AQ_F_0900081_20101209_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY CanAm Yarns LLC
NC Facility ID 0900081
Inspection Report County/FIPS: Bladen/017
Date: 01/15/2010
Facility Data Compliance Data
CanAm Yarns LLC Inspection Date 01/15/2010
820 West Highway 211 Inspector's Name Pam Vivian
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/GO1
Paul Jordan George Perkins Jay Flanary Issued 1/30/2006
Plant Maintenance CEO Director of Expires 4/30/2010
Engineer [phone] Manufacturing Services Classification Small
[phone] [phone] Permit Status Active
Inspector's Signature: y r Comments:
Date of Signature: z-j(S"/ Z s,!0
GACT/MACT Applicability: None
Directions
From the FRO take Highway 87and travel about 34 miles to Elizabethtown;turn right onto 701 South;
travel about 10 miles into Clarkton;turn right onto Highway 211. The facility is about'/2 mile on the
right.
Safety Equipment: Earplugs required; glasses optional.
Process/Facility Description:
Can AM 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 fabric filter systems used to remove larger particle matter before the air is drawn through a
series of water wash scrubber type spray nozzles, and this helps to remove smaller particle matter and
adds to the necessary level of temperature and humidity control. The large amount of water used for the

scrubber system is filtered through a special screen and reused for the emission control device system.
Winter months require less water use,whereas the summer months require a greater usage of water.
Computerized emission release exhaust flaps vent the emissions 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 the emissions do not release into the atmosphere but in the
plant where the particulates travel back through the air filtration systems. The facility can make a 50/50
polyester blend thread,but currently only spins 100% cotton thread which is currently used for cotton
t-shirts, duct tape, and other customer ordered manufacturing needs.
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. The facility runs totally on electricity
and from the heat generated from the manufacturing process.
Current throughputs:
Number of Employees 126
Hours of Operations 24 hours/7 days/wk
Ginned Cotton 59,851,886 lbs
Preinspection Conference:
I met with Paul Jordan,facility contact,Jay Flanary,technical contact,and Ron Daniel,Plant Manager.
Each were aware that my visit was for a routine inspection and to answer any emission inventory
questions. Mr. Flanary has been working on the inventory via AERO and had emission factor
questions. I presented the factors other yarn mills in NC have used for the calculated emissions entered
for their inventory. He has prepared and submitted other facility inventories in the Winston-Salem
Region and showed me the same factors I had brought for the inventory use. We discussed submitting
the inventory by 31 January 2010 and he understood the time requirement for CanAms. Mr. Jordan
presented the current permit and said the facility only operates using electricity and does not have any
combustion sources. He presented the I/M logbook that appeared to be up-to-date with various
inspections and repair dates necessary to maintain the air filtration devices. The devices receive
maintenance more frequent than manufactures recommend but he said this keeps the devices and
facility operating more efficiently. The FACFINDER sheet was reviewed and no changes were needed.
Inspection•
Both Mr.Jordan and Mr. Flanary gave me a detailed tour of the facility and explained the process. We
later inspected all of the air filtration systems located in separate areas around the outside rooms of the
facility. We checked all the air exhaust points venting to the atmosphere. There were 10 filter house
units and 3 air wash points. From the air wash unit the air is put through a drum then exhausted outside.
Mr. Jordan said the maintenance checks are done weekly inside the units,the ductwork is checked and
cleaned monthly, and the pressure checks are done twice daily. These checks are performed by any of
the six employees in the section. These checks,as well as maintenance are recorded in the I/M logbook
and initialed by the employee(s)performing each. Since some pictures were taken during the previous
routine inspection last year,I choose not to take any during this inspection. Mr.Jordan did say some of
the equipment has a potential for a spark and explosion from the flash of a camera.

Stipulations:
A.3 2D .0503 "Particulates from Fuel Burning Indirect Heat Exchangers"—COMPLIANCE
INDICATED-This facility does not burn fuel.
A.4 2D .0515 "Particulates from Miscellaneous Industrial Processes"—COMPLIANCE
INDICATED -Filtration devices are operated and well maintained.
A.5 2D.0516 "Sulfur Dioxide Emissions from Combustion Sources"—COMPLIANCE
INDICATED-The facility does not have any combustion sources.
A.6 2D.0521 "Control of Visible Emissions"—COMPLIANCE INDICATED -None observed.
A.7 2D.0521 "Control of Visible Emissions"- COMPLIANCE INDICATED—Facility does not
have equipment manufactured prior to 1 July 1971.
A.9 NCGS 143-215.107 (a) (4) "Reporting Requirements" -COMPLIANCE INDICATED -The
annual pounds of cotton processed for the previous calendar year was received on time.
A.10 20 .0310"Permitting of Numerous Similar Facilities"-COMPLIANCE INDICATED
• 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 59,851,886 lbs of ginned cotton during the year of 2009.
• The facility does maintain logbooks containing the results of the inspections and maintenance
performed on the air filtration devices based on manufacturer's recommendations and overall
facility concerns for efficiently operating.
• The facility does not have fuel storage tanks.
Inspection Summary:
Mr. Jordan understands the importance of maintaining the required I/M logbooks for all checks and
maintenance performed on the air filtration devices. Mr.Flanary will submit the required emission
inventory with the certification and AA forms by 31 January 2010. This is a well operated and
maintained facility and operates IN COMPLIANCE with its current air permit.
112r Applicability:
Through discussions with facility personnel,this facility is not subject to 112r regulations.
Reporting Requirements:
On 15 January 2010,DAQ FRO received the annual throughput of ginned cotton for CY 2009.
Five Year 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:
The facility was very clean,well maintained,and found to be operating according to its permit.
/pcv
cc: Central Files