Meat and Animal

Processing Industry
Environmental Guidelines
June 1999

1
Do you want to:

Avoid or reduce the amount of

waste your business produces?

Produce environmentally sound

products and services?

Use energy and resources more

efficiently?

Achieve less waste, lower costs and

higher profits?
If you have ticked one or all of the above circles then this
workbook is for you.

It’s an easy step by step approach towards environmental

improvement.

2
Acknowledgements
We would like to thank the participants and MIRINZ Food Technology and
Research for their assistance in the workshops and continuous ongoing support.
Some information in this workbook has been supplied by MIRINZ Food
Technology and Research.

3
Technical Report Number 1999/12

Contents
Introduction 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 Production

into Daily Management 27

4
Introduction
This workbook has been compiled to assist the meat and animal processing
industry to implement better environmental practices.

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

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
Cleaner production is about:
The goal of
• avoiding or reducing the amount of waste produced cleaner
• producing environmentally sound products and services
• using energy and resources efficiently production
• achieving less waste, lower costs and higher profits.
is to help
Cleaner production presents an opportunity for businesses to increase their
competitiveness in both the domestic and international markets. Results indicate
reduce
that significant reductions in resource use (both materials and energy), wastes, any adverse
emissions and cost savings are possible.
impacts that
The Benefits of Being production
Environmentally Responsible
and service
There are enormous benefits to be gained from becoming an environmentally activities
responsible organisation. The company, its employees, the local community
and everyone who is affected by negative impacts from the site can benefit may have
from the improvement in health, safety and quality of life that environmental
awareness creates. on the
Increased awareness, along with a strategy to change the way we do things,
environment.
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.

6
Stages in a Cleaner
Production Programme

• Policy • Implement Projects

- Commitment - Conceptual
- Development - Planning
- Action - Execution
- Termination
• Gather Information
- Flow diagrams of your process • Incorporating into
- Designing measurement strategy Daily Management
- Delegating tasks - Monitoring and review
- Measuring - Implementation into induction programmes
- Gathering information - Including initiatives into job descriptions

• Identify Options
- Collating data
- Ranking options

7
1. Helpful information 1
Blood

Helpful information
By reducing the volume of blood lost to the effluent stream by only 100L each day, a
meat plant disposing of its effluent by land application could reduce the land area
required by 2.5 ha. This blood, if recovered for blood processing, also represents a
gain 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 tissue
Some amount of animal tissue “waste” (including meat and fat trimmings) is
unavoidable in meat processing, but a primary aim should be to minimise the
amount of this material generated.

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

Faecal matter
and gut contents
Another important source of waste in meat processing is the faecal matter and gut
contents of slaughtered animals. These wastes enter the effluent stream in various
amounts 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 other
major by product processing operations, it is estimated that the faeces and gut
contents would typically account for more than 75% of the phosphorous and 50% of
the nitrogen, sodium and organic loading in primary screened or settled effluent
from the plant.

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However there are opportunities to minimise the loading of faecal and gut
content 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 regional
authorities).
• To maximise recovery of resources by screening, your screen should have a
fine 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 of
faeces from under your grating in stockyards.
• Investigate tailgate slaughter.

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Minimising Water
• Implement preventative measures to recover spillage and detect leakage.
This section
• Increase employee water conservation awareness.
summarises
• Reuse clean or contaminated water where possible.
various options
• Measure departmental water inflow to control water usage.
that can be used
• Control water to specific requirements and install flow control valves.
to minimise
• Use Countercurrent rinsing techniques.
wastewater.
• 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.

QUESTIONS TO ASK!

Incoming water Production

• What quantity and quality of feed operations
water is required for each unit of • Can excessive demand peaks or
operation?
washes be avoided or reduced?
• What sources of water are
• Identify the pattern of water use for
available on site? Are they of
each separate unit process. Is the
suitable quality and quantity?
water over-treated prior to use?
• What pre-treatment may be Can lower grade water be used
required? Is the existing pre- satisfactorily?
treatment system operating at its • Identify the pattern of waste
best? Can savings be made by
generation for each separate unit
using alternative
process. Why is it generated? Can
equipment or procedures?
it be reduced or eliminated?
• Has the demand pattern changed
recently or is it likely to do so in
the future? Wastewater
• Is it possible to segregate waste
streams at source?
• How does the cost of increasing the
degrees of treatment compare with
charges arising from effluent
discharge to sewer or watercourse?

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 Stormwater
What do you need to know about
stormwater?
The stormwater from your business travels via the gutters and drains to local
Processing streams or canals and eventually ends up in a river, in a harbour or on a
industries carry beach. If it is contaminated with pollutants such as grease, oil or other
out many chemicals it can kill fish and other water life, and seriously pollute the
activities that environment where people swim, fish and play. Keeping stormwater clean is
could pollute important and will assist in meeting consent conditions.
stormwater.

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

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

What can you do to stop

stormwater 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 wastewater
is directed to the sewer.
• If you cannot hose without getting dirty water in gutters or stormwater
drains, 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.

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Good Hazardous
Substances Practice
Most materials can be hazardous or dangerous to the environment if handled
or stored inappropriately. Businesses must have in place practices and
procedures to prevent accidental leaks and spills. Correct handling, carrying
and storage of materials can help stop pollution of the ground, stormwater
drains and local waterways.

Material safety data sheets (MSDS)

An MSDS is an information sheet on the safe use and disposal of a material. It
is just as important as any tool or piece of machinery in your factory. It contains
information that can save lives in an emergency. You should get an MSDS with
every hazardous substance you buy, handle or use. If you don’t have one for a
material, ask your supplier.

Use of chemicals
Think about the chemicals you are currently using. There may be a less
environmentally 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 from
stormwater drains. Cover, seal and bund the storage area.
• Bund storage areas to contain spills and cover them to prevent rusting of
drums. There must be no access for any spills or leaks to any drains. Protect
drums 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 and
storage is controlled by the Dangerous Goods Act. These substances include
petrol, solvents, liquefied petroleum gas and ammonia.
• Store and dispose of each type of chemical in a separate container. Clearly
label 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 avoid
damage and spills.
• Send all used chemicals to a licensed contractor for recycling or
disposal.
• Clean up all spills immediately. Have a spill kit in a clearly labelled and
easily accessible location.

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Emergency response to spills
• If a spill occurs that threatens or harms the environment, you must tell the
local council as soon as you can after you become aware of it. In the
Waikato 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 a
spill.
• 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 not
take emergency spill action without proper safety equipment, no matter how
urgent the matter appears to you.
• A spill kit might include rags, brooms and mops, booms to contain larger
liquid spills, material to stop any spill entering a drain, and material to soak
up 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 drains
by blocking the drain inlets.
3. Clean up the spill promptly by following the relevant MSDS. It is
important to clean up all spills quickly, even small ones, as they
can easily flow into stormwater drains or be washed there by
rain.

Solvents and oils

• Solvents tend to be highly volatile and flammable. Store them away from
heat, 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 area
well
ventilated.
• 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 land
value will be greatly reduced. If contaminants soak into the ground and reach
groundwater there is a high risk that they will flow off-site and contaminate
neighbouring land, groundwater supplies or local creeks. You may be liable
for any clean-up costs off site too.

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Questions to Ask
During Site Check
• What process controls are already in use to improve process efficiency?
• Which good housekeeping practices are already in force in the business to
limit the generation of waste materials and emissions?

• What investments in energy efficiency measures or energy reduction

management 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 by
the business? What is their quantity?

• From which production processes or treatments do these waste streams and

emissions originate?

• Which waste materials and emissions fall under existing environmental

regulations?

• What raw materials and input materials in the business or production

process generate these waste streams and emissions?

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

stream?

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

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

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15
2. Creating an
Environmental Policy 2

Creatinng an Environmental Policy

STEP 1: Call a meeting involving
management and staff representatives

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 environmental

improvement
because

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 our
environmental performance, management will be responsible for
the personnel department will be responsible for
and employees will be responsible for

Signed:

If you wish to produce an extensive ISO 14000 compliant environmental policy please contact the Environmental
Education 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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17
3. Gather
Information 3

Gather information
STEP 1: Draw flow diagrams of your processes
to assess where you will collect your
measurement 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).

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Measurement Strategy
We will measure:

Area/Unit/Department What will you measure How will you measure it When and how often will
you measure it

E.g. Stockyards Water use per head of cattle Litres of water using water Daily
meter/number of cattle
processed

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 Example
Delegation Sheet
To: Joe Bloggs

Project: Stock yard water measurement

Objective: To identify the total amount of water used to wash

stockyards and to average it out to per head of cattle

Date Needed by: 03/10/99

Steps Expected Result

Gather information Data is recorded daily on worksheet

Communication Communicate with other members in your unit of this project

Present data Present worksheet and a summary on date required above

Delegation Sheet
To:

Project:

Objective:

Date Needed by:

Steps Expected Result

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 STEP 3: Design necessary forms or worksheets
for recording measurements.

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

Measurement Tips
What 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 as

legal requirements, current costs,
work practices, raw material use,
production information.

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Sources of Information
There are many places that you can
gather information from. Here are
a few suggestions.

Regulatory Information Accounting Information

• Environmental audit reports. • Water, energy, and raw material
• Emission inventories. costs and tariff structure.
• Waste, waste water, and air • Waste handling, treatment, and
emissions analyses, including disposal costs.
those arising from intermediate • Waste water and sewer costs,
processes. including surcharges.
• Resource consents and • Operating and maintenance costs.
applications. • Department cost accounting
reports.
Process Information • Invoices.
• Process flow diagrams.
• Design and actual material and Raw Material/
heat balances for: Production Information
• production processes • Product composition and batch
• pollution control processes. sheets.
• Operating manuals and process • Material safety data sheets.
descriptions. • Product and raw material
• Equipment lists. inventory records.
• Equipment specifications and data • Operator data logs.
sheets. • Operating procedures.
• Instruction booklets. • Production schedules.
• Piping and instrument diagrams. • Stock control records.
• Plot and elevation plans.
• Equipment layouts. Other Information
• Environmental policy statements.
Work Practices • Standard procedures.
• Material handling. • Organisation charts.
• Maintenance schedules. • Consumer feedback.
• Occupational health and safety • Sales records.
material.
Site Check
• See “Questions to ask during site
visit” in Helpful Information.

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23
4. Identify Options
and Implement Projects 4

Identify Options and Implement Projects

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

Cleaner Production Options Chosen Reason for Choice

Eg: Stockyards- Investigate option for dry cleaning High water use and costs

STEP 2: Rank options identifying cost, risk, monetary gain and

environmental benefits.

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Implement
Projects
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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Project
Summary
Option Hours Budget Duration Comments Rank

Start Finish

1. Stockyards 80 $6 000 11.1999 02.2000 Delegated to Joe B 6

minimise water use

26
27
5. Incorporate Cleaner
Production into Daily 5
Management

Incorporate Cleaner Production into Daily Management

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

Include environmental information and good

practices into employee induction programmes.

Include Cleaner Production initiatives and work

practices into job descriptions.

Example 1: Section Manager

Key Task Expected Result Control Information

Project Management To have effectively overseen projects Monthly report to General Manager
and initiatives for health, safety,
environmental and quality
improvement.

To have managed staff resources for Staff feedback

the projects and initiatives.

Data Collection All inputs and outputs of processes Monthly report to General Manager
within the company have been
analysed for waste minimisation,
safety, quality efficiency and
productivity.

Monitoring and Review To have set up a monitoring and Quarterly results

review programme for improvement
projects.

Example 2: Factory Worker

Key Task Expected Result Control Information

Machine Operation To have effectively, efficiently and Productivity reports

safely operated machine. Health and safety records

Team Participation To have worked effectively with other Team feedback

team members. 6 month performance review

Improvement Input To have contributed ideas to Team meetings

continually improve processes which Department reporting
will benefit the environment, health
and safety, quality and profit.

Incorporate procedures and policies into a current

health and safety or quality management system manual.

28
Type of organisation Your list
Local authority (district or city
council) for information about
land use, noise, recycling and
landfills
eg, Trade Waste Officer

Regional council for information Environment Waikato

about water, discharges (air and Freephone 0800 800 401
water) and hazardous wastes

Industry Contacts MIRINZ Food Technology and

Research
07 829 9844

Meat Industry Association

04 473 6465

Energy Efficiency and PO Box 388,

Conservation Authority (EECA) for Wellington
advice on energy efficiency
projects: 04 470 2200

Local electricity supplier

Cleaner Production Websites

www.arc.govt.nz/cp/
www.chinacp.com/eng/caselinks.html
www.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

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