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Meat and AnimalProcessing Industry

Environmental GuidelinesJune 1999

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Do you want to:

Avoid or reduce the amount ofwaste your business produces?

Produce environmentally soundproducts and services?

Use energy and resources moreefficiently?

Achieve less waste, lower costs andhigher profits?

If you have ticked one or all of the above circles then thisworkbook is for you.

It�s an easy step by step approach towards environmentalimprovement.

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AcknowledgementsWe would like to thank the participants and MIRINZ Food Technology andResearch for their assistance in the workshops and continuous ongoing support.Some information in this workbook has been supplied by MIRINZ FoodTechnology and Research.

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ContentsIntroduction 4

Cleaner Production 5

Stages in a Cleaner Production Programme 6

1 Helpful Information 7

2 Create an Environmental Policy 15

3 Gather Information 17

4 Identify Options & Implement Projects 23

5 Incorporate Cleaner Productioninto Daily Management 27

Technical Report Number 1999/12

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IntroductionThis workbook has been compiled to assist the meat and animal processingindustry to implement better environmental practices.

The workbook is an outcome from a series of workshops held with meat andanimal processors in the Waikato Region between July 1998 and November1998.

Participants in the workshops were:

• Greenlea Meats• Donald Carter - Consultant• Waikato By Products• Inghams• AgResearch• Diamond International (Petfood)• Te Kuiti Meats• Te Aroha Skins• Richmonds (previously Lowe Walker).

Some of the achievements made by the participants in the workshop:

• Raised environmental awareness• Raised awareness of mutual industry issues• Environmental policies created• Water conservation projects instigated• Storm water improvements made• Hazards identified and spill management implemented• Environmental component included into staff inductions• Cost savings through energy conservation• Alternative solid waste management trials being implemented.

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Cleaner production is about:

� avoiding or reducing the amount of waste produced� producing environmentally sound products and services� using energy and resources efficiently� achieving less waste, lower costs and higher profits.

Cleaner production presents an opportunity for businesses to increase theircompetitiveness in both the domestic and international markets. Results indicatethat significant reductions in resource use (both materials and energy), wastes,emissions and cost savings are possible.

The Benefits of BeingEnvironmentally Responsible

There are enormous benefits to be gained from becoming an environmentallyresponsible organisation. The company, its employees, the local communityand everyone who is affected by negative impacts from the site can benefitfrom the improvement in health, safety and quality of life that environmentalawareness creates.

Increased awareness, along with a strategy to change the way we do things,results in:• cleaner production techniques• improved housekeeping• reductions in emissions to soil, air and water• a reduction of noise levels• the greening and landscaping of unsightly industrial sites• the painting and maintenance of ugly constructions• consideration for sites with heritage, scientific or historical significance• the remediation of contaminated sites• the reduced use of raw materials• reduced energy consumption• improved buying policies• healthier workplaces and communities• improved relationships between companies and communities• reduced risk of non-compliance with current legislation• preparedness for future legislation.

Other long-term benefits include:• increased consumer confidence• improved return on investment• an environmentally healthy corporate image• a positive impact on the bottom line.

CleanerProduction

The goal ofcleaner

productionis to help

reduceany adverse

impacts thatproduction

and serviceactivities

may haveon the

environment.

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Stages in a CleanerProduction Programme

� Policy- Commitment- Development- Action

� Gather Information- Flow diagrams of your process- Designing measurement strategy- Delegating tasks- Measuring- Gathering information

� Identify Options- Collating data- Ranking options

� Implement Projects- Conceptual- Planning- Execution- Termination

� Incorporating intoDaily Management- Monitoring and review- Implementation into induction programmes- Including initiatives into job descriptions

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BloodBy reducing the volume of blood lost to the effluent stream by only 100L each day, ameat plant disposing of its effluent by land application could reduce the land arearequired by 2.5 ha. This blood, if recovered for blood processing, also represents again in product revenue.

• Regularly dry clean the floor.• Install a low concrete nib or similar structure around the areas to be dry cleaned.• Make sure your staff are aware of the downstream effects of allowing blood to

enter the effluent stream.• Install an alarm or notification system that activates if the valve is open in the

blood collection pit/trough while the processing chain is operating.• Investigate the possibility of having backup storage and pumping systems.

Solid tissueSome amount of animal tissue �waste� (including meat and fat trimmings) isunavoidable in meat processing, but a primary aim should be to minimise theamount of this material generated.

Dry cleaning methods should be used to collect the solids as close to source aspossible � this maximises recovery for rendering. Dry cleaning before hosing downthe floor will reduce the amount of water used for cleaning.

Faecal matterand gut contentsAnother important source of waste in meat processing is the faecal matter and gutcontents of slaughtered animals. These wastes enter the effluent stream in variousamounts during the following plant operations:

• stock truck washing• washing of yards used for pre slaughter holding of stock� paunch emptying• viscera cutting and washing• stripping runners.

For meat plants that do not carry out on-site rendering, blood processing or othermajor by product processing operations, it is estimated that the faeces and gutcontents would typically account for more than 75% of the phosphorous and 50% ofthe nitrogen, sodium and organic loading in primary screened or settled effluentfrom the plant.

1. Helpful informationH

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form

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However there are opportunities to minimise the loading of faecal and gutcontent material on the wastewater stream, mainly by recovering the solids�dry� at source

Suggestions for both wet and dry recovery

• Efficiently recover the solids from a segregated wastewater stream (DAF,milliscreening or sedimentation).

� Compost the recovered solids.• If relatively free from animal tissue, consider applying the recovered solids

directly to land (please seek direction from your local and regionalauthorities).

• To maximise recovery of resources by screening, your screen should have afine aperture (e.g. 0.5 � 0.75 mm aperture).

• Use a two stage dry dump and spray wash system for processing paunches.This could reduce your plants total effluents solids, nitrogen and phospho-rous loading by a high percentage.

• Manually collect or use a small wheel loader to assist in the dry collection offaeces from under your grating in stockyards.

• Investigate tailgate slaughter.

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• Implement preventative measures to recover spillage and detect leakage.• Increase employee water conservation awareness.• Reuse clean or contaminated water where possible.• Measure departmental water inflow to control water usage.• Control water to specific requirements and install flow control valves.• Use Countercurrent rinsing techniques.• Ensure frequency of plant cleaning is appropriate.• Separate clean cooling water and uncontaminated clean rainwater from

wastewater flows and reuse again within your process.• Use high pressure washing equipment to reduce the amount of wastewater

generated.• Equip rinse tanks with flow control valves.• Agitate rinse baths to reduce water consumption.• Install water saving sanitary fixtures.• Use treatment technologies that facilitate recycling and reuse of rinse

waters.

Minimising Water

QUESTIONS TO ASK!

This sectionsummarises

various optionsthat can be used

to minimisewastewater.

Incoming water• What quantity and quality of feed

water is required for each unit ofoperation?

• What sources of water areavailable on site? Are they ofsuitable quality and quantity?

• What pre-treatment may berequired? Is the existing pre-treatment system operating at itsbest? Can savings be made byusing alternativeequipment or procedures?

• Has the demand pattern changedrecently or is it likely to do so inthe future?

Productionoperations• Can excessive demand peaks or

washes be avoided or reduced?• Identify the pattern of water use for

each separate unit process. Is thewater over-treated prior to use?Can lower grade water be usedsatisfactorily?

• Identify the pattern of wastegeneration for each separate unitprocess. Why is it generated? Canit be reduced or eliminated?

Wastewater� Is it possible to segregate waste

streams at source?� How does the cost of increasing the

degrees of treatment compare withcharges arising from effluentdischarge to sewer or watercourse?

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StormwaterWhat do you need to know aboutstormwater?

The stormwater from your business travels via the gutters and drains to localstreams or canals and eventually ends up in a river, in a harbour or on abeach. If it is contaminated with pollutants such as grease, oil or otherchemicals it can kill fish and other water life, and seriously pollute theenvironment where people swim, fish and play. Keeping stormwater clean isimportant and will assist in meeting consent conditions.

Wastewater or stormwater?

Wastewater (sometimes called trade wastewater) is any water used orcontaminated as a result of your business�s activities. Wastewater frombusinesses may contain pollutants such as sediment, particles and chemicals.Wastewater must not enter the stormwater system. It should be discharged tothe sewerage system or to storage tanks.

Stormwater is rain that flows across outside surfaces into stormwater drains ordirectly into waterways. Stormwater should not contain pollutants.

What can you do to stopstormwater pollution?

• Mark your stormwater drains so that they are easily identified by staff.• Do not allow anything other than clean rainwater to enter the stormwater

drains on or near your premises.• Prevent any washing water from entering stormwater drains. Confine your

cleaning and washing to a contained or bunded area where the wastewateris directed to the sewer.

• If you cannot hose without getting dirty water in gutters or stormwaterdrains, there are other cleaning options:

• sweep or vacuum the area• use absorbent material to remove most of the grime and then

use some solvent on a rag to remove the rest� don�t store leaky drums or containers out in the open, unless in

bundled areas.

Processingindustries carryout manyactivities thatcould pollutestormwater.

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Most materials can be hazardous or dangerous to the environment if handledor stored inappropriately. Businesses must have in place practices andprocedures to prevent accidental leaks and spills. Correct handling, carryingand storage of materials can help stop pollution of the ground, stormwaterdrains and local waterways.

Material safety data sheets (MSDS)

An MSDS is an information sheet on the safe use and disposal of a material. Itis just as important as any tool or piece of machinery in your factory. It containsinformation that can save lives in an emergency. You should get an MSDS withevery hazardous substance you buy, handle or use. If you don�t have one for amaterial, ask your supplier.

Use of chemicals

Think about the chemicals you are currently using. There may be a lessenvironmentally damaging material on the market that you could use instead.Ask your supplier about alternatives.

Chemical storage, disposal and spills

• Ensure that all chemicals are stored in a designated area away fromstormwater drains. Cover, seal and bund the storage area.

• Bund storage areas to contain spills and cover them to prevent rusting ofdrums. There must be no access for any spills or leaks to any drains. Protectdrums and tanks from possible collision.

• Place drip trays where leakage is likely.• Store empty drums etc in a covered or bunded area because of the risk of

leakage of residual chemicals. Have them removed as soon as possible.Seal drums awaiting collection and store them upright.

• Certain substances are classified as Dangerous Goods, and their use andstorage is controlled by the Dangerous Goods Act. These substances includepetrol, solvents, liquefied petroleum gas and ammonia.

• Store and dispose of each type of chemical in a separate container. Clearlylabel each container with the name of the chemical it contains. Keep an up-to-date and legible list of all chemicals held.

• Inspect storage containers regularly. Replace them if they are rusted,damaged or likely to leak. Allow yourself easy access.

• Keep all sharp parts away from chemical or liquid containers to avoiddamage and spills.

• Send all used chemicals to a licensed contractor for recycling ordisposal.

• Clean up all spills immediately. Have a spill kit in a clearly labelled andeasily accessible location.

Good HazardousSubstances Practice

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• If a spill occurs that threatens or harms the environment, you must tell thelocal council as soon as you can after you become aware of it. In theWaikato Region phone 0800 800 401.

• For large-scale, hazardous spills call the Fire Brigade immediately on 111.For small-scale spills, follow the MSDS for the spilled substance.

• Make all staff aware of emergency telephone numbers to call in case of aspill.

• Prepare and practise a spill clean-up plan. Staff should know what to do,where to find emergency equipment and how to use it.

• Always be careful when responding to spills. Your life is important � do nottake emergency spill action without proper safety equipment, no matter howurgent the matter appears to you.

• A spill kit might include rags, brooms and mops, booms to contain largerliquid spills, material to stop any spill entering a drain, and material to soakup spills. Numerous absorbent materials are available commercially.

• Keep this material in a clearly labelled and easily accessible place.• General spill procedures:

1. Stop the source of the spill immediately if it is safe to do so.2. Contain the spill and control its flow. (Refer to the relevant

MSDS.) Stop the spill from entering any stormwater drainsby blocking the drain inlets.

3. Clean up the spill promptly by following the relevant MSDS. It isimportant to clean up all spills quickly, even small ones, as theycan easily flow into stormwater drains or be washed there byrain.

Solvents and oils

• Solvents tend to be highly volatile and flammable. Store them away fromheat, naked flames, direct sunlight, oil and other flammable liquids.

� Avoid unnecessary human exposure to solvents by storing them in a cov-ered container with a tap (to avoid the need to pour). Keep the storage areawellventilated.

• You must not tip solvent waste into the sewer.� Take care with rags soaked with fish oil or solvent as they are a fire hazard.

Ground and groundwater contamination

You must not allow any hazardous liquids to soak into the ground. If they do,you may end up with a contaminated site that is costly to clean, and your landvalue will be greatly reduced. If contaminants soak into the ground and reachgroundwater there is a high risk that they will flow off-site and contaminateneighbouring land, groundwater supplies or local creeks. You may be liablefor any clean-up costs off site too.

Emergency response to spills

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Questions to AskDuring Site Check• What process controls are already in use to improve process efficiency?

• Which good housekeeping practices are already in force in the business tolimit the generation of waste materials and emissions?

• What investments in energy efficiency measures or energy reductionmanagement practices are being used by the business?

• What overall management practices are used by the business?

• What is the composition of the waste streams and emissions generated bythe business? What is their quantity?

• From which production processes or treatments do these waste streams andemissions originate?

• Which waste materials and emissions fall under existing environmentalregulations?

• What raw materials and input materials in the business or productionprocess generate these waste streams and emissions?

• How much of a specific raw or input material is found in each wastestream?

• What quantity of materials are lost in the form of volatile emissions?

• Are any unnecessary waste materials or emissions produced by mixingmaterials which could otherwise be reused with other waste materials?

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2. Creating anEnvironmental Policy

STEP 1: Call a meeting involvingmanagement and staff representatives

Crea

tinng

an E

nviro

nm

enta

l Policy

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Meeting agenda should cover:� reasons for becoming more environmentally responsible� environmental issues for your company� formalising an environmental policy� integrating environmental performance with health and safety or quality systems.

Environmental Policy

Reason

At we are committed to environmentalimprovementbecause

To be Accomplished

We will accomplish improvement on our environmental performance by

Eg: Reducing our water use by 50%

������

We will continuously improve our performance and aim to complete these actions by (date).

Responsibilities

To ensure we successfully implement procedures and practices to achieve our actions and improve ourenvironmental performance, management will be responsible forthe personnel department will be responsible forand employees will be responsible for

Signed:

If you wish to produce an extensive ISO 14000 compliant environmental policy please contact the EnvironmentalEducation Officer for Business and Industry at Environment Waikato on 0800 800 401.

STEP 2: Type up your policy and present to staff

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STEP 1: Draw flow diagrams of your processesto assess where you will collect yourmeasurement data.

Example:

Total Plant� paunch processing � paunch emptying� offal processing � paunch cleaning machine� boning room � flume conveyance� carcass dressing � apron and hand washing� slaughter area� cattle yards� truck wash

STEP 2: Hold a meeting to:� design a measurement strategy (see form on page 18)� delegate measurement tasks (see example on page 19).

3. GatherInformation

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Measurement StrategyWe will measure:

Area/Unit/Department

E.g. Stockyards

What will you measure

Water use per head of cattle

How will you measure it

Litres of water using watermeter/number of cattleprocessed

When and how often willyou measure it

Daily

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Example

Steps Expected Result

Delegation Sheet

To:

Project:

Objective:

Date Needed by:

Joe Bloggs

Stock yard water measurement

To identify the total amount of water used to washstockyards and to average it out to per head of cattle

03/10/99

Steps

Gather information

Communication

Present data

Expected Result

Data is recorded daily on worksheet

Communicate with other members in your unit of this project

Present worksheet and a summary on date required above

Delegation Sheet

To:

Project:

Objective:

Date Needed by:

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STEP 3: Design necessary forms or worksheetsfor recording measurements.

Remember to include:• processing speed• processing numbers• hours of operation• day of the week.

Measurement TipsWhat to Measure� Measure Volumes � not just flow rates� Measure mass of wastewater contaminants � not just concentrations

When to Measure• For control � measure as often as required• For monitoring � measure regularly• Monthly � will give you a general trend• Weekly � smooths out data over a week• Daily � shows daily variations• Continuous monitoring

- Will show differences between day and night and/or shifts- Requires logging and/or computer facilities

How to Measure� Need to collect flow-proportional samples (e.g. collect a 1L sample per 5m3

of effluent) because collecting grab samples may give inaccurate results� Sample wastewater from a sump to smooth out variations

Relate the Measurement to:� Time� Production

STEP 4: Gather other information such aslegal requirements, current costs,work practices, raw material use,production information.

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Sources of Information

Accounting Information• Water, energy, and raw material

costs and tariff structure.• Waste handling, treatment, and

disposal costs.• Waste water and sewer costs,

including surcharges.• Operating and maintenance costs.• Department cost accounting

reports.• Invoices.

Raw Material/Production Information• Product composition and batch

sheets.• Material safety data sheets.• Product and raw material

inventory records.• Operator data logs.• Operating procedures.• Production schedules.• Stock control records.

Other Information• Environmental policy statements.• Standard procedures.• Organisation charts.• Consumer feedback.• Sales records.

Site Check� See �Questions to ask during site

visit� in Helpful Information.

There are many places that you cangather information from. Here area few suggestions.

Regulatory Information• Environmental audit reports.• Emission inventories.• Waste, waste water, and air

emissions analyses, includingthose arising from intermediateprocesses.

• Resource consents andapplications.

Process Information• Process flow diagrams.• Design and actual material and

heat balances for:• production processes• pollution control processes.

• Operating manuals and processdescriptions.

• Equipment lists.• Equipment specifications and data

sheets.• Instruction booklets.• Piping and instrument diagrams.• Plot and elevation plans.• Equipment layouts.

Work Practices• Material handling.• Maintenance schedules.• Occupational health and safety

material.

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STEP 1: Hold a meeting to collate data gathered and identify options.

4. Identify Optionsand Implement Projects

Cleaner Production Options Chosen

Eg: Stockyards- Investigate option for dry cleaning

Reason for Choice

High water use and costs

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2

3

4

5

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7

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STEP 2: Rank options identifying cost, risk, monetary gain andenvironmental benefits.

Identify O

ptio

ns a

nd

Implem

ent P

rojects

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ImplementProjects

STEP 1: Project Phase 1 � Conceptual

• Determine projects needed.

• Establish goals.

• Estimate the resources the organisation is willing to commit.

• Make key personnel appointments.

STEP 2: Project Phase 2 � Planning

• Define the project organisation approach.

• Define project targets.

• Prepare schedule for execution phase.

• Define and allocate tasks and resources.

• Build the project team.

STEP 3: Project Phase 3 � Execution

� Perform the work of the project (ie. design, construction,production, delivery, etc.)

STEP 4: Project Phase 4 � Termination

• Assist in transfer of project.

• Transfer human and non-human resources.

• Transfer or complete commitments.

• Terminate project.

• Reward personnel.

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ProjectSummaryOption

1. Stockyards minimise water use

Hours Duration Comments Rank

Finish

Budget

Start

80 $6 000 11.1999 02.2000 Delegated to Joe B 6

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5. Incorporate CleanerProduction into DailyManagement

Set up monitoring and review programme andincorporate it into monthly reporting procedures.

Include environmental information and goodpractices into employee induction programmes.

Include Cleaner Production initiatives and workpractices into job descriptions.

Example 1: Section Manager

Example 2: Factory Worker

Key Task

Machine Operation

Team Participation

Improvement Input

Expected Result

To have effectively, efficiently andsafely operated machine.

To have worked effectively with otherteam members.

To have contributed ideas tocontinually improve processes whichwill benefit the environment, healthand safety, quality and profit.

Control Information

Productivity reportsHealth and safety records

Team feedback6 month performance review

Team meetingsDepartment reporting

Incorporate procedures and policies into a currenthealth and safety or quality management system manual.

Key Task

Project Management

Data Collection

Monitoring and Review

Expected Result

To have effectively overseen projectsand initiatives for health, safety,environmental and qualityimprovement.

To have managed staff resources forthe projects and initiatives.

All inputs and outputs of processeswithin the company have beenanalysed for waste minimisation,safety, quality efficiency andproductivity.

To have set up a monitoring andreview programme for improvementprojects.

Control Information

Monthly report to General Manager

Staff feedback

Monthly report to General Manager

Quarterly results

Inco

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Cleaner Production Websites

www.arc.govt.nz/cp/www.chinacp.com/eng/caselinks.htmlwww.unepie.org

References

Ministry for the Environment, Cleaner Production Guidelines 1994

Albert van Oostrom, MIRINZ Food Technology and Research

Lesley Stone, Target Zero Manual, 1997

Anne Vale, Environmental Awareness Training, Disquette

Type of organisation

Local authority (district or citycouncil) for information aboutland use, noise, recycling andlandfillseg, Trade Waste Officer

Regional council for informationabout water, discharges (air andwater) and hazardous wastes

Industry Contacts

Energy Efficiency andConservation Authority (EECA) foradvice on energy efficiencyprojects:

Local electricity supplier

Your list

Environment WaikatoFreephone 0800 800 401

MIRINZ Food Technology andResearch07 829 9844

Meat Industry Association04 473 6465

PO Box 388,Wellington

04 470 2200