AQ_F_0400016_20151112_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Wade Manufacturing Cc -Wadesboro
NC Facility ID 0400016
Inspection Report County/FIPS:Anson/007
Date: 11/20/2015
Facility Data Permit Data
Wade Manufacturing Co-Wadesboro Permit 03577/R18
Highway 74 East Issued 9/11/2015
Wadesboro,NC 28170 Expires 1/31/2019
Lat:34d 57.8720m Long: 80d 2.6476m Classification Synthetic Minor
SIC: 2261/Finishing Plants, Cotton Permit Status Active
NAICS: 313311 /Broadwoven Fabric Finishing Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact L(704)
orized Contact Technical Contact SIP
David Bruton Hodges David Bruton
Industrial Facilities t Industrial Facilities
Manager 4-2131 Manager
[phone] [phone]
Compliance Data
Comments:
Inspection Date 11/12/2015
Inspector's Name Jeffrey D. Cole
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
Action Code FCE
Date of Signature: //�Z G On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2014 12.39 1.02 5.51 9.77 4.49 12.38 1525.84
2013 11.80 0.0300 5.23 12.30 4.46 11.80 1945.30
*Highest HAP Emitted(in ounds
Five Year Violation History:
Date Letter Tyne Rule Violated Violation Resolution Date
11/09/2012 NOV 2D .0521 Control of Visible Emissions 11/19/2012
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

DIRECTIONS:
From downtown Fayetteville,take Raeford Road, Hwy 401, south to Wagram,—32 miles. Just west of
Wagram,turn right onto Old Wire Road(SR 144)to Laurel Hill. Turn right on Highway 74,bypass
Rockingham,to Wadesboro,—35 miles. Wade Mfg. is on the north(right)side of the Hwy 74,just after
the `Welcome to Wadesboro' sign. (Drive past facility and take a left at the stop sign.Vantage point from
neighborhood is perfect for VE observations).
NOTE: Mr. Bruton normally takes lunch from 11:00 AM to Noon, so plan the inspection accordingly.
NOTE: Main office closed from Noon to 1:00 PM. Call Mr. Bruton on his extension(x222) and he will
let you in.
SAFETY:
Standard DAQ FRO Safety Gear.Main safety concert is slips trips and falls from uneven and slippery
floors, stairs,and forklift traffic.
FACILITY DESCRIPTION/PROCESS DESCRIPTION:
Wade Manufacturing is a Synthetic Minor facility for S02,mainly from the burning of No. 6 fuel oil.
Wade Manufacturing makes, dyes and prints cotton and polyester/cotton blend fabric. The process
includes bleaching, dying,printing, and finishing of cloth. This facility has fabric finishing equipment
consisting of natural gas-fired tenter frame ovens and several napping areas. A tenter frame stretches
width under tension and consists of chains fitted with pins or clips to hold the selvages of the fabric,and
travelling on tracks.As the fabric passes through the heated chamber, creases and wrinkles are removed,
the weave is straightened,and the fabric is dried to its final size. The napping process is used to raise a
velvety, soft surface to fabric. The process involves passing the fabric over revolving cylinders covered
with fine wires that lift the short, loose fibres,usually from the weft yarns,to the surface,forming a nap.
The process,which increases warmth, is frequently applied to woollens and worsteds and also to blankets.
The facility does twist some yam for their Rockingham plant and does weave a specialty product for
McDonalds to clean their grills.All other yarn spinning,twisting, and weaving is now done at the
Rockingham plant. Two natural gas/No. 6 fuel oil-fired boilers are used to provide steam for some of
these processes. The company started business in 1926.Wade Manufacturing currently operates under air
permit no. 03577R18,issued 9 Sep 2015,with an expiration date of 31 January 2019.
Employees: —125
Hours: 4 or 5 days a week, 7 AM to 3 PM.
Throu - ut:
NEW Kim=
-- 2014 J- — 6.77 _._ 1.51 0.89 _3.4
2013 0 89-3.4 6.25 1.55

PERMITTED ENIISSION SOURCES (PLUS CONTROLS)_ _
Natural gas/No. 6 fuel oil-fired boiler
Bl ((72 mmBtu/hr maximum heat input) N/A N/A
Operating•12%capacity on NG. VE 0%.
Natural gas/No.6 fuel oil-fired boiler
B2 (24.76 mmBtu/hr maximum heat input) N/A N/A
Not operating
Textile roller printer
(3,600 pounds of cloth per hour process
capacity)consisting of:
PR3 a) 8 print stations N/A N/A
b) 1 natural gas direct-fired dryer
1(2 mmBtu/hr maximum heat input)
Not operating
Textile screen printer —�
(3,600 pounds of cloth per hour process
capacity)consisting of:
PR4 a) 8 rotary screen printing stations N/A N/A
b) 1 natural gas direct-fired dryer
(4.8 mmBtu/hr maximum heat input)with
four zones
Not operating
Textile screen printer
1(3,600 pounds of cloth per hour process
1 capacity)consisting of:
PRS I a) 12 rotary screen printing stations N/A N/A
b) 1 natural gas direct-fired dryer
(4.8 mmBtu/hr maximum heat input)with
four zones j
Operating VE—10%
Finishing range
(5,760 pounds of cloth per hour process
capacity)consisting of:
j a) 1 pad applied finishing station
'b) 1 natural gas direct-fired(12.0 mmBtu/hr
TEN2 N/A N/A
maximum heat input)eight zone tenter frame]
oven
Operating at unknown yards/minute.
Temperature 351-410°F Setpoint 420°F. ( f
Finishing range —
(4,320 pounds of cloth per hour process
1, capacity)consisting of:
1 a) 1 pad applied finishing station
TEN3 b) 1 natural gas direct-fired(6.0 mmBtu/hr N/A N/A
maximum heat input)two zone tenter frame
oven
Operating at 97yards/minute.
Temperature 377°F. Set point 375Y VE
0

One(1)bleach range and one(1)natural gas
�
direct-fired 8.5 mmBw/hr maximum heat
[��dTEN4 N/A N/A
input)three zone tenter frame oven �
Not operating
Steam heated cotton dye range
CRl Not operating _N/A __ -- N/A- -
Pigment range per er hour p pounds of cloth process
capacity)consisting of:
PIG 1 a) 1 natural gas direct-fired dryer(4.0
mmBtu/hr maximum heat input)predryer N/A N/A
b) 1 pad applied ink dyeing station
c) 1 steam heated dryer
Not operating
Thermasol range
(4,800 pounds of cloth per hour process j
capacity)consisting of: j
a) 1 nad applied finishing station
TRl b) 1 natural gas direct-fired dryer N/A N/A
(7.0 mmBtu/hr maximum heat input)dryer ! _
Operating at 70 yardsfminute.
Temperature 280°F. Set point 275°F. VE
Shop lathe
SLl (500 pounds per hour of rubber covered pad SL-IC
Cyclone
rolls) (15 inch diameter)
Not operating
- -'
BF-1 Bagfilter
(12 square feet of filter
area)
Starch storage silo I
SS 1 h(22.5 tons per hour filling rate) In parallel with ( In parallel with
Not operating
BF-2 Bagfilter
(12 square feet of filter
area)
OP-1CA Paper Panel Filter
(6.55 square feet of
filter area)
Blendomat
OPl (2,600 pounds per hour of cotton fiber) j In series with In series with
Operating. VE 0%.
OP-ICB Rotary Drum Filter i
(46.5 square feet of
j filter area
Carding and drawing operation F
yDrum Filter
ACl/CARDl (2100 pounds per hour of cotton fiber) CARD1-1C
square feet of
Operating. VE-10% face area)

-- -
Spinning operation Paper Filter
�F
AC2 (2100 pounds per hour of cotton fiber) FAC2-1C (266.8 square feet of
Operating. VE-10%
surface area)
AC3 Three(3)weaving areas AC34C Paper Filter
I(1,870 pounds per hour of cotton yarn, (371.2 square feet of
total capacity of AC3,AC4,and AC5) surface area)collect n9
C3,AC4,and AC5 were not operating. from AC-3
I I
AC4 AC44C Rotary Drum Filter
(834.9 square feet of
surface area)collecting';
AC-4.
{ i
i
ACS AC5-lC Rotary Drum Filter
(545.3 square feet of
j surface area)collecting
i AC-5.
NAP1 Two(2)napping areas NAP1-IC Rotary Drum Filter
1(2,370 pounds per hour of cotton cloth,total (483.3 square feet of
capacity of NAP l andNAP2) surface area)collecting
11 nappers total 9 napping operating and 2 from NAP 1.
not operating. VE-20%
NAP2 NAP2-1C Rotary Drum Filter
(142.1 square feet of
surface area)collecting
from NAP 2.
RP Retention Pond N/A N/A
;F Operating. VE 0%.No offsite odor.
INSPECTION SUMMARY:
On 12 November 2015, I,Jeffrey Cole of NCDEQ,began the compliance inspection with a check of the
roof stack emissions from the observation point mentioned in the directions;there were no apparent
exceedances. I then met with Mr.David Bruton and began with a FacFinder check and a review of the
required recordkeeping. There were no changes to the Facfinder and the required recordkeeping was
being accomplished. Mr.Bruton stated that the plant was operating normally and no changes had been
made to sources or operations since the last inspection. Mr.Bruton also stated that the company
appreciated the FRO's efforts in the recent Title V to Synthetic Minor permit modification.
I then proceeded on an inspection of all the facility's sources which included(in order):
• Textile roller printer(PR3):Printer hasn't run in a while as foreign competition makes operating
it impractical.
• Textile screen printer(PR4)
• Textile screen printer(PR5)
• Finishing range(TEN2): Tenter frame operating at an unknown yards/minute(didn't find speed gauge
during operation;went back to check but the process had stopped).
• Finishing range(TEN3)

• Bleach range and three zone Tenter Frame Oven(BL1 and TEN4)
• Pigment range(PIG I)
• Thermasol range(TRI)
• Two napping areas(NAPI and NAP2): Filter collects particulate and it drops out into building
below filter. Waste material is collected and sold to another company.
• Shop lathe(SLI)
• Carding and drawing operation(ACl/CARDI)
• Spinning operation(AC2)
• Three(3)weaving areas(AC3,AC4,and AC5):AC4 and AC5's power has been cut and do not
operate. —
• Starch storage silo(SSI)
• Retention Pond(RP)
• Blendomat(OPl):Paper filters automatically roll to expose new filter when pressure drop gets
close to 1.25". Blendomat will shut off when a paper filter roll needs to be replaced. Rolls are
checked daily.
• Natural gas/No. 6 fuel oil-fired boiler(B1)
• Natural gas/No. 6 fuel oil-fired boiler(132)
During the inspection I noticed two bagfilter that I had not noticed in the previous inspection. These
2 identical units sit side by side inside the facility and control the dust created in the facility's quality
control/inspection area. Both bagfilters vent inside the plant and are used solely to reduce dust inside the
facility.
At the inspection's exit summary, I summarized my observations and told Mr. Bruton that I had not seen
any deficiencies during my inspection.
STIPULATION REVIEW:
1. 15A NCAC 2D .0202."EMISSION INVENTORY REOUIREMENT"—Entire facility subject.
Submit permit renewal application and EI at least 90 days prior to permit expiration.
APPEARED IN COMPLIANCE—This facility was TV prior to last permit action, therefore they
had an annual EI requirement, which they met on 3120115. The facility's next renewal/El due date is
11102118.
2. 15A NCAC 2D.0503.PARTICULATES FROM FUEL BURNING INDIRECT HEAT
EXCHANGERS—The particulate emissions from boiler ID No.B 1 shall not exceed an emission
rate of 0.33 lbs/mmBtu and boiler ID No. B2 shall not exceed 0.47 lbs/mmBtu.
APPEARS INCOMPLIANCE—The facility burns NG exclusively with oil as a backup during
curtailment. The worst case fuel is No. 6 at 2.1%sulfur(from current fuel certification),which emits
0.15 lbs/mmBtu. The AP-42 emissions factor for natural gas is 0.007 lbs/mmBtu.
3. 15A NCAC 2D.0515."PARTICULATE CONTROL REOUIREMENT"—Particulate emissions
from miscellaneous sources shall not exceed those limits listed in the permit.
APPEARED IN COMPLIANCE—Compliance was determined during the most recent permit
review based on operating the source as described in the permit conditions. No changes have been
made to their facility since the last permit review.

4. 15A NCAC 2D .0516,"SULFUR DIOXIDE EMISSIONS"—Sulfur dioxide emissions shall not
exceed 2.3 lbs/mmBtu heat input.
APPEARED IN COMPLIANCE—The worst case fuel is No. 6 at 1.61%su fNr (current f sel
certification), would emit SOz at rate of 1.69 lbs/mmBtu. The fuel oil certifications indicated su fsr
content 1.61%the last several times it was purchased. The last purchase of No.6 fuel oil was 313114.
5. 15A 2D NCAC .0521,"VISIBLE EMISSIONS CONTROL REQUIREMENT"—Visible
emissions from source ID Nos. PR4,PR5,TEN2,TEN3, TRl,Bl, B2,BLl,TEN4, OPI, SLl, and
SS 1,manufactured after July 1, 1971, shall not be more than 20 percent opacity when averaged over a
six-minute period.
APPEARED IN COMPLUNCE—Observations of the roof stacks showed that emissions from
these sources were—10% VE or less.
6. 15A 2D NCAC .0521,"VISIBLE EMISSIONS CONTROL REOUD2EMENT"—Visible
emissions from source ID Nos. PIG 1, PR3,ACl/CARD1,AC2,AC3,AC4,AC5,NAP and NAP2,
manufactured before July 1, 1971, shall not be more than 40 percent opacity when averaged over a
six-minute period.
APPEARED IN COMPLIANCE—Observations of the roof stacks showed that emissions f om
these sources were—20% VE or less.
7. 15A NCAC 2D .0535,"NOTIFICATION REQUIREMENT"—The facility is required to notify
DAQ if excess emissions occur for more than a 4-hour period caused by a breakdown or other
abnormal condition.
APPEARED IN COMPLIANCE—The technical contact, David Bruton, stated that the facility has
had no exceedances, breakdowns, or abnormal conditions requiring notification.
8. 15A NCAC 2D .0540,"FUGITIVE DUST CONTROL REOUIREMENT"—Fugitive dust
emissions shall not cause or contribute to substantive complaints or excess visible emissions beyond
the property boundary.
APPEARED IN COMELUNCE—There was no dust on the roadways about the facility. The
facility contact stated that they have not received any dust complaints since the last inspection.
9. 15A NCAC 2D .0611,"CYCLONE REQUIREMENTS"—Annual&periodic I&M and
recordkeeping requirements.
APPEARED IN COMPLUNCE—The facility inspects its single cyclone on a monthly basis. Logs
indicate I&M is done by the facility mechanic Steven Burroughs. Last checked on 14 Sep 2015.
Internal inspection was also done on 13 May 2015.
10. 15A NCAC 2D .0611,"FABRIC FILTER REQUIREMENTS"—Annual&periodic I&M and
recordkeeping requirements.
APPEARED IN COMPLIANCE—The facility inspects rotary drum filters and bagfilters on a
monthly basis. Logs indicate I&M is done by the facility mechanic Steven Burroughs. Last checked
on 14 Sep 2015. Internal inspection was also done on 13 May 2015.
11. 15A NCAC 2D .0958,WORK PRACTICES FOR SOURCES OF VOC's—Requirements include
closed storage of solvent-laden rags, spill management,minimizing splash,generally reducing
evaporation.
APPEARS IN COMPLIANCE—Did not see any violations during inspection.

12. 15A NCAC 2D.1100,TOXIC AIR POLLUTANT EMISSIONS LIMITATION AND
REPORTING REQUIREMENTS-Pursuant to 15A NCAC 2D .1100 and in accordance with the
approved application for an air toxic compliance demonstration,the permit limit shall not be
exceeded. Record daily; report annually.
APPEARED IN COMPLIANCE -Records showed TAP limits had not been exceeded. Records are
maintained for the maximum hourly rate of ammonia input to each printer(ID Nos. PR3, PR4, and
PR5)for each day of production, and the maximum hourly rate of formaldehyde input to each tenter
frame (ID Nos. TEN2, and TENS)for each day ofproduction. Usage and emissions reports are
provided to FRO annually.Ammonia highest emission rate for the last quarter(Jul 2015-Sep 2015)
for PR5 = 1.40 lh1hr (limit: <2.86lh1hr). Formaldehyde highest emission rate for the last quarter for _
(TEN3) =0.097lh1hr (7imit: <0.228 lh1hr) and for (TEN2) = 0.0801b/hr (limit: <0.30 lh1hr).
Quarterly reporting(under the last Title V permit) was submitted on time and appeared to be in
compliance.
Note: The maximum hourly emissions (listed above) are calculated by dividing the worst case dye
chemicals (i.e., having the highest concentrations of ammonia or formaldehyde, respectively) by the
total hours of operation. This would mean the emissions rates listed above would bias higher than
actual emissions. I asked the facility contact if there was any way they could record and report more
realistic emission rates of ammonia and formaldehyde. Mr. Bruton stated that there were too many
different dye combinations to analyze the ammonia and formaldehyde concentration in each mix.
Therefore, the method they are using to estimate emissions is their best option. _-
13. 15A NCAC 2D .1806, "CONTROL AND PROHIBITION OF ODOROUS EMISSIONS." No
objectionable odors beyond property line.
APPEARED IN COMPLIANCE -No objectionable odors were noted during the inspection, the
facility contact stated that no complaints have been received since the last inspection.
14. 15A NCAC 20 .0315,LIMITATION TO AVOID 15A NCAC 20.0501—Facility-wide emissions
of PM10, S02, and NOx shall each be less than 100 tons per consecutive 12-month period; sulfur
content of the No. 6 fuel oil<—2.1%by weight; combust<601,000 gallons of No. 6 fuel oil during
any consecutive 12-month period. The amount fuel oil combusted shall be totaled monthly and
reported annually. Fuel certifications shall also be kept onsite.
APPEARS IN COMPLIANCE—Since the last inspection the facility has not combusted any fuel
oil. Last annual report containing this data was submitted on 07115115. First annual report under
synthetic minor permit due by 01131116.
15. 15A NCAC 2D.1111,AVOIDANCE OF BOILER NESHAP(GACT 6J)—Would-be subject
source are boilers B 1 &132. Facility avoids applicability of this rule by burning Natural Gas,with
fuel oil only as back-up during emergencies,testing and curtailment. Keep records of fuel oil usage
and reason for usage. Notify DAQ within 30 days of switch to fuel oil outside of emergencies,testing
and curtailment.
APPEARS IN COMPLIANCE—Since the last inspection the facility has not combusted any fuel
oil.
16. 15A NCAC 20. 0317,AVOIDANCE OF PREVENTION OF SIGINIFICANT
DETERIORATION-Discharge into the atmosphere less than 250 tons of PMio and S02,
respectively,per consecutive twelve month period.
APPEARED IN COMPLIANCE - The facility has met the requirements of stipulation 15A NCAC
2Q.0315, Limitation to Avoid 15A NCAC 2Q.0501, and therefore has complied with this rule.

NON-COMPLIANCE HISTORY SINCE 2010
20 June 2014 NOD for Visible Emissions for failure to re-establish"normal'VE for emission
sources by 7 March 2014.
10 May 2013 CAI VE Monitoring and Record Keeping
9 Nov 2012 NOV for VE>20%
112R STATUS:
The facility does not store or use any of the listed chemicals above the threshold quantities, and is not
required to maintain a written Risk Management Plan (RMP).
CONCLUSIONS AND RECOMMENDATIONS:
Wade Manufacturing Co.-Wadeshoro (0400016) appeared to he 11V COMPLIANCE with their current
air permit at the time of inspection.
Pink Sheet Notes:
None