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SMITHFIELD PACKING COMPANY BMPs Training Conference 2013 – Chicago, IL

SMITHFIELD PACKING COMPANY BMPs Training Conference 2013 – Chicago, IL. SMITHFIELD PACKING COMPANY BMPs. Training Conference 2013 – Chicago, IL. Smithfield Packing Company BMPs. Sustainability Ideations Tar Heel Critical Control Point Operational Controls Wastewater Operations

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SMITHFIELD PACKING COMPANY BMPs Training Conference 2013 – Chicago, IL

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  1. SMITHFIELD PACKING COMPANY BMPs Training Conference 2013 – Chicago, IL

  2. SMITHFIELD PACKING COMPANY BMPs Training Conference 2013 – Chicago, IL

  3. Smithfield Packing CompanyBMPs • Sustainability Ideations • Tar Heel • Critical Control Point Operational Controls • Wastewater Operations • EMS Training for Plant Managers & Senior Staff • Weekly Environmental/Sustainability Call • Entering PMs related to Significant Aspects in SAP

  4. SUSTAINABILITY

  5. Plant Overview • Year Built: 1992 • Property Size: 888 acres • Building Size: 1million sq ft • Capacity (5 day wk): • Fresh Pork – 191,000 hd/wk • Converted Lbs – 11,725,000 lbs/wk • Marination - 250,000 lbs/wk • Lbs Distributed – 33,000,000 lbs/wk • Headcount: • Hourly = 4,439 • Salary = 300 • Union status: 56 % Union • Average Wage Rate (Oct 2012) • Hourly = $11.85/hr • Loaded = $19.75/hr

  6. Surface Water Plant Main Engine Room WW Water Plant Back-up Generators

  7. Relevant Info • Local Fueling Cost ~ $3.80 / gal diesel (non highway grade) • Refrigerated Storage Trailer $1500.00 / month • Utility Cost • Natural Gas $5.57 / MCF • Electric $0.0756 / KWH • Water $2.02 / 1000gal • Utility Usage • Natural Gas 759,642 MCF/yr • Electric 155,731,838 KWH/yr • Water 809,712 1000gal/yr • Spotter Service – Internal

  8. PLANT TOUR

  9. TEAMS

  10. Identified Opportunities • Plastic Recycling / Recycling Hub – Waste Industries • Shipping Condensers – Switch to Final Effluent versus Potable Water • Cryovac Bag Tails-Recyclable • Heat Exchanger- Boiler Blowdown Water and Boiler Feed Water

  11. Brainstorming • Generates large number of ideas • Goal is for participants to create new ideas off of other ideas • Seems like a “no brainer,” but right approach can improve idea output Rules for Brainstorming • No one interrupts, censors, criticizes, or praises • Questions are allowed only to clarify and idea • Hitchhiking off other ideas is encouraged • Freewheeling, unrelated ideas are okay here

  12. How to Brainstorm • Write a description of the brainstorming objective • Leads to more effective session • One person records the ideas so all can see • Flip chart, white board, or computer/projector will all work • Each person can offer one idea per turn • Avoiding “shout outs” keeps all participants actively involved • People can pass on one turn but come back in later if they think of something • Someone else’s idea may trigger a new idea later on • When everyone passes on a turn, the session is over • Compile the idea list for future use

  13. Determining Complexity

  14. INPUT/OUTPUT • Tar Heel Combined Ideation List.xlsx

  15. Critical Control PointsWastewater Operations • Critical Control Points (CCP) are areas in a process where something is measured to determine • Examples of CCPs in a wastewater system are: • Flow • pH • Turbidity • Oxygen Concentration • MLSS • Chemical Feed

  16. CCP Example – Grayson, KY • Grayson\2013 Critical Controls Grayson052413.xlsx

  17. Plant Manager Training • What is EMS • Benefits of EMS • Goals of EMS • Key Components of EMS • Roles • Environmental Aspects • Training • Communication • Controls • Monitoring & Measuring • Corrective Actions

  18. Plant Manager Training • Reviewed NOVs • Identified Root Causes • Mechanical • Program Execution • Corrective Actions • Equipment Upgrades • Equipment PMs in SAP • Identify Critical Spares • Improve EMS Training • Improve Awareness • Improve Participation • Improve Communication • Weekly Calls with PM

  19. Weekly Environmental/Sustainability Call • Held each Tuesday qt 1130 • VPs, Plant Managers, ECs • Agenda • NOVS • Spills/Releases • SMS Events • Regulatory • ISO 14001 • “SOP Of the Week”

  20. PMs in SAP • Prior top SAP, PMs were in Tab Ware • Included • Air Pollution Control Equipment for Title V Compliance • Weekly/Monthly Inspections for SWPPP and SPCC compliance • WW Equipment • Quick transition to SAP resulted in these items not being programmed into SAP • Ongoing effort to migrate these items and more into SAP

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