AQ_F_0400032_20090709_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Alamac American Knits,LLC
NC Facility ID 7800003
Inspection Report County/FIPS:Robeson/155
Date: 07/16/2009
Facility Data Compliance Data
Alamac American Knits,LLC Inspection Date 07/15/2009
1885 Alamac Road Inspector's Name Jim Moser
Lumberton,NC 28358 Operating Status Operating
Lat: 34d 35.3424m Long: 79d 0.2958m Compliance Code Compliance-inspection
SIC : 2262/Finishing Plants,Synthetics Action Code FCE
NAICS: 313311 /Broadwoven Fabric Finishing Mills On-Site Inspection Result Compliance
F_ Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 03642/R18
Henry Griffin Mark Cabral Henry Griffin Issued 12/14/2005
Vice President President Vice President Expires 7/31/2009
Manufacturing [phone] Manufacturing Classification Title V
[phone] [phone] Permit Status Active
Inspector's Signature: , Comments:
IWO
Date of Signature Appears to be in compliance on 7/15/09
(I) DIRECTIONS TO SITE: From FRO take Interstate 95 to Exit 19 - Carthage Road into Lumberton. Stay on
Carthage it will turn into Water Street. Turn left onto 2nd Street. After one block turn right onto Elm Street. Stay on
Elm and turn right onto Chestnut St. Chestnut will change to Alamac Rd. The facility is on the left about 1.3 miles.
(II) FACILITY DESCRIPTION: Alamac American Knit is a weaving, dyeing, and finishing operation. The facility
operates under NC Air Permit number 03642RI8 issued December 14,2005 and expires July 31,2009. This permit
is a state issued Title V permit. They submitted an application according to guidelines for the `true' Title V permit
in November 2006,but the permit has not yet been issued.They also have submitted a permit renewal application in
late January of this(2009)year.The two permit actions have been consolidated.
Yarn is purchased and stored in the warehouse until needed in the knitting process.The process starts in the spinning
section of the plant where yarn is knitted into tubular fabric. The next step in the process is bleaching the material
white. Acetic acid is used in the dyeing tanks to adjust the ph of the water. This material is then dyed and finished
in either tubular or open width dryers.From there,resins are added for permanent press and soil resistance.Curing is
the next process that sends the material to loop dryers or tenter frames for heat set. Once dried,the fabric is wound
onto a calendar and stored until shipped. Most of the cloth is shipped as tube material. Some is however cut for
open width per customer request. The facility currently has 188 employees (down from 230 last year)and operates
24 hours per day,4 or 5 days per week depending on orders. Their largest customer is Cintas,the uniform supplier.
They have recently expanded into marketing a fire-retardant material for commercial and military use. They are also
supplying material for processing into uniforms for parochial schools.
(III) INSPECTION SUMMARY: On July 15, 2009, I met with Mr. Henry Griffin, Vice President of Manufacturing.
Henry verified the facility contact information for correctness and stated that no emissions sources had been added

or removed from the facility. Henry provided all required records for review. The records were all well maintained
and up-to-date. All reporting has been complete and received on time.
(IV) PERMITTED EMISSION SOURCES: At the time of the inspection,Alamac Knits was operating under Permit
No. 3642R18 which became effective on 14 December 2005, expires 31 July 2009. I assured Mr. Griffin that
although the permit expires at the end of this month,he will still be able to operate under the current permit until a
new permit is issued.The current permit includes the following emission sources:
_.__.. ____-----
Control System ID '
Emission Emission Source ! /Control System
S Description ; y
!Source ID Description
Four Textile
Finishing Open Width Dryers:
;One natural gas/propane-fired open width tenter frame dryer with coating/resin
16 !applicator(9.6 million Btu per hour maximum heat input and maximum
throughput of 10001bs of cloth per hour, [Stentex#1])
Two natural gas/propane-fired open width tenter frame dryers,with a
2F and 3F 'coating/resin applicator(8.0 million Btu per hour maximum heat input,and
N/A
;maximum throughput of 750 lbs of cloth per hour each, [Famatex])
1One natural gas/propane-fired open width tenter frame dryer,with a coating/resin
1K ;applicator(7.2 million Btu per hour maximum heat input,and maximum
:.throughput of 750 lbs of cloth per hour, [Krantz#4]),
i
;Eight Textile Finishing Tubular Dryers
- - ----- __ _-__:_. --- __ _
;One natural gas/propane-fired textile finishing tubular dryer(8.0 million Btu per i
1 ;hour maximum heat input,and maximum throughput of 750 lbs of cloth per hour
'[Fabcon#1]) i
!One natural gas/propane-fired textile finishing tubular dryer(8.1 million Btu per
2 ;hour maximum heat input,and maximum throughput of 750 lbs of cloth per hour,
[Tube-Tex#2]),
:One(1)natural gas/propane-fired textile finishing tubular dryer with
5 ;coating/resin applicator(9.96 million,Btu per hour maximum heat input,and
!maximum throughput of 500 lbs of cloth per hour, [Tube-Tex]) !
_._- _._ -. ._..__...__---------
;One natural gas/propane-fired textile finishing dryer with coating/resin applicator
6 1(6.0 million Btu per hour maximum heat input,and maximum throughput of 750
Ilbs of cloth per hour, [Fabcon]),
N/A
;One natural gas/propane-fired textile finishing dryer with coating/resin applicator
8 (9.0 million Btu per hour maximum heat input,and maximum throughput of 750
lbs of cloth per hour, [Fabcon#8])
One(1)natural gas/propane-fired textile finishing tubular dryer with
9 !coating/resin applicator(9.96 million Btu per hour maximum heat input,and
'maximum throughput of 8601bs of cloth per hour, [Tube-Tex])
;One natural gas/propane-fired textile finishing tubular dryer with coating/resin
10 !applicator(9.96 million Btu per hour maximum heat input,and maximum
!throughput of 750 lbs of cloth per hour, [Tube-Tex])
!One natural gas/propane-fired textile finishing.tubular dryer with coating/resin
15 iapplicator(12 million Btu per hour maximum heat input,and maximum
throughput of 1000 lbs of cloth per hour, [Tube-Tex#4])
:One Textile Finishing Loop Dryer: -
12 !One natural gas/propane-fired textile finishing#2 Loop Dryer(2.4 million Btu N/A

S
•- V
1
°Emi � Contr
urceol Sys em
_ scion ` Emission;So � � .
.� /Contro
on l.S stem f
;Source ID' 'i Descri`t
Descri"`tion 1
P x
per hour.maximum.lieat,'m'ut,and maxiMUM,throu h ut of 750 lbs of cloth :er =, •. S : r<•;'
; Pg.p. p �
r hour;.'
2:
-
r ,.O to a as/. o ane.`fired,textile.finishrn d '`"r" i t g h
coat g/ esm applicator
- 1.4 ,. 7.446rnilhon>Btu er= our maximumheat m ut�and maximum throw h'ut of �� _ '-
� gP
1 80.0 bs of cloth erliour Santex. ;
rTDP 1
.One textile dye"process
r.
, :.F �I N/A
17a•:and ;Two bleach ranges
i
r`
3
-4 t z
rt<
One�aceti ;acid=tank 7 500 allon ca aci
c �: ,g P tY) ti
ESB 1
;One No.6/No.4/No.;2 fuel�oi ;G-fired-198'8 Cleaver`Brooks 3,3.:S1VIBtu/hr max. ..
:•. ' , f ;heat<ln.ut.. ...back.fretube.boiler�tiodel'CB;400=800 •s%n
.fuel�.oi - f." 1/1vG ed 1986 Cleaver.Brooks-`33 S1YIBtu%hr max .
-
,he.st.ri -
a ut -back•:fretubeboiler•model CB 400'800�s/ri L82724�NB#.63294. , .., `r` . ,•,
y ,
i
="APPLICABLE AIR:'=VALITYREGULAThONS.
NCAC 2D :0503 PARTICULATE'S FROM FUEL BURNING:INDIRECT HEAT:EXCHANGERS
1 C
The �_ _ -
articulate:eriissiorisrfr �m° '`• o- boners shall not exceed an'emission=rate of:0.331bs/Mbtu. • = � . �>
p _
..IN C.OMPllANCE , The.:AP 42•emissions•._actors•: or..1Vo. 6;Na.,4 and.No.2 el o'f. f ,_.. fu ils and natural gas are
r_below'
he ermitted lzmzt . Number 6•r.uel oal is the.:worst:case�and its emissaon� actor as:01781b/MBtu .The
- •acila as combus ' ' r r t1',. , .; .ting.p ima,zly natiaral'gas at this time
4--
B 15A..NCAC,2D� ,0515/:PARTICULATE;.CONTROL.RE. .UII2EMENT..`;- Particulate,emissions
.Q r
mi ..,.11V,. s,
sce .aneous sourcessliall•not exceed"tlose'lrnits.Iisted. n"the' ermt.
.; IN COMPlIA= . �E.. ,- : r r•,. •.. .. „:; :>
.;No vistble,emissao_ns,were noted rom an miscellaneous sources.'tenters� d � era etc:on •.-
the day of th'e inspection ,
1 A C. 5 •,.NCAC,.2D,�:0516 SULFUR:DIOXIDEEMISSIONS FROM:COMBUSTION'SO.I7RCES Tfie.sulfur. .<
1 ,..:
d,oxide;erriissionsfron�;ahe"boilers shall riot exceed an"ein=scion rate�of 2.3.1bs/1Vlbtu.�
I M L'IANCE. .The' dcili ;combusts.fn.ostl .;natural as.�but"wall oecasionall _combust uel oil�based.on
_rtce and demand;l7 625: allons:�o #�6,�uel oal�•wth a sul ur.content o�IQ8%��were`combusted"anthe last�18 ; "
p, ( � g .f f f f -
-riaonths.o �oeration ..Sul urcontent is ritonitored and recorded: eruel certiications.
D. 15A NCAC�2D :0521 CONTROL OF VISIBLE EMISSIONS Visible emissions from emission sources
m ri f.
_ a u actured after.197,1 shallnot.:exceed 20•/0.o aci . ,Visibl"e emssions'from�sources manufactured
p �' ,�$ p
1971 shall not exceed 40%opacity.
I MPLIANEC
N CO NC Mr Gri fin stated.that some.rof the�"dryers and:i,tenters were original equapinent"and�older ;
than 971. he on l �visible�emissions"/observ�`d.,.y. . e, on`the day of,the inspection were from.the boiler stack :The
b=oiler,was coriabusting natural gas and had an;opacity of�0%:. , ;r.
E 15A NCAC• 2D,.��0958 r WORK PRACTICES FOR SOURCES OF VOC s _ Solvents.may be used Burin
Y, g
maintenance: `VOC laden.materials are used,in the.d .in�r -rocess:., Re r uirements. include closed story a:of
Y gP q : . g
solvent-laden rags,,.spill•;management,minimizing splash,generally reducing evaporation.
` I

IN COMPLIANCE—There were no open containers, stray rags, or spills noted during the time of inspection.
Alamac uses tank load quantities and dispenses it as such. They do not have wiping rags or small dispensers
in their operation.
F. 15A NCAC 2D .1100 TOXIC AIR POLLUTANT EMISSIONS LIMITATION AND REPORTING
REQUIREMENT — Facility-wide acetic acid emissions shall not exceed 16.4 lbs/hr and formaldehyde
emissions shall not exceed 12.4 lbs/hr. The facility must.maintain records of material usage, formulation data,
hours of operation,and any other pertinent information to calculate emissions. An annual report is required.
IN COMPLIANCE — The facility maintains records detailing hours of operation, chemicals used,
formaldehyde and acetic acid emissions. The records were up to date and very detailed. The actual highest
hourly emission rate for acetic acid was 0.3 lb/hr and formaldehyde was 0.01 lb/hr. The TPERs are acetic acid
16.4 lbs/hr and formaldehyde is 12.4 lbs/hr.
G. 15A NCAC 2D .1806 CONTROL AND PROHIBITION OF ODOROUS EMISSIONS — The odor at the
facility's border should not be objectionable.
IN COMPLIANCE No odor was noted outside the facility.
H. 15A NCAC 2Q .0317 LIMITATION TO AVOID 15A NCAC 2Q .0530—Sulfur dioxide emissions from the
boilers shall not exceed 250 tons per year. The permittee shall maintain records of monthly fuel usage, sulfur
content, and fuel certifications. A semi-annual report is required. The facility shall not combust more than
1,500,000 gallons of fuel oil per 12-month period. The sulfur content of the fuel oil shall not exceed 2.1%
sulfur by weight.
IN COMPLIANCE— The facility is combusting mostly natural gas at this time. The facility did combust a
small amount of fuel oil in July. The last time the facility purchased fuel oil was in October 2006. The fuel
certification for this No. 6 fuel oil showed a sulfur content of 1.99%. The facility keeps records of the fuel
combusted daily and the sulfur content of that fuel. Fuel usage for CY2008 was 17,625 gallons.
I. 15A NCAC 2Q .0711 TOXIC AIR POLLUTANT EMISSIONS LIMITATION REQUIREMENT —
Emissions can not exceed the limits listed in the permit for acetaldehyde,ethyl acetate,and toluene.
IN COMPLIANCE — The facility maintains detailed records of monthly chemical usage and associated
pollutants.
J. The facility must submit a complete Title V application within one year of permit issuance.
IN COMPLIANCE—The facility submitted the application in late November 2006.
K. LIMITATION TO AVOID HAP MAJOR STATUS—Facility-wide total HAP emissions shall be less than
25 TPY and single HAP emissions shall be less than 10 TPY. The facility must maintain records of monthly
total and individual HAP emissions.
IN COMPLIANCE—The facility maintains detailed records of chemicals used and associated HAP content on
a monthly basis and total annually. The facility emitted—0.90 TPY of total HAP.
(VI) COMPLIANCE HISTORY: The facility was issued a NOV for failure to submit a request for permit renewal and
emissions inventory in May 2004.There have been no further instances of non-compliance.
(VII) CONCLUSIONS AND RECOMMENDATIONS: Based on the observations made during the July 15, 2009
inspection, Alamac American Knits, LLC appeared to be in compliance with all requirements outlined in their
current air permit,03642R18.