AQ_F_0900081_20130813_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Gildan Yarns,LLC
NC Facility ID 0900081
Inspection Report County/FIPS:Bladen/017
Date: 08/14/2013
Facility Data Compliance Data
Gildan Yarns,LLC Inspection Date 08/t3/2013
820 West Highway 211 Inspector's Name Robert Hayden
Clarkton,NC 28433 Operating Status Operating
Lat: 34d 29.6060m Long:78d 40.1260m Compliance Code Compliance-inspection
SIC: 2281/Yarn Mills,Except Wool Action Code FCE
NAICS: 313111/Yarn Spinning Mills On-Site Inspection Result Compliance
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 09529/G02
Ron Daniel Chuck Ward Ron Daniel Issued 3/22/2010
Plant Manager Executive Vice President Plant Manager Expires 2/28/2015
[phone] [phone] [phone] Classification Small
[e-mail] [e-mail] [e-mail] Permit Status Active
Inspector's Signature: /� �e Comments:
Date of Signature: 1 U V
Directions:
From FRO take Highway 87 about 34 miles to Elizabethtown(stay on Bypass);turn right onto Hwy
701 South; travel about 10 miles into Clarkton; turn right onto Highway 211. The facility is about 1/2
mile on the right. Park in the first lot and use the door by the flags.
Safety Equipment: Standard DAQ FRO safety gear. Earplugs and shoes are required; glasses
optional. Be aware of various machinery this plant operates. The principal hazards to un unwary
inspector are noise and pinches and scratches because of the air pressure-driven doors.
Process/Facility Description: (checked and confirmed by Mr Daniel)
• Gildan Yarns is a cotton and cotton-blend spinning mill. It is necessary for the plant process
to maintain the air temperature and relative humidity in the plant,respectively at 75 to 78
degrees F and 63 percent.
• Bales of ginned cotton are processed using several cleaner blender-mats to remove the cotton
waste from the usable fibers. The fibers go through multi-mixer CVT guard machines and
are drawn to frames machines where the fibers are spun into continuous loose strands that are
barely held together in thick appearing rope type strands. These spun fiber strands are
accumulated through a special computerized process, into large barrels that are fed to the
open-end spinner machines where it is spun into 8-count thread realms. The cotton waste is
again recycled through the process and the final wasted matter is for agricultural use.

• There are 4 fabric filter systems used to remove larger particle matter before the air is drawn
through a series of water wash scrubber type spray nozzles. This wash removes smaller
particle matter and aids in the needed control of the facility temperature and humidity levels.
The large amount of water used for the scrubber system is filtered through a special screen
and reused for the wet scrubber control device. Winter months require less water use,
whereas the summer months require a greater usage of water. Computerized emission release
exhaust flaps vent the exhaust through the opening or closing of the flaps, according to the
necessary temperature and relative humidity requirements for the process. During those
times when the flaps are closed, no exhaust is released into the atmosphere but re-enters back
into the plant where any particulates travel back through the air filtration systems. The
facility can make a 50150 polyester blend thread,but currently only spins 100%cotton thread
which is currently used for t-shirts, duct tape, etc.
Permitted Sources:
The facility has a general permit for yarn spinning that covers the following:
• Emission sources associated with the air filtration system(s)utilized in the yarn spinning
process.
• Combustion equipment firing No. 2 fuel oil/natural gas with a combined total maximum heat
input not to exceed 45 million Btu per hour. Note: This facility does not have combustion
equipment on site. The facility operates totally on electricity and from the heat generated from
the manufacturing process.
•
Current throughputs:
Number of Employees 115
Hours of Operations 24 hours/7 days/wk
Thread produced in 2012 43,730,643 lbs - (2013 - about 4 million lbs/month)
Opening conference: The facility was in full operation.
On 13 August 2013,I, Robert Hayden, DAQ FRO, arrived at the facility and met Mr Ron Daniel,
Plant Manager. The FacFinder required extensive editing as the plant had changed name, Authorized
Contact and Invoice Contact since the January 2012 inspection. The affiliation continues Frontier
Spinning. DAQ did not receive any change notifications. The plant's new name is Gildan Yarns,
LLC. Gildan is the French component of the same parent company that still owns the plant,Frontier
Spinning, so an ownership change is not warranted. All adjustments have been made to
IBEAM/Facilities and an email was sent to RCO billing for the invoice change. We checked the
only record keeping requirement—filter system I&M. Corporate policy supercedes manufacturer
recommendations and requires monthly external checks, twice daily filter pressure differentials, and
annual filter replacement.
Walking Inspection:
Mr. Bedsole lead me around the facility and explained the process. He took me to the air filtration
systems located in separate areas around the outside rooms of the facility.There are 10 filter house
units and 3 air wash scrubber points. From the air wash units, the air is put through a fabric filter
lined drum and then vents outside. Mr. Bedsole advised against photography because of the
potentially explosive nature of the organic dust.
Stipulations:
A.3 2D.0503"Particulates from Fuel Burning Indirect Heat Exchangers"—Appeared to be in
Compliance-This facility does not have any combustion equipment or combust any type of fuel.

AA 2D.0515 "Particulates from Miscellaneous Industrial Processes"—Appeared to be in
Compliance-Filtration systems are operated and well maintained.
A.5 2D.0516"Sulfur Dioxide Emissions from Combustion Sources"—Appeared to be in
Compliance-The facility does not have any combustion sources.
A.6 2D.0521 "Control of Visible Emissions"—20%limit-Appeared to be in Compliance—No
emissions were observed at the time of this inspection. Nothing was emitting outdoors either. This
inspection must be done in the winter.
A.7 2D .0521 "Control of Visible Emissions"—40%-Appeared to be in Compliance—Facility
does not have equipment manufactured prior to 1 July 1971.
A.9 2D.0540 "Particulates from Fugitive Dust Emission Sources." -Appeared to be in
Compliance—No emissions were observed. Facility grounds are paved.
A.10 NCGS 143-215.107(a)(4) "RCDorting Requirements" -Appeared to be in Compliance-
The annual report for the pounds of cotton processed for 2012 was received 29 January 2013.
A.1120.0310"Permitting of Numerous Similar Facilities"-Appeared to be in Compliance
• Facility does not operate any emission sources other than those listed specifically on the
permit.
• The facility is not subject to any other 15A NCAC 2D or 2Q regulation.
• Ginned cotton processed shall not exceed the 490,000,000 lbs per twelve consecutive months.
The facility processed 43,730,643 lbs of ginned cotton during 2012.
• The facility does maintain logbooks containing the results of the inspections and maintenance
performed on the air filtration devices.
• The facility does not have any fuel storage tanks nor combustion sources.
112r Applicabilitv:
Through observations and discussions with facility personnel, this facility does not reuire a written
RMP under 40 CFR Part 68,Accidental Release Prevention.
Compliance History:
On 12 December 2008, the facility was sent an NOV for not having a copy of the air permit and for
not maintaining I/M logbooks for all checks and maintenance required on the air filtration devices.
Comments and Compliance Statement:
(1) Request a formal name change from the company (Form AA,Section AA3). (2)Update
IBEAM/Facility and G-Drive nomenclature. (3) Send new invoice info to RCO.
Gildan Yarns appeared to be operating IN COMPLIANCE with the current air permit on 13
August 2013.