/Nm3
A2-02 When annual solvent consumption <15tonnes : 150mg/Nm3
When annual solvent consumption ≥15tonnes: 100mg/Nm3
A summary of the air monitoring results is given in the following tables.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 12 of 36 Document No.: 1216-01 v3.00
4.3.1 Results: TOC as C
Table 3 TOC as C results for A2-01
Period Q1 2009 Q1 2009 Q2 2009 Annual
2009 Units
Date 19/03/2009 19/03/2009 23/06/2009 01/02/2010 N/A
TOC as C (mg/Nm3) 166.5 151.8 114.9 85.5 mg/Nm3
Compliance with ELV
(100mg/Nm3)
Non-
Compliant
Non-
Compliant
Non-
Compliant Compliant N/A
Table 4 TOC as C results for A2-02
Period 2009 EPA
Monitoring 2009 Units
Date 19/03/2009 01/10/2008 01/02/2010 N/A
TOC as C (mg/Nm3) 89.9 37.15 37.3 mg/Nm3
Compliance with ELV
(100mg/Nm3)
Compliant Compliant Compliant N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 13 of 36 Document No.: 1216-01 v3.00
4.3.2 Results: Volume Flow Rate
Table 5 Volume flow rate for A2-01
Period Q1 2009 Q1 2009 Q2 2009 Annual
2009 Units
Date 19/03/2009 19/03/2009 23/06/2009 01/02/2010 N/A
Volume Flow (Nm3/hr) 4,915 6,405 6,399 6,633 mg/Nm3
Compliance with ELV
(11,000 Nm3/hr)
Compliant Compliant Compliant Compliant N/A
Table 6 Volume flow rate for A2-02
Period 2009 EPA
Monitoring
Annual
2009 Units
Date 19/03/2009 01/10/2008 01/02/2010 N/A
Volume Flow rate 691 Not reported 1,780 Nm3/hr
Compliance with ELV
(1,800Nm3/hr)
Compliant Compliant Compliant N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 14 of 36 Document No.: 1216-01 v3.00
4.4 Fugitive Emissions to Atmosphere summary
Condition 5.10 of the IPC licence states that:
“fugitive emission (including venting from the ink store) to air of volatile organic
compounds shall be reduced to meet the following limit subject to Condition 3 of this
licence: 25% of the total solvent input, where solvent consumption is 15-25 tonnes per
year or 20% of solvent input where solvent consumption is greater than 25 tonnes per
year”.
The annual solvent input for the year 2009 was calculated at 5,773.7kg (TOC as C)
and thus the limit for the fugitive emission percentage is 25% of the solvent input.
The fugitive emissions represent 10.5% and thus the company is in compliance.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 15 of 36 Document No.: 1216-01 v3.00
4.5 Environmental Noise summary
On the 23/02/2009, the company sent a letter to the EPA to request that noise
monitoring be removed from their regular monitoring. The reason for this request is
that the company is located in an industrial estate and also very close to the M50 (less
than 150m) and that therefore the readings for the noise surveys do not reflect the
noise emissions generated by the company alone. The company is still awaiting the
response from the Agency on this matter.
It should be noted that the company has never received any complaint with regards to
the noise emissions from the site.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 16 of 36 Document No.: 1216-01 v3.00
5 Waste Management Report
Schedule 3i and 3ii of Flight Group's IPC licence details the disposal/recovery methods for specified wastes. All wastes are managed so as to
minimise their impact on the environment and appropriately licensed contractors are used in all cases.
Table 7: Details of Waste Disposal 2009
European
Waste
Code
Quantity
T/Yr Description of Waste
Name and
Licence / Permit
No. of Recoverer
/ Disposer /
Broker
Address of Recoverer /
Disposer / Broker
Name and Address of
Final Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
Licence / Permit
No. of Final
Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
08 03 14 6.8 Waste Sludge Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
15 02 02 0.043 Used cleaning rags Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
08 03 12 0.036 Waste solvent (rationalisation) Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
20 03 01 1.620 General and canteen waste
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 17 of 36 Document No.: 1216-01 v3.00
European
Waste
Code
Quantity
T/Yr Description of Waste
Name and
Licence / Permit
No. of Recoverer
/ Disposer /
Broker
Address of Recoverer /
Disposer / Broker
Name and Address of
Final Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
Licence / Permit
No. of Final
Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
15 01 01 4.16 Paper and cardboard packaging waste
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
15 01 02 49.920 Reels of backing/ Offcuts (PVC/PET) and Plastic wrapping
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
15 01 10 1.128
Empty 200L steel drums (solvent-based inks) and empty 20kg steel pails (solvent-based inks)
Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Environmental Efficiency Page 18 of 36 Document No.: 1216-01 v3.00
6 Agency Monitoring and enforcement
The following table details documentation regarding EPA monitoring and
enforcement in 2009.
Table 8: Details of EPA Correspondence and Enforcement 2009
Date Content
23/02/2009 Letter to EPA re. Noise monitoring
Early July 2009 Meeting with the EPA to discuss the
company’s emissions status
15/07/2009
Letter to EPA requesting a licence technical
amendment as the annual solvent
consumption is now below 15t.
31/07/2009 EPA Letter re. Enforcement Category
19/10/2009 Site Inspection Report
09/11/2009 Response letter to EPA’s Site Inspection
Report
Environmental Efficiency Page 19 of 36 Document No.: 1216-01 v3.00
7 Resource Consumption
7.1 Energy
Table 9: Details of energy consumption 2009
Source Energy Consumption
Electricity 304,571 kWh
Gas 188,294 kWh
7.2 Water Usage
The following table details water use by the company.
Table 10: Details of water usage 2009
Water Source Volume
On-site groundwater N/A
On-site surface water N/A
Municipal Supply 548,000L
N/A - Not applicable, not used by the company
Environmental Efficiency Page 20 of 36 Document No.: 1216-01 v3.00
7.3 Raw materials
The total quantities of solvents and solvent-based inks consumed during 2009 are
summarised in the table below. The detailed figures for each product are provided in
Appendix 2 and Appendix 3.
Table 11 Hazardous raw materials used in 2009
Quantity
consumed
in 2008,
kg
Quantity
consumed
in 2009,
kg
Equivalent
TOC as C
2009
Totals Inks 22,082 5,607 1,557.5
Totals Solvents 15,138 7,835 4,216.2
Total 37,220 13,442 5,773.7
Environmental Efficiency Page 21 of 36 Document No.: 1216-01 v3.00
8 Bund integrity report
The integrity test of all the bunds was carried out on the 07/09/2007.
Table 12 Summary of bund integrity test results
Bund No. Pallet Type/Application Location Pass/Fail
44229 Bunded pallet – Solvent storage Stores Pass
47137 Bunded pallet – Solvent storage Stores Pass
53439 Bunded pallet – Solvent storage Stores Pass
44228 Bunded pallet – Solvent storage Stores Pass
52159 Bunded pallet – Ink storage Press Room Pass
48163 Bunded pallet – Ink storage Press Room Pass
48875 Bunded pallet – Ink storage Press Room Pass
48164 Bunded pallet – Temp storage Press Room Pass
48193 Bunded pallet – Solvent storage Chesnut Pass
53962 Bunded pallet – THF & Sludge Press Room Pass
5632 Bunded pallet – Ink storage Ink Room Pass
5633 Bunded pallet – Ink storage Ink Room Pass
4946 Barrel station (4 x solvent barrel storage) Press Room Pass
66051 Bunded pallet – Empty barrel storage Container Pass
01 Press-side spill tray – Inks & Solvents Aquaflex Pass
02 Press-side spill tray – Inks & Solvents Aquaflex Pass
03 Press-side spill tray – Inks & Solvents Aquaflex Pass
04 Press-side spill tray – Inks & Solvents Chesnut Pass
05 Press-side spill tray – Inks & Solvents Chesnut Pass
06 Press-side spill tray – Inks & Solvents Chesnut Pass
07 Press-side spill tray – Inks & Solvents Chesnut Pass
08 Ink trolley spill trays Press Room Pass
09 Ink trolley spill trays Press Room Pass
10 Toner trolley spill trays Press Room Pass
11 Shelving spill trays (under grated shelves) Ink Room Pass
12 Shelving spill trays (under grated shelves) Ink Room Pass
13 Solvent bath spill tray Ink Room Pass
14 Catchment tray Chesnut Pass
As can be seen in the previous table, all the bunds passed the integrity test.
Environmental Efficiency Page 22 of 36 Document No.: 1216-01 v3.00
9 Environmental Incidences & Complaints
9.1 Environmental Incidences
There were no environmental incidences on site during the course of 2009.
9.2 Environmental Complaints Summary
There were no environmental complaints associated with the site during the course of
2009.
10 Management of the Activity
10.1 Environmental Management Programme (report and proposal)
The table below summarises the objectives (set out in the AER 2005) achieved to date
and sets out a Schedule of Environmental Objectives and Targets for 2010.
Environmental Efficiency Page 23 of 36 Document No.: 1216-01 v3.00
Table 13: Schedule of Environmental Objectives and Targets
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT1 13-Dec-04 Ensure that spill incidents are minimised
and managed N/A Ongoing
This is an ongoing objective. Flight is constantly
striving to minimize spills. Our Environmental
procedures ensure minimal spills but we are always
improving on them. No spills were reported for 2009.
OT2 13-Dec-04
Implement a rationalisation programme to
minimise the storage of redundant solvents
on site
N/A Ongoing
Numerous ink rationalisations have taken place during
the year 2008. Our stock of solvent based inks have
begun to diminish during this period as we have
developed our water-based inks program to a stage
where most orders are produced on water based inks.
With the successful transfer from solvent inks to water
based inks a substantial amount of solvent based inks
were disposed of through the company’s hazardous
waste contractor (GSL). This initiative will be ongoing
in 2010.
Environmental Efficiency Page 24 of 36 Document No.: 1216-01 v3.00
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT4 13-Dec-04 Ensure that all hazardous materials are
managed and stored correctly N/A Ongoing
Flights procedures dictate that all solvents and inks are
managed and stored in the correct manner. These
procedures are ISO14001 based and are policed by day-
to-day inspections and a monthly site inspection, which
is discussed at monthly environmental meetings. As a
result of the water based programme less ink is stored
on site. This has resulted in 3 bunded pallets being made
obsolete and placed into storage. This initiative will
continue on in 2010.
OT5 13-Dec-04 Ensure the protection of surface water N/A Ongoing
This is an ongoing objective. Flight monitor surface
water every two months and submit a report bi-
annually. No unusual activity regarding surface water
monitoring for 2009. Monitoring to continue in 2010.
OT7 13-Dec-04 Minimise the generation of fugitive
emissions N/A Ongoing
Through investigation we have realised new methods of
reducing fugitive emissions and the fugitive emission
level for 2009 was found to be 6.9%, which is a further
reduction.
Environmental Efficiency Page 25 of 36 Document No.: 1216-01 v3.00
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT8 13-Dec-04 Ensure appropriate management of waste
generated by company N/A Ongoing
This is an ongoing objective. Our waste is segregated
and disposed of according to our environmental
procedures, which dictate that all wastes are stored and
disposed of in the correct manner and the correct
documentation is present. In late 2009 the company
employed the services of Greyhound waste contractors.
OT12 21-Aug-06 Investigate compliance with 2007 Toc as C
emissions limits N/A Closed
During 2008 Flight conducted quarterly monitoring.
Through this monitoring and in conjunction with their
water based inks program, the company was able to
analyse their processes and how best to achieve
compliant emissions results. Both monitoring and water
based program implementation to continue in 2009 to
comply with our IPC licence. As the annual solvent
consumption was below 15 tonne in 2009 and
application was made and approved by the EPA to
increase the ELVs, the company is now compliant.
Environmental Efficiency Page 26 of 36 Document No.: 1216-01 v3.00
11 Pollution Emission Register
Table 14 Pollution Emissions Register (all quantities in kilograms)
POLLUTANTS SUMMARY
Outputs
Pollutant Name CAS
Number Input
Note 1 Gross Usage Air MOM
Liquid Effluent
MOM Waste MOM Product MOM Recovered MOM Treated MOM Unaccounted
2-methoxy-1-methylethyl acetate 31.36 31.36 16.2 M, E 0.0 O 11.6 E 0.0 M, E 0.0 E 0.0 O 3.6
4-Methyl-pentane-2-one 41.40 41.40 21.4 M, E 0.0 O 15.3 E 0.0 M, E 0.0 E 0.0 O 4.7
Ethanol 2,115.98 2,115.98 1,094.7 M, E 0.0 O 780.6 E 0.0 M, E 0.0 E 0.0 O 240.7
Ethyl Acetate 1,221.01 1,221.01 631.7 M, E 0.0 O 450.4 E 0.0 M, E 0.0 E 0.0 O 138.9
Methyl Ethyl Ketone 107.33 107.33 55.5 M, E 0.0 O 39.6 E 0.0 M, E 0.0 E 0.0 O 12.2
N-Propyl Acetate 1,011.27 1,011.27 523.2 M, E 0.0 O 373.1 E 0.0 M, E 0.0 E 0.0 O 115.0
Propan-1-ol 86.33 86.33 44.7 M, E 0.0 O 31.8 E 0.0 M, E 0.0 E 0.0 O 9.8
Propan-2-ol 106.69 106.69 55.2 M, E 0.0 O 39.4 E 0.0 M, E 0.0 E 0.0 O 12.1
Ethoxypropanol 228.46 228.46 118.2 M, E 0.0 O 84.3 E 0.0 M, E 0.0 E 0.0 O 26.0
N-Propanol 877.95 877.95 454.2 M, E 0.0 O 323.9 E 0.0 M, E 0.0 E 0.0 O 99.9
Tetrahydrofuran 0.00 0.00 0.0 M, E 0.0 O 0.0 E 0.0 M, E 0.0 E 0.0 O 0.0
TOTAL (kg) 5,827.8 5,827.8 3,015.0 0.0 2,149.9 0.0 0.0 0.0 662.9
MOM = Method of Measurement, Codes taken from the EPA Guidance Note for AER: M = Direct Measurement B = Material Balance E = Engineering Estimates O = Other
Note 1: The purchased quantities were used for the PRTR as the stocks for the individual substances are not known.
Environmental Efficiency Page 27 of 36 Document No.: 1216-01 v3.00
12 Pollution Register and Transfer (PRTR)
| PRTR# : P0674 | Facility Name : Sleever International LTD | Filename :
P0674_2009.xls | Return Year : 2009 |
Version 1.1.10
REFERENCE YEAR 2009
1. FACILITY IDENTIFICATION
Parent Company Name Sleever International LTD
Facility Name Sleever International LTD
PRTR Identification Number P0674
Licence Number P0674-01
Waste or IPPC Classes of Activity
No. class_name
12.2
The manufacture or use of coating materials in processes with a
capacity to make or use at least 10 tonnes per year of organic
solvents, and powder coating manufacture with a capacity to produce
at least 50 tonnes per year.
Address 1 65 Heather Road
Address 2 Sandyford Industrial Estate
Address 3 Dublin 18
Address 4
Country Ireland
Coordinates of Location -6.21314 53.272
River Basin District IEEA
NACE Code 2030
Main Economic Activity
Manufacture of paints, varnishes and similar coatings, printing ink
and mastics
AER Returns Contact Name Sydney Oosthuizen
AER Returns Contact Email Address [email protected]
AER Returns Contact Position Quality/Environment Manager
AER Returns Contact Telephone Number 01-2957588
AER Returns Contact Mobile Phone Number
AER Returns Contact Fax Number 01-2957674
Production Volume 0.0
Production Volume Units
Number of Installations 0
Number of Operating Hours in Year 0
Number of Employees 0
User Feedback/Comments
Web Address
2. PRTR CLASS ACTIVITIES
Activity Number Activity Name
50.1 General
3. SOLVENTS REGULATIONS (S.I. No. 543 of 2002)
Is it applicable? Yes
Have you been granted an exemption ? No
If applicable which activity class applies (as per
Schedule 2 of the regulations) ?
Is the reduction scheme compliance route being
used ? No
AER Returns Worksheet
Environmental Efficiency Page 28 of 36 Document No.: 1216-01 v3.00
4.1 RELEASES TO AIR | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 01/04/2010 18:49
8 8 16 16 24 24 6 6 6
SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
07 Non-methane volatile organic compounds (NMVOC) M ISEN13526-2002 FID 3015.0 3623.8 0.0 608.8
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
Additional Data Requested from Landfill operators
Landfill: Sleever International LTDPlease enter summary data on the
quantities of methane flared and / or
utilised
additional_pollutant_no T (Total) kg/Year M/C/E Method Code
Designation or
Description
Facility Total Capacity m3
per hour
Total estimated methane generation (as per
site model) 0.0 N/A
Methane flared 0.0 0.0 (Total Flaring Capacity)
Methane utilised in engine/s 0.0 0.0 (Total Utilising Capacity)
Net methane emission (as reported in Section
A above) 0.0 N/A
POLLUTANT METHOD
Method Used
For the purposes of the National Inventory on Greenhouse Gases, landfill operators are requested to provide summary data on landfill gas (Methane)
flared or utilised on their facilities to accompany the figures for total methane generated. Operators should only report their Net methane (CH4)
emission to the environment under T(total) KG/yr for Section A: Sector specific PRTR pollutants above. Please complete the table below:
Method Used
Method Used
RELEASES TO AIR
POLLUTANT METHOD
Method Used
POLLUTANT
RELEASES TO AIR
RELEASES TO AIR
METHOD
Environmental Efficiency Page 29 of 36 Document No.: 1216-01 v3.00
4.2 RELEASES TO WATERS | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
8 8 16 16 24 24 6 6 6
SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this onl
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
RELEASES TO WATERS
Method Used
RELEASES TO WATERS
RELEASES TO WATERS
Method Used
POLLUTANT
Method Used
POLLUTANT
POLLUTANT
4.3 RELEASES TO WASTEWATER OR SEWER | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 |30/03/2010 13:27
8 8 16 16 6 6 6 6
SECTION A : PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER
OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER
Method Used
Method Used
POLLUTANT METHOD
POLLUTANT METHOD
Environmental Efficiency Page 30 of 36 Document No.: 1216-01 v3.00
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8 8 16 16 6 6 6 6
SECTION A : PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year
0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year
0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
POLLUTANT METHOD
Method Used
RELEASES TO LAND
RELEASES TO LAND
POLLUTANT METHOD
Method Used
5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
5 11 3
Quantity
(Tonnes per
Year)
Haz Waste : Name and
Licence/Permit No of Next
Destination Facility Non
Haz Waste: Name and
Licence/Permit No of
Recover/Disposer
Haz Waste : Address of Next
Destination Facility
Non Haz Waste: Address of
Recover/Disposer
Name and License / Permit No. and
Address of Final Recoverer /
Disposer (HAZARDOUS WASTE
ONLY)
Actual Address of Final Destination
i.e. Final Recovery / Disposal Site
(HAZARDOUS WASTE ONLY)
Transfer Destination
European Waste
Code Hazardous Quantity T/Year Description of Waste
Waste
Treatment
Operation M/C/E Method Used
Location of
Treatment Name and Licence / Per mit No. of Recoverer / Disposer / Br oker Addr ess of Recoverer / Disposer / Br oker Name and Address of F inal Destination i.e. F inal Recovery / Disposal Site (HAZARDOUS WAST E ONLY) Licence / Permit No. of Final Destination i.e. Final Recover y / Disposal Site ( HAZ ARDOUS WASTE ONLY)
To Other Countries 08 03 14 Yes 6.8 Ink sludge D10 M Weighed Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
To Other Countries 15 02 02 Yes 0.043 Used cleaning rags D10 M Volume Calculation Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
To Other Countries 08 03 12 Yes 0.036 Waste Solvent (Rationalisation) D10 M Weighed Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
Within the Country 20 03 01 No 1.62 General and canteen waste D1 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 01 No 4.16 Paper and cardboard packaging waste R3 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 02 No 49.92
Reels of backing/ Offcuts (PVC/PET) and
Plastic wrapping R5 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 10 Yes 1.128
Empty 200L steel drums (solvent-based
inks) and empty 20kg steel pails (solvent-
based inks) R4 M Weighed Onsite in Ireland
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Method Used
Environmental Efficiency Page 31 of 36 Document No.: 1216-01 v3.00
Appendix 1 Contact details for waste contractors
Company Contact Details
Guardian Silver Lining Unit 61,
Cookstown Industrial Estate,
Belgard Road,
Tallaght,
Dublin 24
01-4587270
OZO Jamestown Road,
Inchicore,
Dublin 8,
Ireland
01 616 0610
Environmental Efficiency Page 32 of 36 Document No.: 1216-01 v3.00
Appendix 2 Details of solvent based inks consumed in 2009
Ink description Qty (kg)
component % kg TOC as C
INK CAP SHRINK WHITE 1360 Ethanol 50 680 354.78
Propan-2-ol 5 68 40.80
P/R FINELAP NT 710 WHITE 920 Ethyl Acetate 37.5 345 188.18
Methyl Ethyl Ketone 17.5 161 107.33
Propan-2-ol 6.25 57.5 34.50
4-Methyl-pentane-2-one 6.25 57.5 41.4
2-methoxy-1-methylethyl acetate 6.25 57.5 31.36
PVC SHRINK 072 BLUE /20KG 20 Ethanol 50 10 5.22
Propan-2-ol 5 1 0.60
PVC SHRINK 872C GOLD /20KG 20 Ethanol 50 10 5.22
Propan-2-ol 5 1 0.60
PVC SHRINK BLACK/20KG 600 Ethanol 50 300 156.52
Propan-2-ol 5 30 18.00
PVC SHRINK GREEN /20KG 30 Ethanol 50 15 7.83
Propan-2-ol 5 1.5 0.90
SOLVENT PRIMER 995 Unknown
STILETTO BLACK TONER /20KG 100 Ethanol 37.5 37.5 19.57
Ethyl Acetate 12.5 12.5 6.82
N-Propyl Acetate 12.5 12.5 7.35
Propan-1-ol 12.5 12.5 7.50
STILETTO BLACKTHORN GOLD 10 Ethanol 37.5 3.75 1.96
Ethyl Acetate 12.5 1.25 0.68
N-Propyl Acetate 12.5 1.25 0.74
Propan-1-ol 12.5 1.25 0.75
STILETTO BLUE TONER 10 Ethanol 37.5 3.75 1.96
Environmental Efficiency Page 33 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
Ethyl Acetate 12.5 1.25 0.68
N-Propyl Acetate 12.5 1.25 0.74
Propan-1-ol 12.5 1.25 0.75
STILETTO CYAN TONER 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO MEDIUM /170-90KG 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO MEDIUM /20KG 220 Ethanol 37.5 82.5 43.04
Ethyl Acetate 12.5 27.5 15.00
N-Propyl Acetate 12.5 27.5 16.18
Propan-1-ol 12.5 27.5 16.50
STILETTO ORANGE TONER /20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO PROCESS BLACK/20KG 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO PROCESS MAGENTA /20KG 100 Ethanol 37.5 37.5 19.57
Ethyl Acetate 12.5 12.5 6.82
N-Propyl Acetate 12.5 12.5 7.35
Propan-1-ol 12.5 12.5 7.50
STILETTO PROCESS YELLOW 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
Environmental Efficiency Page 34 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO RED TONER/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO REFLEX BLUE/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO REFLEX BLUETONER/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO RUBINE RED/20KG 40 Ethanol 37.5 15 7.83
Ethyl Acetate 12.5 5 2.73
N-Propyl Acetate 12.5 5 2.94
Propan-1-ol 12.5 5 3.00
STILLETTO RUBINE RED TON/20KG 60 Ethanol 37.5 22.5 11.74
Ethyl Acetate 12.5 7.5 4.09
N-Propyl Acetate 12.5 7.5 4.41
Propan-1-ol 12.5 7.5 4.50
STILETTO SILVER 15 Ethanol 37.5 5.625 2.93
Ethyl Acetate 12.5 1.875 1.02
N-Propyl Acetate 12.5 1.875 1.10
Propan-1-ol 12.5 1.875 1.13
STILETTO VIOLET /20KG 15 Ethanol 37.5 5.625 2.93
Ethyl Acetate 12.5 1.875 1.02
N-Propyl Acetate 12.5 1.875 1.10
Environmental Efficiency Page 35 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
Propan-1-ol 12.5 1.875 1.13
STILETTO WARM RED/20KG 21 Ethanol 37.5 7.875 4.11
Ethyl Acetate 12.5 2.625 1.43
N-Propyl Acetate 12.5 2.625 1.54
Propan-1-ol 12.5 2.625 1.58
STILETTO WARM RED TONER/20KG 30 Ethanol 37.5 11.25 5.87
Ethyl Acetate 12.5 3.75 2.05
N-Propyl Acetate 12.5 3.75 2.21
Propan-1-ol 12.5 3.75 2.25
STILETTO YELLOW TONER 130 Ethanol 37.5 48.75 25.43
Ethyl Acetate 12.5 16.25 8.86
N-Propyl Acetate 12.5 16.25 9.56
Propan-1-ol 12.5 16.25 9.75
ENERGY WHITE 200 Unknown
Total Purchased 5,296 1,467.87
Stock 01/01/2009 3,012 867.59
Stock 31/12/2009 2,701 778.01
Total Consumption 5,607 1,557.5
average TOC as C proportion 0.28804
Environmental Efficiency Page 36 of 36 Document No.: 1216-01 v3.00
Appendix 3 Details of solvent consumed in 2009
Quantity
purchased (kg) Composition
concentration %
Weight (kg)
Equivalent TOC as C
(kg)
EP 400 Ethoxypropanol 99 396 228.46
MIX 25/m22 1,951 N-Propanol 75 1463.25 877.95
N-propyl acetate 25 487.75 286.915
MIX 03/M16 2,508 Ethyl Acetate 25 627 342
Isopropanol 0.75 18.81 11.29
Ethanol 75 1881 981.39
NPA 1,093 NPA 99.5 1087.535 639.73
EA 1,110 Ethyl Acetate 99.5 1104.45 602.43
NIMROD REDUCER 1,040 Ethanol 70 728 379.84
Ethyl Acetate 1.75 18.2 9.93
Total Purchased 8,102 4,359.91
Taking into account the stocks:
Overall
(kg) TOC as C
(kg)
Total Purchases 8,102 4,359.9
Stock 01/01/2009 3,012 743.2
Stock 31/12/2009 2,701 886.8
Total Consumption 7,835 4,216.2
Tel: 353 1 276 1428 Fax: 353 1 276 1561 Email: [email protected]
www.enviro-consult.com
Registered Office as above. Registered Number 243 412
ANNUAL ENVIRONMENTAL
REPORT
2009
For
Flight Group Ltd. (Sleever International)
IPC Licence No. P0674-01
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 2 of 36 Document No.: 1216-01 v3.00
QF 1. v2 Document Lead Sheet
Document Title AER 2009
Project No. 1216
Document No. 1216-01
Client Flight Group Ltd (Sleever International)
Address 65 Heather Road, Sandyford Industrial Estate, Dublin
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
1.00 Approved 30/03/2010 AR
2.00 Approved 06/04/2010 AR
3.00 Approved 09/04/2010 AR
Where it is a requirement that this report be issued to a regulatory or other authority,
then the client should sign the appropriate place in the above table and, unless
specifically agreed in writing to the contrary, forward copies to the appropriate
authority (e.g. EPA).
EEC Project Manager: Bob Sutcliffe, CEng, MIMechE
EEC Document Author: Agnès Ricoux, Diplôme d’Ingénieur, Industrial
Processes
Conditions relating to the issue of this report:
1. No alteration to this report by third parties is permitted
2. Where this report is reproduced, it shall only be reproduced in full.
3. Reports remain the property of Environmental & Efficiency Consultants
(Ireland) Limited until paid for in full.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 3 of 36 Document No.: 1216-01 v3.00
Table of Contents
1 Introduction ....................................................................................................... 5 1.1 Company Details........................................................................................ 5
2 Environmental Policy ........................................................................................ 6 3 Company Description ........................................................................................ 8
3.1 Previous site history................................................................................... 8 3.2 Company background ................................................................................ 8 3.3 Description of equipment ........................................................................... 8 3.4 Manufacturing process ............................................................................... 8 3.5 Company Organization chart...................................................................... 9
4 Emissions Summary .........................................................................................10 4.1 Emissions to sewer summary ....................................................................10 4.2 Surface water monitoring summary...........................................................10 4.3 Emissions to Atmosphere summary...........................................................11
4.3.1 Results: TOC as C.............................................................................12 4.3.2 Results: Volume Flow Rate ...............................................................13
4.4 Fugitive Emissions to Atmosphere summary.............................................14 4.5 Environmental Noise summary .................................................................15
5 Waste Management Report ...............................................................................16 6 Agency Monitoring and enforcement................................................................18 7 Resource Consumption .....................................................................................19
7.1 Energy ......................................................................................................19 7.2 Water Usage .............................................................................................19 7.3 Raw materials ...........................................................................................20
8 Bund integrity report.........................................................................................21 9 Environmental Incidences & Complaints ..........................................................22
9.1 Environmental Incidences .........................................................................22 9.2 Environmental Complaints Summary........................................................22
10 Management of the Activity..........................................................................22 10.1 Environmental Management Programme (report and proposal) .................22
11 Pollution Emission Register ..........................................................................26 12 Pollution Register and Transfer (PRTR)........................................................27
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 4 of 36 Document No.: 1216-01 v3.00
List of Tables
Table 1 Company details ........................................................................................... 5 Table 2: Results of Surface Water Analysis 2009 .....................................................10 Table 3 TOC as C results for A2-01 .........................................................................12 Table 4 TOC as C results for A2-02 .........................................................................12 Table 5 Volume flow rate for A2-01.........................................................................13 Table 6 Volume flow rate for A2-02.........................................................................13 Table 7: Details of Waste Disposal 2009 ..................................................................16 Table 8: Details of EPA Correspondence and Enforcement 2009..............................18 Table 9: Details of energy consumption 2009 ...........................................................19 Table 10: Details of water usage 2009 ......................................................................19 Table 11 Hazardous raw materials used in 2009 .......................................................20 Table 12 Summary of bund integrity test results .......................................................21 Table 13: Schedule of Environmental Objectives and Targets...................................23 Table 14 Pollution Emissions Register (all quantities in kilograms)..........................26
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 5 of 36 Document No.: 1216-01 v3.00
1 Introduction
1.1 Company Details
Table 1 Company details
Company Flight Group Ltd
Trading Name Flight Flexible
Address 65 Heather Road, Sandyford Industrial
Estate, Dublin
IPC Registration Number 674
IPPC Class of Activity (Schedule 1 of the
EPA Act 1992 as amended by PoE Act
2003)
12.2.2 The manufacturing or use of coating
materials in processes with a capacity to
make or use at least 10 tonnes per year of
organic solvent not included in paragraph
12.2.1
NACE Code*1
DE – manufacture of pulp, paper and paper
products, publishing and printing
Number of full-time staff equivalents 25
Contact Name Sydney Oosthuizen
Position QSE Manager
Telephone (01) 295 5133
Fax (0)1 295 7673
Email Email: [email protected]
*1 As according to NACE codes referenced from Commission Regulation EC No 29/2002 amending
Council Regulation (EEC) No 3037/90 on the statistical classification of economic activates in the
European Community
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 6 of 36 Document No.: 1216-01 v3.00
2 Environmental Policy
Flight Group Ltd (Sleever International) regards environmental protection as an
essential requirement of its operations. The company will undertake to conduct its
business in a manner which protects the environment in which it operates. The
company’s objective is to balance the need to achieve its business aims with the need
to protect the environment.
To achieve this goal the company will adhere to the following guiding principles:
Guiding Principles:
� Ensure continued compliance with all Irish and EU legislative environmental
requirements.
� Continually assess activities with the specific goal of preventing pollution,
minimising and reducing the environmental impact.
� Ensure that Environmental Policy objectives and targets have equality with
other business interests.
� Maintain a programme of Environmental awareness training (train staff to act in
an environmentally responsible manner).
� Communicate its Environmental Policy to employees, suppliers, visitors and
interested parties.
� Maintain an open information policy towards all parties affected, interested and
involved in its activities and to issues, which concern the environment.
� Ensure that its employees have the knowledge, resources and authority to
implement these guiding principles.
In particular, Flight Group Ltd (Sleever International) will:
� Establish and comply with an Environmental Management System.
� Meet environmental objectives and targets set in the Environmental
Management Programme and review within each management review meeting
for their continuing suitability and effectiveness in achieving the aims of the
Environmental Policy.
� Ensure all hazardous materials are stored in an environmentally safe manner
� Reduce wherever practicable the level of effluent, air and noise emissions
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 7 of 36 Document No.: 1216-01 v3.00
� Ensure good Waste Management practices e.g. reuse rather than dispose
whenever possible, promote recycling and used licensed waste contractors
The objectives of this policy are achieved through the implementation of the
Environmental Management System documented in the Environmental Manual,
Environmental Procedures and Environmental Forms. This Environmental Policy
covers all activities at Flight Group Ltd (Sleever International) site, and has the full
commitment and support of Management. Commitment to this policy involves almost
every aspect of the company’s business and its employees and resources shall be
made available to implement these guiding principles.
Signed: _____________________ Date: __________________
(Company Director)
Signed: _____________________ Date: __________________
(Environmental Manager)
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 8 of 36 Document No.: 1216-01 v3.00
3 Company Description
3.1 Previous site history
Flight Group Ltd (Sleever International) was set up in 1991. No environmental issues
are associated with the previous nature of the site.
3.2 Company background
Flight Group Ltd (Sleever International) primarily manufactures gravure printed
shrink sleeves for various companies but has also facilities to produce flexo and plain
printed sleeves as well as tamper evident sleeves. The company primarily provides
product to Irish and UK markets.
The company was awarded ISO 9002 in 1992 and re-assessed and accredited for ISO
9001:2008 in 2009. The company has only required and received an IPC licence since
May 2004. The company employs approximately 25 staff and during times of high
demand operates on a two-shift basis Monday to Friday.
3.3 Description of equipment
The main energy consuming equipment is:
� Flexographic Printing Press
� Rotogravure Printing Press
3.4 Manufacturing process
Sleeves are mainly printed on PET, OPS or PVC and range in micronage from 40 mic
to 75 mic
Gravure printed sleeves are produced on the 8 colour Rotogravure printer while flexo
printed sleeves are produced on the 6 colour press and are generally supplied to
contract packers who specialize in their application onto the product. Lead times on
flexo sleeves are quicker than gravure because of the use of plates rather than
engraved cylinders. Tear tape may be added to produce tamper evident packaging.
Flight Flexible currently use water based inks and solvent based inks with the
objective of eliminating solvent based inks.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 9 of 36 Document No.: 1216-01 v3.00
3.5 Company Organization chart
Chairman/Owner
Eric Fresnel (Sleever)
Plant Manager
Jason Dingle
QSE Manager:
Sydney Oosthuizen
Purchasing and Production co-ordinator
Brian Byrne
Sales and Customer service:
Kevin Cleary
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 10 of 36 Document No.: 1216-01 v3.00
4 Emissions Summary
4.1 Emissions to sewer summary
Condition 6.2 and Schedule 2ii of the company's IPC licence dictate that the company
must conduct quarterly monitoring of emissions to SE-01. The company ceased
discharging any trade emissions to sewer in June 2003 on the advice of their suppliers
who informed them that the inks that were being used are not suitable for discharge to
sewer. It was therefore not necessary to collect any sewer samples during 2008. A
report was sent to the EPA out-lining this decision (Environmental Efficiency
Document No: 593-01 and 593-02)
4.2 Surface water monitoring summary
According to Condition 9.1.2 and Schedule 4i, surface water monitoring is to occur
bimonthly and the results are to be submitted to the EPA bi-annually. The IPC licence
does not define any limits for the parameters that are monitored at Flight Group Ltd
(Sleever International) Following high BOD and COD results in September 2008, the
Agency requested that warning levels be defined. Above these thresholds, an
investigation will be carried out to investigate the origin of the high results. The table
below shows the analysis results of all surface water samples collected by
Environmental Efficiency Consultants Ltd in 2009 along with the warning levels.
Table 2: Results of Surface Water Analysis 2009
Sample
Number 593/44 593/45 593/46 593/47 593/48 593/49 Proposed
Period Jan/Feb Mar/Apr May/June Jul/Aug Sep/Oct Nov/Dec Warning
Levels
BOD mg/L 17.0 26 24 21 3 26 20
COD mg/L 31.8 <15 115 <15 16.7 19.6 100
Conductivity µS/cm 352.0 136.8 298.0 235 271 298 N/A
pH pH Units
7.80 7.48 7.39 8.49 7.94 7.06 N/A
Temperature ˚C _ 11.3 16.6 16.4 13.8 7.4 N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 11 of 36 Document No.: 1216-01 v3.00
4.3 Emissions to Atmosphere summary
Condition 5.6 and Schedule 1ii of Flight Group Ltd (Sleever International)’s IPC
licence requires air emission monitoring of TOC as C and volume flow rates be
carried out at the Rotogravure Printer (A2-01) on a quarterly basis and the
Flexographic Printer (A2-02) on an annual basis.
With the water-based ink programme, the company was able to reduce their solvent
consumption under 15 tonnes per year. A Technical Amendment was issued on the 20
January 2010 to reflect this and the limits for the TOC as C were changed as follows:
Please note that on the 20 January 2010, the limits for TOC as C were changed as to:
Emission Point New Limit
A2-01 When annual solvent consumption <15tonnes : 630mg/Nm3
When annual solvent consumption ≥15tonnes: 100mg/Nm3
A2-02 When annual solvent consumption <15tonnes : 150mg/Nm3
When annual solvent consumption ≥15tonnes: 100mg/Nm3
A summary of the air monitoring results is given in the following tables.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 12 of 36 Document No.: 1216-01 v3.00
4.3.1 Results: TOC as C
Table 3 TOC as C results for A2-01
Period Q1 2009 Q1 2009 Q2 2009 Annual
2009 Units
Date 19/03/2009 19/03/2009 23/06/2009 01/02/2010 N/A
TOC as C (mg/Nm3) 166.5 151.8 114.9 85.5 mg/Nm3
Compliance with ELV
(100mg/Nm3)
Non-
Compliant
Non-
Compliant
Non-
Compliant Compliant N/A
Table 4 TOC as C results for A2-02
Period 2009 EPA
Monitoring 2009 Units
Date 19/03/2009 01/10/2008 01/02/2010 N/A
TOC as C (mg/Nm3) 89.9 37.15 37.3 mg/Nm3
Compliance with ELV
(100mg/Nm3)
Compliant Compliant Compliant N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 13 of 36 Document No.: 1216-01 v3.00
4.3.2 Results: Volume Flow Rate
Table 5 Volume flow rate for A2-01
Period Q1 2009 Q1 2009 Q2 2009 Annual
2009 Units
Date 19/03/2009 19/03/2009 23/06/2009 01/02/2010 N/A
Volume Flow (Nm3/hr) 4,915 6,405 6,399 6,633 mg/Nm3
Compliance with ELV
(11,000 Nm3/hr)
Compliant Compliant Compliant Compliant N/A
Table 6 Volume flow rate for A2-02
Period 2009 EPA
Monitoring
Annual
2009 Units
Date 19/03/2009 01/10/2008 01/02/2010 N/A
Volume Flow rate 691 Not reported 1,780 Nm3/hr
Compliance with ELV
(1,800Nm3/hr)
Compliant Compliant Compliant N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 14 of 36 Document No.: 1216-01 v3.00
4.4 Fugitive Emissions to Atmosphere summary
Condition 5.10 of the IPC licence states that:
“fugitive emission (including venting from the ink store) to air of volatile organic
compounds shall be reduced to meet the following limit subject to Condition 3 of this
licence: 25% of the total solvent input, where solvent consumption is 15-25 tonnes per
year or 20% of solvent input where solvent consumption is greater than 25 tonnes per
year”.
The annual solvent input for the year 2009 was calculated at 5,773.7kg (TOC as C)
and thus the limit for the fugitive emission percentage is 25% of the solvent input.
The fugitive emissions represent 10.5% and thus the company is in compliance.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 15 of 36 Document No.: 1216-01 v3.00
4.5 Environmental Noise summary
On the 23/02/2009, the company sent a letter to the EPA to request that noise
monitoring be removed from their regular monitoring. The reason for this request is
that the company is located in an industrial estate and also very close to the M50 (less
than 150m) and that therefore the readings for the noise surveys do not reflect the
noise emissions generated by the company alone. The company is still awaiting the
response from the Agency on this matter.
It should be noted that the company has never received any complaint with regards to
the noise emissions from the site.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 16 of 36 Document No.: 1216-01 v3.00
5 Waste Management Report
Schedule 3i and 3ii of Flight Group's IPC licence details the disposal/recovery methods for specified wastes. All wastes are managed so as to
minimise their impact on the environment and appropriately licensed contractors are used in all cases.
Table 7: Details of Waste Disposal 2009
European
Waste
Code
Quantity
T/Yr Description of Waste
Name and
Licence / Permit
No. of Recoverer
/ Disposer /
Broker
Address of Recoverer /
Disposer / Broker
Name and Address of
Final Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
Licence / Permit
No. of Final
Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
08 03 14 6.8 Waste Sludge Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
15 02 02 0.043 Used cleaning rags Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
08 03 12 0.036 Waste solvent (rationalisation) Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
20 03 01 1.620 General and canteen waste
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 17 of 36 Document No.: 1216-01 v3.00
European
Waste
Code
Quantity
T/Yr Description of Waste
Name and
Licence / Permit
No. of Recoverer
/ Disposer /
Broker
Address of Recoverer /
Disposer / Broker
Name and Address of
Final Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
Licence / Permit
No. of Final
Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
15 01 01 4.16 Paper and cardboard packaging waste
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
15 01 02 49.920 Reels of backing/ Offcuts (PVC/PET) and Plastic wrapping
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
15 01 10 1.128
Empty 200L steel drums (solvent-based inks) and empty 20kg steel pails (solvent-based inks)
Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Environmental Efficiency Page 18 of 36 Document No.: 1216-01 v3.00
6 Agency Monitoring and enforcement
The following table details documentation regarding EPA monitoring and
enforcement in 2009.
Table 8: Details of EPA Correspondence and Enforcement 2009
Date Content
23/02/2009 Letter to EPA re. Noise monitoring
Early July 2009 Meeting with the EPA to discuss the
company’s emissions status
15/07/2009
Letter to EPA requesting a licence technical
amendment as the annual solvent
consumption is now below 15t.
31/07/2009 EPA Letter re. Enforcement Category
19/10/2009 Site Inspection Report
09/11/2009 Response letter to EPA’s Site Inspection
Report
Environmental Efficiency Page 19 of 36 Document No.: 1216-01 v3.00
7 Resource Consumption
7.1 Energy
Table 9: Details of energy consumption 2009
Source Energy Consumption
Electricity 304,571 kWh
Gas 188,294 kWh
7.2 Water Usage
The following table details water use by the company.
Table 10: Details of water usage 2009
Water Source Volume
On-site groundwater N/A
On-site surface water N/A
Municipal Supply 548,000L
N/A - Not applicable, not used by the company
Environmental Efficiency Page 20 of 36 Document No.: 1216-01 v3.00
7.3 Raw materials
The total quantities of solvents and solvent-based inks consumed during 2009 are
summarised in the table below. The detailed figures for each product are provided in
Appendix 2 and Appendix 3.
Table 11 Hazardous raw materials used in 2009
Quantity
consumed
in 2008,
kg
Quantity
consumed
in 2009,
kg
Equivalent
TOC as C
2009
Totals Inks 22,082 5,607 1,557.5
Totals Solvents 15,138 7,835 4,216.2
Total 37,220 13,442 5,773.7
Environmental Efficiency Page 21 of 36 Document No.: 1216-01 v3.00
8 Bund integrity report
The integrity test of all the bunds was carried out on the 07/09/2007.
Table 12 Summary of bund integrity test results
Bund No. Pallet Type/Application Location Pass/Fail
44229 Bunded pallet – Solvent storage Stores Pass
47137 Bunded pallet – Solvent storage Stores Pass
53439 Bunded pallet – Solvent storage Stores Pass
44228 Bunded pallet – Solvent storage Stores Pass
52159 Bunded pallet – Ink storage Press Room Pass
48163 Bunded pallet – Ink storage Press Room Pass
48875 Bunded pallet – Ink storage Press Room Pass
48164 Bunded pallet – Temp storage Press Room Pass
48193 Bunded pallet – Solvent storage Chesnut Pass
53962 Bunded pallet – THF & Sludge Press Room Pass
5632 Bunded pallet – Ink storage Ink Room Pass
5633 Bunded pallet – Ink storage Ink Room Pass
4946 Barrel station (4 x solvent barrel storage) Press Room Pass
66051 Bunded pallet – Empty barrel storage Container Pass
01 Press-side spill tray – Inks & Solvents Aquaflex Pass
02 Press-side spill tray – Inks & Solvents Aquaflex Pass
03 Press-side spill tray – Inks & Solvents Aquaflex Pass
04 Press-side spill tray – Inks & Solvents Chesnut Pass
05 Press-side spill tray – Inks & Solvents Chesnut Pass
06 Press-side spill tray – Inks & Solvents Chesnut Pass
07 Press-side spill tray – Inks & Solvents Chesnut Pass
08 Ink trolley spill trays Press Room Pass
09 Ink trolley spill trays Press Room Pass
10 Toner trolley spill trays Press Room Pass
11 Shelving spill trays (under grated shelves) Ink Room Pass
12 Shelving spill trays (under grated shelves) Ink Room Pass
13 Solvent bath spill tray Ink Room Pass
14 Catchment tray Chesnut Pass
As can be seen in the previous table, all the bunds passed the integrity test.
Environmental Efficiency Page 22 of 36 Document No.: 1216-01 v3.00
9 Environmental Incidences & Complaints
9.1 Environmental Incidences
There were no environmental incidences on site during the course of 2009.
9.2 Environmental Complaints Summary
There were no environmental complaints associated with the site during the course of
2009.
10 Management of the Activity
10.1 Environmental Management Programme (report and proposal)
The table below summarises the objectives (set out in the AER 2005) achieved to date
and sets out a Schedule of Environmental Objectives and Targets for 2010.
Environmental Efficiency Page 23 of 36 Document No.: 1216-01 v3.00
Table 13: Schedule of Environmental Objectives and Targets
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT1 13-Dec-04 Ensure that spill incidents are minimised
and managed N/A Ongoing
This is an ongoing objective. Flight is constantly
striving to minimize spills. Our Environmental
procedures ensure minimal spills but we are always
improving on them. No spills were reported for 2009.
OT2 13-Dec-04
Implement a rationalisation programme to
minimise the storage of redundant solvents
on site
N/A Ongoing
Numerous ink rationalisations have taken place during
the year 2008. Our stock of solvent based inks have
begun to diminish during this period as we have
developed our water-based inks program to a stage
where most orders are produced on water based inks.
With the successful transfer from solvent inks to water
based inks a substantial amount of solvent based inks
were disposed of through the company’s hazardous
waste contractor (GSL). This initiative will be ongoing
in 2010.
Environmental Efficiency Page 24 of 36 Document No.: 1216-01 v3.00
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT4 13-Dec-04 Ensure that all hazardous materials are
managed and stored correctly N/A Ongoing
Flights procedures dictate that all solvents and inks are
managed and stored in the correct manner. These
procedures are ISO14001 based and are policed by day-
to-day inspections and a monthly site inspection, which
is discussed at monthly environmental meetings. As a
result of the water based programme less ink is stored
on site. This has resulted in 3 bunded pallets being made
obsolete and placed into storage. This initiative will
continue on in 2010.
OT5 13-Dec-04 Ensure the protection of surface water N/A Ongoing
This is an ongoing objective. Flight monitor surface
water every two months and submit a report bi-
annually. No unusual activity regarding surface water
monitoring for 2009. Monitoring to continue in 2010.
OT7 13-Dec-04 Minimise the generation of fugitive
emissions N/A Ongoing
Through investigation we have realised new methods of
reducing fugitive emissions and the fugitive emission
level for 2009 was found to be 6.9%, which is a further
reduction.
Environmental Efficiency Page 25 of 36 Document No.: 1216-01 v3.00
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT8 13-Dec-04 Ensure appropriate management of waste
generated by company N/A Ongoing
This is an ongoing objective. Our waste is segregated
and disposed of according to our environmental
procedures, which dictate that all wastes are stored and
disposed of in the correct manner and the correct
documentation is present. In late 2009 the company
employed the services of Greyhound waste contractors.
OT12 21-Aug-06 Investigate compliance with 2007 Toc as C
emissions limits N/A Closed
During 2008 Flight conducted quarterly monitoring.
Through this monitoring and in conjunction with their
water based inks program, the company was able to
analyse their processes and how best to achieve
compliant emissions results. Both monitoring and water
based program implementation to continue in 2009 to
comply with our IPC licence. As the annual solvent
consumption was below 15 tonne in 2009 and
application was made and approved by the EPA to
increase the ELVs, the company is now compliant.
Environmental Efficiency Page 26 of 36 Document No.: 1216-01 v3.00
11 Pollution Emission Register
Table 14 Pollution Emissions Register (all quantities in kilograms)
POLLUTANTS SUMMARY
Outputs
Pollutant Name CAS
Number Input
Note 1 Gross Usage Air MOM
Liquid Effluent
MOM Waste MOM Product MOM Recovered MOM Treated MOM Unaccounted
2-methoxy-1-methylethyl acetate 31.36 31.36 16.2 M, E 0.0 O 11.6 E 0.0 M, E 0.0 E 0.0 O 3.6
4-Methyl-pentane-2-one 41.40 41.40 21.4 M, E 0.0 O 15.3 E 0.0 M, E 0.0 E 0.0 O 4.7
Ethanol 2,115.98 2,115.98 1,094.7 M, E 0.0 O 780.6 E 0.0 M, E 0.0 E 0.0 O 240.7
Ethyl Acetate 1,221.01 1,221.01 631.7 M, E 0.0 O 450.4 E 0.0 M, E 0.0 E 0.0 O 138.9
Methyl Ethyl Ketone 107.33 107.33 55.5 M, E 0.0 O 39.6 E 0.0 M, E 0.0 E 0.0 O 12.2
N-Propyl Acetate 1,011.27 1,011.27 523.2 M, E 0.0 O 373.1 E 0.0 M, E 0.0 E 0.0 O 115.0
Propan-1-ol 86.33 86.33 44.7 M, E 0.0 O 31.8 E 0.0 M, E 0.0 E 0.0 O 9.8
Propan-2-ol 106.69 106.69 55.2 M, E 0.0 O 39.4 E 0.0 M, E 0.0 E 0.0 O 12.1
Ethoxypropanol 228.46 228.46 118.2 M, E 0.0 O 84.3 E 0.0 M, E 0.0 E 0.0 O 26.0
N-Propanol 877.95 877.95 454.2 M, E 0.0 O 323.9 E 0.0 M, E 0.0 E 0.0 O 99.9
Tetrahydrofuran 0.00 0.00 0.0 M, E 0.0 O 0.0 E 0.0 M, E 0.0 E 0.0 O 0.0
TOTAL (kg) 5,827.8 5,827.8 3,015.0 0.0 2,149.9 0.0 0.0 0.0 662.9
MOM = Method of Measurement, Codes taken from the EPA Guidance Note for AER: M = Direct Measurement B = Material Balance E = Engineering Estimates O = Other
Note 1: The purchased quantities were used for the PRTR as the stocks for the individual substances are not known.
Environmental Efficiency Page 27 of 36 Document No.: 1216-01 v3.00
12 Pollution Register and Transfer (PRTR)
| PRTR# : P0674 | Facility Name : Sleever International LTD | Filename :
P0674_2009.xls | Return Year : 2009 |
Version 1.1.10
REFERENCE YEAR 2009
1. FACILITY IDENTIFICATION
Parent Company Name Sleever International LTD
Facility Name Sleever International LTD
PRTR Identification Number P0674
Licence Number P0674-01
Waste or IPPC Classes of Activity
No. class_name
12.2
The manufacture or use of coating materials in processes with a
capacity to make or use at least 10 tonnes per year of organic
solvents, and powder coating manufacture with a capacity to produce
at least 50 tonnes per year.
Address 1 65 Heather Road
Address 2 Sandyford Industrial Estate
Address 3 Dublin 18
Address 4
Country Ireland
Coordinates of Location -6.21314 53.272
River Basin District IEEA
NACE Code 2030
Main Economic Activity
Manufacture of paints, varnishes and similar coatings, printing ink
and mastics
AER Returns Contact Name Sydney Oosthuizen
AER Returns Contact Email Address [email protected]
AER Returns Contact Position Quality/Environment Manager
AER Returns Contact Telephone Number 01-2957588
AER Returns Contact Mobile Phone Number
AER Returns Contact Fax Number 01-2957674
Production Volume 0.0
Production Volume Units
Number of Installations 0
Number of Operating Hours in Year 0
Number of Employees 0
User Feedback/Comments
Web Address
2. PRTR CLASS ACTIVITIES
Activity Number Activity Name
50.1 General
3. SOLVENTS REGULATIONS (S.I. No. 543 of 2002)
Is it applicable? Yes
Have you been granted an exemption ? No
If applicable which activity class applies (as per
Schedule 2 of the regulations) ?
Is the reduction scheme compliance route being
used ? No
AER Returns Worksheet
Environmental Efficiency Page 28 of 36 Document No.: 1216-01 v3.00
4.1 RELEASES TO AIR | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 01/04/2010 18:49
8 8 16 16 24 24 6 6 6
SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
07 Non-methane volatile organic compounds (NMVOC) M ISEN13526-2002 FID 3015.0 3623.8 0.0 608.8
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
Additional Data Requested from Landfill operators
Landfill: Sleever International LTDPlease enter summary data on the
quantities of methane flared and / or
utilised
additional_pollutant_no T (Total) kg/Year M/C/E Method Code
Designation or
Description
Facility Total Capacity m3
per hour
Total estimated methane generation (as per
site model) 0.0 N/A
Methane flared 0.0 0.0 (Total Flaring Capacity)
Methane utilised in engine/s 0.0 0.0 (Total Utilising Capacity)
Net methane emission (as reported in Section
A above) 0.0 N/A
POLLUTANT METHOD
Method Used
For the purposes of the National Inventory on Greenhouse Gases, landfill operators are requested to provide summary data on landfill gas (Methane)
flared or utilised on their facilities to accompany the figures for total methane generated. Operators should only report their Net methane (CH4)
emission to the environment under T(total) KG/yr for Section A: Sector specific PRTR pollutants above. Please complete the table below:
Method Used
Method Used
RELEASES TO AIR
POLLUTANT METHOD
Method Used
POLLUTANT
RELEASES TO AIR
RELEASES TO AIR
METHOD
Environmental Efficiency Page 29 of 36 Document No.: 1216-01 v3.00
4.2 RELEASES TO WATERS | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
8 8 16 16 24 24 6 6 6
SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this onl
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
RELEASES TO WATERS
Method Used
RELEASES TO WATERS
RELEASES TO WATERS
Method Used
POLLUTANT
Method Used
POLLUTANT
POLLUTANT
4.3 RELEASES TO WASTEWATER OR SEWER | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 |30/03/2010 13:27
8 8 16 16 6 6 6 6
SECTION A : PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER
OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER
Method Used
Method Used
POLLUTANT METHOD
POLLUTANT METHOD
Environmental Efficiency Page 30 of 36 Document No.: 1216-01 v3.00
4.4 RELEASES TO LAND | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
8 8 16 16 6 6 6 6
SECTION A : PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year
0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year
0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
POLLUTANT METHOD
Method Used
RELEASES TO LAND
RELEASES TO LAND
POLLUTANT METHOD
Method Used
5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
5 11 3
Quantity
(Tonnes per
Year)
Haz Waste : Name and
Licence/Permit No of Next
Destination Facility Non
Haz Waste: Name and
Licence/Permit No of
Recover/Disposer
Haz Waste : Address of Next
Destination Facility
Non Haz Waste: Address of
Recover/Disposer
Name and License / Permit No. and
Address of Final Recoverer /
Disposer (HAZARDOUS WASTE
ONLY)
Actual Address of Final Destination
i.e. Final Recovery / Disposal Site
(HAZARDOUS WASTE ONLY)
Transfer Destination
European Waste
Code Hazardous Quantity T/Year Description of Waste
Waste
Treatment
Operation M/C/E Method Used
Location of
Treatment Name and Licence / Per mit No. of Recoverer / Disposer / Br oker Addr ess of Recoverer / Disposer / Br oker Name and Address of F inal Destination i.e. F inal Recovery / Disposal Site (HAZARDOUS WAST E ONLY) Licence / Permit No. of Final Destination i.e. Final Recover y / Disposal Site ( HAZ ARDOUS WASTE ONLY)
To Other Countries 08 03 14 Yes 6.8 Ink sludge D10 M Weighed Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
To Other Countries 15 02 02 Yes 0.043 Used cleaning rags D10 M Volume Calculation Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
To Other Countries 08 03 12 Yes 0.036 Waste Solvent (Rationalisation) D10 M Weighed Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
Within the Country 20 03 01 No 1.62 General and canteen waste D1 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 01 No 4.16 Paper and cardboard packaging waste R3 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 02 No 49.92
Reels of backing/ Offcuts (PVC/PET) and
Plastic wrapping R5 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 10 Yes 1.128
Empty 200L steel drums (solvent-based
inks) and empty 20kg steel pails (solvent-
based inks) R4 M Weighed Onsite in Ireland
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Method Used
Environmental Efficiency Page 31 of 36 Document No.: 1216-01 v3.00
Appendix 1 Contact details for waste contractors
Company Contact Details
Guardian Silver Lining Unit 61,
Cookstown Industrial Estate,
Belgard Road,
Tallaght,
Dublin 24
01-4587270
OZO Jamestown Road,
Inchicore,
Dublin 8,
Ireland
01 616 0610
Environmental Efficiency Page 32 of 36 Document No.: 1216-01 v3.00
Appendix 2 Details of solvent based inks consumed in 2009
Ink description Qty (kg)
component % kg TOC as C
INK CAP SHRINK WHITE 1360 Ethanol 50 680 354.78
Propan-2-ol 5 68 40.80
P/R FINELAP NT 710 WHITE 920 Ethyl Acetate 37.5 345 188.18
Methyl Ethyl Ketone 17.5 161 107.33
Propan-2-ol 6.25 57.5 34.50
4-Methyl-pentane-2-one 6.25 57.5 41.4
2-methoxy-1-methylethyl acetate 6.25 57.5 31.36
PVC SHRINK 072 BLUE /20KG 20 Ethanol 50 10 5.22
Propan-2-ol 5 1 0.60
PVC SHRINK 872C GOLD /20KG 20 Ethanol 50 10 5.22
Propan-2-ol 5 1 0.60
PVC SHRINK BLACK/20KG 600 Ethanol 50 300 156.52
Propan-2-ol 5 30 18.00
PVC SHRINK GREEN /20KG 30 Ethanol 50 15 7.83
Propan-2-ol 5 1.5 0.90
SOLVENT PRIMER 995 Unknown
STILETTO BLACK TONER /20KG 100 Ethanol 37.5 37.5 19.57
Ethyl Acetate 12.5 12.5 6.82
N-Propyl Acetate 12.5 12.5 7.35
Propan-1-ol 12.5 12.5 7.50
STILETTO BLACKTHORN GOLD 10 Ethanol 37.5 3.75 1.96
Ethyl Acetate 12.5 1.25 0.68
N-Propyl Acetate 12.5 1.25 0.74
Propan-1-ol 12.5 1.25 0.75
STILETTO BLUE TONER 10 Ethanol 37.5 3.75 1.96
Environmental Efficiency Page 33 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
Ethyl Acetate 12.5 1.25 0.68
N-Propyl Acetate 12.5 1.25 0.74
Propan-1-ol 12.5 1.25 0.75
STILETTO CYAN TONER 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO MEDIUM /170-90KG 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO MEDIUM /20KG 220 Ethanol 37.5 82.5 43.04
Ethyl Acetate 12.5 27.5 15.00
N-Propyl Acetate 12.5 27.5 16.18
Propan-1-ol 12.5 27.5 16.50
STILETTO ORANGE TONER /20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO PROCESS BLACK/20KG 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO PROCESS MAGENTA /20KG 100 Ethanol 37.5 37.5 19.57
Ethyl Acetate 12.5 12.5 6.82
N-Propyl Acetate 12.5 12.5 7.35
Propan-1-ol 12.5 12.5 7.50
STILETTO PROCESS YELLOW 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
Environmental Efficiency Page 34 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO RED TONER/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO REFLEX BLUE/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO REFLEX BLUETONER/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO RUBINE RED/20KG 40 Ethanol 37.5 15 7.83
Ethyl Acetate 12.5 5 2.73
N-Propyl Acetate 12.5 5 2.94
Propan-1-ol 12.5 5 3.00
STILLETTO RUBINE RED TON/20KG 60 Ethanol 37.5 22.5 11.74
Ethyl Acetate 12.5 7.5 4.09
N-Propyl Acetate 12.5 7.5 4.41
Propan-1-ol 12.5 7.5 4.50
STILETTO SILVER 15 Ethanol 37.5 5.625 2.93
Ethyl Acetate 12.5 1.875 1.02
N-Propyl Acetate 12.5 1.875 1.10
Propan-1-ol 12.5 1.875 1.13
STILETTO VIOLET /20KG 15 Ethanol 37.5 5.625 2.93
Ethyl Acetate 12.5 1.875 1.02
N-Propyl Acetate 12.5 1.875 1.10
Environmental Efficiency Page 35 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
Propan-1-ol 12.5 1.875 1.13
STILETTO WARM RED/20KG 21 Ethanol 37.5 7.875 4.11
Ethyl Acetate 12.5 2.625 1.43
N-Propyl Acetate 12.5 2.625 1.54
Propan-1-ol 12.5 2.625 1.58
STILETTO WARM RED TONER/20KG 30 Ethanol 37.5 11.25 5.87
Ethyl Acetate 12.5 3.75 2.05
N-Propyl Acetate 12.5 3.75 2.21
Propan-1-ol 12.5 3.75 2.25
STILETTO YELLOW TONER 130 Ethanol 37.5 48.75 25.43
Ethyl Acetate 12.5 16.25 8.86
N-Propyl Acetate 12.5 16.25 9.56
Propan-1-ol 12.5 16.25 9.75
ENERGY WHITE 200 Unknown
Total Purchased 5,296 1,467.87
Stock 01/01/2009 3,012 867.59
Stock 31/12/2009 2,701 778.01
Total Consumption 5,607 1,557.5
average TOC as C proportion 0.28804
Environmental Efficiency Page 36 of 36 Document No.: 1216-01 v3.00
Appendix 3 Details of solvent consumed in 2009
Quantity
purchased (kg) Composition
concentration %
Weight (kg)
Equivalent TOC as C
(kg)
EP 400 Ethoxypropanol 99 396 228.46
MIX 25/m22 1,951 N-Propanol 75 1463.25 877.95
N-propyl acetate 25 487.75 286.915
MIX 03/M16 2,508 Ethyl Acetate 25 627 342
Isopropanol 0.75 18.81 11.29
Ethanol 75 1881 981.39
NPA 1,093 NPA 99.5 1087.535 639.73
EA 1,110 Ethyl Acetate 99.5 1104.45 602.43
NIMROD REDUCER 1,040 Ethanol 70 728 379.84
Ethyl Acetate 1.75 18.2 9.93
Total Purchased 8,102 4,359.91
Taking into account the stocks:
Overall
(kg) TOC as C
(kg)
Total Purchases 8,102 4,359.9
Stock 01/01/2009 3,012 743.2
Stock 31/12/2009 2,701 886.8
Total Consumption 7,835 4,216.2
Tel: 353 1 276 1428 Fax: 353 1 276 1561 Email: [email protected]
www.enviro-consult.com
Registered Office as above. Registered Number 243 412
ANNUAL ENVIRONMENTAL
REPORT
2009
For
Flight Group Ltd. (Sleever International)
IPC Licence No. P0674-01
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 2 of 36 Document No.: 1216-01 v3.00
QF 1. v2 Document Lead Sheet
Document Title AER 2009
Project No. 1216
Document No. 1216-01
Client Flight Group Ltd (Sleever International)
Address 65 Heather Road, Sandyford Industrial Estate, Dublin
Signed for and on behalf of Issue Status Date Author Environmental
Efficiency Client
1.00 Approved 30/03/2010 AR
2.00 Approved 06/04/2010 AR
3.00 Approved 09/04/2010 AR
Where it is a requirement that this report be issued to a regulatory or other authority,
then the client should sign the appropriate place in the above table and, unless
specifically agreed in writing to the contrary, forward copies to the appropriate
authority (e.g. EPA).
EEC Project Manager: Bob Sutcliffe, CEng, MIMechE
EEC Document Author: Agnès Ricoux, Diplôme d’Ingénieur, Industrial
Processes
Conditions relating to the issue of this report:
1. No alteration to this report by third parties is permitted
2. Where this report is reproduced, it shall only be reproduced in full.
3. Reports remain the property of Environmental & Efficiency Consultants
(Ireland) Limited until paid for in full.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 3 of 36 Document No.: 1216-01 v3.00
Table of Contents
1 Introduction ....................................................................................................... 5 1.1 Company Details........................................................................................ 5
2 Environmental Policy ........................................................................................ 6 3 Company Description ........................................................................................ 8
3.1 Previous site history................................................................................... 8 3.2 Company background ................................................................................ 8 3.3 Description of equipment ........................................................................... 8 3.4 Manufacturing process ............................................................................... 8 3.5 Company Organization chart...................................................................... 9
4 Emissions Summary .........................................................................................10 4.1 Emissions to sewer summary ....................................................................10 4.2 Surface water monitoring summary...........................................................10 4.3 Emissions to Atmosphere summary...........................................................11
4.3.1 Results: TOC as C.............................................................................12 4.3.2 Results: Volume Flow Rate ...............................................................13
4.4 Fugitive Emissions to Atmosphere summary.............................................14 4.5 Environmental Noise summary .................................................................15
5 Waste Management Report ...............................................................................16 6 Agency Monitoring and enforcement................................................................18 7 Resource Consumption .....................................................................................19
7.1 Energy ......................................................................................................19 7.2 Water Usage .............................................................................................19 7.3 Raw materials ...........................................................................................20
8 Bund integrity report.........................................................................................21 9 Environmental Incidences & Complaints ..........................................................22
9.1 Environmental Incidences .........................................................................22 9.2 Environmental Complaints Summary........................................................22
10 Management of the Activity..........................................................................22 10.1 Environmental Management Programme (report and proposal) .................22
11 Pollution Emission Register ..........................................................................26 12 Pollution Register and Transfer (PRTR)........................................................27
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 4 of 36 Document No.: 1216-01 v3.00
List of Tables
Table 1 Company details ........................................................................................... 5 Table 2: Results of Surface Water Analysis 2009 .....................................................10 Table 3 TOC as C results for A2-01 .........................................................................12 Table 4 TOC as C results for A2-02 .........................................................................12 Table 5 Volume flow rate for A2-01.........................................................................13 Table 6 Volume flow rate for A2-02.........................................................................13 Table 7: Details of Waste Disposal 2009 ..................................................................16 Table 8: Details of EPA Correspondence and Enforcement 2009..............................18 Table 9: Details of energy consumption 2009 ...........................................................19 Table 10: Details of water usage 2009 ......................................................................19 Table 11 Hazardous raw materials used in 2009 .......................................................20 Table 12 Summary of bund integrity test results .......................................................21 Table 13: Schedule of Environmental Objectives and Targets...................................23 Table 14 Pollution Emissions Register (all quantities in kilograms)..........................26
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 5 of 36 Document No.: 1216-01 v3.00
1 Introduction
1.1 Company Details
Table 1 Company details
Company Flight Group Ltd
Trading Name Flight Flexible
Address 65 Heather Road, Sandyford Industrial
Estate, Dublin
IPC Registration Number 674
IPPC Class of Activity (Schedule 1 of the
EPA Act 1992 as amended by PoE Act
2003)
12.2.2 The manufacturing or use of coating
materials in processes with a capacity to
make or use at least 10 tonnes per year of
organic solvent not included in paragraph
12.2.1
NACE Code*1
DE – manufacture of pulp, paper and paper
products, publishing and printing
Number of full-time staff equivalents 25
Contact Name Sydney Oosthuizen
Position QSE Manager
Telephone (01) 295 5133
Fax (0)1 295 7673
Email Email: [email protected]
*1 As according to NACE codes referenced from Commission Regulation EC No 29/2002 amending
Council Regulation (EEC) No 3037/90 on the statistical classification of economic activates in the
European Community
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 6 of 36 Document No.: 1216-01 v3.00
2 Environmental Policy
Flight Group Ltd (Sleever International) regards environmental protection as an
essential requirement of its operations. The company will undertake to conduct its
business in a manner which protects the environment in which it operates. The
company’s objective is to balance the need to achieve its business aims with the need
to protect the environment.
To achieve this goal the company will adhere to the following guiding principles:
Guiding Principles:
� Ensure continued compliance with all Irish and EU legislative environmental
requirements.
� Continually assess activities with the specific goal of preventing pollution,
minimising and reducing the environmental impact.
� Ensure that Environmental Policy objectives and targets have equality with
other business interests.
� Maintain a programme of Environmental awareness training (train staff to act in
an environmentally responsible manner).
� Communicate its Environmental Policy to employees, suppliers, visitors and
interested parties.
� Maintain an open information policy towards all parties affected, interested and
involved in its activities and to issues, which concern the environment.
� Ensure that its employees have the knowledge, resources and authority to
implement these guiding principles.
In particular, Flight Group Ltd (Sleever International) will:
� Establish and comply with an Environmental Management System.
� Meet environmental objectives and targets set in the Environmental
Management Programme and review within each management review meeting
for their continuing suitability and effectiveness in achieving the aims of the
Environmental Policy.
� Ensure all hazardous materials are stored in an environmentally safe manner
� Reduce wherever practicable the level of effluent, air and noise emissions
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 7 of 36 Document No.: 1216-01 v3.00
� Ensure good Waste Management practices e.g. reuse rather than dispose
whenever possible, promote recycling and used licensed waste contractors
The objectives of this policy are achieved through the implementation of the
Environmental Management System documented in the Environmental Manual,
Environmental Procedures and Environmental Forms. This Environmental Policy
covers all activities at Flight Group Ltd (Sleever International) site, and has the full
commitment and support of Management. Commitment to this policy involves almost
every aspect of the company’s business and its employees and resources shall be
made available to implement these guiding principles.
Signed: _____________________ Date: __________________
(Company Director)
Signed: _____________________ Date: __________________
(Environmental Manager)
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 8 of 36 Document No.: 1216-01 v3.00
3 Company Description
3.1 Previous site history
Flight Group Ltd (Sleever International) was set up in 1991. No environmental issues
are associated with the previous nature of the site.
3.2 Company background
Flight Group Ltd (Sleever International) primarily manufactures gravure printed
shrink sleeves for various companies but has also facilities to produce flexo and plain
printed sleeves as well as tamper evident sleeves. The company primarily provides
product to Irish and UK markets.
The company was awarded ISO 9002 in 1992 and re-assessed and accredited for ISO
9001:2008 in 2009. The company has only required and received an IPC licence since
May 2004. The company employs approximately 25 staff and during times of high
demand operates on a two-shift basis Monday to Friday.
3.3 Description of equipment
The main energy consuming equipment is:
� Flexographic Printing Press
� Rotogravure Printing Press
3.4 Manufacturing process
Sleeves are mainly printed on PET, OPS or PVC and range in micronage from 40 mic
to 75 mic
Gravure printed sleeves are produced on the 8 colour Rotogravure printer while flexo
printed sleeves are produced on the 6 colour press and are generally supplied to
contract packers who specialize in their application onto the product. Lead times on
flexo sleeves are quicker than gravure because of the use of plates rather than
engraved cylinders. Tear tape may be added to produce tamper evident packaging.
Flight Flexible currently use water based inks and solvent based inks with the
objective of eliminating solvent based inks.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 9 of 36 Document No.: 1216-01 v3.00
3.5 Company Organization chart
Chairman/Owner
Eric Fresnel (Sleever)
Plant Manager
Jason Dingle
QSE Manager:
Sydney Oosthuizen
Purchasing and Production co-ordinator
Brian Byrne
Sales and Customer service:
Kevin Cleary
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 10 of 36 Document No.: 1216-01 v3.00
4 Emissions Summary
4.1 Emissions to sewer summary
Condition 6.2 and Schedule 2ii of the company's IPC licence dictate that the company
must conduct quarterly monitoring of emissions to SE-01. The company ceased
discharging any trade emissions to sewer in June 2003 on the advice of their suppliers
who informed them that the inks that were being used are not suitable for discharge to
sewer. It was therefore not necessary to collect any sewer samples during 2008. A
report was sent to the EPA out-lining this decision (Environmental Efficiency
Document No: 593-01 and 593-02)
4.2 Surface water monitoring summary
According to Condition 9.1.2 and Schedule 4i, surface water monitoring is to occur
bimonthly and the results are to be submitted to the EPA bi-annually. The IPC licence
does not define any limits for the parameters that are monitored at Flight Group Ltd
(Sleever International) Following high BOD and COD results in September 2008, the
Agency requested that warning levels be defined. Above these thresholds, an
investigation will be carried out to investigate the origin of the high results. The table
below shows the analysis results of all surface water samples collected by
Environmental Efficiency Consultants Ltd in 2009 along with the warning levels.
Table 2: Results of Surface Water Analysis 2009
Sample
Number 593/44 593/45 593/46 593/47 593/48 593/49 Proposed
Period Jan/Feb Mar/Apr May/June Jul/Aug Sep/Oct Nov/Dec Warning
Levels
BOD mg/L 17.0 26 24 21 3 26 20
COD mg/L 31.8 <15 115 <15 16.7 19.6 100
Conductivity µS/cm 352.0 136.8 298.0 235 271 298 N/A
pH pH Units
7.80 7.48 7.39 8.49 7.94 7.06 N/A
Temperature ˚C _ 11.3 16.6 16.4 13.8 7.4 N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 11 of 36 Document No.: 1216-01 v3.00
4.3 Emissions to Atmosphere summary
Condition 5.6 and Schedule 1ii of Flight Group Ltd (Sleever International)’s IPC
licence requires air emission monitoring of TOC as C and volume flow rates be
carried out at the Rotogravure Printer (A2-01) on a quarterly basis and the
Flexographic Printer (A2-02) on an annual basis.
With the water-based ink programme, the company was able to reduce their solvent
consumption under 15 tonnes per year. A Technical Amendment was issued on the 20
January 2010 to reflect this and the limits for the TOC as C were changed as follows:
Please note that on the 20 January 2010, the limits for TOC as C were changed as to:
Emission Point New Limit
A2-01 When annual solvent consumption <15tonnes : 630mg/Nm3
When annual solvent consumption ≥15tonnes: 100mg/Nm3
A2-02 When annual solvent consumption <15tonnes : 150mg/Nm3
When annual solvent consumption ≥15tonnes: 100mg/Nm3
A summary of the air monitoring results is given in the following tables.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 12 of 36 Document No.: 1216-01 v3.00
4.3.1 Results: TOC as C
Table 3 TOC as C results for A2-01
Period Q1 2009 Q1 2009 Q2 2009 Annual
2009 Units
Date 19/03/2009 19/03/2009 23/06/2009 01/02/2010 N/A
TOC as C (mg/Nm3) 166.5 151.8 114.9 85.5 mg/Nm3
Compliance with ELV
(100mg/Nm3)
Non-
Compliant
Non-
Compliant
Non-
Compliant Compliant N/A
Table 4 TOC as C results for A2-02
Period 2009 EPA
Monitoring 2009 Units
Date 19/03/2009 01/10/2008 01/02/2010 N/A
TOC as C (mg/Nm3) 89.9 37.15 37.3 mg/Nm3
Compliance with ELV
(100mg/Nm3)
Compliant Compliant Compliant N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 13 of 36 Document No.: 1216-01 v3.00
4.3.2 Results: Volume Flow Rate
Table 5 Volume flow rate for A2-01
Period Q1 2009 Q1 2009 Q2 2009 Annual
2009 Units
Date 19/03/2009 19/03/2009 23/06/2009 01/02/2010 N/A
Volume Flow (Nm3/hr) 4,915 6,405 6,399 6,633 mg/Nm3
Compliance with ELV
(11,000 Nm3/hr)
Compliant Compliant Compliant Compliant N/A
Table 6 Volume flow rate for A2-02
Period 2009 EPA
Monitoring
Annual
2009 Units
Date 19/03/2009 01/10/2008 01/02/2010 N/A
Volume Flow rate 691 Not reported 1,780 Nm3/hr
Compliance with ELV
(1,800Nm3/hr)
Compliant Compliant Compliant N/A
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 14 of 36 Document No.: 1216-01 v3.00
4.4 Fugitive Emissions to Atmosphere summary
Condition 5.10 of the IPC licence states that:
“fugitive emission (including venting from the ink store) to air of volatile organic
compounds shall be reduced to meet the following limit subject to Condition 3 of this
licence: 25% of the total solvent input, where solvent consumption is 15-25 tonnes per
year or 20% of solvent input where solvent consumption is greater than 25 tonnes per
year”.
The annual solvent input for the year 2009 was calculated at 5,773.7kg (TOC as C)
and thus the limit for the fugitive emission percentage is 25% of the solvent input.
The fugitive emissions represent 10.5% and thus the company is in compliance.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 15 of 36 Document No.: 1216-01 v3.00
4.5 Environmental Noise summary
On the 23/02/2009, the company sent a letter to the EPA to request that noise
monitoring be removed from their regular monitoring. The reason for this request is
that the company is located in an industrial estate and also very close to the M50 (less
than 150m) and that therefore the readings for the noise surveys do not reflect the
noise emissions generated by the company alone. The company is still awaiting the
response from the Agency on this matter.
It should be noted that the company has never received any complaint with regards to
the noise emissions from the site.
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 16 of 36 Document No.: 1216-01 v3.00
5 Waste Management Report
Schedule 3i and 3ii of Flight Group's IPC licence details the disposal/recovery methods for specified wastes. All wastes are managed so as to
minimise their impact on the environment and appropriately licensed contractors are used in all cases.
Table 7: Details of Waste Disposal 2009
European
Waste
Code
Quantity
T/Yr Description of Waste
Name and
Licence / Permit
No. of Recoverer
/ Disposer /
Broker
Address of Recoverer /
Disposer / Broker
Name and Address of
Final Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
Licence / Permit
No. of Final
Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
08 03 14 6.8 Waste Sludge Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
15 02 02 0.043 Used cleaning rags Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
08 03 12 0.036 Waste solvent (rationalisation) Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Recyfuel (Belgium) Not available
20 03 01 1.620 General and canteen waste
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
Flight Group Ltd (Sleever International) AER 2009
Environmental Efficiency Page 17 of 36 Document No.: 1216-01 v3.00
European
Waste
Code
Quantity
T/Yr Description of Waste
Name and
Licence / Permit
No. of Recoverer
/ Disposer /
Broker
Address of Recoverer /
Disposer / Broker
Name and Address of
Final Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
Licence / Permit
No. of Final
Destination i.e.
Final Recovery /
Disposal Site
(HAZARDOUS
WASTE ONLY)
15 01 01 4.16 Paper and cardboard packaging waste
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
15 01 02 49.920 Reels of backing/ Offcuts (PVC/PET) and Plastic wrapping
OZO/ DCC Waste Permit WP 98101 DCC Waste Collection Permit CPD961
Jamestown Road Inchicore, Dublin 8
15 01 10 1.128
Empty 200L steel drums (solvent-based inks) and empty 20kg steel pails (solvent-based inks)
Guardian Silver Lining/ W0122-01
Unit 61, Cookstown Industrial Estate, Tallaght, Dublin 24, Ireland
Environmental Efficiency Page 18 of 36 Document No.: 1216-01 v3.00
6 Agency Monitoring and enforcement
The following table details documentation regarding EPA monitoring and
enforcement in 2009.
Table 8: Details of EPA Correspondence and Enforcement 2009
Date Content
23/02/2009 Letter to EPA re. Noise monitoring
Early July 2009 Meeting with the EPA to discuss the
company’s emissions status
15/07/2009
Letter to EPA requesting a licence technical
amendment as the annual solvent
consumption is now below 15t.
31/07/2009 EPA Letter re. Enforcement Category
19/10/2009 Site Inspection Report
09/11/2009 Response letter to EPA’s Site Inspection
Report
Environmental Efficiency Page 19 of 36 Document No.: 1216-01 v3.00
7 Resource Consumption
7.1 Energy
Table 9: Details of energy consumption 2009
Source Energy Consumption
Electricity 304,571 kWh
Gas 188,294 kWh
7.2 Water Usage
The following table details water use by the company.
Table 10: Details of water usage 2009
Water Source Volume
On-site groundwater N/A
On-site surface water N/A
Municipal Supply 548,000L
N/A - Not applicable, not used by the company
Environmental Efficiency Page 20 of 36 Document No.: 1216-01 v3.00
7.3 Raw materials
The total quantities of solvents and solvent-based inks consumed during 2009 are
summarised in the table below. The detailed figures for each product are provided in
Appendix 2 and Appendix 3.
Table 11 Hazardous raw materials used in 2009
Quantity
consumed
in 2008,
kg
Quantity
consumed
in 2009,
kg
Equivalent
TOC as C
2009
Totals Inks 22,082 5,607 1,557.5
Totals Solvents 15,138 7,835 4,216.2
Total 37,220 13,442 5,773.7
Environmental Efficiency Page 21 of 36 Document No.: 1216-01 v3.00
8 Bund integrity report
The integrity test of all the bunds was carried out on the 07/09/2007.
Table 12 Summary of bund integrity test results
Bund No. Pallet Type/Application Location Pass/Fail
44229 Bunded pallet – Solvent storage Stores Pass
47137 Bunded pallet – Solvent storage Stores Pass
53439 Bunded pallet – Solvent storage Stores Pass
44228 Bunded pallet – Solvent storage Stores Pass
52159 Bunded pallet – Ink storage Press Room Pass
48163 Bunded pallet – Ink storage Press Room Pass
48875 Bunded pallet – Ink storage Press Room Pass
48164 Bunded pallet – Temp storage Press Room Pass
48193 Bunded pallet – Solvent storage Chesnut Pass
53962 Bunded pallet – THF & Sludge Press Room Pass
5632 Bunded pallet – Ink storage Ink Room Pass
5633 Bunded pallet – Ink storage Ink Room Pass
4946 Barrel station (4 x solvent barrel storage) Press Room Pass
66051 Bunded pallet – Empty barrel storage Container Pass
01 Press-side spill tray – Inks & Solvents Aquaflex Pass
02 Press-side spill tray – Inks & Solvents Aquaflex Pass
03 Press-side spill tray – Inks & Solvents Aquaflex Pass
04 Press-side spill tray – Inks & Solvents Chesnut Pass
05 Press-side spill tray – Inks & Solvents Chesnut Pass
06 Press-side spill tray – Inks & Solvents Chesnut Pass
07 Press-side spill tray – Inks & Solvents Chesnut Pass
08 Ink trolley spill trays Press Room Pass
09 Ink trolley spill trays Press Room Pass
10 Toner trolley spill trays Press Room Pass
11 Shelving spill trays (under grated shelves) Ink Room Pass
12 Shelving spill trays (under grated shelves) Ink Room Pass
13 Solvent bath spill tray Ink Room Pass
14 Catchment tray Chesnut Pass
As can be seen in the previous table, all the bunds passed the integrity test.
Environmental Efficiency Page 22 of 36 Document No.: 1216-01 v3.00
9 Environmental Incidences & Complaints
9.1 Environmental Incidences
There were no environmental incidences on site during the course of 2009.
9.2 Environmental Complaints Summary
There were no environmental complaints associated with the site during the course of
2009.
10 Management of the Activity
10.1 Environmental Management Programme (report and proposal)
The table below summarises the objectives (set out in the AER 2005) achieved to date
and sets out a Schedule of Environmental Objectives and Targets for 2010.
Environmental Efficiency Page 23 of 36 Document No.: 1216-01 v3.00
Table 13: Schedule of Environmental Objectives and Targets
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT1 13-Dec-04 Ensure that spill incidents are minimised
and managed N/A Ongoing
This is an ongoing objective. Flight is constantly
striving to minimize spills. Our Environmental
procedures ensure minimal spills but we are always
improving on them. No spills were reported for 2009.
OT2 13-Dec-04
Implement a rationalisation programme to
minimise the storage of redundant solvents
on site
N/A Ongoing
Numerous ink rationalisations have taken place during
the year 2008. Our stock of solvent based inks have
begun to diminish during this period as we have
developed our water-based inks program to a stage
where most orders are produced on water based inks.
With the successful transfer from solvent inks to water
based inks a substantial amount of solvent based inks
were disposed of through the company’s hazardous
waste contractor (GSL). This initiative will be ongoing
in 2010.
Environmental Efficiency Page 24 of 36 Document No.: 1216-01 v3.00
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT4 13-Dec-04 Ensure that all hazardous materials are
managed and stored correctly N/A Ongoing
Flights procedures dictate that all solvents and inks are
managed and stored in the correct manner. These
procedures are ISO14001 based and are policed by day-
to-day inspections and a monthly site inspection, which
is discussed at monthly environmental meetings. As a
result of the water based programme less ink is stored
on site. This has resulted in 3 bunded pallets being made
obsolete and placed into storage. This initiative will
continue on in 2010.
OT5 13-Dec-04 Ensure the protection of surface water N/A Ongoing
This is an ongoing objective. Flight monitor surface
water every two months and submit a report bi-
annually. No unusual activity regarding surface water
monitoring for 2009. Monitoring to continue in 2010.
OT7 13-Dec-04 Minimise the generation of fugitive
emissions N/A Ongoing
Through investigation we have realised new methods of
reducing fugitive emissions and the fugitive emission
level for 2009 was found to be 6.9%, which is a further
reduction.
Environmental Efficiency Page 25 of 36 Document No.: 1216-01 v3.00
Ref.
No. Date Objective description
Licensee’s
Target
EMP
status Current status
OT8 13-Dec-04 Ensure appropriate management of waste
generated by company N/A Ongoing
This is an ongoing objective. Our waste is segregated
and disposed of according to our environmental
procedures, which dictate that all wastes are stored and
disposed of in the correct manner and the correct
documentation is present. In late 2009 the company
employed the services of Greyhound waste contractors.
OT12 21-Aug-06 Investigate compliance with 2007 Toc as C
emissions limits N/A Closed
During 2008 Flight conducted quarterly monitoring.
Through this monitoring and in conjunction with their
water based inks program, the company was able to
analyse their processes and how best to achieve
compliant emissions results. Both monitoring and water
based program implementation to continue in 2009 to
comply with our IPC licence. As the annual solvent
consumption was below 15 tonne in 2009 and
application was made and approved by the EPA to
increase the ELVs, the company is now compliant.
Environmental Efficiency Page 26 of 36 Document No.: 1216-01 v3.00
11 Pollution Emission Register
Table 14 Pollution Emissions Register (all quantities in kilograms)
POLLUTANTS SUMMARY
Outputs
Pollutant Name CAS
Number Input
Note 1 Gross Usage Air MOM
Liquid Effluent
MOM Waste MOM Product MOM Recovered MOM Treated MOM Unaccounted
2-methoxy-1-methylethyl acetate 31.36 31.36 16.2 M, E 0.0 O 11.6 E 0.0 M, E 0.0 E 0.0 O 3.6
4-Methyl-pentane-2-one 41.40 41.40 21.4 M, E 0.0 O 15.3 E 0.0 M, E 0.0 E 0.0 O 4.7
Ethanol 2,115.98 2,115.98 1,094.7 M, E 0.0 O 780.6 E 0.0 M, E 0.0 E 0.0 O 240.7
Ethyl Acetate 1,221.01 1,221.01 631.7 M, E 0.0 O 450.4 E 0.0 M, E 0.0 E 0.0 O 138.9
Methyl Ethyl Ketone 107.33 107.33 55.5 M, E 0.0 O 39.6 E 0.0 M, E 0.0 E 0.0 O 12.2
N-Propyl Acetate 1,011.27 1,011.27 523.2 M, E 0.0 O 373.1 E 0.0 M, E 0.0 E 0.0 O 115.0
Propan-1-ol 86.33 86.33 44.7 M, E 0.0 O 31.8 E 0.0 M, E 0.0 E 0.0 O 9.8
Propan-2-ol 106.69 106.69 55.2 M, E 0.0 O 39.4 E 0.0 M, E 0.0 E 0.0 O 12.1
Ethoxypropanol 228.46 228.46 118.2 M, E 0.0 O 84.3 E 0.0 M, E 0.0 E 0.0 O 26.0
N-Propanol 877.95 877.95 454.2 M, E 0.0 O 323.9 E 0.0 M, E 0.0 E 0.0 O 99.9
Tetrahydrofuran 0.00 0.00 0.0 M, E 0.0 O 0.0 E 0.0 M, E 0.0 E 0.0 O 0.0
TOTAL (kg) 5,827.8 5,827.8 3,015.0 0.0 2,149.9 0.0 0.0 0.0 662.9
MOM = Method of Measurement, Codes taken from the EPA Guidance Note for AER: M = Direct Measurement B = Material Balance E = Engineering Estimates O = Other
Note 1: The purchased quantities were used for the PRTR as the stocks for the individual substances are not known.
Environmental Efficiency Page 27 of 36 Document No.: 1216-01 v3.00
12 Pollution Register and Transfer (PRTR)
| PRTR# : P0674 | Facility Name : Sleever International LTD | Filename :
P0674_2009.xls | Return Year : 2009 |
Version 1.1.10
REFERENCE YEAR 2009
1. FACILITY IDENTIFICATION
Parent Company Name Sleever International LTD
Facility Name Sleever International LTD
PRTR Identification Number P0674
Licence Number P0674-01
Waste or IPPC Classes of Activity
No. class_name
12.2
The manufacture or use of coating materials in processes with a
capacity to make or use at least 10 tonnes per year of organic
solvents, and powder coating manufacture with a capacity to produce
at least 50 tonnes per year.
Address 1 65 Heather Road
Address 2 Sandyford Industrial Estate
Address 3 Dublin 18
Address 4
Country Ireland
Coordinates of Location -6.21314 53.272
River Basin District IEEA
NACE Code 2030
Main Economic Activity
Manufacture of paints, varnishes and similar coatings, printing ink
and mastics
AER Returns Contact Name Sydney Oosthuizen
AER Returns Contact Email Address [email protected]
AER Returns Contact Position Quality/Environment Manager
AER Returns Contact Telephone Number 01-2957588
AER Returns Contact Mobile Phone Number
AER Returns Contact Fax Number 01-2957674
Production Volume 0.0
Production Volume Units
Number of Installations 0
Number of Operating Hours in Year 0
Number of Employees 0
User Feedback/Comments
Web Address
2. PRTR CLASS ACTIVITIES
Activity Number Activity Name
50.1 General
3. SOLVENTS REGULATIONS (S.I. No. 543 of 2002)
Is it applicable? Yes
Have you been granted an exemption ? No
If applicable which activity class applies (as per
Schedule 2 of the regulations) ?
Is the reduction scheme compliance route being
used ? No
AER Returns Worksheet
Environmental Efficiency Page 28 of 36 Document No.: 1216-01 v3.00
4.1 RELEASES TO AIR | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 01/04/2010 18:49
8 8 16 16 24 24 6 6 6
SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
07 Non-methane volatile organic compounds (NMVOC) M ISEN13526-2002 FID 3015.0 3623.8 0.0 608.8
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (As required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
Additional Data Requested from Landfill operators
Landfill: Sleever International LTDPlease enter summary data on the
quantities of methane flared and / or
utilised
additional_pollutant_no T (Total) kg/Year M/C/E Method Code
Designation or
Description
Facility Total Capacity m3
per hour
Total estimated methane generation (as per
site model) 0.0 N/A
Methane flared 0.0 0.0 (Total Flaring Capacity)
Methane utilised in engine/s 0.0 0.0 (Total Utilising Capacity)
Net methane emission (as reported in Section
A above) 0.0 N/A
POLLUTANT METHOD
Method Used
For the purposes of the National Inventory on Greenhouse Gases, landfill operators are requested to provide summary data on landfill gas (Methane)
flared or utilised on their facilities to accompany the figures for total methane generated. Operators should only report their Net methane (CH4)
emission to the environment under T(total) KG/yr for Section A: Sector specific PRTR pollutants above. Please complete the table below:
Method Used
Method Used
RELEASES TO AIR
POLLUTANT METHOD
Method Used
POLLUTANT
RELEASES TO AIR
RELEASES TO AIR
METHOD
Environmental Efficiency Page 29 of 36 Document No.: 1216-01 v3.00
4.2 RELEASES TO WATERS | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
8 8 16 16 24 24 6 6 6
SECTION A : SECTOR SPECIFIC PRTR POLLUTANTS Data on ambient monitoring of storm/surface water or groundwater, conducted as part of your licence requirements, should NOT be submitted under AER / PRTR Reporting as this onl
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
RELEASES TO WATERS
Method Used
RELEASES TO WATERS
RELEASES TO WATERS
Method Used
POLLUTANT
Method Used
POLLUTANT
POLLUTANT
4.3 RELEASES TO WASTEWATER OR SEWER | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 |30/03/2010 13:27
8 8 16 16 6 6 6 6
SECTION A : PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year F (Fugitive) KG/Year
0.0 0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER
OFFSITE TRANSFER OF POLLUTANTS DESTINED FOR WASTE-WATER TREATMENT OR SEWER
Method Used
Method Used
POLLUTANT METHOD
POLLUTANT METHOD
Environmental Efficiency Page 30 of 36 Document No.: 1216-01 v3.00
4.4 RELEASES TO LAND | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
8 8 16 16 6 6 6 6
SECTION A : PRTR POLLUTANTS
QUANTITY
No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year
0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)
QUANTITY
Pollutant No. Name M/C/E Method Code Designation or Description Emission Point 1 T (Total) KG/Year A (Accidental) KG/Year
0.0 0.0 0.0
* Select a row by double-clicking on the Pollutant Name (Column B) then click the delete button
POLLUTANT METHOD
Method Used
RELEASES TO LAND
RELEASES TO LAND
POLLUTANT METHOD
Method Used
5. ONSITE TREATMENT & OFFSITE TRANSFERS OF WASTE | PRTR# : P0674 | Facility Name : Sleever International LTD | Filename : P0674_2009.xls | Return Year : 2009 | 30/03/2010 13:27
5 11 3
Quantity
(Tonnes per
Year)
Haz Waste : Name and
Licence/Permit No of Next
Destination Facility Non
Haz Waste: Name and
Licence/Permit No of
Recover/Disposer
Haz Waste : Address of Next
Destination Facility
Non Haz Waste: Address of
Recover/Disposer
Name and License / Permit No. and
Address of Final Recoverer /
Disposer (HAZARDOUS WASTE
ONLY)
Actual Address of Final Destination
i.e. Final Recovery / Disposal Site
(HAZARDOUS WASTE ONLY)
Transfer Destination
European Waste
Code Hazardous Quantity T/Year Description of Waste
Waste
Treatment
Operation M/C/E Method Used
Location of
Treatment Name and Licence / Per mit No. of Recoverer / Disposer / Br oker Addr ess of Recoverer / Disposer / Br oker Name and Address of F inal Destination i.e. F inal Recovery / Disposal Site (HAZARDOUS WAST E ONLY) Licence / Permit No. of Final Destination i.e. Final Recover y / Disposal Site ( HAZ ARDOUS WASTE ONLY)
To Other Countries 08 03 14 Yes 6.8 Ink sludge D10 M Weighed Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
To Other Countries 15 02 02 Yes 0.043 Used cleaning rags D10 M Volume Calculation Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
To Other Countries 08 03 12 Yes 0.036 Waste Solvent (Rationalisation) D10 M Weighed Abroad
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Recyfuel,Not
available,.,.,.,.,Belgium .,.,.,.,Belgium
Within the Country 20 03 01 No 1.62 General and canteen waste D1 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 01 No 4.16 Paper and cardboard packaging waste R3 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 02 No 49.92
Reels of backing/ Offcuts (PVC/PET) and
Plastic wrapping R5 M Weighed Offsite in Ireland
OZO,DCC Waste Permit WP
98101
Jamestown
Road,.,Inchicore,Dublin
8,Ireland
Within the Country 15 01 10 Yes 1.128
Empty 200L steel drums (solvent-based
inks) and empty 20kg steel pails (solvent-
based inks) R4 M Weighed Onsite in Ireland
Guardian Silver
Lining,W0122-01
Unit 61,Cookstown Industrial
Estate,Tallaght,Dublin
24,Ireland
Method Used
Environmental Efficiency Page 31 of 36 Document No.: 1216-01 v3.00
Appendix 1 Contact details for waste contractors
Company Contact Details
Guardian Silver Lining Unit 61,
Cookstown Industrial Estate,
Belgard Road,
Tallaght,
Dublin 24
01-4587270
OZO Jamestown Road,
Inchicore,
Dublin 8,
Ireland
01 616 0610
Environmental Efficiency Page 32 of 36 Document No.: 1216-01 v3.00
Appendix 2 Details of solvent based inks consumed in 2009
Ink description Qty (kg)
component % kg TOC as C
INK CAP SHRINK WHITE 1360 Ethanol 50 680 354.78
Propan-2-ol 5 68 40.80
P/R FINELAP NT 710 WHITE 920 Ethyl Acetate 37.5 345 188.18
Methyl Ethyl Ketone 17.5 161 107.33
Propan-2-ol 6.25 57.5 34.50
4-Methyl-pentane-2-one 6.25 57.5 41.4
2-methoxy-1-methylethyl acetate 6.25 57.5 31.36
PVC SHRINK 072 BLUE /20KG 20 Ethanol 50 10 5.22
Propan-2-ol 5 1 0.60
PVC SHRINK 872C GOLD /20KG 20 Ethanol 50 10 5.22
Propan-2-ol 5 1 0.60
PVC SHRINK BLACK/20KG 600 Ethanol 50 300 156.52
Propan-2-ol 5 30 18.00
PVC SHRINK GREEN /20KG 30 Ethanol 50 15 7.83
Propan-2-ol 5 1.5 0.90
SOLVENT PRIMER 995 Unknown
STILETTO BLACK TONER /20KG 100 Ethanol 37.5 37.5 19.57
Ethyl Acetate 12.5 12.5 6.82
N-Propyl Acetate 12.5 12.5 7.35
Propan-1-ol 12.5 12.5 7.50
STILETTO BLACKTHORN GOLD 10 Ethanol 37.5 3.75 1.96
Ethyl Acetate 12.5 1.25 0.68
N-Propyl Acetate 12.5 1.25 0.74
Propan-1-ol 12.5 1.25 0.75
STILETTO BLUE TONER 10 Ethanol 37.5 3.75 1.96
Environmental Efficiency Page 33 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
Ethyl Acetate 12.5 1.25 0.68
N-Propyl Acetate 12.5 1.25 0.74
Propan-1-ol 12.5 1.25 0.75
STILETTO CYAN TONER 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO MEDIUM /170-90KG 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO MEDIUM /20KG 220 Ethanol 37.5 82.5 43.04
Ethyl Acetate 12.5 27.5 15.00
N-Propyl Acetate 12.5 27.5 16.18
Propan-1-ol 12.5 27.5 16.50
STILETTO ORANGE TONER /20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO PROCESS BLACK/20KG 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO PROCESS MAGENTA /20KG 100 Ethanol 37.5 37.5 19.57
Ethyl Acetate 12.5 12.5 6.82
N-Propyl Acetate 12.5 12.5 7.35
Propan-1-ol 12.5 12.5 7.50
STILETTO PROCESS YELLOW 80 Ethanol 37.5 30 15.65
Ethyl Acetate 12.5 10 5.45
Environmental Efficiency Page 34 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
N-Propyl Acetate 12.5 10 5.88
Propan-1-ol 12.5 10 6.00
STILETTO RED TONER/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO REFLEX BLUE/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO REFLEX BLUETONER/20KG 20 Ethanol 37.5 7.5 3.91
Ethyl Acetate 12.5 2.5 1.36
N-Propyl Acetate 12.5 2.5 1.47
Propan-1-ol 12.5 2.5 1.50
STILETTO RUBINE RED/20KG 40 Ethanol 37.5 15 7.83
Ethyl Acetate 12.5 5 2.73
N-Propyl Acetate 12.5 5 2.94
Propan-1-ol 12.5 5 3.00
STILLETTO RUBINE RED TON/20KG 60 Ethanol 37.5 22.5 11.74
Ethyl Acetate 12.5 7.5 4.09
N-Propyl Acetate 12.5 7.5 4.41
Propan-1-ol 12.5 7.5 4.50
STILETTO SILVER 15 Ethanol 37.5 5.625 2.93
Ethyl Acetate 12.5 1.875 1.02
N-Propyl Acetate 12.5 1.875 1.10
Propan-1-ol 12.5 1.875 1.13
STILETTO VIOLET /20KG 15 Ethanol 37.5 5.625 2.93
Ethyl Acetate 12.5 1.875 1.02
N-Propyl Acetate 12.5 1.875 1.10
Environmental Efficiency Page 35 of 36 Document No.: 1216-01 v3.00
Ink description Qty (kg)
component % kg TOC as C
Propan-1-ol 12.5 1.875 1.13
STILETTO WARM RED/20KG 21 Ethanol 37.5 7.875 4.11
Ethyl Acetate 12.5 2.625 1.43
N-Propyl Acetate 12.5 2.625 1.54
Propan-1-ol 12.5 2.625 1.58
STILETTO WARM RED TONER/20KG 30 Ethanol 37.5 11.25 5.87
Ethyl Acetate 12.5 3.75 2.05
N-Propyl Acetate 12.5 3.75 2.21
Propan-1-ol 12.5 3.75 2.25
STILETTO YELLOW TONER 130 Ethanol 37.5 48.75 25.43
Ethyl Acetate 12.5 16.25 8.86
N-Propyl Acetate 12.5 16.25 9.56
Propan-1-ol 12.5 16.25 9.75
ENERGY WHITE 200 Unknown
Total Purchased 5,296 1,467.87
Stock 01/01/2009 3,012 867.59
Stock 31/12/2009 2,701 778.01
Total Consumption 5,607 1,557.5
average TOC as C proportion 0.28804
Environmental Efficiency Page 36 of 36 Document No.: 1216-01 v3.00
Appendix 3 Details of solvent consumed in 2009
Quantity
purchased (kg) Composition
concentration %
Weight (kg)
Equivalent TOC as C
(kg)
EP 400 Ethoxypropanol 99 396 228.46
MIX 25/m22 1,951 N-Propanol 75 1463.25 877.95
N-propyl acetate 25 487.75 286.915
MIX 03/M16 2,508 Ethyl Acetate 25 627 342
Isopropanol 0.75 18.81 11.29
Ethanol 75 1881 981.39
NPA 1,093 NPA 99.5 1087.535 639.73
EA 1,110 Ethyl Acetate 99.5 1104.45 602.43
NIMROD REDUCER 1,040 Ethanol 70 728 379.84
Ethyl Acetate 1.75 18.2 9.93
Total Purchased 8,102 4,359.91
Taking into account the stocks:
Overall
(kg) TOC as C
(kg)
Total Purchases 8,102 4,359.9
Stock 01/01/2009 3,012 743.2
Stock 31/12/2009 2,701 886.8
Total Consumption 7,835 4,216.2