EIS : Nestle Cereal Milling Plant Expansion Project
ENVIRONMENTAL IMPLICATION STUDIES
OF
NESTLE CEREALS MILLING PLANT FACILITY EXPANSION PROJECT
PREPARED BY
RAMBIGAS NIGERIA LIMITED
FOR
NESTLE NIGERIA PLC
AGBARA INDUSTRIAL ESTATE,
AGBARA, OGUN STATE
SUBMITTED TO
OGUN STATE ENVIRONMENTAL PROTECTION AGENCY, ABEOKUTA, OGUN STATE.
MAY, 2009
13
EIS : Nestle Cereal Milling Plant Expansion Project
TABLE OF CONTENTS
PAGE
TABLE OF CONTENTS ii
LIST OF TABLES v
LIST OF FIGURES vi
LIST OF APPENDICES vii
LIST OF ABBREVIATIONS & ACRONYMS viii
STUDY TEAM xii
EXECUTIVE SUMMARY xiii
ACKNOWLEDGEMENT xxiii
CHAPTER 1 INTRODUCTION
1.0 The Applicant And Background Information 1
1.1 Nestle Nigeria Plc 1
1.2 Background Information 1
1.3 Legal and Administrative Framework 4
1.4 Objectives of EIA / EIS 6
CHAPTER 2 PROJECT JUSTIFICATION AND VIABILITY
2.1 Need for the Project 7
2.2 Level of Investment and Envisaged Sustainability of
Project 9
2.3 Warehouse Expansion Project Justification and
Sustainability 10
2.4 Terms of Reference ( TOR ) 11
CHAPTER 3 PROJECT DESCRIPTION
3.1 Nature of Project 14
3.2 Project Location 14
3.3 Consideration of Project Alternatives 16
3.4 Overview of Project Facilities 18
3.5 Process Description 20
3.6 Life Cycle Analysis ( inputs & Output Data ) 25
CHAPTER 4 DESCRIPTION OF THE ENVIRONMENT AND BASELINE
INFORMATION
4.1 Focus / Approach 28
4.2 Site Selection, Preparation & Construction 28
4.3 Project Land Area & Ecological Characteristics 30
4.4 Geology, Hydrogeology & Climatic Conditions 32
4.5 Socio – economic Features 36
4.6 Infrastructural Facilities 37
4.7 Identification, Quantification & Characterisation of Waste 38
CHAPTER 5 ASSOCIATED AND POTENTIAL ENVIRONMENTAL
IMPACTS
5.1 Focus / Associated / Potential Impacts and Specific Risk / Hazard
Assessment 50
5.2 Impact Assessment Method 50
5.3 Estimate of Magnitude and Significance of Potential
Project impacts 58
5.4 Hazards and Effects Management Process (HEMP) 62
5.5 Summary of Potential Environmental Risks and
Hazards Associated with Nestle MWFE Project 63
CHAPTER 6 MITIGATION MEASURES
6.1 Summary of Impacts, Source of Impacts and
Mitigation Measures. 65
CHAPTER 7 ENVIRONMENTAL MANAGEMENT PLAN
7.1 EMP / NEMS 67
7.2 Objectives of EMP 69
7.3 Relationship Between EMS & EMP 70
7.4 Supplementary EMP 72
7.5 Nestle EMP/S 75
7.6 Rehabilitation Plan Following Decommissioning / Closure 77
CHAPTER 8 CONCLUSION AND RECOMMENDATIONS 78
BIBLIOGRAPHY 80
LIST OF TABLES
PAGE
Table 3.1 : Overview of Project Facilities 18
Table 3.2 : Life Cycle Analysis – Showing Inputs, Output &
Losses as Waste 25
Table 4.1 : Air Borne Particulates measurement For Factory
Complex / Project Site 40
Table 4.2 : Noxious Gases Measurement for Expansion Plant 41
Table 4.3 : Analytical Results of Treated Effluent Leaving the
Factory Complex 44
Table 4.4 : Analytical Results of Noise Level Measurement in
the Factory Complex 47
Table 5.1 : Environmental Components / Impact Indicators 53
Table 5.2 : Rating Quantification For Impact Assessment 54
Table 5.3 : Degree of Importance Rating 55
Table 5.4 : Impact Matrix For Project Construction Phase 56
Table 5.5 : Impact Matrix For Project Operation Phase 57
Table 5.6 : Estimation of Magnitude and Significance of
Potential impacts of project 58
Table 5.7 : Applicable Risks by Project Components 61
Table 5.8 : HEMP Methodology 62
Table 5.9 : Summary of Potential Environmental risk & Hazards
Associated with the Project 63
Table 6.1 : Potential Negative Impacts & Mitigation measures 65
Table 7.1 : Management Plan/ Programme for Nestle
MWFE (Project Specific) 72
LIST OF FIGURES
PAGE
Figure 3.1 : Schematic Diagram of EHPM Processing Line 22
Figure 3.2 : Mixing Line Process Flow Chart 23
Figure 3.3 : Culinary Processing Line Flow Chart 24
Figure 4.1 : Geological Map of part of South West
of Nigeria – Covering the MWFE Project Site 31
Figure 4.2: Well / Borehole log : Lithology &
Construction 35
Figure 7.3 : Relationship between EMS & EMP 70
Figure 7.4 : Nestle Environmental Management System
(NEMS) Flow Chart. 71
LIST OF APPENDICES
PAGES
APPENDIX 1 : Factory Complex layout / Master Plan – showing
the Maggi & Warehouse Facility Expansion Project
Site Location. 82
2 : NEMS – Policy on Environment. 83
3 : National & State Environmental laws applicable
to the Food and Drink Industries. 84
4 : NEMS – Manual to Staff on health & safety. 86
5 : NEMS – Structure / organogram 87
LIST OF ABBREVIATIONS & ACRONYMS
AIE – Agbara Industrial Estate.
AEPSL – Agbara Estate Property Services Limited
BOD – Biological (Biochemical) Oxygen Demand
Ca – Calcium
CacO3 – Calcium carbonate
Cm – Centimeter
CSTP – Central Sewage Treatment Plant
COD – Chemical Oxygen Demand
CFC – ChloroFloroCarbon
Cl – Centiliter
Cr – Chromium
Cu – Copper
DO – Dissolved Oxygen
CPFEP – Cereal Products Facility Expansion Programme
CPFE – Cereal Product Facility Expansion
dB – Decibel
DS – Dissolved Solids
EIA – Environmental Impact Assessment
EIS – Environmental Implication Studies / Statement
EMP – Environmental Management Plan
EMS – Environmental Management System
Fe – Iron
FEPA – Federal Environmental Protection Agency
Fig. – Figure
FMEnv – Federal Ministry of Environment
g – Gram
H2O – Water
h – hour
H2S – Hydrogen Sulphide
HCO3 – Bicarbonate
H – Hydrogen
ISO – International Organisation for Standardisation
Kg – Kilogram
LGA – Local Government Authority / Area
LP – Low Pressure
LPG – Liquefied Petroleum Gas (Natural Gas)
M3 / d – Meter Cube / Cubic Meter Per day
M2 – Meter Square
Mg / L – Milligram Per Liter
Mm – Millimeter
Mg – Manganese
MPWFEP – Maggi Products & Warehouse Facility Expansion
Project
MWth – MegaWatt Thermal
N - Nitrogen
NaOH – Sodium Hydroxide (Caustic Soda)
PHCN – Power Holding Company of Nigeria
NEMS / P – Nestle Environmental Management System / Plan
NESREA – National Environmental Standards and Regulatory
Enforcement Angency
NH3 – Ammonia
NOx – Nitrogen Oxides
NSE – Nigerian Stock Exchange
% - Percentage
ODS – Ozone Deplecting Substance
P – Phosphorus
Pb – Lead
PH – Hydrogen ion Concentration
PVC – Poly Vinyl Chloride
PPm – Part Per Million
QMS – Quality Monitoring Scheme
RH – Relative Humidity
SHE – Safety, Health & Environment
SO2 – Sulphur dioxide
TDS – Total Dissolved Solids
TSP – Total Suspended Particulates
TSS – Total Suspended Solids
µ - Micron
µg – Micro – gramme
µs – Micron Siemen
UV – Ultra violet
WHEP – Warehouse Expansion Project
WWTP – Waste Water Treatment Plant
µg/L – Microgram per Litre
VES – Vertical Electrical sounding
oC – Degree Celsius
WHO – World Health Organisation.
EIS TEAM
The following represents the EIS Report Prepares and their various roles :
AUTHORS
Alhaji Gbolahan A. Solabi, BSc, MSc FNIFST, FIPAN – Team Leader
Mr Joseph A. Bamtefa, BSc. – Project Coordinator
CONSULTANTS & PARTICIPANTS :
Alhaji Gbolahan A. Solabi, - Environmental Chemistry, Data
Analysis, Socio – economic &
Health Impact Assessment.
Mr Eppi Fanio Joseph, – Geology, Hydrogeology
AMITSA, BCF & Climatic Data Collection.
Mr Joseph A. Bamtefa Bsc – Environmental Biochemistry
and Data Processing.
Mr Adewunmi Okumodi MSc – Analytical Chemistry & Air
Quality Assessment
DR. Sola Ojosipe (BATO) – Laboratory Analysis & Results
(Associate) Presentation.
NESTLE
Engr. Alex Richoz – Project Manager.
Background Information– Technical .
Engr. Ezekiel Aluko – Project Engineer
(Process Data Collection Facilitator)
Engr. (Mrs) Adeola Remi - John – Factory Safety & Environment Manager.
(Project Plant Coordinator)
Engr. Femi Ojumu – Factory Safety & Environment Officer.
Mr Kingsley Augustine – Data Collection Facilitator.
EXECUTIVE SUMMARY
1. THE APPLICANT
Nestle Nigeria PLC is a Multinational Company. It operates from three locations. The Head office is located at ILUPEJU, Lagos State. Both the Factory Complex and Distribution Deport / Centre are sited at Agbara and Ota respectively in Ogun State.
Simple trading operations in Nigeria began in 1961. The Factory Complex commenced Manufacturing Operations since 1979.
Nestle Nigeria was listed on the Nigerian Stock Exchange (NSE) in 1979 with about 22,843 Nigerian Shareholders. Currently Nestle S. A. of Switzerland and Nestle CWA Limited, Ghana are the major Shareholders of the company. As at 31st December 2008, the number of Nigerian Shareholders was about 31,000 with 37.7% Shareholdings.
The local processing of Maggi Products (cubes / tablets) began at Ilupeju prior to the commissioning of the Factory Complex in Agbara Industrial Estate in 1980.
Today, three decades, after the introduction of the Maggi Products, the culinary / kitchen aids have become very popular household cooking items both at domestic level and for hospitality outlets in the country.
The acceptability of the products as seasoning / culinary items by consumers has necessitated the current facility and storage capacity expansion project
LEGAL AND ADMINISTRATIVE FRAMEWORK
Nestle Nigeria Plc (NNP) is an integral part of Nestle S. A of Switzerland, and therefore adheres to the principle of sustainable development which conforms with International and National Requirements on the protection of the environment with respect to new developments.
Some of the specific statutes, guidelines and standards which regulate the Food (and Drink) Industries in Nigeria include :
i) Federal Environmental Protection Agency Decree No 58 of 1988 (now replaced by National Environmental Standards and Regulations Enforcement Agency (NESREA) Act 2007)
ii) Federal Ministry of Environment (FMEnv) Act of 1999
iii) Environmental Impact Assessment Decree (EIA) No 86, 1992. – This requires that EIA be prepared for all new major projects / activities.
iv) Ogun State of Nigeria, Environmental Protection Agency (OGEPA) Edict No 1, 1995. – Under this Edict, an industry undertaking any new project / expansion that does not fall fully under EIA, must conduct Environmental Implication Studies (EIS) which is what applies to Maggi Products and Warehouse Facility Expansion Project (MPWFEP).
The layout of the MWFE Project is in conformance with the existing national and international requirements that a Modern Food Industry is expected to comply with, regarding environmental protection during construction and operation phases of the project. It has also been endorsed by the Bureau of Lands, Survey and Town Planning of Ogun State of Nigeria.
The EIS has been prepared as a Pseudo EIA, using the OGEPA approved guidelines / regulations (2005).
2. PROJECT JUSTIFICATION & VIABILITY
The Maggi Products and Warehouse Facility Expansion (MWFE) Project was undertaken in order to :
o Increase the volume of Maggi Products for the numerous consumers nationwide.
o Introduce new generation of cubing and wrapping machinery for improved efficiency of processing the culinary products.
o Increase the holding / storage capacity of the warehouse and there by reducing the movement of Raw / Packaging Materials and Finished Products between Agbara Factory and the Main Warehouse at Ota depot.
o Provide additional job opportunities to Nigerians directly and indirectly and thereby assisting the country in her poverty alleviation programme.
o Enlarge the scope of the company’s operations in Nigeria and to enhance its desire to remain an attractive financial investment to its shareholders.
2.2 The viability and / or sustainability of the Expansion Project is hinged on : -
§ Usage / acceptability of the products which cuts across social strata, affordability coupled with continuous quality improvement and aggressive marketing support.
§ High local contents of the products with relatively low inputs from importation.
3. PROCESS DESCRIPTION / ACTIVITIES.
Maggi Products Facility Expansion (MPFE) project is best summarized from two perspectives, namely
1) Facilities for Processing which include :
q Those for Supply & Storage of Raw materials – weighbridge, forklift, pallets, Warehouse, platform weighing machine, Lansing, Big Bags, Big Bag Rings / Hangers / Cover, Chain Hoist, Big Bag Safety Bracket etc.
q Those for Processing / Manufacturing – Hopper, Pressing & Wrapping Machines, Collecting Conveyor, Cubes / Tablets Collecting crates etc.
q Those for Cleaning and Date Marking – Packers, Brushes, Scrappers, Printers & Computer.
2) Processing Operations – which can be described in THREE distinctive stages, comprising of about EIGHTEEN different steps :
The 3 main stages are ; Maggi Mass Processing, Maggi Cubes / tablets Processing & maggi Machop Processing.
STAGE ONE involves – cleaning of soyabeans, Fermentation, Cooking, Drying, Milling, Tipping / Weighing, Mixing & Sampling for QC and Packing of Finished Maggi Mass.
STAGE TWO involves – Sieving of Maggi Mass, Pressing of Sieved Mass, Cubing / Tableting, Wrapping & Sampling for QC and Packaging, Date Marking of cubes / tablets.
STAGE THREE involves tipping of Raw materials for the Maggi Machop, Satcheting and Sealing, monitoring of foreign bodies (metals), palleting and QC testing.
4. DESCRIPTION OF THE EXISTING ENVIRONMENT
The MWFE Project is located in Agbara Industrial Estate (AIE). This is a Private Estate, cited on about 454 hectares of land, in Ado – Odo Ota Local Government Area of Ogun State.
The Nestle Factory Complex, which houses the MWFE Project occupies an approximate 19.25 hectares of the total available land of the Estate (3.6%) while the Maggi Products Area and Warehouse Expansion cover a total of (1,600m2 + 5,000m2) which amounts to 3.4% of the Factory Complex.
The Project site required only minimal land preparation because the Factory Complex has been in operation for nearly three decades. The expansion location had been provided for in the factory.
Also the usual problem of land acquisition, ownership settlement / compensation payment and bush clearing, characteristic of new industrial project in Nigeria, were not encountered.
The Project site is not a VIRGIN Land. The Expansion sites (Maggi & Warehouse) are part of the existing processing and storage location.
However, some baseline information / data were obtained and presented. These include ;
4.1 Ecological Characteristics :
Showing that area falls within Lowland Rain Forest. The vegetation in and around the Estate is mainly farmland, bush fallow, secondary forest and fresh swamp forest.
4.2 Geology, Hydrogeology and Climatic Conditions :
Indicating that the Project location is part of Eastern portion of Dahomey (Benin) basin which extends into Ogun State (South West Nigeria). The sediments of the basin vary significantly in lithology and texture. The Vertical Electric Sounding (VES) data of the area revealed that the soil of the area is stratigraphically made up of FIVE geoelectric layers. These are essentially Sandy Ferrugenous / Reddish clay top soil, Clayey units, Sandy aquifers and Grayish Dark Clay.