flight group ltd. · ipc licence no. p0674-01 . ... diplôme d’ingénieur, industrial processes...

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

2008

For

Flight Group Ltd.

IPC Licence No. P0674-01

Flight Group Ltd. AER 2008

Environmental Efficiency of 43 Document No.: 1124-01 v2.00

QF 1. v2 Document Lead Sheet Document Title Flight AER 2008

Project No. 1124

Document No. 1124-01

Client Flight Group Ltd

Address 65 Heather Road, Sandyford Industrial Estate, Dublin

Signed for and on behalf of Issue Status Date Author Environmental

Efficiency Client

1.00 Approved 03/04/2009 AR

2.00 Approved 17/04/2009 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.



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.............................................................................27 12 Pollution Register and Transfer (PRTR)..........................................................28



List of Tables

Table 1 Company details ...............................................................................................5 Table 2: Results of Surface Water Analysis 2008 .......................................................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 TOC as C results for A2-02 ............................................................................13 Table 6: Details of Waste Disposal 2008.....................................................................16 Table 7: Details of EPA Correspondence and Enforcement 2008...............................18 Table 8: Details of energy consumption 2008 .............................................................19 Table 9: Details of water usage 2008...........................................................................19 Table 10 Hazardous raw materials used in 2008 .........................................................20 Table 11 Summary of bund integrity test results .........................................................21 Table 12: Schedule of Environmental Objectives and Targets....................................23 Table 13 Pollution Emissions Register (all quantities in kilograms)...........................27



1 Introduction

1.1 Company Details

Table 1 Company details

Company Flight Group Ltd

Trading Name Flight Flexible Ltd

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 Environmental Manager/ Quality Manager/

Health and Safety

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



2 Environmental Policy

Flight Group Ltd. 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. 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

� 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. 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)



3 Company Description

3.1 Previous site history

Flight Group Ltd. was set up in 1991. No environmental issues are associated with the

previous nature of the site.

3.2 Company background

Flight Group Ltd. 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 for ISO 9001 in 2002

but 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.



3.5 Company Organization chart

Chairman/Owner

Eric Fresnel (Sleever)

Plant Manager

Jason Dingle

Quality and Environmental Manager:

Sydney Oosthuizen

Purchasing and Production co-ordinator

Brian Byrne

Sales and Customer service:

Kevin Cleary



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.

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

2008 along with the warning levels that were proposed.

Table 2: Results of Surface Water Analysis 2008

Sample

Number 593/33 593/36 593/38 593/40 593/42 593/43 Proposed

Period Jan/Feb Mar/Apr May/June Jul/Aug Sep/Oct Nov/Dec Warning

Levels

BOD mg/L 2 6 2 2 104 7 20

COD mg/L 108 303 <15 16.20 530 38.90 100

Conductivity µS/cm 365 221 265 475 120 415 N/A

pH pH Units

6.03 6.63 7.16 5.83 6.86 7.09 N/A

Temperature ˚C 7 8.5 13 18.90 15.10 10.60 N/A



4.3 Emissions to Atmosphere summary

Condition 5.6 and Schedule 1ii of Flight Group Ltd.’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.

During 2008 numerous trials and test were conducted to reduce TOC as C levels in

the air emissions. All have been recorded accordingly. The company was able to

reduce our TOC as C emissions readings substantially (Please see following

breakdown of quarterly monitoring). Further initiatives are to follow in 2009.

The water based inks program has been successful in 2008. The water based ink

purchases have increased from 14.70% in January 2008 to 38.61% in Quarter 3 of

2008 and 53.55% in Quarter 4 of 2008. This percentage is expected to increase in

early 2009. The company continues to use away their current stock of solvent based

inks. All orders that are produced at Flight Flexible are now scrutinized for suitability

for water based inks production. Most orders are produced with water based inks and

only in exceptional circumstances are solvent based inks utilized. Detailed records are

kept on a weekly basis outlining water based / solvent based ink production. Detailed

records are also maintained on a monthly, quarterly and annual basis for ink

purchased.

Progress reports were submitted to the EPA on a quarterly basis as part of the

quarterly air monitoring for the A2-01 press in 2008.

A summary of the air monitoring results is given in the following tables.



4.3.1 Results: TOC as C

Table 3 TOC as C results for A2-01

Sample number 593/37 593/39 593/41 N/A

Period Q1 2008 Q2 2008 Q3 2008 Q4 2008 Units

Date 18/04/2008 25/06/2008 01/10/2008 22/01/2008 N/A

TOC as C (mg/Nm3) 198.7 331.1 194.9 134.2 mg/Nm3

Compliance with ELV

(100mg/Nm3)

Non-Compliant Non-Compliant Non-Compliant Non-Compliant N/A


Sample number N/A

Period 2008 Units

Date 22/01/2009 N/A

TOC as C (mg/Nm3) 90.6 mg/Nm3

Compliance with ELV

(100mg/Nm3)

Compliant N/A



4.3.2 Results: Volume Flow Rate

Table 5 Volume flow rate for A2-01


Sample Number N/A

Period 2008 Units

Date 22/01/2009 N/A

Volume Flow rate 184 Nm3/hr

Compliance with ELV

(1,800Nm3/hr)

Compliant N/A

Sample Number 593/37 593/34 593/41 N/A

Period Q1 2008 Q2 2008 Q3 2008 Q4 2008 Units

Date 18/04/2008 25/06/2008 01/10/2008 22/01/2009 N/A

Volume Flow rate 7,464 10,349 9,436 5,483 Nm3/hr

Compliance with ELV

(11,000Nm3/hr)

Compliant Compliant Compliant Compliant N/A



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 2008 was calculated at 15,604.8kg (TOC as C)

and thus the limit for the fugitive emission percentage is 20% of the solvent input.

The fugitive emissions represent 15.7% and thus the company is in compliance.



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. Flight Group is still awaiting the

response from the Agency on this matter.



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 2008

EWC Haz Waste

Materials Quantity

Method of Disposal/ Recovery*1

Location of

Disposal/Recovery*1

Waste

Contractor

Licence/

Permit Ref.

08 03 14 YES Waste Sludge 10,620 Kg

D10 - Incineration

15 02 02 YES Used cleaning rags

7,400 lts ~ 111 Kg

D15- Were stored in black bags in 1000L FIBC fabric bags on a pallet in a designated waste collection area (signs). Now stored in sealed, air tight steel barrels D10 – Incineration

C – Offsite (Recyfuel, Belgium)

Guardian Silver Lining

W0122-01

08 03 12 YES Waste Solvent 1,490.15 Kg

D10 - Incineration C – Offsite (Recyfuel, Belgium)


W0122-01

20 01 21 YES Fluorescent tubes

130 units ~ 13 Kg

R4 – Bulbs collected, Glass segregated and cleaned, aluminium refined and mercury distilled and sold to dentists.

B – Offsite Ireland – Irish Lamp Recycling Site, Athy Co Kildare


W0122-01

20 03 01 NO General and canteen waste

3,425 Kg Green bin collected by Onyx on a callout basis for disposal in a local landfill. (20 x 1000 litre wheelie bin in 2006)

B – Offsite Ireland Disposal Local landfill (Ballaly-EPAReg9\2 KTK-EPAReg82\2)

Veolia Ireland Ltd

EPAReg39-2 CPD 89\1

15 01 01 NO Paper and cardboard packaging waste

5,550 Kg R0 Majority is reused by the company R13 – Compacted and segregated for recycling R3 – Recycling/Reclamation of organic substances which are not used as solvents

B – Offsite Ireland Segregation and compaction (premises of Onyx) and recycled (Smurfit Recycling usually)

Veolia Ireland Ltd

EPAReg39-2 CPD 89\1



EWC Haz Waste

Materials Quantity

Method of Disposal/ Recovery*1

Location of

Disposal/Recovery*1

Waste

Contractor

Licence/

Permit Ref.

15 01 02 NO Reels of backing/Offcuts (PVC/PET)

48,419 Kg R0 Majority is reused by the company R13 – Compacted and segregated for recycling R5 – Recycling/reclamation of other inorganic materials

B – Offsite Ireland Segregation and compaction (premises of Onyx) and recycled (Smurfit Recycling usually)

Veolia Ireland Ltd

EPAReg39-2 CPD 89\1

15 01 02 NO Plastic wrapping 134 Kg R0 Majority is reused by the company R13 – Compacted and segregated for recycling R5 – Recycling/reclamation of other inorganic materials

A Onsite reuse B Off-site segregation (Onyx premises) and recycling (Thorndale Env. Recycling)

Veolia Ireland Ltd

EPAReg39-2 CPD 89\1

15 01 10 YES 200L Empty Steel Drums (solvent-based inks)

57 Barrels ~ 855 Kg

15 01 10 YES 20kg empty Steel pails (solvent-based inks)

1,658 Containers ~ 1,658 Kg

R13 Stored on site in a designated area while awaiting collection R5 Containers are washed out and reused D10 – Drum washings are incinerated

B – Off site Ireland washing for reuse C – Offsite Disposal of washings (Recyfuel, Belgium)


W0122-01

*1 Codes taken from EPA Guidance Note for AER


6 Agency Monitoring and enforcement

The following table details documentation regarding EPA monitoring and

enforcement in 2008.

Table 8: Details of EPA Correspondence and Enforcement 2008

Date Reference Content

09/10/2008 EPA Site Inspection

10/11/2008 P0674-01/08/SI04mor EPA Site Inspection Report


7 Resource Consumption

7.1 Energy

Table 9: Details of energy consumption 2008

Source Energy Consumption

Electricity 218,200 kWh

Gas 246,475 kWh

7.2 Water Usage

The following table details water use by the company.

Table 10: Details of water usage 2008

Water Source Volume

On-site groundwater N/A

On-site surface water N/A

Municipal Supply Unknown volume. Volume consumed is

thought be very small as water is only used

for domestic purposes in the company.

N/A - Not applicable, not used by the company


7.3 Raw materials

The total quantities of solvents and solvent-based inks consumed during 2008 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 2008

Quantity

consumed

in 2007, kg

Quantity

consumed

in 2008, kg

Equivalent

TOC as C

2008

Totals Inks 19,700.3 22,082 7,169.2

Totals Solvents 13,473.7 15,138 8,435.6

Total 33,174 37,220 15,604.8


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




52159 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



04 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.


9 Environmental Incidences & Complaints

9.1 Environmental Incidences

There were no environmental incidences on site during the course of 2008.

9.2 Environmental Complaints Summary

There were no environmental complaints associated with the site during the course of

2008.

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 2009.


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.

OT2 13-Dec-04

Implement a rationalisation programme to

minimise the storage of redundant solvents

on site

1-Jan-10 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.


Ref.


Licensee’s

Target

EMP


OT3 13-Dec-04 Construct a bunded store room of adequate

size and capacity 1-Feb-05 Closed

In 2006 Flight purchased prefabricated bunds for our

ink room. Flight also purchased spill trays for the

shelving units in the ink room and a spill tray for the

solvent bath in the ink room. The shelving units were

fitted with grating to ensure any leaks/spills drain into

the spill trays. A barrel station was purchased to house

our supply of various solvents. Flight is also keeping in

mind the possibility of a premises move to a location

with a purpose built ink room.

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.

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.

OT6 13-Dec-04 Ensure that emissions to sewer are

managed appropriately 1-Dec-04 Closed

Emissions to sewer monitoring have ceased as no

harmful substances enter the drains in our factory.


Ref.


Licensee’s

Target

EMP


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 2008 was found to be 15.7%, which represents

a reduction of 58%. In 2009 the company expects to

reduce our over all fugitive emissions results.

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.

OT9 13-Dec-04 Introduce a formal complaints policy 1-Mar-05 Closed A formal complaints procedure is included in the

environmental procedures.

OT10 13-Dec-04 Audit the company for energy efficiency N/A Closed Flight Flexible has been audited for energy efficiency.

OT11 13-Dec-04 Define a residuals management plan 1-May-05 Closed Residuals management plan defined.


Ref.


Licensee’s

Target

EMP


OT12 21-Aug-06 Investigate compliance with 2007 Toc as C

emissions limits 1-Jan-10 Ongoing

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.

OT13 30-Aug-06 The construction of safe, permanent access

to emissions monitoring points. 30-Jun-07 Closed

Flight are currently looking at various options with

regards to safe, permanent access to all monitoring

points. They are keeping in mind the possible move to

new premises.

With the approval of the EPA, Flight Flexible purchased

mobile stairs/platform which will serve the monitoring

needs until such time as the company moves premises.

OT14 6-Sep-06 Preparation and implementation of ISO

14001 1-Feb-07 Closed

ISO14001 is close to completion and should be

audited/accredited for this in June 2007.

Although the company’s environmental procedures are

ISO14001 based, Flight Flexible decided not to pursue

this accreditation due to lack of resources


11 Pollution Emission Register

Table 14 Pollution Emissions Register (all quantities in kilograms)

POLLUTANTS SUMMARY

Outputs

Pollutant Name CAS Number Input1 Gross

Usage Air2

MOM Liquid

Effluent3 MOM Waste MOM Product

4 MOM Recovered

5 MOM Treated MOM Unaccounted

2-methoxy-1-methylethyl acetate 296.59 296.59 129.5 M, E 0.0 O 104.4 E 0.0 M, E 0.0 E 0.0 O 62.7

4-Methyl-pentane-2-one 391.50 391.50 170.9 M, E 0.0 O 137.8 E 0.0 M, E 0.0 E 0.0 O 82.8

Ethanol 4,559.02 4,559.02 1,989.8 M, E 0.0 O 1,605.2 E 0.0 M, E 0.0 E 0.0 O 963.9

Ethyl Acetate 3,345.46 3,345.46 1,460.2 M, E 0.0 O 1,177.9 E 0.0 M, E 0.0 E 0.0 O 707.4

Methyl Ethyl Ketone 1,015.00 1,015.00 443.0 M, E 0.0 O 357.4 E 0.0 M, E 0.0 E 0.0 O 214.6

N-Propyl Acetate 2,800.64 2,800.64 1,222.4 M, E 0.0 O 986.1 E 0.0 M, E 0.0 E 0.0 O 592.2

Propan-1-ol 386.18 386.18 168.6 M, E 0.0 O 136.0 E 0.0 M, E 0.0 E 0.0 O 81.7

Propan-2-ol 478.77 478.77 209.0 M, E 0.0 O 168.6 E 0.0 M, E 0.0 E 0.0 O 101.2

Ethoxypropanol 68.54 68.54 29.9 M, E 0.0 O 24.1 E 0.0 M, E 0.0 E 0.0 O 14.5

N-Propanol 2,203.20 2,203.20 961.6 M, E 0.0 O 775.8 E 0.0 M, E 0.0 E 0.0 O 465.8

Tetrahydrofuran 59.94 59.94 26.2 M, E 0.0 O 21.1 E 0.0 M, E 0.0 E 0.0 O 12.7

TOTAL (kg) 15,604.8 15,604.8 6,810.9 0.0 5,494.5 0.0 0.0 0.0 3,299.4

MOM = Method of Measurement, Codes taken from the EPA Guidance Note for AER: M = Direct Measurement B = Material Balance E = Engineering Estimates O = Other *1

Please refer Appendix 2 and Appendix 3 for detailed calculation of inputs *2

The TOC as C emissions through the stacks, the fugitive emissions and the wastes were calculated as part of the fugitive emission assessment. The emissions from each

compound were calculated assuming that the proportions were similar to the input proportions. *3

There is no effluent emission from the site *4

It is assumed that no solvent remains on the product. The solvent is believed to evaporate in the printer and to be emitted in the stack, or to be part of the fugitive emissions. *5

There is no solvent recovery or treatment on the site.


12 Pollution Register and Transfer (PRTR)

| PRTR# : P0674 | Facility Name : Flight Group Limited | Filename : P0674_2008.xls |

Return Year : 2008 |

Version 1.1.04

REFERENCE YEAR 2008

1. FACILITY IDENTIFICATION

Parent Company Name Flight Group Limited

Facility Name Flight Group Limited

PRTR Identification Number P0674

Licence Number P0674-01

Waste or IPPC Classes of Activity

No. class_name

Address 1 65 Heather Road

Address 2 Sandyford Industrial Estate

Address 3 Dublin 18

Address 4

Country Ireland

Coordinates of Location 31922261

River Basin District

NACE Code 203

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

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) ? 8

Is the reduction scheme compliance route being

used ? No

AER Returns Worksheet


4.1 RELEASES TO AIR | PRTR# : P0674 | Facility Name : Flight Group Limited | Filename : P0674_2008.xls | Return Year : 2008 | 02/04/2009 17:07

8 8 16 16 24 24 6 6 6 7

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

A2-01

No. Annex II Name M/C/E Method Code Designation or Description Emission Point 1 Emission Point 2 T (Total) KG/Year

A (Accidental)

KG/Year

F (Fugitive)

KG/Year

07 Non-methane volatile organic compounds (NMVOC) M ISEN13526-2002 FID 6750.89 60.01 10110.3 0.0 3299.4


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


Additional Data Requested from Landfill operators

Landfill: Flight Group LimitedPlease 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

METHOD

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

RELEASES TO AIR

POLLUTANT METHOD

Method Used

POLLUTANT

RELEASES TO AIR

RELEASES TO AIR

Method Used


4.2 RELEASES TO WATERS | PRTR# : P0674 | Facility Name : Flight Group Limited | Filename : P0674_2008.xls | Return Year : 2008 | 02/04/2009 17:07

8 8 16 16 24 24 6 6 6 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 only concerns Releases from your facility

QUANTITY


0.0 0.0 0.0 0.0


SECTION B : REMAINING PRTR POLLUTANTS

QUANTITY


0.0 0.0 0.0 0.0


SECTION C : REMAINING POLLUTANT EMISSIONS (as required in your Licence)

QUANTITY


0.0 0.0 0.0 0.0


RELEASES TO WATERS

RELEASES TO WATERS

Method Used

POLLUTANT

Method Used

POLLUTANT

POLLUTANT

RELEASES TO WATERS

Method Used

4.3 RELEASES TO WASTEWATER OR SEWER | PRTR# : P0674 | Facility Name : Flight Group Limited | Filename : P0674_2008.xls | Return Year : 2008 | 02/04/2009 17:07

8 8 16 16 6 6 6 6

SECTION A : PRTR POLLUTANTS

QUANTITY


0.0 0.0 0.0 0.0


SECTION B : REMAINING POLLUTANT EMISSIONS (as required in your Licence)

QUANTITY


0.0 0.0 0.0 0.0


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


4.4 RELEASES TO LAND | PRTR# : P0674 | Facility Name : Flight Group Limited | Filename : P0674_2008.xls | Return Year : 2008 | 02/04/2009 17:07

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


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


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 : Flight Group Limited | Filename : P0674_2008.xls | Return Year : 2008 | 17/04/2009 15:33

5 12 10

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 / 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)

To Other Countries 08 03 14 Yes 10.62 Waste Sludge D10 M Weighed Abroad

Guardian Silver Lining/

W0122-01

Unit 61, Cookstown Industrial

Estate, Tallaght, Dublin 24,

Ireland Recyfuel (Belgium) Not available

To Other Countries 15 02 02 Yes 0.111 Used cleaning rags D10 C Volume Calculation Offsite in Ireland


W0122-01




To Other Countries 08 03 12 Yes 0.149015 Waste solvent (rationalisation) D10 M Weighed Abroad


W0122-01




Within the Country 20 01 21 Yes 0.013 Fluorescent tubes R4 C Volume Calculation Offsite in Ireland


W0122-01



Ireland

Irish Lamp Recycling, Athy,

Co. Kildare Not available

Within the Country 20 03 01 No 3.425 General and canteen waste D10 M Weighed Offsite in Ireland Veolia Ireland EPA Reg 39-2

Dublin Ballymount Cross,

Tallaght, D24

Within the Country 15 01 01 No 5.55 Paper and cardboard packaging waste R3 M Weighed Offsite in Ireland Veolia Ireland EPA Reg 39-2


Tallaght, D24

Within the Country 15 01 02 No 48.553

Reels of backing/ Offcuts (PVC/PET) and

Plastic wrapping R5 M Weighed Offsite in Ireland Veolia Ireland EPA Reg 39-2


Tallaght, D24

Within the Country 15 01 10 Yes 2.513

Empty 200L steel drums (solvent-based

inks) and empty 20kg steel pails (solvent-

based inks) R4 C Volume Calculation Offsite in Ireland


W0122-01



Ireland

Method Used


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

Conroy Recycling Kildallon,

Mullingar,

Co. Westmeath

(044) 45819

Veolia Ireland Ltd. Ballymount Cross, Tallaght, Dublin 24

Tel (01) 4136500

National Recycling & Environmental Protection

Ltd.

Naas Road,

Dublin

01-4500905


Appendix 2 Details of solvent based inks consumed in 2008

Ink description Qty (kg) component % kg TOC as C

(kg)

ASBF-04-10958/MPL 20 Unknown

INK - EVASION CAP WHITE 180 Ethanol 50 90 46.96

Propan-2-ol 5 9 5.40

Ink - PVC Shrink - Silver XL22794 200 Ethanol 50 100 52.17

Propan-2-ol 5 10 6.00

ink 072 pvc schrink blue 40 Ethanol 50 20 10.43


INK CAP SHRINK WHITE 708 Ethanol 50 354 184.70

Propan-2-ol 5 35.4 21.24

ink P/R finelap NT 710 white 4020 Ethyl Acetate 37.5 1507.5 822.27

Methyl Ethyl Ketone 17.5 703.5 469.00

Propan-2-ol 6.25 251.25 150.75

4-Methyl-pentane-2-one 6.25 251.25 180.9

2-methoxy-1-methylethyl acetate 6.25 251.25 137.04

ink pvb shrink white flexo 357 Ethanol 50 178.5 93.13

Propan-2-ol 5 17.85 10.71

ink pvc flexoschrink blacktoner 20 Ethanol 50 10 5.22


ink pvc schrink black 300 Ethanol 50 150 78.26

Propan-2-ol 5 15 9.00

ink pvc schrink medium 40 Ethanol 50 20 10.43


ink pvc schrink pantone yellow 20 Ethanol 50 10 5.22


ink pvc schrink PMS blue toner 10 Ethanol 50 5 2.61



(kg)

Propan-2-ol 5 0.5 0.30

ink pvc schrink purplec 10 Ethanol 50 5 2.61

Propan-2-ol 5 0.5 0.30

ink pvc schrink rubine red 20 Ethanol 50 10 5.22


ink pvc schrink rubine redtoner 20 Ethanol 50 10 5.22


ink pvc schrink silver 60 Ethanol 50 30 15.65


ink pvc schrink violet 20 Ethanol 50 10 5.22


INK STILETTO 072 BLUE XL20336 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

INK STILETTO 072 BLUE TONER 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

INK STILETTO 662c BLUE TONER 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

INK STILETTO CYAN TONER / 20 KG 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

ink stiletto medium /170 328 Ethanol 37.5 123 64.17

Ethyl Acetate 12.5 41 22.36



(kg)

N-Propyl Acetate 12.5 41 24.12

Propan-1-ol 12.5 41 24.60 INK STILETTO PROCESS BLACK / 20 KG 280 Ethanol 37.5 105 54.78



Propan-1-ol 12.5 35 21.00 INK STILETTO PROCESS YELLOW / 20 KG 40 Ethanol 37.5 15 7.83



Propan-1-ol 12.5 5 3.00

INK STILETTO REFLEX BLUE / 20 KG 40 Ethanol 37.5 15 7.83



Propan-1-ol 12.5 5 3.00

ink stilletto blackthorn black 160 Ethanol 37.5 60 31.30



Propan-1-ol 12.5 20 12.00

INK STILLETTO GREEN PMS 5845 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

INK STILLETTO MATT LACQUER 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

ink stilletto pvc F/scent white 20 Ethanol 37.5 7.5 3.91




(kg)


Propan-1-ol 12.5 2.5 1.50

ink stilletto rubine red tone 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

ink stilletto UV F/scent lacquer 40 Ethanol 37.5 15 7.83



Propan-1-ol 12.5 5 3.00

ink stilletto Vice silver 200 Ethanol 37.5 75 39.13



Propan-1-ol 12.5 25 15.00

KIM MATT (LESS) LACQUER /20KG 77 Unknown

Luco Red F21688 546 Unknown

Luco Yellow F21687 888 Unknown

P/R FINELAP NT 710 WHITE 2160 Ethyl Acetate 37.5 810 441.82

Methyl Ethyl Ketone 17.5 378 252.00

Propan-2-ol 6.25 135 81.00

4-Methyl-pentane-2-one 6.25 135 97.2

2-methoxy-1-methylethyl acetate 6.25 135 73.63

PVC SHRINK 072 BLUE /20KG 40 Ethanol 50 20 10.43


PVC SHRINK B/O SILVER 60 Ethanol 50 30 15.65


PVC SHRINK BLACK 340 Ethanol 50 170 88.70

Propan-2-ol 5 17 10.20



(kg)

PVC SHRINK BLACK/20KG 300 Ethanol 50 150 78.26

Propan-2-ol 5 15 9.00

PVC SHRINK MEDIUM /20KG 40 Ethanol 50 20 10.43


PVC SHRINK PANTONE YELLOW/20KG 40 Ethanol 50 20 10.43


PVC SHRINK RUBINE RED /20KG 20 Ethanol 50 10 5.22


PVC SHRINK SILVER /20KG 40 Ethanol 50 20 10.43


PVC SHRINK VIOLET /20KG 10 Ethanol 50 5 2.61

Propan-2-ol 5 0.5 0.30

PVC SHRINK WHITE 160 Ethanol 50 80 41.74


S90678 360 Unknown

SOLVENT PRIMER 80 Unknown

STILETTO 072C G/V BLUE /20KG 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

STILETTO BLACK 60 Ethanol 37.5 22.5 11.74



Propan-1-ol 12.5 7.5 4.50

STILETTO BLUE TONER 10 Ethanol 37.5 3.75 1.96



Propan-1-ol 12.5 1.25 0.75

STILETTO CYAN TONER 40 Ethanol 37.5 15 7.83



(kg)



Propan-1-ol 12.5 5 3.00

STILETTO GREEN 69 Ethanol 37.5 25.875 13.50



Propan-1-ol 12.5 8.625 5.18

STILETTO MEDIUM /170-90KG 360 Ethanol 37.5 135 70.43



Propan-1-ol 12.5 45 27.00

STILETTO PROCESS BLACK/20KG 311 Ethanol 37.5 116.625 60.85

Ethyl Acetate 12.5 38.875 21.20


Propan-1-ol 12.5 38.875 23.33

STILETTO PROCESS MAGENTA /20KG 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

STILETTO PROCESS YELLOW 79 Ethanol 37.5 29.625 15.46



Propan-1-ol 12.5 9.875 5.93

STILETTO RUBINE RED/20KG 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

STILETTO SILVER 80 Ethanol 37.5 30 15.65




(kg)


Propan-1-ol 12.5 10 6.00

STILETTO VODKA ICE SILVER 320 Ethanol 37.5 120 62.61



Propan-1-ol 12.5 40 24.00

STILETTO WARM RED/20KG 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

STILETTO YELLOW TONER 40 Ethanol 37.5 15 7.83



Propan-1-ol 12.5 5 3.00

STILETTOUV F/SCENT LACQUER20KG 100 Ethanol 37.5 37.5 19.57



Propan-1-ol 12.5 12.5 7.50

XL10152/MPL 56 Ethanol 37.5 21 10.96



Propan-1-ol 12.5 7 4.20

XL10251/MPL 100 Ethanol 37.5 37.5 19.57



Propan-1-ol 12.5 12.5 7.50

XL1110/MPL 80

XL13791/MBO 996 Ethanol 37.5 373.5 194.87




(kg)


Propan-1-ol 12.5 124.5 74.70

XL14485/MPL 40 Ethanol 37.5 15 7.83



Propan-1-ol 12.5 5 3.00

XL14865 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

XL15617/MPL 10 Ethanol 37.5 3.75 1.96



Propan-1-ol 12.5 1.25 0.75

XL15803/MPL 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

XL17866/MPL 260 Ethanol 50 130 67.83

Propan-2-ol 5 13 7.80

XL17890/MPL 20 Unknown

XL18327/MPL 40 Ethanol 50 20 10.43



XL18386/MPL 40 Ethanol 37.5 15 7.83



Propan-1-ol 12.5 5 3.00

XL18387/MPL 20 Ethanol 37.5 7.5 3.91



(kg)



Propan-1-ol 12.5 2.5 1.50

XL19100/MPL 20 Ethanol 50 10 5.22


XL19922/MPL 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50

XL20003/MPL 20 Ethanol 50 10 5.22


XL20076/MPL 40 Ethanol 50 20 10.43


XL20207 21 Ethanol 37.5 7.875 4.11



Propan-1-ol 12.5 2.625 1.58

XL20806 20 Ethanol 37.5 7.5 3.91



Propan-1-ol 12.5 2.5 1.50


XL21745 40 Ethanol 37.5 15 7.83



Propan-1-ol 12.5 5 3.00

XL21783/MPL 710 Ethanol 37.5 266.25 138.91





(kg)

Propan-1-ol 12.5 88.75 53.25

XL22008/MPL 40 Ethanol 50 20 10.43


XL22741/MPL 239 Ethanol 37.5 89.625 46.76

Ethyl Acetate 12.5 29.875 16.30


Propan-1-ol 12.5 29.875 17.93

XL22755/MPL 20 Ethanol 50 10 5.22


XL22785/MPL 518 Ethanol 50 259 135.13

Propan-2-ol 5 25.9 15.54

XL22794/MPL 240 Ethanol 50 120 62.61

Propan-2-ol 5 12 7.20

XL22808/PCC 40 Unknown

YSBL-01-16722/MBO 2520 Ethyl Acetate 37.5 945 515.45

Methyl Ethyl Ketone 17.5 441 294.00

Propan-2-ol 6.25 157.5 94.50

4-Methyl-pentane-2-one 6.25 157.5 113.4

2-methoxy-1-methylethyl acetate 6.25 157.5 85.90

Totals 22082 12617.15 7169.21


Appendix 3 Details of solvent consumed in 2008

Total

Barrels Annual

Kg/barrel Total kg Annual

Stock 01/01/08

Stock 31/12/08

Consumption Composition Concentration

% Weight

(kg).

Equivalent TOC as C

(kg)

EP 1 180 182 0 62 120 Ethoxypropanol 99 118.8 68.53846

MIX 25/m22 28 169 4732 328 164 4896 N-Propanol 75 3672 2203.2

N-propyl acetate

25 1224 720

MIX 03/M16 32 168 5376 330 165 5541 Ethyl Acetate 25 1385.25 755.5909

Isopropanol 0.75 41.5575 24.9345

Ethanol 75 4155.75 2168.217

NPA 17 182 3094 360 546 2908 NPA 99.5 2893.46 1702.035

EA 5 185 925 92 184 833 ethyl actetate 99.5 828.835 452.0918

THF 1 180 180 90 180 90 Tetrahydrofuran 99.9 89.91 59.94 NIMROD REDUCER 750 0 0 750 Ethanol 70

525 273.913

Ethyl Acetate 1.75 13.125 7.159091

Totals 15239 15138 8435.621

flight group ltd. · ipc licence no. p0674-01 . ... diplôme d’ingénieur, industrial processes...

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