AQ_F_0400039_20120626_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Venture Milling-Ansonville
NC Facility ID 0400039
Inspection Report County/FIPS: Anson/007
Date: 06/27/2012
Facility Data Compliance Data
Venture Milling-Ansonville Inspection Date 06/26/2012
North State Road 1627 and US 52 Inspector's Name Cindy Grimes
Ansonville,NC 28007 Operating Status Operating
Lat: 35d l l.1320m Long: 80d 7.2160m Compliance Code Compliance-inspection
SIC: 2048/Prepared Feeds Nee Action Code FCE
NAICS: 311119/Other Animal Food Manufacturing On-Site Inspection Result Compliance
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 07495/R06
Hayne Haigler Richard Willey Joey Baggett Issued 9/15/2008
Plant Manager President Perdue Agribusiness Expires 11/30/2012
[phone] [phone] Environmental Classification Small
[phone] Permit Status Active
Inspector's Signature- � _ � Comments:
Date of Signature: -7( 1 J ( LJ l zi
MACT/GACT Applicability:Subject to: Subpart 7D -Prepared Feeds Manufacturing- facility uses a
premix supplement that contains 22% Manganese.In 2011,—2100 tons/quarter(or 8400 tons/year) of the
mix were used; in 2012,only 2.8 tons had been used from January-June. See specific requirements under
comments in Section 9.Not subject to: Subpart 4Z—Reciprocating Internal Combustion Engines—facility
has no emergency or non-emergency generators on site.
1) Location
Venture Milling-Ansonville is located at 2755 Old US Hwy 52 North(SR 1627), north of Ansonville,NC,
Anson County.Facility phone number is 704-826-8318.
Directions
From FRO,take Hwy 401 South to Wagram.Turn right at Old Wire Road(Hwy144) and go— 11 '/z miles to
Laurel Hill. Turn right onto Hwy 74 West and go—35 miles to Wadesboro. Go all the way through town, and
then turn right onto Hwy 52 North. Go—9 miles to Ansonville. Continue another 2.2 miles to Cedar Hill
Crossroads. Turn left onto Old Hwy 52 and drive—2 miles until you see a Perdue sign on the left side at a dirt
drive. Turn left onto this drive, and mill will be at the end of the road. Office is on the right side of building.
Safety considerations: Standard DAQ safety equipment required.While driving into facility,watch for trucks
entering and exiting on haul roads; during inspection,be alert for trucks/railcars in receiving and load out areas; be
careful up on the mill/silo roof,as inspector will need to ride up in elevator to observe one control system there.
2) Facility and Process Description
Venture Milling-Ansonville is a feed mill blending operation, producing feed for poultry growers.This
facility is permitted under Air Permit No.74951106,effective from 15 September 2008 until 30
November 2012. Cindy Grimes conducted the last compliance inspection on 20 April 2011.
This facility is strictly a blending operation;they receive grain,animal byproduct meal, and additives, and
then blend and ship them by truck to poultry growers.They produce 3 types of blending feeds—Vegetative
(non-animal feed),Non-prohibitive (dairy feed), and Prohibitive.Venture Milling is also used as an excess
storage facility for the Perdue Eagle Springs facility.

a) Current Throughputs for 2011
Employees: 14,with 10 in actual mill(12 total in 2010)
Hours: 24hrs/day, 5 days/wk, 52 wks/year(3 shifts)(same in 2010)
(3rd shift employees are mainly unloading railcars or restocking commodities)
Production: 149,792 tons/-2880 tons/week(162,969 tons/-3134 tons/week in 2010)
b Permitted Sources
s � �i� z rx y ' �s z '� F rF
Control
Emission mission ource Control System
Source ID �`i� � �escri ion System r Descr ton
p ID'3 A
No. A Railcar,choke-fed receiving pit within a two sided, I N/A N/A
roofed enclosure
No. B Truck receiving pit within a two sided,roofed I CD-1 Fabric filter(620 sq. ft. filter area)
enclosure
No. I Three storage silos,two with a capacity of 11,300 CD-1 Fabric filter(620 sq. ft. filter area)
cu.yds.and one with a capacity of 9,600 cu.yds. I�
No. C Pneumatic truck receiver I CD-2 Fabric filter(245 sq. ft.filter area)
No. H Truck load out operation within a three-sided,roofed) N/A N/A
enclosure
c Insignificant/Exempt Activities
'Ag ,I 4 3 3� ( KSource of Source ofT�tle'
E�eemptton Regulation
ru SnrCC TAPs� }aAM
ntS�
r_
O s
I-S 1 -Truck loadout spout on silo 1 I 2Q .0102(c)(2)(E)(i) I' No No
I-S2-Truck loadout spout on silo 2 I' 2Q.0102(c)(2)(E)(i) I No No
I-S3 -Truck loadout spout on silo 3 I 2Q .0102(c)(2)(E)(i) No No
3) Inspection Conference
On 26 June 2012,I (Cindy Grimes)met with Hayne Haigler,compliance contact and mill manager.This
inspection was pre-arranged since it was for permit renewal. We discussed the following:
a) Some of the FACFINDER information has changed.Mr. Haigler will be the new Facility Contact since
he is the plant manager and on site daily(previous contact Martin Stewart is not on site).Joey Baggett,
Supervisor of Environmental Services,will be the new Technical Contact(replacing Martin Stewart).
b) I examined the bag filter logbook. Weekly inspections are performed, which include checks on all
systems(receiving,methionic, hammer mill, and pneumatic),the magnehelic gauges, corrosion (for
structural integrity)and leaks. An annual inspection,which includes replacing all the bags, is done
usually near the end or the beginning of the year;the latest was completed on 28 January 2012. The
housing unit has also been repaired in previous years. The logbook maintained here is excellent and
even has before and after pictures of major repairs.Note: There had been an issue in the past with
some bag blowouts,so Mr.Haigler said now he just replaces all the bags every year so there won't be
any problems.
c) There have been no equipment or process changes since the last compliance inspection.The facility was
planning on installing a new conveyor that would strictly handle the railcar load out, but those plans have
been put on long-term hold(currently,there is only one conveyor to both the railcar and truck load out
pits).

d) The facility is still using the blending premix("Perdue boiler trace mineral premix")that contains 22%
Manganese,thus, subjecting them to NESHAP Subpart 71). The standard batch of this mixed blend is
low in tonnage,and the usage has dropped dramatically since last year.This is because less feed is
being shipped to its sole customer in the country of Georgia(Note: a bag tag for this premix is already
included within the facility's file folder at FRO).
e) Apparently, Joey Baggett,Env. Mgr. at the Perdue Farms main office in Lewiston,NC,will be
completing the permit renewal forms and submission of the emissions inventory thru AERO. I told Mr.
Haigler to tell Mr. Baggett to call me if he had any questions and reminded him that the due date is I
September 2012.
4) Inspection Summary(facility was operating during inspection)
a) Railcar and Truck Receiving(ES-A and ES-B): Railcars and trucks unload at these areas. The truck
pit is choke-fed and emissions are controlled by bagfilter ID No. CD-1. There were several trucks and 1
railcar unloading during my inspection. I observed 0%VE from this bag house, which also controls the
3 storage silos(ES-I). The bag filter appeared to be in good condition, with no visual indications of any
compromises.
b) Pneumatic Truck Receiver(ES-C): I went to the top of the silo to view the bagfilter(ID No. CD-2)
for this limited operation(D,L-Methionine silo),which only runs—once/month.This area has had
rust problems in the past(due to the use of salt),but I saw no dust accumulation or holes due to the
previous corrosion; everything appeared to be in good condition.I observed 0%VE.
c) Bin inspection holes with covers: In 2007, some of the covers were rusted completely through where
the metal meets the cement(again,this was due to the use of salt). These covers have been replaced and
still appeared to be in good condition.
d) Truck Load out(ES-IT) and Truck Load out spouts (I-S1,2,3): I watched 2 trucks loading out
during my inspection and observed 5%VE. I saw no problems in this area. The 3 mobile load-out
spouts are only used with special feed supplement mixes.
5) Permit Stipulations
a) A.3 2D .0515—PARTICULATE CONTROL REQUIREMENT—Particulate control emissions from
emission sources shall not exceed allowable emission rates.
Compliance Indicated—Latest permit review shows compliance.
b) A.4 2D .0521 — VISIBLE EMISSIONS CONTROL REQUIREMENT—Visible emissions from
emissions sources shall not be more than 20%opacity.
Compliance Indicated—This facility was operating, and I observed<20%VE from each of the
emission sources.
c) A.6 2D.0540—FUGITIVE DUST CONTROL REQUIREMENT—The Permittee shall not allow
fugitive dust emissions to cause or contribute to complaints or excessive emissions beyond the
facility's boundary.
Compliance Indicated—I did not observe any fugitive dust when driving into the facility or during my
inspection. Mr. Haigler told me that he has not received any complaints and that the facility has a truck
with a water sprayer on it that can be used when conditions are excessively dry.
d) A.7 2D.0611—BAGFILTER REQUIREMENTS- Particulate matter emissions shall be controlled
by the permitted equipment and maintained according to the permit, and all maintenance kept in a
logbook.
Compliance Indicated—This facility performs and records biweekly inspections and one annual
inspection per year. All records are well-kept and in good order, and the bagfilters appeared to be in good
working condition. Mr. Haigler also takes before and after pictures of the baghouses during the annual
inspection, as well as the pressure gauges.The pictures are kept within the logbook.

e) A.8 2D .1806—CONTROL AND PROHIBITION OF ODOROUS EMISSIONS-The Perm ittee
shall not allow odorous emissions beyond the facility's boundary.
Compliance Indicated—I did not notice any objectionable odors coming into the facility or during my
inspection.
6) Reporting Requirements
There are no reporting requirements in their current permit.
7) 112R Status
This facility neither uses nor stores chemical compounds that require a written risk management plan
tinder the Clean Air Act, Section 112R.
8) DAQ Compliance History
a)28 September 2007—NOV for improper record keeping on bagfilter and for failure to operate and
maintain a bagfilter
b) 17 June 2002—NOV for late Quarterly Reporting
c) 13 September 2000-NOV for late Quarterly Reporting, Improper Maintenance Recordkeeping and
Requesting Permit Application for an Emission Source(D,L-Methionine silo)
9) Comments and Compliance Statement
This facility has worked hard to comply with their permit since they were issued an NOV in 2007 for not
recording the bagfilter's deterioration and properly maintaining it. They now change all the bags in the
bagfilters annually and keep excellent records, including before and after photographs of major maintenance
completed.
Note: Pictures were taken of this facility and are under G: Drive,Anson, Venture Milling,Pics
Venture Milling-Ansonville appeared to be in compliance on 26 June 2012.
GACT 7D INFORMATION
DAQ sent facility an initial notification letter on 19 April 2010, in which it submitted a response on 5 May
2010 confirming the use of Manganese as an ingredient of one of its trace mineral supplements.
The following is a summary of the GACT 7D requirements that this facility currently has to comply with
(as of 5 January 2012). Future compliance inspections should ensure the implementation of the practices
listed below:
a) Good Management Practices
i) Utilize vacuum system or manual sweeping—facility sweeps daily; mixing area, including walls and
equipment, is swept and cleaned more thoroughly once a week—compliance indicated
ii) Doors kept shut — facility has implemented practice of doors being kept shut except during normal
entering and exiting—compliance indicated
b) Equipment Standards
i) Store Mn raw materials in closed containers — facility keeps bin containing Mn supplement
closed/secured; supplement area is swept daily and cleaned weekly—compliance indicated
ii) Operate mixer so as to minimize dust — facility keeps bin cover closed except when materials are
added; Mn supplement is added to feed via a mobile truck loadout spout that extends well into the
opening of the truck—compliance indicated
iii) During bulk loadout, reduce distance b/t loading arm and receiving truck/railcar— facility has canvas
bags that extend into the opening of truck/railcars to help reduce excess emissions — compliance
indicated
iv) Cyclones operate with manufacturer's specs and are at least 95% efficient, with quarterly inspections
for damage— facility does not have any cyclones on site, as there are no grinding or pelleting
operations here—compliance indicated

c) Monitoring
i) Monthly inspections of loadout area, with recording of results — Plant manager inspects daily and
records results in maintenance logbook. Loadout area is swept every day—compliance indicated
ii) Quarterly inspections of cyclones — facility does not have any cyclones on site, as there are no
grinding or pelleting operations here—compliance indicated
iii) Operate cyclones within appropriate parameters and record results — facility does not have any
cyclones on site, as there are no grinding or pelleting operations here—compliance indicated
d) Notifications,Reporting,and Recordkeeping
i) Initial notification by 5 May 2010—facility was notified with letter sent out from DAQ on 19 April
2010 and responded on 5 May 2010—compliance indicted
ii) Notification of compliance status by 4 May 2012—facility submitted required information/notification
on 4 May 2012—compliance indicated
iii) Annual compliance certification by 1 March every year—facility will submit starting 1 March 2013 —
compliance yet to be determined
iv) All appropriate maintenance records kept on site—facility maintains all inspection records on site and
has started keeping compliance notification records on site—compliance indicated
v) Notify DAQ if discontinue Mn usage—if applicable, facility will notify FRO-compliance yet to be
determined
/clg