ATTACHMENT NO. C.1 SITE MANAGEMENT AND - epa.ie fileCarton Bros in 1975 built the first, and still the only, dedicated poultry Feedmill on the island under the control of the processor

Carton Bros (Feed Mill) Industrial Emissions Activities Licence

June 2015

ATTACHMENT NO. C.1

SITE MANAGEMENT AND CONTROL

CARTON BROTHERS (FEED MILL)

APPLICATION FOR AN

INDUSTRIAL EMISSIONS ACTIVITIES LICENCE

Traynor Environmental Ltd. Attachment No. C.1- C.4

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June 2015

History of the Site

Carton Bros in 1975 built the first, and still the only, dedicated poultry Feedmill on the island under the control

of the processor. I t is a vital part in the vertical integration of all the stages of production. It provides Carton

Bros complete control over raw materials used, as well as traceability from farm to fork. I t aiso eliminates the

risk of cross-contamination from feeds intended for other species. Having control means that the finished feed

specifications are tailored to exactly what the bird requires for optimal health and growth. The use of some

whole grain and coarse ground grain is possible because the “customer” is part of the contracted grower

group. This coarse ground grain mimics the diet the bird would have access to under natural conditions (seeds

and grains), and is important in maintaining the healthy functioning of the digestive system of the bird and

minimises the need for antibiotics.

Traynor Environmental t td. Attachment No. C.1 - C.4

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June 2015

POLICY STATEMENT

Carton Brothers (Feed Mill) Environment Policy Statement

Carton Brothers (Feed Mill) is committed to supplying products that meet or exceed the expectations of i t s customers and to conducting its activities in an environmentally friendly and responsible manner. This will be achieved through:

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Commitment to continual improvement and prevention of pollution in all aspects of the business. Adapting appropriate measures to comply with environmental legislation and regulations and with other requirements to which the organisation subscribes.

Setting and reviewing specific environmental objectives and targets based on this policy including targets relating to the conservation of energy and material resources, emissions to air, land, water and risk management.

Managing the impact of the environment in a pro-active way through waste prevention and minimisation, re-use, recycling, and ultimately safe disposal. Conserving energy and natural resources in the site’s operations as an integral part of this environmental policy.

Taking account of the environment a t all stages, including product development, raw material procurement, manufacturing and distribution operations.

Putting in place necessary structures and resources, including training and awareness programmers to underpin this policy.

Site Manager


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June 2015

ATTACHMENT NO. C.2

ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)

CARTON BROS (FEED MILL)

APPLICATION FOR AN

i N DUSTRIAL EMISSIONS ACTIVITIES LICENCE


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June 2015

C. 2 Environmental Management System (EMS)

Carton Bros (Feed Mill) are currently installing a Environmental Management System. The following procedure and forms and being developed.

E nvi ro n m enta I Po I i cy EMS 01 - Environmental Manual EMS 02 - Register of Environmental Aspects and objectives EMS 03 - Register of Legislation EMS 04 - Emergency Procedures Manual EMS 05 - Resource Register

SOP 02 -Identifying, Evaluating and Accessing Legal Compliance and any other requirements SOP 03 - Objectives, targets and programme SOP 04 - Resources, roles, responsibility and authority SOP 05 - Competence, training and awareness SOP 06 -Communication SOP 07 - Control of Documents SOP 08 - Chemical awareness SOP 09 Bund Inspection SOP 10 - Waste Management SOP 11 - Emergency prepardness and Response SOP 12 - Monitoring and measurement SOP 13 - Evaluation of Compliance SOP 14 - Non Conformity, corrective action and preventative action SUP 15 - Control of records SOP 16 -Auditing SOP 17 - Management Review SOP 18 - Housekeeping Procedure SOP 19 - Accident Prevention SOP 20 - Waste Sampling, analysis and characterisiation SOP 21 - Interceptor Maintenance and Checking


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lune 2015

ATTACHMENT NO. C.3

HOURS OF OPERATION


APPLICATION FOR AN



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Carton Bros (Feed Mill) industria{ Emissions Activities Licence

June 2015

C. 3 Hours cif Operation

Proposed Hours of Operation

Carton Bros (Feed Mili) operates 24 hours a day, 7 days a week, all year round, with a scheduled week for

maintenance and cleaning.

Production staff work a three-shift pattern: 8 a.m. to 4 p.m.; 4 p.m. to 12 p.m.; and 1 2 p.m. to 8 a.m.

Administrative, IT, HR, accounting and managerial staff operate mainly normal working hours (9 a.m. to 5:30

p.m.1

Traynor Environmental Ltd. Attachment No. C . 1 - C.4

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lune 2015

ATTACHMENT NO. C.4

FIT AND PROPER PERSON


APPLICATION FOR AN


Traynor Environmental I td. Attachment No. C . 1 - C.4

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June 2015

--

C.4

The Feed Mill at Shinan, Shercock, Co. Cavan is accredited by UFAS. The UFAS scheme aims to protect human

and animal health by ensuring safe and hygienic practices in manufacture and distribution of animal feeding

stuffs based on HACCP principles. UFAS is a voluntary scheme developed, owned and implemented by the

Agricultural Industries Confederation (AIC). It verifies that our food mill, where our chicken feed is milled and

prepared, meets the obligations under the appropriate feed safety related legislation and codes of practice in

maintaining safety in the feed and food chain.

Feedmill Accreditations & Fit and Proper Person

Carton Bros Accreditations

Carton Bros champion standards as they become known and were the first company in the Republic to be

certified with IS0 22000 in October 2007 and audited annually until 2012. BRC is now the most internationally

recognised certification required by customers of Carton 8ros and as such BRC has replaced I S 0 22000 on site.

Hazard Analysis and Critical Control Point (HACCP) Plan

Carton Bros (Feed Mill) have an established HACCP control plan to ensure the safety and quality of i t s animal

feed. This was a novel industry quality standard then but one which is now a legal requirement for all Feed

Business Operators.

Universal Feed Assurance Scheme (UFAS)

The facility is certified under the Universal Feed Assurance Scheme (UFAS). Certificate No. 76835.

The Universal Feed Assurance Scheme (UFAS) was launched in 1998 and accounts for in excess of 95% of the

commercially produced compound feed in the Ireland and the UK. UFAS now has approximatly 700

participants .The programme is based on HACCP principles, which form the bedrock of EU Food and Feed

legislation. The scheme is audited and certified by an independent certification body, in accordance with the

internationally recognised standard EN45011 (also known as I S 0 Guide 65). This means that the certification

body is itself independently assessed every year to ensure that the standard is implemented and administered

consistently and fairly. Please see attached UFAS Certificate of conformity.

Bord 8ia Irish Food 3oard

Carton Brothers are a certified member of Bord Bia and as such conform to all standards laid down by the Bord

Bia Quality Assurance Scheme. The Poultry Products Quality Assurance Scheme operated by Bord Bia is

designed to enable poultry producers and processors meet the ever increasing demands of customers and

consumers. The scheme is kept under review to ensure that it continues to reflect the emerging requirements

of the marketplace. Please see attached Bord Bia Certificate of conformity.

Traynor Environmental Ltd. Attachment No. C.1 - C.4

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Carton Bros (Feed Mill) industria! Emissions Activities Licence

June 2015

OriRin Green Sustainability P r o g r a m

Carton Bros is a proud member of Origin Green, Origin Green i s a sustainability programme which enables

Carton Bros to set and achieve measurable sustainability targets - reducing environmental impact, serving

locai communities more effectively and protecting natural resources that are present in the local area. Please

see attached Origin Green Certificate.

Fit and Proper Person- Mr. Torn Horan - Feedmill Manager

Torn Horan has been employed by Carton Bros for over 20 years and has arnmassed a great knowledge in all

operations at arton Bros feedmill. Tom has a Bachelors of Science Degree in Agriculture (UCP). His key

responsibilities within the company include managing all feedmill operations.

Fit and Proper Person- Mr. Christopher McHuRh -Quality Feed Manager

Christopher McHugh has been employed by Carton Bros for 5 years. Christopher has a Bacholors of Science

Degree in Agriculture,. Christopher is responsible for quality systems and assurance, dealing with audits and he

is responsible for Carton Bros participation in the Origin Green programme.

Traynor Environmental Ctd. Attachment No. C.1 I C.4

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June 2015

Bord BIa Certificate

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Carton BrOS (Feed Mill) tndustrial Emissions Activities Licence

June 2015

Universal Feed Assurance Scheme WFAS1

Certificate of Conformity Prorjucf Authenlicalion Inlemationol certifies that

Carton Brothers complies w ih fhe requiremenis of the following scheme:

U FAS Unlversal Feed Arrwancs kheme

k o p e d Operollon I h s m b r d a l ~ id corrrXx#id M i


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Orirrin Green Certificate

June 2015

k Sustainability Programme

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AIdan Cottar. chkf ~xecullve. Bord ma

Traynor Environmental Ltd. Attachment No, Col - C.4

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