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Presentation 4 th December 2013. by 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

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by Derek Doherty Operations Director

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4th December 2013


Derek Doherty

Operations Director



  • 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 & Europe

“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