ABP CLONES: A VITAL PART OF BEEF INDUSTRY

Northern Standard reporter Michael Fisher was among a group from the Guild of Agricultural Journalists invited to tour the ABP meat plant at Clones last Thursday. The company organised a visit to a local beef farmer near Carrickmacross and sponsored a barbeque and dinner. The event was organised three months ago. NORTHERN STANDARD Thursday 16th June 2016 p.14

QUALITY IRISH BEEF

Irish beef has begun to re-establish its first class reputation on the menus of leading restaurants and the shelves of supermarkets in Britain and Europe. The Bord Bia Origin Green scheme of which the ABP Group is a founder member emphasises sustainability and the reduction of environmental impact. So any development in the agri-sector that could affect the reputation of quality beef is potentially worrying.

The ABP Group owned by businessman Larry Goodman is the largest beef processor in Ireland and the UK. It is proud of its record in producing quality Irish beef mainly for export to the United Kingdom and Europe. Various measures are taken at processing plants such as Clones to ensure that high standards are maintained at all times.

Visits to the ABP factory in Clones are strictly regulated. Human hygiene is crucial, as in any meat or food plant. On entry to the plant, visitors must wear protective clothing and hairnets, as well as removing jewellery. Footwear must be replaced by wellington boots, which are scrubbed meticulously in a special walk-through unit before entry is permitted to the boning and other sections. Hands must be washed and disinfectant gels applied.

The boning plant has different sections and each part of the animal carcass is used up along the line, starting with the hide. By-products are sent to some of the company’s other units.

The top class steak cuts were skillfully removed and later packaged, labelled with ABP’s own brand. In the packing hall differently coloured boxes indicated the various countries the meat was destined for, such as the Netherlands, Germany and Italy.

TRACEABILITY

Veterinary inspectors from the Department of Agriculture check the carcasses and stamp them before they are processed. Each carcass is given a tag with details of the farm it came from and where it was slaughtered. Photographs are taken of each individual carcass as it passes along the production line. New tags with barcodes are attached and after chilling they are sent to the boning hall. This is to ensure traceability of the meat to help reassure customers at the end of the food chain and to ensure quality can be maintained.

The tour of the plant then moves outside to the lairage facility where cattle arrive to be processed. The ABP Food Group say animal welfare is a cornerstone of their business, so they have invested heavily in ensuring that customers can be 100% secure in the integrity of their processes.

The company source farm-assured cattle from throughout Ireland (including Co. Monaghan) and the UK. Although the fields of Co. Fermanagh are just a stone’s throw away, the company processes only cattle from the Republic, within a 50 mile distance of the plant. This is because there are special regulations for processing cattle from the North and they could not be handled at the same time as animals from the Republic.

ABP worked closely with the bestselling author and world-renowned livestock-expert Dr Temple Grandin to design and plan their facilities and procedures. She approved every aspect of the holding pens (lairage), assisting the company’s goal to ensure cattle are relaxed and stress-free prior to slaughter. There is a special slat rubber system for the cattle to walk on. Not only does this give livestock the respect and integrity they deserve, but the lower pre-mortem glycogen levels and PH balance of stress-free animals make for a higher quality and tenderness of carcass, according to ABP.

Dr Grandin campaigned to reduce the prodding of cattle with electric goads by showing a humane approach makes much better quality meat. She designed the lairage with curved solid walls, baffled gate latches to cut down noise, and uniform colour and lighting to reduce stress on the cattle. The curved walls ensure each animal is prevented from seeing what lies ahead and just concentrates on the hind quarters of the animal in front of it.

George Mullan, general manager of ABP Clones, who showed the visiting group around the plant, said since the lairage was opened three years ago he had noticed a huge difference in the behaviour of cattle at the plant. They’re happier animals and calmer at all times, he said. “Animal welfare is a very major concern of the consumer in this present day”, he added.

Mr Mullan explained how following slaughter the patented hanging process increased the natural breakdown of muscle fibres in each carcass while it hung and matured prior to de-boning. ABP Food Group has also created a method of sympathetically chilling the carcass to prevent cold shortening and guarantee absolute tenderness in the beef.

The Managing Director of ABP Beef (Ireland) Finbarr McDonnell outlined the group’s four divisions. ABP Food Group Ireland is Europe’s leading beef exporter, specialising in beef processing, de-boning and retail packing. It has a long tradition of working with farmers and customers, operating highly efficient factories supplying quality beef to European and worldwide retail markets.

The UK branch of ABP is a leading supplier of fresh and frozen meat and meat-free products. It continues to drive innovation in every aspect of business, including collaborative partnerships with customers, to industry leading practices in processing and product development. The ABP Ellesmere development near Liverpool is an example of embedding sustainability at the heart of the company’s operations. Over £20million has been invested to make this plant a carbon neutral operation.

ABP Pet Foods is one of Europe’s leading manufacturers of private label pet food, producing 570,000 tonnes every year from seven facilities. C&D Foods with headquarters in Mullingar is headed by Philip Reynolds, whose father set up the original company. Philip sold a majority interest in the business to ABP in 2011.

The fourth arm of the group is Olleco, the largest collector of used cooking oil in these islands, employing 550 people. It helps many of the biggest restaurants and catering groups to maximise the environmentally sustainable treatment of waste food and oil products.

More than 30 years ago used cooking oil was collected and used in animal feed. When this was banned owing to tighter regulations, a huge amount of used cooking oil ended up in landfill or was illegally poured into drains. Olleco looked at other ways to recover the value from this resource. The company started to collect both used cooking oil and food waste and convert them into renewable energy instead of throwing it away.

With fourteen depots across the UK the company is one of the UK’s largest distributors of cooking oils to the catering trade. In 2013 a specialist biodiesel plant was constructed in Liverpool. Capable of producing 16 million litres of biodiesel it is the UK’s largest purpose built plant dedicated to producing biodiesel from used cooking oil. Two years later Olleco opened the first anaerobic digestion plant, providing the heat and power to operate the biodiesel plant. Tallow is collected at the Clones plant and is sent to England for processing.

Finbarr McDonnell joined ABP in 1973 and held a variety of positions with the company including Group Production Manager and Factory Manager at the Cahir plant. He was appointed Chief Executive of ABP Beef (Ireland) in January 2008. He predicted that with a market turning its back on Friesian types and a re-nationalisation of the French market, cattle prices could be hit in the latter half of 2016.

“It is unfortunate that sterling is where it is and unfortunate that live exports are dead in the water,” he told the Guild of Agricultural Journalists. He urged the country’s expanding dairy sector to prioritise cross-breeding with the traditional Irish Hereford and Angus breeds for which ABP were pushing an open door on export markets. He said the company was ‘concerned’ about how the Brexit referendum next Thursday might turn out.

Mr McDonnell said the market was now ten times more in favour of Hereford and Angus than Friesian beef, adding that he was “very worried” about the consequences for the progeny of dairy farms unless they adapted to breeding more for market requirements. ABP currently handled over a fifth of national output, equivalent to 125,000t per year. It planned to expand further on its 41 sites within the EU employing up to 9000 people. The company was optimistic of a successful outcome to its bid to buy 50pc of Slaney Foods within the coming weeks. The move would result in ABP controlling 28% of the national beef kill.

A year ago ABP Food Group completed a €50 million redevelopment of its facilities in Cahir, Co. Tipperary. It included an extension and upgrade of food processing facilities as well as the introduction of a new state-of-the-art gel bone production plant at its neighbouring by-products site. A report by Oxford Economics and KPMG found that the upgraded facilities employing over 600 people are expected to be worth over €200 million a year to the local economy in Tipperary and surrounding counties.

The plant in Clones employs around 300, with 60% of the staff coming from abroad, including Lithuania and Poland. Based on the Cahir study, this would indicate that the Teehill factory brings in a benefit of around €100 million a year to Co. Monaghan and the surrounding area. This is taking into account employment created by the factory in subsidiary areas like haulage and canteen supplies. ABP is one of the largest employers in the county. It also contributes to the local community through charitable activities such as sport.

THE SUPPLIERS

Freddie and Caroline Merrin farm land at Ballyloughan, Lough Fea, outside Carrickmacross. The Merrins operate a weanling to beef system and have received Bord Bia awards for their product. They are members of the 150-strong Monaghan Quality Cattle Producer Group that supplies cattle to ABP in Clones. Freddie is originally from Killanny and Caroline comes from Kells, Co. Meath.

The farm is 170 acres and there is a similar acreage on a long-term lease from the adjoining Lough Fea estate. The Merrins are helped by their three children, Emma, George, and Linda, a Leaving Certificate student at St Louis secondary school, Carrickmacross. Emma and George are both attend UCD, studying history and science respectively.

Weanlings are grazed and finished out of the shed as either bulls or steers the following winter. The sheds are multi-functional and there is a huge emphasis on grass utilisation. At the moment there are around 700 cattle on the farm. Freddie bought in 350 calves over a five-week period starting in mid-February. He would usually go to the mart in Bandon to buy them.

After a spell in the sheds the calves are out out to grass between mid-May and mid-June. Bull calves would usually be brought to be killed before 24 months and heifer calves before 20 months. When it came to sending them to the factory there could be no room for sentimentality, Freddie said.

ABP Group Livestock Manager Paul Mathews said the company was investing in genetics and had its own herd for research. He said they needed to build up a strong database about breeds and they were working alongside the Irish Aberdeen Angus Association. The Merrins enterprise was one of the best examples of a family farm amongst their suppliers, according to the company.