THORNTON PARK MANUFACTURING FACILITY: ENVIRONMENTAL PERMIT APPLICATION Best Available Techniques and Operating Techniques Prepared for: Thorntons Limited Client Ref: 410.08504.00001 SLR Ref: 416.08504.00001 Version No: Final April 2020 Thorntons Limited Chocolate and Confectionary Manufacturing Facility Environmental Permit Application SLR Ref No: 416.08504.00001 Best Available Techniques and Operating Techniques April 2020 BASIS OF REPORT This document has been prepared by SLR Consulting Limited with reasonable skill, care and diligence, and taking account of the manpower, timescales and resources devoted to it by agreement with Thorntons Limited (the Client) as part or all of the services it has been appointed by the Client to carry out. It is subject to the terms and conditions of that appointment. SLR shall not be liable for the use of or reliance on any information, advice, recommendations and opinions in this document for any purpose by any person other than the Client. Reliance may be granted to a third party only in the event that SLR and the third party have executed a reliance agreement or collateral warranty. Information reported herein may be based on the interpretation of public domain data collected by SLR, and/or information supplied by the Client and/or its other advisors and associates. These data have been accepted in good faith as being accurate and valid. The copyright and intellectual property in all drawings, reports, specifications, bills of quantities, calculations and other information set out in this report remain vested in SLR unless the terms of appointment state otherwise. This document may contain information of a specialised and/or highly technical nature and the Client is advised to seek clarification on any elements which may be unclear to it. Information, advice, recommendations and opinions in this document should only be relied upon in the context of the whole document and any documents referenced explicitly herein and should then only be used within the context of the appointment. Thorntons Limited Chocolate and Confectionary Manufacturing Facility Environmental Permit Application SLR Ref No: 416.08504.00001 Best Available Techniques and Operating Techniques April 2020 CONTENTS INTRODUCTION ............................................................................................................... 1 1.1 Proposed Combined Heat and Power Plant (CHP) .................................................................... 1 1.2 The Site ..................................................................................................................................... 2 1.3 Working Hours and Staff ........................................................................................................... 3 THE INSTALLATION .......................................................................................................... 4 2.1 Exclusions from the Installation ................................................................................................ 4 OVERVIEW OF MANUFACTURING ACTIVITIES ................................................................... 5 3.1 Toffee and Boiled Sweets Manufacture .................................................................................... 5 3.2 Centres Manufacture ................................................................................................................ 5 3.3 Starch Moulding ........................................................................................................................ 5 3.4 Moulding Lines (Carle and Bhuler Lines)) .................................................................................. 5 3.5 Awema Filling Line .................................................................................................................... 6 3.6 Chocolate Enrobing Lines (enrobing lines 1, 3, 4, 5 & 6) ........................................................... 6 3.7 Packaging of Finished Confectionery Products ......................................................................... 8 3.8 Storage of Finished Goods ...................................................................................................... 12 3.9 Distribution of Products .......................................................................................................... 12 3.9.1 HGV Refuelling ................................................................................................................................................................ 12 OPERATIONAL ACTIVITIES .............................................................................................. 13 4.1 Receipt and Storage of Raw Materials .................................................................................... 13 4.2 Refrigeration ........................................................................................................................... 16 4.2.1 Cooling Towers ............................................................................................................................................................... 18 4.3 Cleaning .................................................................................................................................. 19 4.3.1 Process Lines and Manufacturing Areas ....................................................................................................................... 19 4.3.2 Raw Material Tanks ........................................................................................................................................................ 19 4.3.3 Tray Wash and Plaques and Pallets Wash ..................................................................................................................... 19 4.3.4 Moulds and Centre Trays ............................................................................................................................................... 19 4.3.5 Fat Traps and Drains ....................................................................................................................................................... 19 4.4 Diesel Storage ......................................................................................................................... 22 4.4.1 Vehicle Refuelling ........................................................................................................................................................... 22 4.4.2 Fire Water Sprinkler System .......................................................................................................................................... 22 4.5 Maintenance ........................................................................................................................... 23 4.6 Effluent Treatment .................................................................................................................. 23 . Thorntons Limited Chocolate and Confectionary Manufacturing Facility Environmental Permit Application SLR Ref No: 416.08504.00001 Best Available Techniques and Operating Techniques April 2020 4.7 Boilers ..................................................................................................................................... 24 4.7.1 Medium Combustion Plant Directive ............................................................................................................................ 25 4.7.2 Boiler Dosing Chemicals ................................................................................................................................................. 25 4.8 Transformers ........................................................................................................................... 26 BEST AVAILABLE TECHNIQUES ASSESSMENT ................................................................... 28 EMISSIONS .................................................................................................................... 29 6.1 Point Source Emissions to Atmosphere .................................................................................. 29 6.2 Odour ...................................................................................................................................... 29 6.3 Point Source Emissions to Sewer ............................................................................................ 29 6.3.1 Effluent Monitoring ........................................................................................................................................................ 30 6.4 Point Source Emissions to Water ............................................................................................ 31 6.5 Point Source Emissions to Land .............................................................................................. 32 6.6 Fugitive Emissions ................................................................................................................... 32 6.7 Noise and Vibration ................................................................................................................ 33 6.8 Pests ........................................................................................................................................ 34 6.9 Accidents and Emergencies .................................................................................................... 35 MONITORING ................................................................................................................ 35 7.1 Point Source Emissions to Atmosphere .................................................................................