AQ_F_1600128_20220913_CMPL_CAV-Rpt

NORTH CAROLINA DIVISION OF Wilmington Regional Office
AIR QUALITY Bally Refrigerated Boxes, Inc.
NC Facility ID 1600128
Inspection Report County/F1PS: Carteret/031
Date: 09/13/2022
Facility Data Permit Data
Bally Refrigerated Boxes, Inc. Permit n/a
135 Little Nine Drive Issued n/a
Morehead City,NC 28557 Expires n/a
Lat: 34d 44.2690m Long: 76d 48.8720m Class/Status Registered
SIC: 5078/Refrigeration Equip& Supplies Permit Status Inactive
NAICS: 42374/Refrigeration Equipment and Supplies Merchant Wholesalers Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Donovan Johnson Mike Coyle Paul Spangenberg MACT Part 63: Subpart 6X,Subpart ZZZZ
President EH&S Compliance
[phone] [phone] Director
[phone]
Comments: Compliance Data
Inspection Date 09/09/2022
Inspector's Name Tony Sabetti
Inspector's Signature: Operating Status Operating
Compliance Status Compliance-inspection
Action Code FCE
Date of Signature: 9// 3/Z - Inspection Result Compliance
27 ZZ
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2014 0.0100 --- --- 7.21 --- 0.0100 3333.00
2009 0.0000 --- --- 7.48 --- 0.0000 407.80
*Highest HAP Emitted in pounds)
Five Year Violation Violation Histo�: None
Date Letter Tvvp Rule Violated Violation Resolution Date
Performed Stack Tests since 1;ia c( G: None
Date Test Results Test Mcfl-mf s $
t� nurcc(s1 Tested
Compliance HistorvHistory
Bally has a history of operating in compliance with DAQ Rules. This assessment is based on a review of
the office file documcros and 1-beam modU!c. The review revealed that no NOV's have been issued during
the past 5 years.

Compliance Inspection
Contact for the inspection was with Donavon ,lular,on, Maintenance Manager. Facility was operating
during the compliance inspection.
General Information
This plant manufactures insulated panels and doors for the construction of walk-in freezers, refrigerated
warehouses, and environmental chambers. MDI (Methylisocyanate) is used in the manufacturing process.
Reeistration
Bally Refrigerated Boxes, Inc. was issued a registration permit on January 9, 2017. Actual emission at the
time were evaluated to be approximately 7 tons/year VOC and.01 tons/year PM.Air emissions sources and
air cleaning devices at the facility are described below:
Emission Emission Source Control Control System
Source ID Description System ID Description
ES-1 one paint spray booth CD-1 1 370 square feet of
P � P Y 9 dry
equipped with one airless panel filters
spray gun
ES-2 one coating operation
consisting of two (auto)
conveyor fed spray coating N/A N/A
lines with two electric heat
lamps
ES-MDI two storage tanks for MDI CD-2 one portable carbon
lbed adsorber
ES-4 miscellaneous production
activities including gluing N/A N/A
and clean-up F
ES-5 (NESHAP) one welding operation N/A N/A
ES-6(NESHAP) ,one abrasive blasting N/A N/A
operation
�— Source
IES-HW 1 -Natural gas fired hot water heater
(222,000 Btu/hr. heat input)
IES-Gen-1 - one emergency back-up diesel
fuel-fired generator(60 kw rating, 2017 model
year,ZZZZ NESHAP)
[IES-Gen-2 - one eme)ency bac6-up dieselel-fired generator(I I kw rating, 2003 model
ar,ZZZZ NESHAP

Registration Criteria: Pursuant to 15A NCAC 2D .0202 "Registration of Air Pollution Sources," and 15A
NCAC 2Q .0102(e), the facility-wide actual total aggregate emissions of particulate matter 10, sulfur
dioxide, nitrogen oxides, volatile organic compounds, carbon monoxide, hazardous air pollutants, and
toxic air pollutants shall be less than 25 tons per year.
Record Keeping: (15A NCAC 2D .0202) - Bally Refrigerated Boxes, Inc. is maintaining records on site to
establish that facility-wide annual air pollutant emissions remain below the 25 ton per year threshold level
listed above.
Notification Requirements: (15A NCAC 21) 00202) - Bally Refrigerated Boxes, Inc. shall notify DAQ as
soon as possible of the followimo occurrcn(cs:
Process Modifications: No modifications of the processes from that listed in the Emissions Equipment
Table has occurred during this inspection cycle.
Name/Ownership/Location Chance: No changing the ficility name, ownership or location from that as
listed in this Registration.
Emissions Increase: Facility has not increased emissions such that the 25 ton per year emission threshold
would be expected to he exceeded.
Liabili : An Air Emission Sources Regis,,ruion shall not alter or affect the power of the Commission,
Secretary of the Dep:irtmcni_ or t ovvi i r i- the liability of an owner or operator of a facility for any
violation of the applicable requirements.
Department of Environmental Oivility hi,­ 1h,ns: No refusal of entry to any representative of the DEQ.
Environmental Management Commission (EMC)Regulations: Bally Refrigerated Boxes, Inc. is
complying with applicable I NC PcLii1:o ­­�.
Particulates from Misecll:w,�wls_Indnslri-d '­ocesses: 05A NCAC 02D .0515) Paint spray booth filter
change log isattachcd. La I on `;rhlcmht'r 20".
Control of Visible EmIS5111a5: (I jj1 LD .0521) -Visible emissions of emission sources were
evaluated with zero percent opacity.
Excess Emissions Notification Requirements: (15A NCAC 2D .0535) - Bally Refrigerated Boxes, Inc. has
not had any excess emissions rcl,orts.
Fugitive Dust Control Rc l ' . .... •..1: (1 " 'AC 2D .0540) —No fugitive emissions were observed.
Control ofEmissinns 1'r:,i,, ' (15:1 `,irA(' �n ,0, 11) _Abrasive blasting operation is
conducted indoors ana c not vented outside to the atmosphere.
Maximum Achievable C(­'--,,I '1'�•r1no1o!,v_Suhpart 7,7.77 (47) IFS-Gen-1 and IES-Gen-2 are serviced
annually.

Generally Available Control Technology. XXXXXX (6X) - Abrasive Ig a11d Melding operations.
Management Practices
The abrasive blasting operation is conducted inside the facility in a blasting cabinet enclosure equipped
with a bag-filter vented inside. Bag-filter is maintained according to manufacturer's instructions.
As required by 40 CFR 63.11516(t), the following management practices are required to minimize the
emissions of the metal fabrication and finishing hazardous our pollutants (MF11A1's: cadmium, chromium,
lead, or nickel> 0.1 % in welding rod or manganese > 1.0 % in welding rod).
Per 40 CFR 63.11516 (f)(1) Bally Refrigerated Boxes, Inc. is operating al I equipment associated with
welding operations according to manufacturer's instructions. A copy of the manufacwrer's specifications
is maintained on site.
Per 40 CFR 63.11516 (f)(2), Bally Refrigerated Boxes, Inc.is using gas metal are welding (GMAW)
processes that reduced fume generation capabilities.
Monitoring Requirements
Bally Refrigerated Boxes, Inc. performs visual determinations of fugitive emissions, as specilled in 40
CFR 63.11517(b). Most recent quarterly observations were performed on 8/10/22, with no visible fugitive
emissions detected.
Record Keeping
Wielding wire usage log is attached.
Reporting Requirements
Annual Compliance Certification(ACC) was received on January 10, 2022 with no deviations reported for
CY 2021 copy attached.
Inspection Summary
From the observed information, recommend accept this facility as operating in compliance with applicable
EMC Air Quality Regulations at this time.

_1 T 'u jT �.
LOG
DATE INITIALS
J�-
� /6
3 -17
7-7
7-
�-z
q -3

BALLY REFRIGERATED BOXES, INC.
WELDING PRODUCTION DATA
DATE PIECES POUNDS
9, J Ei
z2 73 ,S
2 0 3s
-5-91
2 736
22 3t
4111zz.
8 2 8
2 3
22 3ys
22 s -2
22 2 ?t
22 2 , .S
22 y
2 2 0
/32 2 0 S
o 22 O
/ 22 S;S
22 ,
0 2
7 22 y5 ,3-
2 63 ,s
z 2- 6 38
-71 2Z
sz2 0 15-
71
2 "22 61O,s
z 9 4. >
S 22 7S S
S e3 /.5S
/9 22 S8 ,A9
2 2 9.S
2

VISIBLE EMISSION OBSERVATION REPORT
WELDING
(DISCHARGE OUTDOORS)
BALL REFRIGERATED BOXES, INC.
MOREHEAD CITY, NORTH CAROLINA
Date: D Time: /O
Sky Condif ons:(clear part, partly cloudy,cloudy,overcast) Wind Direction:(North,South, East,West)
C' B—
Wind Speed:(Calm,Gentle, Moderate,Strong)
Steam Present: 0 G
Precipitation: (Yes/No)
Observer Name: Donovan Johnson Observers Signature:
Observation Point Diagram:
t N
Observation
Location#1
WELDING
C OBSERVATION
Clock Time - —� Observation Period ' Actual Emissions
Duration Time
min:sec) minaec _
Observation Location'#1 :Start __/D : �' �.t-. � �•
Observation Location#1 : Stop '
No Emissions Emissions, but less than 6 minutes ❑ Abnormal Emissions ❑
Corrective Action:
Make observations for 15 minutes or more.
*Emissions will be considered to be present if detected for more than 6 min.

VISIBLE EMISSION OBSERVATION REPORT
DRY ABRASIVE BLASTING
(DISCHARGE INDOORS)
BALL REFRIGERATED BOXES, INC.
MOREHEAD CITY, NORTH CAROLINA
Date: 2 Time:
Observer Name: Donovan Johnson Observers Signature:
Observation Point Diagram:
Observation t
Location#1 ® N
BLASTING
OBSERVATIONS
TimeObservation Period Actual Emissions
n Duration Time
fr 9
--min_sew — minaec —
Observation Location#1 Starts
1
Observation Determinatlon `t
No Emissions Emissions, but less than 6 minutes � Abnormal Emissions (]
Corrective Action:
Make observations for 15 minutes or more.
*Emissions will be considered to be present if
detected for more than 6 minutes.

VISIBLE EMISSION OBSERVATION REPORT
WELDING
(DISCHARGE INDOORS)
BALL REFRIGERATED BOXES, INC.
MOREHEAD CITY, NORTH CAROLINA
Date: n /a Time: D ---
�"} —
Observer Name: Donovan Johnson Observers 5ignature: I
Observation Point Diagram:
N
Observation
Location#1
i WELDING
OBSERVATIONS
Clock Time Observation Period Actual Emissions
Duration Time
minas jmin sec
Observation Location#1 : Start
Observation Location#1 : Stop f _-
`µ` Observation Determination
No Emissions Emissions, but less than 6-minute, ❑- Abnormal Emissions ❑
Corrective Action:
Make observations for 15 minutes or more.
"Emissions will be considered to be present if
detected for more than 6 minutes.

ANNUAL CERTIFICATION AND COMPLIANCE REPORT
Area Source Rule for Nine Metal Fabrication and Finishing Source Categories
40 Code of Federal Regulations (CFR) 63.11514—63.11523 (Subpart X3XKXX) (6X)
For reporting period: 2021
This annual certification and compliance report is due no later than January 31'of thefiflowing yea'
Facility Information
Company Name: Facility Number if known :
Bally Refrigerated Boxes, Inc.
Facility Street Address; Ci State:+28557
i :
135 Little Nine Road Morehead City NC
Owner/Operator Name and Title: Phone number: Email if available):
Michael Coyle, President [phone] [e-mail]
Mailing Address(if different from facility street
address): City: State: I Zip:
135 Little Nine Road Morehead City NC 28557
Facility SIC codes : Fac ity NAILS codes :
3585,3444 333415
Method 22 Visible Emissions Monitorine
Method 22 visible emissions monitoring is required for:
• Welding operations, if the facility-wide usage of MFHAP-containing* welding rod or wire is
2,000 pounds or more annually
• Dry abrasive blasting of objects over 8 feet in any dimension, if blasting is done without a
filtration control device, and MFHAP* are emitted
*Metal fabrication and finishing HAP(MFHAP)means any compound of the following metals:
cadmium, chromium, lead,manganese,or nickel,or any of these metals in the elemental form,with the
exception of lead.
Check the box below that best applies to your situation:
❑ Method 22 visible emissions monitoring is not required for this facility.
® Method 22 visible emissions monitoring is required for this facility.Visible emissions were
not found to be "present"during this annual reporting period. (Visible emissions are
considered to be "present" if they are detected for more than six minutes of the fifteen minute
test period.)
❑ Method 22 visible emissions monitoring is required for this facility. Method 22 visible
emissions were determined to be "present" during this annual reporting period. The
following information is included with this report:

■ All dates on which Method 22 visible emissions were found to be "present";
■ A description of the corrective actions taken subsequent to the test; and
■ The date and results of follow-up visible emissions monitoring performed after the
corrective actions. Note:For welding operations, if visible emissions are found to be
"present"more than once per year, additional reporting documentation is required.
Certification
Check the appropriate box below:
® This facility complied with all applicable 6X requirements during the reporting period.
❑ This facility did not comply with all applicable 6X requirements during the reporting period.
Please explain the reason below, and describe any corrective action taken.
Explanation of Noncompliance:
I certify the truth, accuracy, and completeness of this report.
Responsible Official Name I Responsible Official Signature Date
Michael Coyle, President I // I S Y