AQ_F_0200089_20170420_PRMT_Permit

ROY COOPER
Governor
MICHAEL S. REGAN
Secretary
Air Quality MICHAEL A. ABRACZINSKAS
ENVIRONMENTAL QUALITY Director
April 20, 2017
Mr. Clyde Goble
President
Royale Comfort Seating Inc., Plant No. 1
P. O. Box 235
Taylorsville, NC 28681
SUBJECT: Air Permit No. 08939R03
Facility ID No. 0200089
Royale Comfort Seating Inc., Plant No. 1
Taylorsville, Alexander County,North Carolina
Fee Class: Title V
PSD Status: Minor
Dear Mr. Goble:
In accordance with your completed Application Nos. 0200089.14A and 0200089.14B, we
are forwarding herewith Permit No. 08939R03 to Royale Comfort Seating Inc., Plant No. 1,
Taylorsville, Alexander County,North Carolina for the construction and operation of air
emissions sources or air cleaning devices and appurtenances. Additionally, any emissions
activities determined from your air permit application as meeting the exemption requirements
contained in 15A NCAC 02Q .0102 have been listed for information purposes as an
"ATTACHMENT" to the enclosed air permit. Please note the records retention requirements are
contained in General Condition 2 of the General Conditions and Limitations.
If any parts, requirements, or limitations contained in this permit are unacceptable to you,
you have the right to request a formal adjudicatory hearing within 30 days following receipt of
this permit, identifying the specific issues to be contested. Such a request will stay the
effectiveness of the entire permit. This hearing request must be in the form of a written petition,
conforming to NCGS 150B-23 of the North Carolina General Statutes, and filed with the Office
of Administrative Hearings, 6714 Mail Service Center, Raleigh, NC 27699-6714. The form for
requesting a formal adjudicatory hearing may be obtained upon request from the Office of
Administrative Hearings. Unless a request for a hearing is made pursuant to NCGS 15013-23,this
air permit shall be final and binding.
You may request modification of your air permit through informal means pursuant to
NCGS 15013-22. This request must be submitted in writing to the Director and must identify the
specific provisions or issues for which the modification is sought. Please note that the permit will
become final and binding regardless of a request for informal modification unless a request for a
hearing is also made under NCGS 15013-23.
State of North Carolina I Environmental Quality I Air Quality
217 W.Jones Street ;1641 Mail Service Center i Raleigh.North Carolina 276999641
919 707 8400

Mr. Clyde Goble
April 20, 2017
Page 2
Unless exempted by a condition of this permit or the regulations, construction of new air
pollution sources or air cleaning devices, or modifications to the sources or air cleaning devices
described in this permit must be covered under a permit issued by the Division of Air Quality
prior to construction. Failure to do so is a violation of NCGS 143-215.108 and may subject the
Permittee to civil or criminal penalties as described in NCGS 143-215.114A and 143-215.114B.
For PSD increment tracking purposes,Alexander County has been triggered for SOz.
However, no tracking is necessary for this modification as there is no change in SOz emissions.
This permit shall be effective from April 20, 2017 until March 31, 2025 is
nontransferable to future owners and operators, and shall be subject to the conditions and
limitations as specified therein.
Should you have any questions concerning this matter,please contact Brian Bland at
[phone].
Sincerely yours,
William D. Willets, P.E., Chief, Permitting Section
Division of Air Quality, NCDEQ
Enclosure
c: Central Files
Mooresville Regional Office
Connie Horne (cover letter only)

NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENTAL QUALITY
DIVISION OF AIR QUALITY
AIR PERMIT NO. 08939R03
Issue Date: April 20, 2017 Effective Date: April 20, 2017
Expiration Date: March 31, 2025 Replaces Permit: 08939R02
To construct and operate air emission source(s) and/or air cleaning device(s), and for the
discharge of the associated air contaminants into the atmosphere in accordance with the provisions
of Article 21 B of Chapter 143, General Statutes of North Carolina (NCGS) as amended, and other
applicable Laws, Rules and Regulations,
Royale Comfort Seating Inc., Plant No. 1
141 Alspaugh Dam Road
Taylorsville, Alexander County,North Carolina
Permit Class: Title V
Facility ID No. 0200089
(the Permittee) is hereby authorized to construct and operate the air emissions sources and/or air
cleaning devices and appurtenances described below:
Emission Emission Source Control i Control System
Source ID Description System ID Description
2 ;foam fabrication process
;consisting of glue spraying N/A N/A
operation j
in accordance with the completed Application Nos. 0200089.14A and 0200089.14B received
October 17, 2014 and December 29, 2014, respectively, including any plans, specifications,
previous applications, and other supporting data, all of which are filed with the Department of
Environmental Quality, Division of Air Quality (DAQ)and are incorporated as part of this permit.
This permit is subject to the following specified conditions and limitations including any
TESTING, REPORTING, OR MONITORING REQUIREMENTS:

Permit No. 08939R03
Page 2
A. SPECIFIC CONDITIONS AND LIMITATIONS
1. Any air emission sources or control devices authorized to construct and operate above must
be operated and maintained in accordance with the provisions contained herein. The
Permittee shall comply with applicable Environmental Management Commission
Regulations, including Title 15A North Carolina Administrative Code (NCAC), Subchapter
02D .0515, 2D .0521, 02D .0535, 02D .0540, 02D. 1806, 02Q .0207, 02Q .0317 (PSD
Avoidance), 02Q .0504(d) and 02Q .0507.
2. PERMIT RENEWAL REQUIREMENT- The Permittee, at least 90 days prior to the
expiration date of this permit, shall request permit renewal by letter in accordance with 15A
NCAC 02Q .0304(d) and (f). Pursuant to 15A NCAC 02Q .0203(i), no permit application
fee is required for renewal of an existing air permit (without a modification request). The
renewal request (with AA application form) should be submitted to the Regional Supervisor,
DAQ.
3. ANNUAL EMISSION INVENTORY REQUIREMENT- Pursuant to 15A NCAC 02Q
.0207, the Permittee shall submit an air pollution emission inventory report (with
Certification Sheet)by June 30 of each year in accordance with 15A NCAC 02Q .0207(a).
The report shall include the actual emissions of each air pollutant listed in 15A NCAC
.0207(a) from each emission source within the facility during the previous calendar year and
be submitted to the Regional Supervisor, DAQ. The report shall be in or on such form as
may be established by the Director. The accuracy of the report shall be certified by a
responsible official of the facility as defined under 40 CFR 70.2. This condition shall
become effective on January 1, 2018.
4. PARTICULATE CONTROL REQUIREMENT - As required by 15A NCAC 02D .0515
"Particulates from Miscellaneous Industrial Processes," particulate matter emissions from
the foam fabrication process consisting of glue spraying operation (ID No. ES-2) shall not
exceed allowable emission rates. The allowable emission rates are, as defined in 15A NCAC
02D .0515, a function of the process weight rate and shall be determined by the following
equation(s), where P is the process throughput rate in tons per hour (tons/hr) and E is the
allowable emission rate in pounds per hour (lbs/hr).
E= 4.10 * (P) 1.67 for P <=30 tons/hr, or
E= 55 * (P) all-40 for P>30 tons/hr
The Permittee shall maintain production records such that the process rates "P" in tons per
hour, as specified by the formulas contained above (or the formulas contained in 15A NCAC
2D .0515) can be derived, and shall make these records available to a DAQ authorized
representative upon request. The Permittee shall be deemed in noncompliance with 15A
NCAC 2D .0515 if the production records are not maintained or the types of materials and
finishes are not monitored.

Permit No. 08939R03
Page 3
5. VISIBLE EMISSIONS CONTROL REQUIREMENT -As required by 15A NCAC 02D
.0521 "Control of Visible Emissions," visible emissions from the emission sources,
manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged
over a six-minute period, except that six-minute periods averaging not more than 87 percent
opacity may occur not more than once in any hour nor more than four times in any 24-hour
period. However, sources which must comply with 15A NCAC 02D .0524 "New Source
Performance Standards" or .1110 "National Emission Standards for Hazardous Air
Pollutants" must comply with applicable visible emissions requirements contained therein.
6. NOTIFICATION REQUIREMENT - As required by 15A NCAC 02D .0535, the Permittee
of a source of excess emissions that last for more than four hours and that results from a
malfunction, a breakdown of process or control equipment or any other abnormal
conditions, shall:
a. Notify the Director or his designee of any such occurrence by 9:00 a.m. Eastern time
of the Division's next business day of becoming aware of the occurrence and
describe:
i. the name and location of the facility,
ii. the nature and cause of the malfunction or breakdown,
iii. the time when the malfunction or breakdown is first observed,
iv. the expected duration, and
V. an estimated rate of emissions.
b. Notify the Director or his designee immediately when the corrective measures have
been accomplished.
This reporting requirement does not allow the operation of the facility in excess of
Environmental Management Commission Regulations.
7. FUGITIVE DUST CONTROL REQUIREMENT - As required by 15A NCAC 02D .0540
"Particulates from Fugitive Dust Emission Sources," the Permittee shall not cause or allow
fugitive dust emissions to cause or contribute to substantive complaints or excess visible
emissions beyond the property boundary. If substantive complaints or excessive fugitive
dust emissions from the facility are observed beyond the property boundaries for six minutes
in any one hour (using Reference Method 22 in 40 CFR, Appendix A), the owner or
operator may be required to submit a fugitive dust plan as described in 02D .0540(f).
"Fugitive dust emissions" means particulate matter from process operations that does not
pass through a process stack or vent and that is generated within plant property boundaries
from activities such as: unloading and loading areas, process areas stockpiles, stock pile
working, plant parking lots, and plant roads (including access roads and haul roads).

Permit No. 08939R03
Page 4
8. CONTROL AND PROHIBITION OF ODOROUS EMISSIONS - As required by 15A
NCAC 02D .1806 "Control and Prohibition of Odorous Emissions," the Permittee shall not
operate the facility without implementing management practices or installing and operating
odor control equipment sufficient to prevent odorous emissions from the facility from
causing or contributing to objectionable odors beyond the facility's boundary.
9. LIMITATION TO AVOID 15A NCAC 02D .0530 "PREVENTION OF SIGNIFICANT
DETERIORATION" - In accordance with 15A NCAC 02Q .0317, to comply with this
permit and avoid the applicability of 15A NCAC 02D .0530 "Prevention of Significant
Deterioration," as requested by the Permittee, emissions shall be limited as follows:
'Affected Source(s) jPollutant Emission Limit
(Tons Per Consecutive 12-month Period)
Facility Wide VOC 250
10. REPORTING REQUIREMENT - Pursuant to 15A NCAC 02Q .0504(d) "Option for
Obtaining Construction and Operation Permit," the Permittee shall have one year from the
permit issuance date of Permit No. 08939R03, to submit a complete Title V application to
Raleigh Central Office and the Regional Supervisor.
11. 15A NCAC 02Q .0507 "APPLICATION" - Pursuant to 02Q .0507 "Application" and
following the submittal of the required Title V application, the Permittee, upon becoming
aware that any relevant facts were omitted or incorrect information was submitted in the
Title V application, shall promptly submit such supplementary facts or corrected
information to:
B. GENERAL CONDITIONS AND LIMITATIONS
1. In accordance with G.S. 143-215.108(c)(1), TWO COPIES OF ALL DOCUMENTS,
REPORTS, TEST DATA, MONITORING DATA, NOTIFICATIONS, REQUESTS FOR
RENEWAL, AND ANY OTHER INFORMATION REQUIRED BY THIS PERMIT shall
be submitted to the:
Regional Air Quality Supervisor
North Carolina Division of Air Quality
Mooresville Regional Office
610 East Center Avenue, Suite 301
Mooresville, NC 28115
[phone]
For identification purposes, each submittal should include the facility name as listed on the
permit, the facility identification number, and the permit number.

Permit No. 08939R03
Page 5
2. RECORDS RETENTION REQUIREMENT - In accordance with 15A NCAC 02D .0605,
any records required by the conditions of this permit shall be kept on site and made available
to DAQ personnel for inspection upon request. These records shall be maintained in a form
suitable and readily available for expeditious inspection and review. These records must be
kept on site for a minimum of 2 years, unless another time period is otherwise specified.
3. ANNUAL FEE PAYMENT- Pursuant to 15A NCAC 02Q .0203(a), the Permittee shall pay
the annual permit fee within 30 days of being billed by the DAQ. Failure to pay the fee in a
timely manner will cause the DAQ to initiate action to revoke the permit.
4. EQUIPMENT RELOCATION - In accordance with 15A NCAC 02Q .0301, a new air
permit shall be obtained by the Permittee prior to establishing, building, erecting,using, or
operating the emission sources or air cleaning equipment at a site or location not specified in
this permit.
5. REPORTING REQUIREMENT- In accordance with 15A NCAC 02Q .0309, any of the
following that would result in previously unpermitted, new, or increased emissions must be
reported to the Regional Supervisor, DAQ:
a. changes in the information submitted in the application regarding facility emissions;
b. changes that modify equipment or processes of existing permitted facilities; or
c. changes in the quantity or quality of materials processed.
If appropriate, modifications to the permit may then be made by the DAQ to reflect any
necessary changes in the permit conditions. In no case are any new or increased emissions
allowed that will cause a violation of the emission limitations specified herein.
6. In accordance with 15A NCAC 02Q .0309, this permit is subject to revocation or
modification by the DAQ upon a determination that information contained in the application
or presented in the support thereof is incorrect, conditions under which this permit was
granted have changed, or violations of conditions contained in this permit have occurred. In
accordance with G.S. 143-215.108(c)(1), the facility shall be properly operated and
maintained at all times in a manner that will effect an overall reduction in air pollution.
Unless otherwise specified by this permit, no emission source may be operated without the
concurrent operation of its associated air cleaning device(s) and appurtenances.
7. In accordance with G.S. 143-215.108(c)(1), this permit is nontransferable by the Permittee.
Future owners and operators must obtain a new air permit from the DAQ.
8. In accordance with G.S. 143-215.108(c)(1), this issuance of this permit in no way absolves
the Permittee of liability for any potential civil penalties which may be assessed for
violations of State law which have occurred prior to the effective date of this permit.
9. In accordance with G.S. 143-215.108(c)(1), this permit does not relieve the Permittee of the
responsibility of complying with all applicable requirements of any Federal, State, or Local
water quality or land quality control authority.

Permit No. 08939R03
Page 6
10. In accordance with 15A NCAC 02D .0605, reports on the operation and maintenance of the
facility shall be submitted by the Permittee to the Regional Supervisor, DAQ at such
intervals and in such form and detail as may be required by the DAQ. Information required
in such reports may include, but is not limited to, process weight rates, firing rates, hours of
operation, and preventive maintenance schedules.
11. A violation of any term or condition of this permit shall subject the Permittee to enforcement
pursuant to G.S. 143-215.114A, 143-215.114B, and 143-215.114C, including assessment of
civil and/or criminal penalties.
12. Pursuant to North Carolina General Statute 143-215.3(a)(2), no person shall refuse entry or
access to any authorized representative of the DAQ who requests entry or access for
purposes of inspection, and who presents appropriate credentials, nor shall any person
obstruct, hamper, or interfere with any such representative while in the process of carrying
out his official duties. Refusal of entry or access may constitute grounds for permit
revocation and assessment of civil penalties.
13. In accordance with G.S. 143-215.108(c)(1),this permit does not relieve the Permittee of the
responsibility of complying with any applicable Federal, State, or Local requirements
governing the handling, disposal, or incineration of hazardous, solid, or medical wastes,
including the Resource Conservation and Recovery Act (RCRA) administered by the
Division of Waste Management.
14. PERMIT RETENTION REQUIREMENT - In accordance with 15A NCAC 02Q .0110, the
Permittee shall retain a current copy of the air permit at the site. The Permittee must make
available to personnel of the DAQ, upon request, the current copy of the air permit for the
site.
15. CLEAN AIR ACT SECTION 112(r)REQUIREMENTS - Pursuant to 15A NCAC 02D
.2100 "Risk Management Program," if the Permittee is required to develop and register a
risk management plan pursuant to Section 112(r) of the Federal Clean Air Act, then the
Permittee is required to register this plan with the USEPA in accordance with 40 CFR Part
68.
16. PREVENTION OF ACCIDENTAL RELEASES - GENERAL DUTY - Pursuant to Title I
Part A Section 112(r)(1) of the Clean Air Act "Hazardous Air Pollutants -Prevention of
Accidental Releases - Purpose and General Duty," although a risk management plan may not
be required, if the Permittee produces, processes, handles, or stores any amount of a listed
hazardous substance, the Permittee has a general duty to take such steps as are necessary to
prevent the accidental release of such substance and to minimize the consequences of any
release. This condition is federally-enforceable only.
17. GENERAL EMISSIONS TESTING AND REPORTING REQUIREMENTS - If emissions
testing is required by this permit, or the DAQ, or if the Permittee submits emissions testing
to the DAQ in support of a permit application or to demonstrate compliance, the Permittee
shall perform such testing in accordance with 15A NCAC 02D .2600 and follow all DAQ
procedures including protocol approval, regional notification, report submittal, and test
results approval.

Permit No. 08939R03
Page 7
Permit issued this the 20r" of April, 2017.
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
William D. Willets,P.E.
Chief, Permitting Section
By Authority of the Environmental Management Commission
Air Permit No. 08939R03