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CGPP Report 2004/23

AT A GLANCE
As part of its involvement in the Cleaner
Greener Production Programme (CGPP),
Seaborn Limited, a fish processing
company based in a highly populated
area of Dublins inner city, introduced an
advanced fish-smoking system which
has virtually eliminated nuisance
emissions of smoke and fish odours to
the external environment. Seaborns
involvement in this CGPP project has
also led to a reduction in the quantity of
waste and associated wastewaters
generated by the company during the
overall production process. The system,
which has been integrated into an
improved on-site environmental
management programme, continues to
consistently demonstrate the benefits of
using high environmental performance
measures to enhance product quality.

SEABORN LTD

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Seaborn Ltd is a subsidiary of Hanlon

Ltd fish processors, which was founded
in the Liberties area of Dublin in 1845.
Seaborn Ltd was established to cater
specifically for the production of
premium-priced smoked fish for the
upper end of the market. The
company, which was founded in 1950,
currently employs six people and
produces vacuum-packed smoked
salmon, trout and, to a lesser extent,
smoked mackerel, cod and haddock.
While its main customer base is in
Dublin, the company also exports a
range of products to Europe and the
USA. Seaborn was one of the earliest
recipients of the Irish Export Award,
which it won in 1969.

VIRTUAL ELIMINATION OF NUISANCE

ODOUR EMISSIONS CAUSED BY THE
PRODUCTION OF SMOKED FISH
AIMS OF THIS PROJECT
The main aim of this project was to design
and create an effective means of
combating odour emissions and noise
nuisance in the neighbourhood of Cork
Street, where the Seaborn operation is
based. Earlier attempts at end-of-pipe
treatment of dust pollution containing the
smoke particulates had failed and
therefore the company set out to eliminate
this environmental nuisance at source. This
objective was to be achieved through the
use of improved technological processes
and by adopting an integrated, proactive
approach to improved on-site
environmental performance generally.

hand-operated pressure hoses. Typically,

this is done in a fairly haphazard
manner.
After carrying out extensive
investigations, Seaborn identified a
technology which, in terms of
environmental benefits, appeared to
deliver greatly improved performance
compared to the system that
traditionally had been used by Seaborn.
Prior to its adoption by Seaborn (as part
of its involvement in the CGPP project),
this technology had not been tested
commercially in Ireland.

A secondary aim of the project was to use

the creation of a cleaner, greener brand
image as a marketing tool: this would be
aimed at overseas customers in particular.

PROJECT DESCRIPTION
Traditionally, in Ireland, the smoking of
food products is carried out in a smoke
house, where the smoke is generated by
means of a slow smouldering of wood
chips: this process tends to be poorly
controlled.
When a number of smoke cycles have
been completed, the systems are washed
down with caustic detergents sprayed by

Figure 1: New smokehouse unit in-situ,

showing walk- through smoke chamber
for fish fillet racks

BETTER BUSINESS IN A BETTER IRELAND

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The new system, which is manufactured by Ness in Germany,

incorporates some important features. They are as follows:
The entire drying and smoking cycle is executed using
computer-enabled process control.
Virtual elimination of smokehouse emissions to air is
achieved through the closely controlled generation of smoke
by means of friction created on a wooden block.
The smoke within the unit is contained in an enclosed
recirculation system.
Condensers are used for the reduction of vapour in the
air exhaust that is generated over the course of the drying
cycle.
Figure 3: Smoke-generation friction block
The units washing cycle programme is controlled in such
a way that it optimises the efficiency of the cleaning cycle in
terms of water, energy and cleaning agent consumption.

ACHIEVEMENTS
The companys overall processing operations have been
transformed as a result of introducing the new fish-smoking
system. The plant is now managed to a high environmental
standard. Emissions of smoke and fish odours to air, and
extractor fan noise have also been eliminated. The quantity
of wastewater generated during periodic clean-downs has
also been significantly reduced.
In addition, as the new fish-smoking system lends itself to
close automated control of the production process, waste
from off-specification fish product is no longer being
generated.

Figure 2: Laden fish fillet rack for placement in the

smokehouse unit.

Smokehouse production has continued to operate at normal

capacity, and, since November 2002 previous complaints
from neighbourhood residents about noise, smoke and
odour have not arisen.

During the summer and autumn of 2002, Seaborn installed

a new smokehouse unit, which has proven its capability in
terms of attaining high environmental performance without,
in any way, compromising product quality. During the same
period in 2002, the company embarked on a programme of
improved on-site environmental management, and it
introduced new training procedures, which were aimed at
raising employee awareness of the central role that cleaner
production will continue to play in the future development
of the company.
Figure 4: New smokehouse emission point to left of centre;
former smoke unit to right of centre.

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The table below shows comparisons of historic and current

emissions status.
Table 1: Comparative environmental performance
historical and current

Parameter

Previous
production

Cleaner
greener
production

Air

Nuisance
levels
of
smoke and
fish odours
Noise
nuisance

Virtual
elimination of
emissions to
air
Noise below
background
levels
120 litres per
year
4 m3/year

Noise

Cleaning
chemicals
Concentrate
wash water

360 litres per

year
9 m3 /year

To date, the company has received very positive customer

feedback, (most notably in Germany,) about this new clean,
green aspect to its operations and its range of products.
This particular dimension will continue to be promoted by
the company to its customers and in every aspect of its
marketing operations.

COST RECOVERY
While savings in operating expenses are insufficient to
provide meaningful cost recovery, other benefits, (while
non-quantifiable at this early stage), are expected to
become significant over time. These benefits include
improved marketability that has resulted from the brands
cleaner greener status and quality; savings in the
investment that would have been necessary in alternative
end-of-pipe treatments; the flexibility of Seaborn to
increase production (if desired) without any environmentally
related constraints being imposed.

LESSONS
Spoiled
product

Inputs
(wood)

1.5 7.5
tonnes per
year
1 tonnes per
year
20 tonnes per
year.

Inputs
(electricity)

Peak-time
electricity

Waste ash

None to date

Insignificant
Less than two
tonnes per
year
Off-peak
(night rate)

Product quality has been proven to be enhanced rather than

compromised as a result of introducing the cleaner greener
production system. Moreover, unlike traditional smokehouse
technology, the system appears to have no known
disadvantages.
Prior to its involvement in this CGPP project, and the
subsequent adoption of cleaner greener production
methods, the company was seriously limited from expansion
by virtue of the constraints imposed as a result of its
sensitive location i.e. in a highly populated city centre area.
However, the improved environmental performance that
Seaborn has managed to achieve has eliminated any such
constraints.
The cleaner greener credentials that the company have
gained are being actively used to market Seaborn products.

Use of this technology could enable many value-added food

manufacturers to operate in locations such as industrial
estates, where proximity to neighbours would previously
have presented a number of difficulties particularly in
relation to noise and odour.
While Seaborns use of this clean technology is for the
smoking of fish, the system is entirely suitable for use in the
production of a wide range of smoked foods including
meats, sausages, poultry and cheeses.
The favourable outcomes achieved as a result of the
approach taken by Seaborn, should act as a strong incentive
for other companies to adopt similar measures.

MORE INFORMATION
For more information on this project contact:
Mark McMahon
Managing Director
Seaborn Ltd
75-78 Cork Street
Dublin 8
Tel: 01-473 7425
Fax: 01-473 7479
E-Mail: sales@hanlon.ie
Website: www.smokedsalmon.ie

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CLEANER GREENER
PRODUCTION IS
the application of integrated preventive environmental
strategies to processes, products, and services to increase
overall efficiency and reduce risks to humans and the
environment.
Production processes: conserving raw materials and
energy, eliminating toxic raw materials, and reducing the
quantity and toxicity of all emissions and wastes
Products: reducing negative impacts along the life cycle
of a product, from raw materials extraction to its
ultimate disposal.
Services: incorporating environmental concerns into
designing and delivering services.

CLEANER GREENER
PRODUCTION REQUIRES
new attitudes, better environmental management, and
evaluating available technology options. We need to take
good environmental practice to the stage where it is an
inherent part of any business operation.

HOW IS CLEANER GREENER

PRODUCTION DIFFERENT?
Much of the current thinking on environmental protection
focuses on what to do with wastes and emissions after they
have been created. The goal of cleaner, greener production
is to avoid generating pollution in the first place.
This means:

Better efficiency
Better business
Better environmental protection
Lower costs
Less waste
Less emissions
Less resource consumption

WHY IS THE CLEANER

GREENER PRODUCTION
PROGRAMME BEING RUN?

The long-term goal is to ensure that cleaner, greener production

becomes the established norm in Ireland. The programme seeks to
promote environmentally friendly business through increased
resource productivity, waste reduction, recovery of materials,
improved efficiency in a product value chain, energy management,
and a change of culture within organisations.
The programme aims are focussed on avoiding and preventing
adverse environmental impact rather than treating or cleaning up
afterwards. This approach brings better economic and
environmental efficiency.

PROGRAMME MANAGERS:
The Clean Technology Centre (CTC) at Cork Institute of
Technology was appointed to manage the programme in
association with OSullivan Public Relations Ltd, and Energy
Transport Actions Ltd, (ENTRAC).
The CTC was established in 1991 and is now nationally and
internationally regarded as a centre of excellence in cleaner
production, environmental management and eco-innovation across
a range of industrial sectors.

WHERE CAN I GET

FURTHER INFORMATION?
This case study report is one of 29 reports
available from the organisations that
participated in the first phase of the Cleaner
Greener Production Programme. A summary
of all the projects and CD containing all the reports
are also available. More information on the Programme
is available from the Environmental Protection Agency
Ms. Helen Walsh,
CGPP,
Environmental Protection Agency,
Richview, Clonskeagh Road, Dublin 14, Ireland.
Tel. 01 2680100
Website

Fax. 01 2680199

www.epa.ie

select link to cleaner production.

Email. ertdi@epa.ie
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The Irish Government, through the National Development

Plan 2000 - 2006, has allocated funds to a programme for
Environmental Research, Technological Development and
Innovation (ERTDI).

The Department of the Environment and Local Government asked

the Environmental Protection Agency (EPA) to run the CGPP as
part of the ERTDI programme. With the programme continuing to
2006 about 60 businesses will be supported to implement cleaner
greener production and to demonstrate their achievements to the
rest of Ireland.