AQ_F_1200107_20220510_CMPL_InspRpt

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NORTH CAROLINA DIVISION OF Asheville Regional Office
AIR QUALITY Valdese Weavers, LLC - Lovelady Road Plant
NC Facility ID 1200107
Inspection Report County/FIPS: Burke/023
Date: 05/10/2022
Facility Data Permit Data
Valdese Weavers, LLC - Lovelady Road Plant Permit 09762/R03
705 Lovelady Road,NE Issued 3/2/2017
Valdese,NC 28690 Expires 2/28/2025
Lat: 35d 45.7562m Long: 8 1 d 32.6161m Class/Status Synthetic Minor
SIC: 2269/Finishing Plants,Nec Permit Status Active
NAICS: 313312/Textile and Fabric Finishing(except Broadwoven Fabric) Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Scott McLaughlin Roger Berrier Scott McLaughlin NSPS: Subpart Dc
Facility Engineer Chief Operating Officer Facility Engineer
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 05/10/2022
Inspector's Name Mamie Colburn
Inspector's Signature: �� Operating Status Operating
Compliance Status Compliance- inspection
Action Code PCE
Date of Signature: 6//D t Inspection Result Compliance
Total Actual emissions in TONSIYEAR:
TSP S02 NOX VOC CO PM10 * HAP
2015 7.84 0.0100 2.26 0.5700 1.90 5.14 944.70
2011 7.83 0.0100 2.29 0.6100 2.09 7.83 967.50
* 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
1. Summary: This spring, on February 16, 2022, I observed potential excess visible
emissions from tenter frame stacks at Valdese Weavers Lovelady. A follow up visit was

2,Valdese Weavers Lovelady
conducted on March 1, 2022 and Michael Koerchner and I did not document a violation
of visible emissions -though emissions were visible. Since that time, Valdese Weavers
engaged in efforts to reduce the potential emissions, mainly by cleaning the stacks. The
details of their efforts to address the visible emissions were outlined in a letter to DAQ
dated March 25, 2022.
Today's visit was a second follow up to see if any visible emissions were present from
the tenter frames. Visible emissions today were estimated to be 10% or below from
tenter frame #l, and 5% or below from tenter frames #2 and 43. A full VE was not
completed since there did not appear to be significant emissions.
2. Partial compliance visit narrative: On 5/10/22 I was in the area of Valdese Weavers
Lovelady and drove by to view the facility stacks. From Lovelady Road, no visible
emissions were seen. When I drove into the parking lot, a small amount of VE was
visible from tenter frame #1 stack. Those emissions appeared to be under 10% and
abruptly started and stopped after a few minutes.
I called Mr. Scott McLaughlin to let him know that I was on site and to ask if someone at
the plant was available to accompany me inside and on the roof. Mr. Phil Eller was
called and he had another employee, Kevin, meet me at the front door. I went into the
facility to see if the tenter frames were in operation.
When I arrived inside, tenter frame 91 was shut down and tenter frames #2 and#3 were
being brought back online. I could see that they were changing out the large rolls of
material at the end of each production line. I waited a few minutes and lines 42 & 93
were re-started.
While inside the building:
• Tenter Frame 41 was not operating.
• Tenter Frame #2 was running at 245 °F with a 245 °F set point.
• Tenter Frame 93 was operating at 241 °F with a 240 °F set point.
I went onto the roof with Kevin to view the stacks. Visible emissions were negligible
from tenter frame #2 and#3 with estimated range under 5%. No visible emissions were
seen from tenter frame #1 (not in operation). Heat haze was visible from all tenter frame
stacks. I was prepared to do a full method 9 but did not think it was necessary. I thanked
the operator for his time and proceeded to the next inspection.