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Wrights Pies (Shelton) Ltd Weston Road Crewe CW1 6XQ

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Wrights Pies (Shelton) Ltd Weston Road Crewe CW1 6XQ Wrights Pies (Shelton) Ltd Weston Road Crewe CW1 6XQ EPR Application Document & BAT Assessment CL1001 1 Wrights Food Group CL1001 Table of Contents page Part A – Application Forms 3 • Application Form Part A • Application Form Part B2 • Application Form Part B3 • Application Form Part F1 Part B - Non-Technical Summary 4 Part C - Process Description 6 Part D - Section 1: Managing Your Activities 10 1.1 Accident Management 10 1.2 Energy Efficiency 13 1.3 Efficient Use of Raw Materials and Water 14 1.4 Avoidance, Recovery and Disposal of Waste 15 Part E - Section 2: Operations 16 2.1 Operating Techniques 16 2.2 Process Control 19 2.3 Raw Materials Preparation 20 2.4 Heat Processing Using Steam or Water 21 2.5 Cooling, Chilling, Freezing and Freeze Drying 22 2.6 Separation and Concentration of Food Components – Extraction 23 2.7 Cleaning and Sanitation 24 Part F - Section 3: Emissions and Monitoring 25 3.1 Point Source Emissions 25 3.2 Fugitive Emissions 26 3.3 Odour 27 3.4 Monitoring 28 Part G - Supporting Documentation 29 2 Wrights Food Group CL1001 Part A - Application Forms The following application forms are attached with this document and are appropriate to the type of application being made. • Application Form Part A • Application Form Part B2 • Application Form Part B3 • Application Form Part F1 3 Wrights Food Group CL1001 Part B - Non-Technical Summary Overview of the Scope of the Variation This environmental permit application is for Wrights Pies (Shelton Ltd) located in Crewe. The installation occupies an area of approximately 7.86 acres and is designed to produce savoury products, ready meals, confectionary and bread of all varieties which are distributed throughout the UK/EU and worldwide. The finished product capacity at the site is approximately 85 tonnes per day. Other activities on site include refrigeration, freezing, chilling of products and the generation of steam from natural gas boilers, which supply the site energy cooking processes and cleaning and technical backup services. There are a number of air and surface water emission points at the site. There are no direct surface water emissions to groundwater or surface water bodies. Instead, the wastewater from the site is released to sewer following treatment in an on-site effluent treatment plant. Wrights has a United Utilities discharge consent and undertakes regular monitoring of the wastewater to ensure compliance. The permit application is for the following scheduled activity: • Section 6.8 Part A(1)(d)(iii) Treatment and processing, other than exclusively packaging, of the following raw materials, whether previously processed or unprocessed, intended for the production of food or feed (where the weight f the finished product excludes packaging) – (ii)animal and vegetable raw materials (other than milk only), both in combined and separate products, with a finished product production capacity in tonnes per day greater than- (aa) 75 if A is equal to 10 or more Application Content This document has been compiled using the Environment Agency’s ‘The Food and Drink Sector (EPR 6.10)’ guidance document in relation to environmental permits. In order to satisfy the requirements of the Environment Agency (EA) such that an Environment permit can be granted, the permit application includes the following documents and assessments: • EA application forms A, B2, B3 and F1 • Site plans (Section G) • A Site Condition / Baseline Report (CL1002) • A H1 environmental risk assessment (CL1003) • Detailed Air Dispersion Modelling (CL1004) • Other supporting information (e.g. process descriptions, accident risk assessment, raw materials inventory) 4 Wrights Food Group CL1001 This application is being made in accordance with the Environmental Permitting Regulations and using the relevant available Environment Agency tools and guidance documents. 5 Wrights Food Group CL1001 0 Part C - Process Description Overview Wrights is a privately-owned business, with a manufacturing facility located in Crewe. The site occupies an area of approximately 7.86 acres. The installation is designed to produce savoury, ready meals, confectionary and bread of all varieties which are distributed throughout the UK/EU and worldwide. Other activities on site include refrigeration, freezing, chilling of products and the generation of steam from natural gas boilers, which supply the site energy cooking processes and cleaning and technical backup services. A site location and a site layout plan are included in the Site Condition/Baseline Report (Ref. CL1002). Process Descriptions Cooking and Baking The cooking processes that are undertaken on-site involve the use of a steam injection vessel either pressurised or atmospheric. The product in the vessel are cooked to the required temperature and cooled before being used on the production lines. Ready Meals are produced within a BCH (Rochdale Ltd) cooking vessel and then transferred to the various process lines. A Pro-seal line produces the finished product in C pet (Trays) ready to heat and eat. Multivac machinery produces product in pouches ready to heat and eat. All the ready meal products are spiral frozen and packaged in spiral 3 packaging hall for distribution to customers. The baking of products is undertaken for baked distribution. Baking of product is based from a low care environment through the oven into high risk and high care areas. In these areas the product is cooled using air cooling tunnels and then moved into blast chilling. All products are chilled within four hours of baking to comply with food safety guidelines. Fresh baked or frozen baked products are dispatched to wholesale shop or third-party distributors. The production of bread is carried out in the cake factory, Vmi plantry mixers, mix the required recipe and then the dough is transferred to the konig forming plant. Here, the dough is rested and shaped to the required bread shape (e.g. rolls, baps). The moulded product is then placed on trays and transferred to proofers which are supplied from Mive. The proofer stage is completed under temperature and humidity controls and this takes about six hours to complete. After this, the product is transferred to the deck oven. Baked and then cooled ready for packaging and dispatch Confectionary products are produced in multi machinery, ranging from small range kitchen machinery to industrial sized machines. In some of the process’s, product is decorated by hand. Once formed the products are packed either through flow wrapping or boxed either at ambient temperature or frozen. 6 Wrights Food Group CL1001 There are two flour silo’s on site and they both have a maximum capacity of 30 tonne. The two silos hold different types of flour. One has puff pastry flour and the second has Golden Dawn. The silos are fitted with high level alarms (internal and external). The flour comes from ACM (Air Compressor Management) and a standard operating procedure is in place to ensure the silos are not overfilled during delivers. Metal and X ray detection is undertaken for protection against foreign objects that have the potential to cause harm. The system looks for ferrous, non-ferrous, plastic, stone objects. Directly Associated Activities Packaging There are a number of packaging areas located across the site. They are: 1. Spiral 1 packaging - this is for sausage rolls. 2. Spiral 2 packaging – this is for pasties and slices. 3. Spiral 3 packaging – this is for ready meals and some finished baked products. 4. Spiral 4 packaging – this is for pies 5. Spiral 5 packing – this is for various different cakes and frozen products In the packaging areas all products are placed into boxes and sealed and then palletised and sent to the distribution facility. Packaging materials are delivered to the dry goods warehouse and stored there until required (1600 item storage capacity). Packaging comprises cardboard, plastic, cans, foils and plastic bottles. Call offs occur from the different factories, depending upon what is required, and the packing is transported to the required factory by a forklift truck. Once packed products are transferred to cold store or wholesale distribution. There is a standard operating procedure in place at the site for packaging and all staff are fully trained. No waste is generated from the packaging process. Refrigeration The site operates various refrigeration units that supply the process equipment. Refrigeration systems are part of a service contract with Brooktherm Refrigeration and EJM Refrigeration. The service contract involves 5 main visits (big plant) and 26 minor visits (small plant). The ammonia-based system is for spiral freezing and frozen distribution storage and are also under service contract and all details are kept on the equipment list F gas inventory log. Cleaning in Place Cleaning in Place is undertaken at the site and the process is designed to comply with food safety standards. There are standard operating procedures in place for CIP and full cleaning records are maintained Effluent Treatment Plant Effluent treatment is undertaken onsite through a DAF process plant. The plant capacity is a maximum of 2m3 per hour. The process is automated, and the facility is located on 7 Wrights Food Group CL1001 hardstanding. Wastewater from the factories is collected in a balancing tank, then pumped through a sieve, black water tank and DAF. The site has a discharge consent in place with Untied Utilities. During the process the conductivity is monitored, and chemicals are dosed accordingly to bring the levels discharge to sewer to concentrations below the discharge consent. This process is monitored on a daily basis by trained competent staff and is verified by ESS (effluent site service) who are the service contractor for the site. ESS complete regular sampling and analysis on the wastewater. United Utilities also complete their own checks to ensure compliance. Chemical dosing substances are stored in IBCs on hardstanding in the location of the effluent treatment plant (ETP).
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