Nestlé USA - Beverage Division, Jacksonville, IL 2007 APR View/Print

OMB No. 2010-0032
Expiration Date 01/31/2010

2007 Performance Track Annual Performance Report

Nestlé USA - Beverage Division, Jacksonville, IL
A050128
Year 1 Annual Performance Report
Member Since 2007 (1st Member Term)

SECTION A: GENERAL FACILITY INFORMATION

A.1

Name of your facility:

Nestlé USA - Beverage Division, Jacksonville, IL

A.2

Name of your parent company:

Nestle USA, Inc.

A.3

Facility contact person for the Performance Track program:

Name:	Mr. Daniel Gunasekaran
Title:	Engineering Manager
Phone:	(217) 479-2257
Fax:	217-479-2280
Email:	daniel.gunasekaran@us.nestle.com

A.4

Facility location:

Facility Address

Street Address:	1111 Carnation Drive
Address Cont:
City:	Jacksonville
State:	IL
Zip Code:	62650

If your facility has multiple street addresses, please list any other addresses for its sites or buildings.

A.5

Facility's website address (if any):

http://www.nestle.com

A.6

Number of employees (full-time equivalents) who currently work in the facility:

100-499

A.7

For the purposes of where your facility would be listed in our Member Directory, please list the North American Industrial Classification System (NAICS) Code(s) that is (are) used to classify business at the facility:

Primary	Secondary	Tertiary	Quaternary	Quinary
311514

A.8.a

List the activities, products, or services that take place at your facility:

Nestlé Jacksonville produces and packages a non-dairy creamer, Coffee-mate.

A.8.b

Provide the size and general description of your site:

The Jacksonville facility is located on approximately 30 acres surrounded by farmland and located just outside the city limits of Jacksonville, Morgan County, Illinois. The facility has a total floor space of approximately 237,400 square feet. The original facility was constructed in 1970 and consists of the main building ranging in height from one to six stories, with mezzanines of 20 to 126 feet; a utility building, a recycling building and a small company store trailer.

A.9

Have the environmental requirements applicable to your facility changed during this reporting period?

SECTION B: ENVIRONMENTAL MANAGEMENT SYSTEM

B.1.a

Is your facility certified to ISO 14001?

B.2

Note: On this facility's Application or a previous Annual Performance Report, they reported having an independent assessment of their EMS in calendar year 2007. Since they are required to have an independent assessment every three years to remain a member of the Performance Track program, they will next report their independent assessment in calendar year 2010.

B.3

EPA recommends that Performance Track members conduct an internal EMS assessment (partial or complete) every year. Did you conduct one in calendar year 2007?

Yes

Internal EMS Assessment #1

When was this EMS assessment?	April 2007
Which EMS elements were included in the audit?	Policy, Planning, Implementation, Checking, Management
Did the assessment cover the entire facility or part of the facility?	Entire Facility

Internal EMS Assessment #2

When was this EMS assessment?	October 2007
Which EMS elements were included in the audit?	Policy, Planning, Implementation, Checking, Management
Did the assessment cover the entire facility or part of the facility?	Entire Facility

B.4

EPA recommends that Performance Track members conduct a regulatory compliance audit every year. Did your facility conduct any audits in calendar year 2007 to verify compliance with regulatory statutes?

Yes

Regulatory Compliance Audit #1

When was this regulatory compliance audit?

April 2007

Which regulations were included in the audit?

Clean Air Act (CAA)
Clean Water Act (CWA)
Emergency Planning & Community Right-To-Know Act (EPCRA)
National Pollutant Discharge Elimination System (NPDES)
Resource Conservation and Recovery Act (RCRA)
Safe Drinking Water Act (SDWA)
Superfund Amendments and Reauthorization Act/Comprehensive Environmental Response, Compensation, and Liability Act (SARA/CERCLA)
Underground Storage Tank (UST) Regulations

B.5

Note: Facility will be asked to report other audits and inspections in their 3rd reporting year.

B.6.a

Has your facility corrected all instances of potential non-compliance and EMS non-conformance identified during your audits and other assessments?

No such instances identified

B.6.b

Performance Track members should have a Senior Management Review of their EMS every year. Did this review take place in calendar year 2007?

Yes

Who was the senior manager present at the review?

Name: Mr. Rakesh Sreenivasam

Title: Plant Manager

B.6.c

Performance Track members should conduct a systematic identification and/or review of their environmental aspects at least once every two years. When was your last one conducted?

January 2008

SECTION C: ENVIRONMENTAL PERFORMANCE RESULTS

Goal 1: Nestlé USA - Beverage Division, Jacksonville, IL's first goal is to reduce the facility's total water use.
This is a challenge goal.
C.1.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	In 2007 the Jacksonville facility reduced water usage by 7.24% through water reduction awareness training and implementing a water savings project on the spray dryer. The dryer project involved increasing solids on the spray dryer, which in turn reduced moisture in the product leading to a decrease in water usage.
C.1.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	Water meter readings are used to measure progress toward this goal. Water usage data is recorded via meters and totalized on a monthly basis into an energy matrix. Energy matrix data is then input into Rockwell RS Energy Metrix which is then put into NEST (Nestle Environmental & Safety Performance Tracking) for analysis versus our goals.
C.1.c	Please report your facility's actual performance.

Performance Data
	Baseline	Year 1	Year 2	Year 3	Perform.
Calendar Year	2006	2007	2008	2009	Goal	Units
Actual Quantity (per year)	24,172,891	20,893,585			n/a	Gallons Specify other:

C.1.d

Normalized progress toward goal.

Normalized Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	.93
Normalized Quantity	24,172,891	22,466,220.43			20,546,957	Gallons Specify other:
Basis for your Normalizing Factor:	Pounds of Coffee-mate, non-dairy creamer, produced.

Goal 2: Nestlé USA - Beverage Division, Jacksonville, IL's second goal is to reduce the facility's total (non-transportation) energy use.
C.2.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	Progress towards this goal was delayed this year due to the installation of an indirect heater on our spray dryer. This project, a corporate safety technology mandate, allows for the use of a CO detection system on our spray dryer. The indirect heater has an efficiency of 90% compared to 100% efficiency of the direct fired heater that was replaced. We are in the process of looking at energy recovery projects for the next calendar year to offset this change.
C.2.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	Energy usage data is recorded via meters from each utility (electricity & natural gas) and totalized on a monthly basis into an energy matrix. We then input energy matrix data into Rockwell RS Energy Metrix which is then put into NEST (Nestle Environmental & Safety Performance Tracking) for analysis versus our goals. We monitor our usage and spending on a monthly basis to track our progress.
C.2.c	Please report your facility's actual performance.

Energy Generated Off-Site
	Baseline	Year 1	Year 2	Year 3	Units
Calendar Year	2006	2007	2008	2009	Units
Electricity Purchased
Electricity from Grid/Utility	20,463,709	20,343,698			Kwh Specify:
Electricity from Off-Grid Renewable Sources	0	0			Kwh Specify:
Total Electricity Purchased	69,822.18	69,412.70			MMBtus
	If your facility purchases electricity from the grid, please confirm that the electricity geographic region shown below is correct. If incorrect, please contact the Performance Track Information Center. SERC Mississippi Valley
Steam EPA will be determining the greenhouse gases associated with the generation of the steam that you purchase. We will be contacting you for additional information regarding the source of the steam generated.					Btus Specify:
Total Energy Generated Off-Site	69,822.18	69,412.70			MMBtus

Sources of Energy Generated On-Site
	Baseline	Year 1	Year 2	Year 3	Units
Calendar Year	2006	2007	2008	2009	Units
Coal					Specify:
Natural Gas	231,394	225,901			MMBtus Specify:
Crude Oil					Specify:
Fuel Oil					Specify:
Diesel					Specify:
Propane/LPG					Specify:
Gasoline					Specify:
Hydrogen Powered Fuel Cells					Specify:
Natural Gas/Methane Powered Fuel Cells					Specify:
Biomass					Specify:
Biodiesel					Specify:
Solar					Specify:
Wind					Specify:
Landfill Gas					Specify:
Geothermal					Specify:
Hydroelectric					Specify:
Tire Derived Fuel					Specify:
Other Fuel or Source Specify:					Specify:
Total Energy Generated On-Site	231,394.00	225,901.00			MMBtus

C.2.d Total energy use and associated greenhouse gas emissions.

Actual Energy Use Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Total Renewable Energy Use	2,792.89	2,776.51			n/a	MMBtus
Total Non-Renewable Energy Use	298,423.29	292,537.19			n/a	MMBtus
Total Energy Use	301,216.18	295,313.70			n/a	MMBtus
Metric Tons of CO₂ Equivalents	22,780.43	22,428.03			n/a	MTCO2E
Metric Tons of CO₂ Equivalents Offset due to Investments in Green Energy, e.g. green tags						MTCO2E
Net Metric Tons of CO₂ Equivalents	22,780.43	22,428.03			n/a	MTCO2E

Normalized Energy Use Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	.93
Total Energy Use	301,216.18	317,541.61			286,155.06	MMBtus Specify other:
Net Metric Tons of CO₂ Equivalents	22,780.43	24,116.16			21,641.39	MTCO2E Specify other:
Basis for your Normalizing Factor:	Pounds of Coffee-mate, non dairy creamer, produced

Goal 3: Nestlé USA - Beverage Division, Jacksonville, IL's third goal is to reduce the facility's generation of non-hazardous waste.

C.3.a Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.

In 2007, our awareness training and our recycling efforts are the main factors helping the Jacksonville facility achieve its sustainability goals. Our landfill volumes were reduced in 2007, while our recycled and animal feed increased, even with a 7% reduction in production. Our total non hazardous waste increased in 2007, since we generated a larger amount of substandard product during the manufacturing process. However, the substandard product was collected and sold as animal feed, which avoided landfill disposal. This is the main cause of our increased non hazardous waste.

C.3.b Describe the data collection process and data source(s) that you used to measure progress towards this goal.

Weights of non-hazardous waste leaving the facility are tracked on a monthly basis by our Recycling coordinator. The data is also included into NEST (Nestle Enviornmental & Safety Performance Tracking) for analysis versus our goals.

C.3.c Please report your facility's actual performance.

Performance Data

Waste Management Method Baseline Year 1 Year 2 Year 3 Units

2006 2007 2008 2009

Landfill

Specify other:
471 402 Tons

Specify other:

Reused/recycled off-site

Specify other:
481 482 Tons

Specify other:

Other management

Specify other: animal feed
730 770 Tons

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

C.3.d Summarized progress toward goal.

Actual Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Total Non Hazardous Waste 1,682.00 1,654.00 n/a Tons

Specify other:

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 .93

Total Non Hazardous Waste 1,682.00 1,778.49 1,632.00 Tons

Specify other:

Basis for your Normalizing Factor:
Pounds of Coffee-mate, non dairy creamer, produced

Progress Towards Other Significant Aspects of your EMS

In the table below, please provide a narrative summary of progress made toward EMS objectives and targets other than those reported as Environmental Performance Goals. You may limit the summary to environmental aspects that are significant and towards which progress has been made during the reporting year.

Do you have additional environmental aspects to report? Yes

Environmental Aspect Progress Made This Year (e.g., quantitative or qualitative improvements, activities conducted)

Installed high efficiency boiler At the end of 2007, the #2 Boiler was replaced with a smaller / high efficiency unit. The new boiler is smaller and energy efficient since it was designed to operate at 75-85% load during normal running conditions. Our Boiler #1 or larger boiler will be used as a back-up and during clean-ups when steam demand is high.

BOD reduction BOD reduced by 3% in 2007.

Emission Cap Evaluation Emission data is compiled & scrutinized on a monthly basis (12-month running total) to verify that we are compliant with our EMSA Limits on Emissions specifications.

Installed indirect fired heater Obtained an IEPA construction permit for the installation of the indirect fired heater on the spray dryer. This installation was mandated by Nestle corporate as part of an safety enhancement.

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING

D.1.a Please describe your process to identify potential community environmental concerns.

Nestlé Jacksonville has established and maintains a local community Stakeholder Group. The Stakeholder Group was originally formed in 2001 and consists of eleven participating individuals from but not limited to state and local agencies, businesses and special interest groups.

D.1.b If you identified community environmental concerns, how did you respond to them?

To date, no community environmental concerns have been identified or communicated to Nestlé Jacksonville.

D.1.c Please describe how you informed the community about environmental matters related to your facility.

Stakeholder Group meetings are scheduled at a minimum annually (more frequently if needed) plus Nestlé Jacksonville communicates via certified mail to the group throughout the year to finalize objectives & targets, report audit results, share environmental project status reports, and provide a year-end summary.

D.2 Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public. Please check all that apply.

Meetings, Bulletin Board, Building Lobby, Other
Please Specify Other: Mailings via certified mail to our stakeholder group.

OMB No. 2010-0032
SECTION E: SELF-CERTIFICATION OF CONTINUED PROGRAM PARTICIPATION FOR ANNUAL PERFORMANCE REPORT
The U.S. Environmental Protection Agency is not yet in a position to accept electronic signatures and therefore requests a faxed, signed copy of the Section E page. Please complete Section E online, then print Section E using the link on the Overview page. Section E should be signed by the senior manager of your facility and faxed it to the Performance Track Information Center at (617) 354-0463.
On behalf of Nestlé USA - Beverage Division, Jacksonville, IL, I certify that: I have read and agree to the terms and conditions as specified in the National Enviromental Performance Track Program Guide. This facility, to the best of my knowledge, continues to meet all program criteria; I have personally examined and am familiar with the information contained in this Annual Performance Report. The information contained in this report is, to the best of my knowledge and based on reasonable inquiry, true, accurate, and complete; My facility has an environmental management system (EMS), as defined in the Performance Track EMS criteria, including systems to maintain compliance with all applicable federal, state, tribal, and local environmental requirements, in place at the facility, and the EMS will be maintained for the duration of the facility's participation in the program; My facility has conducted an objective assessment of its compliance with all applicable federal, state, tribal, and local environmental requirements; and the facility has corrected all identified instances of potential or actual noncompliance; and Based on the foregoing compliance assessments and subsequent corrective actions (if any were necessary), my facility is, to the best of my knowledge and based on reasonable inquiry, currently in compliance with applicable federal, state, tribal, and local environmental requirements. I agree that EPA's decision whether to accept participants into or remove them from the National Environment Performance Track is wholly discretionary, and I waive any right that may exist under any law to challenge EPA's acceptance or removal decision. I am the senior manager with responsibility for the facility and am fully authorized to execute this statement on behalf of the corporation or other legal entity whose facility is part of the National Environmental Performance Track program.
Signature/Date:	______________________________________________________
Name:	Mr. Rakesh Sreenivasam
Title:	Plant Manager
Facility Name:	Nestlé USA - Beverage Division, Jacksonville, IL
Facility Street Address:	1111 Carnation Drive Jacksonville, IL 62650
Mailing Address:	,
Performance Track ID#:	A050128

Goal 3: Nestlé USA - Beverage Division, Jacksonville, IL's third goal is to reduce the facility's generation of non-hazardous waste.
C.3.a	Briefly describe your activities and achievements related to this goal or, if relevant, any circumstances that delayed progress this year.
	In 2007, our awareness training and our recycling efforts are the main factors helping the Jacksonville facility achieve its sustainability goals. Our landfill volumes were reduced in 2007, while our recycled and animal feed increased, even with a 7% reduction in production. Our total non hazardous waste increased in 2007, since we generated a larger amount of substandard product during the manufacturing process. However, the substandard product was collected and sold as animal feed, which avoided landfill disposal. This is the main cause of our increased non hazardous waste.
C.3.b	Describe the data collection process and data source(s) that you used to measure progress towards this goal.
	Weights of non-hazardous waste leaving the facility are tracked on a monthly basis by our Recycling coordinator. The data is also included into NEST (Nestle Enviornmental & Safety Performance Tracking) for analysis versus our goals.
C.3.c	Please report your facility's actual performance.

Performance Data
Waste Management Method	Baseline	Year 1	Year 2	Year 3	Units
Waste Management Method	2006	2007	2008	2009	Units
Landfill Specify other:	471	402			Tons Specify other:
Reused/recycled off-site Specify other:	481	482			Tons Specify other:
Other management Specify other: animal feed	730	770			Tons Specify other:
Specify other:					Specify other:
Specify other:					Specify other:

Actual Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Total Non Hazardous Waste	1,682.00	1,654.00			n/a	Tons Specify other:

D.1.a	Please describe your process to identify potential community environmental concerns.
	Nestlé Jacksonville has established and maintains a local community Stakeholder Group. The Stakeholder Group was originally formed in 2001 and consists of eleven participating individuals from but not limited to state and local agencies, businesses and special interest groups.
D.1.b	If you identified community environmental concerns, how did you respond to them?
	To date, no community environmental concerns have been identified or communicated to Nestlé Jacksonville.
D.1.c	Please describe how you informed the community about environmental matters related to your facility.
	Stakeholder Group meetings are scheduled at a minimum annually (more frequently if needed) plus Nestlé Jacksonville communicates via certified mail to the group throughout the year to finalize objectives & targets, report audit results, share environmental project status reports, and provide a year-end summary.
D.2	Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public. Please check all that apply.
	Meetings, Bulletin Board, Building Lobby, Other
	Please Specify Other: Mailings via certified mail to our stakeholder group.

SECTION A: GENERAL FACILITY INFORMATION

SECTION B: ENVIRONMENTAL MANAGEMENT SYSTEM

SECTION C: ENVIRONMENTAL PERFORMANCE RESULTS

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING

SECTION E: SELF-CERTIFICATION OF CONTINUED PROGRAM PARTICIPATION FOR ANNUAL PERFORMANCE REPORT