AQ_F_0000031_20190429_CMPL_InspRpt (4)

NORTH CAROLINA DIVISION OF Asheville Regional Office
AIR QUALITY Hickory Springs Manufacturing Company -
Micaville
Inspection Report NC Facility ID 0000031
Date: 04/29/2019 County/FIPS: Yancey/199
Facility Data Permit Data
Hickory Springs Manufacturing Company-Micaville Permit 05148/R07
455 Hickory Springs Road Issued 12/22/2017
Micaville,NC 28755 Expires 11/30/2025
Lat: 35d 52.8000m Long: 82d 13.2833m Class/Status Small
SIC: 3495/Wire Springs Permit Status Active
NAICS: 332612/Spring(Light Gauge)Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Kevin Franklin Rick Anthony Steve Hannah
Operations Manager VP of Home Furnishings Corporate EHS Manager
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 04/29/2019
Inspector's Name Angela Hopper
Inspector's Signature:// /7 Operating Status Operating
Compliance Code Compliance-inspection
Action Code FCE
LF26
ature: On-Site Inspection Result Compliance
al emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
0.0400 --- 0.5100 3.78 0.4300 0.0400
0.0600 0.0100 0.8200 7.63 0.6900 0.0600 ---Hi est HAP Emitted in oundsiolation History:None
Date Letter Type Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested
Directions:
From Burnsville: travel East on Highway 19 to Highway 80 South through Micaville. Approximately two and
half miles South of Micaville,turn right onto Hickory Springs Road, and the facility will be located on the left.

There is a HSM Solutions sign as well as a Convenience Center sign at the intersection of 80 South and Hickory
Springs Road. Visitor's parking is located near the loading docks.
Facility Overview:
Required Safety Equipment: Safety shoes and glasses
Facility Contacts: I went over the contact information from the IBEAM Database FacFinder Report
with Mr. George Beauvias,Plant Manager and Mr. Kevin Franklin, Operations Manager. Mr.
Franklin will now be the Facility Contact. Mr. Steve Hannah, Corporate EHS Manager is the
Technical Contact. Mr. Hannah's office is located in Hickory,NC.
Facility Description: This facility manufactures inner springs for mattresses and is permitted because of VOC
emissions. It operates three shifts, 4 or 5 days per week and has approximately 82 employees including office
staff.
Inspection Narrative: On April 29,2019, I traveled to Hickory Springs Manufacturing Company, located in
Micaville,to conduct an annual unannounced routine compliance inspection. I arrived on site at approximately
10:15am and was on site for an hour. I met and toured with Mr. George Beauvias,Plant Manager and Mr.
Kevin Franklin, Operations Manager prior to touring the facility with Mr.Beauvias.
The facility has changed the type of mattress that is manufactured at the site to pocket coil mattresses. Mineral
spirits and mineral oil are no longer used in the manufacturing process. Hot melt glues are used in the
manufacturing of the pocket coil mattresses. A review of the SDS for the hot melt glues was conducted by DAQ
personnel and it was determined that the glues contain no VOCs. The facility has two pocket coil assembly lines
and one cable coil assembly line. The facility estimates that they currently used 4,500 pounds of glue monthly.
Permit Exemption:
It appears that Hickory Springs Manufacturing Company-Micaville is now eligible to be exempt from air
permitting based on the fact that mineral spirits are no longer being used and the hot melt glue does not contain
VOCs. The facility was informed of the eligibility to be exempt from air permitting. The facility may choose to
maintain their air permit.
Emission Source and Regulatory Review:
Emission Emission Source
Source ID Description
FUG-1 one mattress assembly operation including a bending and
; cutting process
Source Listing:
Emission Source ID FUG-l: The facility is permitted to operate one mattress assembly operation including a
bending and cutting process and one propane and natural gas-fired heat-treat oven (5.2 million Btu per hour heat
input) utilizing mineral spirits and mineral oil. The mattress assembly operation was observed in operation with
no visible emissions during the inspection. Note: The oven is listed as Source ID. I-3 on the Insignificant/
Exempt Activities List and is no longer being used. The oven has been disconnected but remains on site. The
facility no longer uses mineral spirits and mineral oil in the manufacturing of the mattresses.

Pocket Coil Process: The facility operates a pocket coil process where coils (approximately 6 inches long)are
enclosed in fabric pockets. The two pieces of fabric are fused around each coil to form a pocket then the
individual pockets are glued together. The number of pockets glued together depend on the size of the mattress.
Permit Conditions:
2D .0521 -Control of Visible Emissions - I observed the sources in operation with no VEs. The
facility appeared to be in compliance with this rule.
2D .0535 —Notification Requirement-This regulation requires timely reporting and appropriate
actions during periods of excess emissions and malfunctions. The facility appeared to be in
compliance with this rule.
2D .0540 -Fugitive Dust Control requirement-No fugitive dust issues were noted during this site
visit. The facility appeared to be in compliance with this rule.
Note: "Fugitive dust emissions" means particulate matter that does not pass through a process stack or
vent and that is generated within plant property boundaries from activities such as: unloading and
loading areas,process areas stockpiles, stock pile working, plant parking lots, and plant roads
(including access roads and haul roads).
2D .1806 -Control and Prohibition of Odorous Emissions-The purpose of this rule is to provide for
the control and prohibition of objectionable odorous emissions. During this inspection, no odors were
noted. The facility appeared to be in compliance with this rule.
Record KeePine and Renortine Requirements Review:
The facility does not currently have a reporting or reporting requirement.
Insignificant Sources Listing:_
Source
I-2 -one propane/natural gas-fired edge clip oven(0.08 million Btu per hour heat input)
f
I-3 - one propane/natural gas-fired heat-treat oven(5.2 million Btu per hour heat input)
The facility has a propane and natural gas-fired Edge Clip Oven(0.08 million Btu per hour heat input), Source
ID 1-2, listed on the permit as an insignificantlexempt activity. This oven was observed in operation firing on
natural gas with no visible emissions. Propane is no longer used to fuel this oven. Currently,the facility only
uses propone for the fork trucks.
The facility also has a propane/natural gas-fired heat-treat oven(5.2 million Btu per hour heat input), Source ID-
1-3, listed on the permit as an insignificant/except activity. This oven is no longer being used and has been
disconnected.
Generator:
During the last inspection,facility personnel told me that the facility had a small generator on site that was
purchased quite some time ago. It has never been installed. Mr. Woody told me that he was not even sure it
could be operated at this point because it had sat for so long. I asked Mr. Franklin and Mr. Beauvias about the
generator during this inspection and neither of them were aware of any generator ever being on site. It is unclear

if there is a generator at the site. I told Mr. Franklin and Mr. Beauvias to contact our office if the facility ever
installed or operated a generator.
Five-year compliance history is as follows:
This facility has had no documented violations in the last five years.
Stack Test Review:
The facility currently has no stack test requirements.
112r:
The facility is not subject to 112(r).
Recommendations:
If the facility chooses to keep their air permit,I recommend the heat treat oven (I-3) be
removed from the Insignificant/Exempt Activities List and that propane be removed as a fuel
for the clip oven (I-2) during the next permit renewal or modification.
Compliance Statement/Conclusion:
Hickory Spring Manufacturing Company-Micaville appeared to be in compliance with applicable air quality
standards and regulations at the time of the inspection.