rich sauces presentation

4th December 2013
Derek Doherty
Operations Director
Company Background
• Rich Sauces was founded in 1985 by Trevor Kells
• The business is privately owned
• We manufacture a broad range of the highest quality
mayonnaise, sauces, dressings and bouillons
• Our factory is located in Newtownards
• We supply customers in UK, Ireland, USA, Middle East &
“Every solution breeds new problems”
Arthur Bloch
Author, Murphy‘s Law
Do we need an Environmental Policy?
• Why does an SME need to have an environmental policy when we
have very little waste?
• We only have a few pallets of compacted waste going to landfill
every 4-5 weeks
• We attended a seminar in 2007 which highlighted the need to look
at waste streams entering the factory and the impact this had on
waste internally and externally
• Although at this stage we had no written policy we began our
environmental journey
Key Factors in our Policy
We assessed our energy and waste streams:
• Water – mains water
• Electricity – lighting / refrigeration
• Dry Waste – paper / cardboard / plastic / wood
• Wet Waste – wash water / waste product / effluent
• Train Staff – buy in and accountability
Meter and measure water volumes
Reduce hose dimensions / attach guns to hoses, for example:
1” hose = 60lpm x 12hrs = 43,200L
¾” hose = 40lpm x 12hrs =28,800L
½” hose = 25lpm x 12hrs =18,800L
The operatives complained about reduced water pressure and increased wash down
time. We stated to operatives that this was are new policy and it will take longer
Reduce rinse cycles for CIP system (subsequent impact on hygiene results)
Staff awareness - turn off taps / never leave hoses running / attach guns to hoses at
all times
• Measure where the electricity is going
• Explore market tariffs – are we on the right tariff
• Staff training: turn off lights, installation of PIR sensors for offices and factory,
and make people responsible for checking
• Power factor correction
• Refrigeration – update to inverter pack system
• Change lighting to energy efficient were practical – we have adopted a change
as they blow policy
• Inverters for motors over 2.2kw
Outside security lights 22 x 400w x 10hours = £4818 per annum
Change to 125w led 22 x 125w x 10hours = £1505
Dry Waste
How do we separate our waste which is currently going to compactor/landfill?
Cardboard - 7 Tonne per annum
Plastic – ½ Tonne
Metal – 2 Tonne
Secondary plastic – 1 Tonne
General waste – 8 Tonne
The benefit from separating this waste is that we now have an income from
this waste stream, we have reduced our landfill costs by 50%
Wet Waste / Effluent
Meter the WTP and assess overall volume
What can we take out at source – start up and final production 300-500lpw - this is
recycled by a 3rd party for bio-diesel
• 2008 WTP cost £53,000 per annum
• Investment £65,000
• Target figure £30,000
• Payback 34 months
• Review annually to improve
• 2014 approx spend £22,000
Possibilities to reduce this further:
• Anaerobic digestion / de-watering system / composting
How Stem Continue to Add Value
• After all this hard work the company can consider itself to be
Environmental experts…or so we thought.
• Stem contacted Rich Sauces in December 2012 to assess our EMS
and conduct a free audit with a view to completing ISO 14001
• We soon realised that although we were committed on the practical
aspects we had no written policy with no real targets or aspirations
How Stem Continue to Add Value
• With Stem’s help we started to build an Environmental Management
System which would compliment our previous endeavours.
• We achieved our accreditation on 1st August 2013, 8 months after
being introduced to Stem.
• We have benefited from their experience and networking forums
which has allowed us to explore other revenue streams whilst
meeting our targets and obligations.
• By using the sustainable plan which Stem have provided we will
continue to learn and develop our Environmental strategy

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