Developing An Effective Environmental Management System For Yorkshire Brewery

Aim

Develop an effective Environmental Management System for the Yorkshire Brewery.

The purpose of this report is to develop an effective Environmental Management System for the Yorkshire Brewery.

An Environmental Management System is a site-specific plan that aims to outline current and future strategies and systems to be put in place in order to protect the environmental and comply with current and future environmental legislation. This process includes an initial environmental review, an environmental policy, an analysis of environmental aspects and impacts, the development of environmental targets and objectives, as well as a proposed action plan.

The objectives compiled under the environmental management plan pertains to the recovery of the demolition and monitor as well as to improve the existing situation.

An environmental management plan is a site-specific plan that aims to outline current and future strategies systems to be put in place in order to protect the environmental and comply with environmental legislation. This section will outline base lining plans, benchmarking against other breweries, as well as proposed actions to be taken in order to achieve objectives and targets.

The larger issues at the Brewery became evident quickly during the interview stage: carbon emissions and water. One of the biggest contributors to brewery emissions is transportation of the product. As Yorkshire brewery is a small organization, they do not have as large of a footprint as international brands, however they do deliver and import their grain creating ample carbon emissions. According to their sustainability plan from last year, their biggest contributor to carbon emissions is their electricity consumption. Another sustainability issue is water consumption and waste water treatment. The water consumption is not monitored outside of their bills and there are no large scale water reduction policies in place. Water is required in large volumes to make a quality product, which is where the brewery’s priorities lie. Any water reduction plan would need to allow for ample supply to continue creating a superior product (Pickrell et al, 2001). 

The purpose of the Legal obligations) is to establish a starting point for an Environmental Management System (EMS). By constructing an IER, the current state of environmental performance can be determined for analysis and improvement. Existing systems and policies will be investigated and discussed. Strengths, weaknesses, challenges and risks for the Yorkshire Brewery is small microbrewery that is owned by a developer of Yorkshire Brewery (Nehring, 2003). The brewery values its environmentally beneficial policies which are currently in place. Although some aspects of the brewery are environmentally efficient, Yorkshire Brewery strives to continuously improve on how it impacts the environment. To keep improving, the key operational aspects in the following document that will be reviewed are water consumption, wastewater disposal, energy use, and carbon emissions. Potential opportunities to improve on efficiency while carefully reviewing these key areas will be highlighted. A major limitation to the brewery may be its size and budget. Larger industrial operations can make small modifications to equipment and have noticeable results; larger operations also tend to have a larger budget to replace equipment and technology ( et al, 2008). These factors have put microbreweries at a minor disadvantage to becoming as environmentally efficient as their larger competitors (Schalk, 2010). Changes to the way the beer is manufactured pose as risks to the quality of the beer. Each time a change is made, the outcome it has on the quality of beer will have to be monitored and assessed to ensure that the high standard The Yorkshire Brewery is small microbrewery that is owned by a developer of Yorkshire Brewery (Szwajgier, 2011). The brewery values its environmentally beneficial policies which are currently in place. Although some aspects of the brewery are environmentally efficient, Yorkshire Brewery strives to continuously improve on how it impacts the environment (Schalk et al, 2008). To keep improving, the key operational aspects in the following document that will be reviewed are water consumption, wastewater disposal, energy use, and carbon emissions (Rasool et al , 2000). Potential opportunities to improve on efficiency while carefully reviewing these key areas will be highlighted. A major limitation to the brewery may be its size and budget. They are, however, making positive strides in other ways such as the use of boxboard for carrying cases made from recycled materials. (Russell, 2011) All spent grain on site is not put into the waste stream; it is instead sold to local farmers as livestock feed, resulting in strong waste diversion. Since the Brewery was established, there have been no environmental accidents on site and they have protocol in place in case of spills or gas leaks. In addition to Yorkshire brewery policy the Brewery also contributes to sustainability by:

• Reusing water that is used to heat the machinery by steam after condensation;
• Having an emergency spill plan in place; however the spill still goes into the municipal sewage system along with normal waste water;
• Insulating all equipment/machinery to prevent heat loss and reduce energy consumption;
• turning on machinery only when in use;
• Keeping doors and windows closed to prevent heat loss in the winter;
• Avoiding heating water unnecessarily; and
• participating in the recycling program supplied to them through the Yorkshire brewery.
• Review and revise the EMP

Objectives

The larger issues at the Brewery became evident quickly during the interview stage: carbon emissions and water. One of the biggest contributors to brewery emissions is transportation of the product. As Yorkshire brewery is a small organization, they do not have as large of a footprint as international brands, however they do deliver and import their grain creating ample carbon emissions (El-Gilany et al, 2010). According to their sustainability plan from last year, their biggest contributor to carbon emissions is their electricity consumption. Another sustainability issue is water consumption and waste water treatment. The water consumption is not monitored outside of their bills and there are no large scale water reduction policies in place (Taylor, 2009).

In order to make improvements to operations and prevent as much pollution as possible, the Yorkshire Brewery will identify the significant environmental impacts of their activities and create goals and reduction targets to mitigate these impacts (Yoder- et al, 2011). Their goal is to implement changes to minimize significant environmental impacts while complying with all laws, regulations and guidelines applicable. The Brewery aims to prevent pollution through minimizing waste water discharge, energy reduction, and control carbon emissions throughout both the brewing and distribution process. In order for the policy to successful, they recognize that all employees must be informed of, and trained in, all company policies regarding environmental stewardship (Morris- et al, 2011).

The policy found both areas of environmental stewardship as well as areas of significant environmental impact that need to be addressed in the Environmental Management System.

The Brewery is governed by the environmental rules and policy of Niagara College and is involved in any initiatives and targets set by the school. The authority has released an Environmental Policy Statement in July of 2011 stating the direction and goals of their approach to sustainability and environmental stewardship (Niagara College, 2011).

The significant environmental aspects were chosen based on the activities, products and services (APS) at the Brewery and four significance criteria. The impacts of each APS were ranked under each significance criteria between Low (1) and High (3). The impacts that ranked the highest are considered Significant Environmental Aspects.

As the Brewery produces water-based beverages, water consumption is a very significant and necessary aspect of the brewing process. Large amounts of water are used during the mashing process as well as for cleaning and sanitizing the equipment after each use. The 2013 Sustainability Plan for Brewery (Okpala, 2013) estimates that 150 liters of water is used at the brewery for cleaning per week, and that generally five to six liters of water is used to make one liter of beer.

Environmental management plan

Monitoring and measuring

Internal audits must be done periodically to monitor the progress of the objectives and targets over the established time period.

Non-conformance, preventative & corrective action

Due diligence must be done to ensure that any issues identified during the Monitoring and Measuring is corrected and prevented in the future.

Records

Records must be kept to ensure that the ems is being followed accordingly. These records will be required to be seen by an auditor.

Audits

An internal auditing procedure must be put in place for the environmental management system, including a process and a schedule. 

Management review

Top management must periodically review the Environmental Management System to ensure that it is being followed. Resources shall be allocated to resolve any issues and aim towards improving the environmental initiatives in place.

1. K) Emergency Preparedness and Response
2. I) Existing emergency plans and procedures for dealing with environmental incidents (e.g. Accidental emissions, discharge, leakage…etc.) In the event of a spill, employees are trained to shut off the supply to the spill. Any and all discharges are permitted to pass into the municipal sewer system.
3. L) Monitoring and Measurement At minimum, annual water audits will need to be completed for the Brewery.
4. M) Evaluation of Compliance Results from the annual audits should be compared to assigned targets to evaluate compliance (Zaghloul et al, 2008).
5. P) Internal Audit A waste audit and a carbon audit were completed in 2013.

However, audits should include water and energy in the future.

Audits will need to be made annual in order to properly monitor objectives and targets.

The materials provided have been developed by Infotech Research with support from the Department of State and Regional Development, Victoria.  Many sources of information have been used including the valuable experience of micro brewers, the Victorian Wine Industry Association, AUSAID, World Bank and UNEP programs involving brewing. We would like to thank these people for their help and also point out that brewing technologies are changing and new opportunities for improved environmental performance are always occurring. So brewers should be vigilant in their efforts to continuously improve their operations.

Bullfrog Power has enabled the brewery to offset their energy consumption with green energy onto the power grid. They have chosen to support bullfrog in such a way that 100% of their energy is accounted as coming from renewable sources (Steam Whistle, 2014).

Catchment and Land Protection Act 1994 (Department of Natural Resources and Environment)

• Are you operating in a special water supply catchment area?  Refer to local water catchment management authority ( Rabin, 1995).

Water Industry Act 1994 (Department of Natural Resources and Environment)

• Do you discharge trade waste to a sewer operated by a water authority?  Refer to the water authority for specific requirements (Dargahi et al, 2007).

Annual external water audits will allow the NC Teaching Brewery to determine their baseline waste water production. In order to this, it is recommended that a waste water measuring meter be installed. This will allow the Yorkshire Brewery to accurately measure the amount of waste water being produced. In addition to this, it is recommended that a settling tank be installed on-site. This will reduce waste water production by collecting waste water and allowing a small level of treatment to occur, so that the waste water can be reused in the brewing process (Dargahi, 2012). 

Scope

Impact	Brewing	Fermenting	Packaging	Auxiliary
Air emissions	Steam and odour from wort boiling	Odour from wort aeration		Waste water odour
	Dusts from milling	Carbon dioxide from fermentation		Odour from solid wastes
				Loss of coolant to air
Waste water	Hot water	Hot water
	Cooling water
	Cleaning waste water	Cleaning waste water	Container cleaning waste water	General wash down waste
			Spills and breakages
Solid wastes	Dusts	Yeast to waste	Packaging wastes	Greases and oily rags
	Trub – spent grain	Fermentation solids	Broken product wastes
	Cleaning sludges /alkaline	Cleaning sludges /alkaline	Floor sweeps
	Filtration sludges / DE
Noise			High noise levels due to bottles…	Compressors and other motors
Energy consumption	High due to heating requirements	Energy consumption due to cooling	High due to heating
Water resource depletion	High water use due to extraction, boiling losses and cleaning	Water consumption due to cleaning	High water consumption due to bottle washing and cleaning

Water is required in large volumes to make a quality product, which is where the brewery’s priorities lie. Any water reduction plan would need to allow for ample supply to continue creating a superior product is located on-the-Lake campus and believes in investing in sustainability (Caffel, 1995).

To achieve this strategy, the Yorkshire Brewery has set goals in order to be successful in this strategy and demonstrate their commitment to continuous improvement and pollution prevention (NC Teaching Brewery, 2015).

Water.

The brewing process requires a large volume of water for a quality product; a great deal with which is discarded as waste water (Okpala, et al, 2013). The brewery neither monitors their water consumption nor their waste water discharge volume, which is release directly into the municipal storm water drains on campus (Wunderlich, 2013). During the interview, employees mentioned that they would like to see the waste water repurposed much like they have repurposed the spent grain in the past. Electricity is also a significant environmental impact for the brewery and the main contributor to their carbon footprint. , et al, 2008)

Views of stakeholders

The Yorkshire Brewery recognizes that stakeholders are essential for the business’ success both as a brewery and as environmental stewards (Rajesh, 2013). Consumers and investors are becoming increasingly aware and invested in companies who place priority on environmental integrity and these are the relationships we wish to attract. By participating in the goals and reduction targets set in the Niagara College Environmental Policy, reducing the significant environmental impacts will benefit the business as well as impress stakeholders (Ministry of Health. Statistics, 2012)

The regulations are as under-

Category

Waste minimisation  opportunities

Production efficiency improvement – the best way to reduce wastes is to make them into more product.

· Careful temperature control for malt cooking operation and beer fermentation process, proper control of yeast concentration in fermentation tanks, etc (Fix,, 2000). · Regular calibration of measuring instruments,  checking of pumps, mixers to ensure that they are in good operating conditions at all times. · Use Vertical Cylindrical Filter instead of the conventional filter press to maximise solids recovery ( Gellore, 1992). · Use a single fermentation tank system instead of a two fermentation tank system to reduce tank washing  requirement; · Use the  efficient filtration systems instead of filter press to filter beer to minimise the waste discharge; · Use fully biodegradable cleaning chemicals · Allow tanks to drain fully

Category	Waste minimisation  opportunities
Solid waste reduction	o Segregate waste streams to enable more efficient disposal.  For example separate plastics from cardboard packaging to enable recycling. o Look at the brewery’s packaging waste. o Divert organic solid wastes such as yeast wastes, trub, grain dusts, spillages from general waste to animal feed, or compost applications (Hornsey I, 2004).

Waste Water Management

In un-sewered areas land application through an irrigation system is the preferred approach which requires the treatment of the brewery effluent to achieve a water quality satisfactory for irrigation plus the implementation of sustainable irrigation practices (Barrett J, 1975). Direct application of treated effluent to land will generally be subjected to an EPA licence (Maltby et al, 2006).

The details of waste water treatment systems.

Category	Waste minimisation  opportunities
Waste water volume reduction	· Separate stormwater from general process effluent.  Stormwater is clean and does not require treatment.  Ideally it should be collected and used.  Including it with general effluent unnecessarily increases wastewater volumes. · Segregate tank sludges and incorporate into composting activities.  This will reduce solid loading of the liquid effluent stream (Almalk et al, 2012).
Recovery	· Recovery of  cooked malt for animal feed; · Recover CIP chemicals (acids or alkali solutions) for reuse · Recover CIP rinses for use in other operations such as neutralisation of wastewater; · Improve the wort recovery with membrane filtration techniques; · Heat exchange hot waste water streams with incoming water; · CO2 can be recovered from fermentation for use in carbonation, or waste water neutralization; · Even the biogas generated from waste biodegradation can be recovered and burnt as an energy source (Bland, 1993).

The categorisation of the consumption of the EMP strategies-

Category

Waste minimisation  opportunities

Energy savings

· Switch off equipment and lighting when not required (Al-Enezi, 2009). · Recover heat from wort boiling using heat exchangers with incoming water (Blanpain-Avet. 1999). · Recover energy from steam generated during wort boiling to preheat wort, or preheat incoming water. · Utilize natural ventilation and lighting wherever possible. · Consider variable speed drives if pumping loads with variable duties. · Make sure that compressed air leaks are promptly repaired. · Ensure that the compressed air system pressure is as low as possible (set to 50 kpa above greatest end user pressure requirement). · Eliminate compressed air usage for activities such as water blow off and sweeping or install high pressure-low flow nozzles. · Insulate chilled water lines. · Check door seals in coolrooms.  Minimise moisture and heat loads (such as lighting) in coolrooms. · Ensure that refrigeration condensers are kept clean (Almutairi et al, 2011). · Ensure that cooling water temperature is as high as possible (Alhusaini H, 2006).

To help sites identify legal issues that may be of relevance a checklist of questions and a guide to provisions is given below (Caffal, 1999).

Environment Protection Act 1970 (Environment Protection Authority)

• Does your site require Works Approval and/or Licensing?  (Refer to “EPA Works Approval and Licensing Flowsheet” to determine approvals and licensing requirements.) (Delvaux F et al, 2001)
• Do you discharge any liquid to a natural water body? (Refer to State Environment Protection Policy (SEPP) “Waters of Victoria”.) (Bamforth, 2001).
• Continuous improvement process

Environmental Monitoring is an essential tool in relation to environmental management as it provides the basis for rational management decisions regarding impact control. Monitoring shall be performed during all stages of the project (namely: construction, and operation) to ensure that the impacts are no greater than predicted, and to verify the impact predictions (Askounis, 1998).  

Legal obligations

Contingencies:

1. Disposal of bad beer batch
   1. Check holding tank capacity to treat a full batch
   2. Check ability to treat / neutralise
   3. If not sufficient to accommodate the batch tanker away the wastes using a licensed contractor
2. Septic tank operation failure (not on sewer)
   1. Examine the potential for diversion of wastes to other functioning septic tanks
   2. If not acceptable pump out the tank contents and tanker away
3. Mal odour from waste water storage tank
   1. Increase aeration if BOD is high(Zakari, 2011)
   2. Check ph and adjust if necessary
   3. Tanker away sludge and residues
4. Mal odour from solids
   1. Aerate the solids / or enclose
   2. Remove solids from site(Miedaner, 1996)
5. Caustic / chemical spill
   1. Neutralize spill (Sodium Bicarb or other neutralizing agent)
   2. Absorb onto sand / soil
   3. Collect for licensed disposal
6. Storm water contamination
   1. Prevent storm water outflow from reaching open drains
   2. Contain the contamination
   3. Neutralize
   4. Absorb or pump to containment
   5. Dispose of contaminated water in accordance with hazard.
   6. Improvement areas 

Site Inspection

• Bunding, shut off valves, interceptor pits and other containment devices serviceable (Anheuser-Busch. 2000). 

• Procedure for regular inspection of containment devices (Dargahi, 2010).
• Defines potential environmental emergencies for the site.
• Contains a site plan showing drainage, storage areas and location of spill kits.
• Has a communication procedure.
• Lists contact numbers for Fire Authority, EPA, Water Authority and Waste Management Contractors (Bkontakt, 2000).
• Reference to Material & Safety Data Sheets.

Identification of emergency response staff.

Training of emergency response staff (e.g. Use of spill kits, diversion).

General awareness on emergency response.

Drills and hazard identification.

Contractor awareness (particularly those loading and unloading).

Signage

Conclusions

In order to move towards the set targets and objectives, a series of steps will need to be taken. A proposed action plan outlines and defines the different steps to be taken towards the end goal. To start, internal and external audits will need to be done for water and energy in order to determine a baseline to compare future progress against. A year of auditing and monitoring will be necessary for creating a baseline year. The following sections outline proposed actions to be taken in order to achieve targets and objectives. The brewing process requires a large volume of water for a quality product; a great deal with which is discarded as waste water. The brewery neither monitors their water consumption nor their waste water discharge volume, which is release directly into the municipal storm water drains on campus. During the interview, employees mentioned that they would like to see the waste water repurposed much like they have repurposed the spent grain in the past. 

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