Permit Fact Sheet
1General Information
Permit Number: / WI-0064815-01-0Permittee Name: / Richfield Dairy LLC
Address: / N3569 Vanden Bosch Rd
City/State/Zip: / KaukaunaWI54130
Discharge Location: / AdamsCounty, Town of Richfield
Receiving Water: / Fordham & Little Roche Cri Creeks, CentralWisconsinRiver Basin
Number and Type of Animals: / 4,300 Milking / Dry Cows and 250 Steers (400 lbs. to Market)
Number of Animal Units (AU): / 6,270 AU
Animal Units
Current AU / Proposed AU
(Note: If all zeroes, expansions are not expected during permit term)
Animal Type / Mixed / Individual / Mixed / Individual / Date of Proposed Expansion
Milking and Dry Cows / 0 / 0 / 6020 / 6149 / 01/01/2012
Steers or Cows (400 lbs. to market) / 0 / 0 / 250 / 250 / 01/01/2012
Total / 0 / 0 / 6270 / 6149
2Facility Description
Richfield Dairy is a proposed new dairy facility owned and operated by Milk Source Holdings, Inc. The proposed dairy facility would house 4300 milking / dry cows and 250 steers for a total of 6270 animal units. Proposed facility structures include a sand-bedded cross-ventilated freestall barn (416’x1232’), 80 stall milking parlor (106’x164’), livestock holding area (74’x194’), concrete feed storage pad (680’x765’), vegetated treatment area for precipitation runoff after collection of first flush (932’x348’), sweet corn silage bunker (658’x221’x12’height), HDPE lined sweet corn silage attenuation basin (23,500 sq. ft.), manure processing building (92’x210’), concrete lined separated manure solids storage area (202’x384’x12’height), animal mortality storage facility (14’x24’), covered concrete lined waste storage pond (480’x400’x28’deep), uncovered concrete lined waste storage pond (480’x250’x15’deep), commodity shed (120’x300’), shop (60’x120’), two high capacity water wells, four stormwater management ponds, Fuel Depot (24’x70’), weigh scale (12’x75’), potable water supply system, a domestic waste sewerage system and other lesser facilities. The proposed Richfield Dairy facility would be located is the southeast corner of the intersection of 1rst Drive and Cypress Avenue. Primary access to the facility would be from 1rst Drive. Total site disturbance entails the conversion of 115 acres of existing cropland to farm buildings, production area and ancillary area.
All livestock would be housed within a cross-ventilated and sand-bedded freestall barn. The combined annual estimated quantity of manure and process wastewater (including precipitation runoff) is 55.3 million gallons, plus an additional 8,552 tons of separated manure solids. Waste storage ponds (WSP #1 & #2), will have a combined design capacity of 33.2 million gallons (excluding freeboard), which represents approximately 205 days of storage for the proposed wastewater stream. WSP #1 will have a 6” thick concrete base with underlying 8” compacted clay liner which provides a secondary liner in the event of a concrete failure. An 8” clay liner will also be placed under the feed storage pad and manure solids storage area. WSP #2 includes a loading station for containment of any liquid spills while wastewater is being pumped to tanker trucks. After loaded, tanker trucks will then landspread on area farm fields in accordance with the DNR approved Nutrient Management Plan (NMP). Richfield Dairy owns or has agreements for landspreading manure and process wastewater on ~16,429 acres, which are generally located within a five mile radius of the farm site.
Stormwater runoff from the production and ancillary areas of the proposed Richfield Dairy facility will be handled by a series of culverts, swales and diversions directing flow to the stormwater detention ponds.
Richfield Dairy is required to submit a high capacity well permit application to the DNR to construct two high capacity wells. The proposed wells would be drilled to a depth of ~150’. Based upon 2010 soil borings, the static groundwater level at the proposed site is no less than 32 feet from the ground surface. Water usage at the facility is estimated to be about 52.5 million gallons per year, which includes 44 million gallons for animal watering / cleaning and 8.5 million gallons for evaporative cooling of the barn during hot weather.
The proposed construction start date for the Richfield Dairy facility is March, 2012. The facility anticipates reaching the 6,270 AU threshold by 2013. The project cost is estimated at $35 million. The facility expects to employ ~ 40 staff with an estimated annual payroll of $1.5 million. The applicant owns and operates four other permitted confined animal feeding operations in Wisconsin: Tidy View Dairy (7000 dairy cows/9400 animal units, Outagamie County), Omro Dairy (2500 dairy cows/3500 animal units, Winnebago County), Rosendale Dairy (8000 dairy cows/11,500 animal units, Fond du Lac County) and the recently permitted New Chester Dairy (4300 dairy cows, 250 steers/6270 animal units, Adams County).(In table below also enter annual average discharge flow(s) and other applicable flows including averaging period such as annual average flow value in MGD.. or sludge in dry Tons/Year..)
(For animal waste include details of animal types, animal numbers, total animal units, any future expansion plans, dates of construction of existing operation, storages, runoff control systems ...)
Page 1 of 7
Sample Point Designation For Animal WasteSample Point Number / Sample Point Location, WasteType/sample Contents and Treatment Description (as applicable)
001 / Waste Storage Pond #1 (WSP #1). This sample point addresses liquid manure and process wastewater stored within the HDPE covered concrete lined storage pond located on southwest side of the facility and immediately north of WSP#2. WSP #1 was constructed in 2012 with top dimension of 480'x400'x28 deep, with a useable capacity of 25.3 million gallons or 156 days of storage capacity. Manure and process wastewater overflows WSP#2 into WSP #1 and are connected by two 18" HDPE pipes.
002 / Waste Storage Pond #2 (WSP #2). This sample point addresses all liquid manure and process wastewater stored within the uncovered concrete lined waste storage pond located on the southwest side of facility and immediately south of WSP#1. Constructed in 2012 with top dimension of 480'x250'x15 deep, with a useable capacity of 7.9 million gallons or 49 days of storage capacity. WSP#2 receives wastewater from the manure separation system and was designed to increase settling of suspended solids prior to overflowing into WSP #1 by means of two 18" diameter HDPE pipes.
003 / Separated solids. This sample point addresses separated manure solids and separated sand stacked on a concrete pad located on the south side of the facility. The stacking pad was constructed in 2012 with dimensions of 202'x384x12' height. All runoff flows into the roofed separation tank facility. Separated solid manure is hauled and land applied twice per annum while the separated sand is re-used for bedding.
004 / Waste Feed. This sample point addresses all waste feed generated at the facility at the feed storage area and sweet corn silage bunkers, including all waste material scraped from within the scrape lanes, waste solids removed from the collection trenches and any solids removed from the attenuation basin.
005 / Settled Solids (WSP #1). This sample point addresses manure land sand recovered from liquid manure storage pond #1. The sand is a result of settling within the multi staged system.
006 / Settled Solids (WSP #2). This sample point addresses manure land sand recovered from liquid manure storage pond #2. The sand is a result of settling within the multi staged system.
007 / Stormwater Management Pond #1. The concrete lined SWP #1 was constructed in 2012. This sample point addresses stormwater runoff from the feed storage area beyond the 0.15 inches of first flush that is collected and pumped to the WSF or flush flume. Stormwater overflows through four concrete notches onto a designed Vegetated Treatment Area. Sample for nutrient content prior to land application if the pond is pumped and applied.
008 / Settled Solids (SWP #1). This sample point addresses the removal of any accumulated settled solids remaining after the pond has been pumped. Representative samples for nutrient content of settled solids shall be taken prior to land application..
009 / AttenuationBasin. This sample point addresses settled solid removal from within the attenuation basin which collects runoff from the Sweet Corn Silage Bunkers located on the northeast side of the facility. Representative samples for nutrient content analysis shall be taken prior to land application.
Page 1 of 7
3Livestock Operations - Proposed Operation and Management
Page 1 of 7
Production Area Discharge Limitations
Beginning on the effective date of the permit, the permittee may not discharge pollutants from the operation’s production area (e.g., manure storage areas, outdoor animal lots, composting and leachate containment systems, milking center wastewater treatment/containment systems, raw material storage areas) to navigable waters.
Runoff Control
The permit requires control of contaminated runoff from all elements of the production area to prevent a discharge of pollutants to navigable waters in accordance with the Production Area Discharge Limitations and to comply with surface water quality standards and groundwater standards. Beginning on the effective date of this permit, (if needed) interim measures shall be implemented to prevent discharges of pollutants to navigable waters. In addition, permanent runoff control system(s) shall be designed, operated and maintained in accordance with the requirements found in USDA Natural Resources Conservation Service standards and ch. NR 243, Wis. Adm. Code. If any upgrading or modifications to runoff controls are necessary, formal engineering plans and specifications must submitted to the Department for approval.
Manure and Process Wastewater Storage
The permit requires the operation to have adequate storage for manure and process wastewater and that storage or containment facilities are designed, operated and maintained to prevent overflows and discharges to waters of the state. In order to prevent overflows, the permittee must maintain levels of materials in liquid storage or containment facilities at or below certain levels including a one foot margin of safety that can never be exceeded. If any upgrading or modifications to the storage facilities are necessary, formal engineering plans and specifications must submitted to the Department for approval.
The permittee currently has approximately seven months or 205 days of storage for liquid manure. The permittee must maintain 180 days of storage, unless temporary reductions in required storage are approved by the Department.
Solid Manure Stacking
The operation has proposed to stack solid manure. All stacking of solid manure shall be done in accordance ch. NR 243, Wis. Adm. Code, which includes restrictions from NRCS Standard 313. Stacking of manure is considered to be part of the production area and is subject to the Production Area Discharge Limitations.
Ancillary Service and Storage Areas
The permittee shall take preventative maintenance actions and conduct visual inspections to minimize pollutant discharges from areas of the operation that are not part of the production area or land application areas. These areas are called ancillary service and storage areas and include access roads, shipping and receiving areas, maintenance areas, refuse piles and CAFO outdoor vegetated areas.
Nutrient Management
With 4,300 Milking / Dry Cows and 250 Steers (440 lbs. to Market), it is estimated that approximately 52.5 million gallons of manure and process wastewater and 8,552 tons of separated manure solids will be produced per year. The permittee owns or has agreements for land spreading on approximately 16,429 acres of cropland. The permit requires all land spreading of manure and process wastewater be completed in accordance with an approved nutrient management plan. The permit will require sampling and analysis of manure and process wastewater that will be land spread. Land spreading rates must be adjusted based on sample analysis. The permit requires the permittee to maintain a daily log that documents land spreading activities. The permit also requires the submittal of an annual report that summarizes all land spreading activities. Plans must be updated annually to reflect cropping plans and other operational changes. Among the requirements, the plans must include detailed land spreading information including field by field nutrient budgets.
The permittee is required to implement a number or practices to address potential water quality impacts associated with the land application of manure and process wastewater. Among the permit conditions are restrictions on manure ponding, restrictions on runoff of manure and process wastewater from cropped fields, and setbacks from wells and direct conduits to groundwater (e.g., sinkholes, fractured bedrock at the surface). In addition, the permittee must implement a phosphorus based nutrient management plan that addresses phosphorus delivery to surface waters by basing manure and process wastewater applications on soil test phosphorus levels or the Wisconsin Phosphorus index. Additional phosphorus application restrictions apply to fields that are high in soil test phosphorus (>100 ppm).
The permitee must also implement conservation practices when applying manure near navigable waters and their conduits, referred to as the Surface Water Quality Management Area (SWQMA). These practices include a 100-foot setback from navigable waters and their conduits, a 35-foot vegetated buffer adjacent to the navigable water or conduit, or a practice that provides equivalent pollutant reductions equivalent to or better than the 100-foot setback.
In addition, the permittee must comply with restrictions on land application of manure and process wastewater on frozen or snow-covered ground. Included in these restrictions is a prohibition on surface applications of solid manure (12% solids) on frozen or snow-covered ground during February and March. Beginning January 1, 2010, WPDES Permitted CAFO’s are prohibited from making non-emergency surface applications of liquid manure (<12%) on frozen or snow-covered ground.
Monitoring and Sampling Requirements
The permittee must submit a monitoring and inspection program that outlines how the permittee will conduct self-inspections to determine compliance with permit conditions. These self-inspections include visual inspections of water lines, diversion devices, storage and containment structures and other parts of the production area. The permit requires periodic inspections and calibrations of land spreading equipment. The permittee must take corrective actions to problems identified inspections or otherwise notify the Department. Samples of manure, process wastewater and soils receiving land applied materials from the operation must also be collected and analyzed.
Sampling Points
The permit identifies the different sources of land applied materials (e.g., manure storage facilities, milking centers, egg-washing facilities) as “Sampling Points.” For these Sampling Points, the permittee is required to sample and analyze the different sources for nutrients and other parameters which serve as the basis for determining rates of application for these materials. Other areas are also identified as Sampling Points as a means of identifying them as areas requiring action by the permittee, such as an upgrade or evaluation of a certain system or structure (e.g., runoff control systems), even though sampling is not actually required.
3.1Sample Point Number:001- WSP #1; 002- WSP #2
Monitoring Requirements and LimitationsParameter / Limit Type / Limit and Units / Sample Frequency / Sample Type / Notes
Nitrogen, Total / lb/1000gal / 2/Month / Grab
Nitrogen, Available / lb/1000gal / 2/Month / Calculated
Phosphorus, Total / lb/1000gal / 2/Month / Grab
Phosphorus, Available / lb/1000gal / 2/Month / Calculated
Solids, Total / Percent / 2/Month / Grab
Page 1 of 7
3.2Sample Point Number:003- Separated Manure / Sand; 004- Waste Feed; 005- Settled Solids (WSP#1); 006- Settled Solids (WSP#2)
Monitoring Requirements and LimitationsParameter / Limit Type / Limit and Units / Sample Frequency / Sample Type / Notes
Nitrogen, Total / lbs/ton / Quarterly / Grab
Nitrogen, Available / lbs/ton / Quarterly / Calculated
Phosphorus, Total / lbs/ton / Quarterly / Grab
Phosphorus, Available / lbs/ton / Quarterly / Calculated
Solids, Total / Percent / Quarterly / Grab
Page 1 of 7
(also include any standard considerations for permit conditions (Code\Guidance) such asNitrogen Based Land spreading Requirements; Phosphorus Based Land spreading Requirements; Water Resource Based Land spreading Requirements and Groundwater Monitoring Requirements..)
Page 1 of 7
3.3Sample Point Number:007- Stormwater Management Pond #1; 008- Settled Solids (SWP #1) , and 009- AttenuationBasin Solids
(also include any standard considerations for permit conditions (Code\Guidance) such asNitrogen Based Land spreading Requirements; Phosphorus Based Land spreading Requirements; Water Resource Based Land spreading Requirements and Groundwater Monitoring Requirements..)
In accordance with the Production Area Discharge Limitations subsection of the WPDES permit, the permittee shall control contaminated runoff from all elements of the livestock operation to prevent a discharge of pollutants to navigable waters and to comply with surface water quality standards and groundwater standards. No sampling is required for runoff control sample points 007,008 & 009. In the event that removal of liquids or solids becomes necessary to perform maintenance or repair of the structure, representative samples shall be taken and analyzed for nutrient content prior to land application.
Page 1 of 7
4Schedules
4.1Emergency Response Plan
Develop / Update an Emergency Response Plan.
Required Action / Date DueDevelop Emergency Response Plan: Develop a written Emergency Response Plan within 30 days of permit coverage; available to the Department upon request. / 02/01/2012
4.2Monitoring & Inspection Program
Submit a plan detailing items necessary for permit reporting and compliance.
Required Action / Date DueProposed Monitoring and Inspection Program: Consistent with the Monitoring and Sampling Requirements subsection, the permittee shall submit a proposed monitoring and inspection program within 90 days of the effective date of this permit. / 04/01/2012
4.3Annual Reports
Submit Annual Reports by January 31rst of each year in accordance with the Annual Reports subsection in Standard Requirements.
Required Action / Date DueSubmit Annual Report #1: / 01/31/2013
Submit Annual Report #2: / 01/31/2014
Submit Annual Report #3: / 01/31/2015
Submit Annual Report #4: / 01/31/2016
Ongoing Annual Reports: Continue to submit Annual Reports until permit reissuance has been completed.
4.4Nutrient Management Plan
Submit annual updates of the nutrient management plan.