AQ_F_1400092_20221117_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Asheville Regional Office
AIR QUALITY McCreary Modern, Inc. - Upholstery Plant
NC Facility ID 1400092
Inspection Report County/FIPS: Caldwell/027
Date: 11/17/2022
Facility Data Permit Data
McCreary Modern, Inc. -Upholstery Plant Permit 05207/R13
2978 Rocky Road Issued 8/9/2017
Lenoir,NC 28645 Expires 7/31/2025
Lat: 35d 52.0320m Long: 81 d 35.8140m Class/Status Small
SIC: 2512/Upholstered Household Furniture Permit Status Active
NAILS: 337121 /Upholstered Household Furniture Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Tyler Smith Rick Coffey Ryan Coulter
Plant Manager President Director of Engineering
[phone] [phone]
Compliance Data
Comments:
Inspection Date 11/17/2022
Inspector's Name Bob Graves
Inspector's Signature: �j� -2J Operating Status Operating
Compliance Status Compliance- inspection
Action Code FCE
Date of Signature: Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 * HAP
2016 0.4900 --- --- 24.64 --- 0.0500 2521.00
2011 0.4800 --- --- 28.40 --- 0.0500 3494.00
* Highest HAP Emitted inpounds)
Five Year Violation 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
L-
1) Location: McCreary Modern Inc. - Upholstery Plant is located at 2978 Rocky Road in
Lenoir,NC. Caldwell County.

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Directions: From Morganton, take Hwy 18N to the Gamewell Community. The facility is on
the right at the corner of Morganton Blvd (Hwy 18) and Rocky Road.
2) Description: McCreary Modern Inc. - Upholstery Plant is a furniture finishing plant. This
facility is permitted under Air Permit No. 05207RI3, effective from August 9, 2017, until July 1,
2025. Last compliance inspection conducted on December 13, 2021, by Bob Graves.
Current throughputs: 2022
Employees: 77
Hours: 40 hrs./wk., 50 wks./yr.
Permitted Sources are:
Emission Emission Source Control Control System
Source ID Description System ID Description
one furniture finishing operation including:
SB-1 through SB-8 eight d filter-type spray booths N/
g g dry tYP P Y A N/A
T-1 and T-2 two wash-off tanks N/A N/A
3) Inspection:
On November 17, 2022, I, Bob Graves with the NCDAQ went to the facility and met with
Tyler Smith, Plant Manager. Based on my conversation with him, we discussed the following:
a) Verified the contacts based on FACFINDER printout. Correct as listed.
b) No changes have been made to the plant that would change the current air
permit.
5) Inspection observations:
a) Spray booths, SB-1 thru SB-8: I observed the spray booths in operation. Filters are
usually changed weekly. Spray booths are labeled:
Booth# Application Type
1 in operation Finish coating
2 not operating Sealer coating
3 in operation Sealer coating
4 no longer in Used for storage only
operation
5 in operation Lacquer coating
6 in operation Lacquer coating
7 in operation Finish coating (glaze,
lacquer)
8 in operation stain/sealer/lacquer coating

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The spray booth area was clean, and the spray booth filters were in good condition. I
did not observe any visible emissions coming from the outside spray booth stacks.
b) Wash-off tanks: Not observed. One wash-off tank was onsite (the second tank has
not been installed). This tank is kept outside and covered and has not been used in
three years.
6) Stipulation Review:
A.2 2D.0512—Particulate Control. In compliance. There are no wood working
operations that vent to the atmosphere at this site. All painting operations are
performed in dry-filter paint spray booths.
A.4 2D.0521 —Visible Emissions. In compliance. I did not observe any visible
emissions from the outside stacks.
A.6 2D.0540—Fugitive Dust Control. In compliance. I did not observe any fugitive
dust emissions during my inspection.
A.7 2D.1806—Control and Prohibition of Odorous Emissions. In compliance. I did
not detect any odors during my inspection.
A.8 2Q. 0711 —TAP Emission Limit. Appears in compliance. Previous TAP
emission rates have been well-below TPER emission limits and anticipated
emission rates for these TAPS are expected to remain well-below applicable
limits.
A.10 2Q. 0803 —Exclusionary rule. Compliance Indicated. Last annual report
indicated compliance.
7) Reporting requirements: Annual report for summarizing emissions of VOC and HAPs is
required and must be submitted before March 1 annually. Last annual report was submitted
on 02/28/2022 and indicated compliance. The facility uses Sherwin Williams coatings.
Ryan Coulter tracks and submits these reports. For 2021, Total VOC was 38,937.54 lbs.
Total HAPS was 4, 567.07 lbs. Single highest HAP was xylene = 2, 017.78 lbs.
8) 112R Status: Not subject to 112R reporting requirements.
9) Five Year Compliance History: No violations recorded in previous 5 years.
10) Comments and Compliance Statement:
Based on review of records and visual observations, this facility appeared to be operating in
compliance with the Air Quality standards and regulations at the time of this inspection.