AQ_F_0200083_20210830_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Hickory Springs Hiddenite
NC Facility ID 0200083
Inspection Report County/FIPS: Alexander/003
Date: 08/18/2021
Facility Data Permit Data
Hickory Springs Hiddenite Permit 08502/R04
161 Sharpe Lane Issued 4/13/2016
Hiddenite,NC 28636 Expires 3/31/2024
Lat: 35d 54.0973m Long: 8ld 5.3202m Class/Status Small
SIC: 3086/Plastics Foam Products Permit Status Active
NAILS: 32614/Polystyrene Foam Product Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Candy Duffey Isaac Spears Zenaida Camacho MACT Part 63: Subpart 60
Plant Manager Vice President of Foam EHS Manager
[phone] Fabrication [phone]
[phone]
Compliance Data
Comments:
Inspection Date 08/18/2021
Inspector's Name Emily Supple
Inspector's Signature: &n `I Supp& Dix Operating Status Operating
�`�`� Compliance Status Compliance-inspection
Action Code FCE
Date of Signature: 8/30/2021 Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2015 --- --- --- 11.38 --- --- ---
2010 --- --- --- 7.44 --- --- ---
Highest HAP Emitted(in pounds)
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

Hickory Springs Hiddenite
August 18,2021
Page 2
Type Action: X Full Compliance _Partial Compliance _Complaint Other:
Evaluation Evaluation/Reinspection Investigation
Data Date submitted for initial review 8/25/2021 _IBEAM WARNING/OB,NOD,NOV,NRE
Tracking: X IBEAM Document
X IBEAM Inspection,list date inspected X IBEAM LAT/LONG,Facility Locked
X IBEAM Inspection,list date draft is submitted X IBEAM LAT/LONG,Coordinates checked
X IBEAM Inspection,pollutants/programs checked IBEAM Complaint
X IBEAM Planning,Next Inspection Date 08/01/2023
Directions: Traveling I-77 north to Statesville,take I-40 west to exit 148. Turn right onto highway 64/90
west. Travel approximately.25 miles and turn right onto highway 90 west. After 13 miles,turn right onto
sulfur springs road. Travel approximately 200 feet, cross the railroad tracks, and then turn right onto
Sharpe street. The facility is located on the left.
Safety Equipment: Safety glasses are required.
Safety Issues: Watch for moving conveyor belts and forklifts.
Lat/Long: A review of the facility's coordinates on"Maps of DAQ Regulated Facilities"indicates the
facility's latitude and longitude coordinates are accurate.
Email Contacts: Email contacts found in IBEAM were verified. The technical contact,Mr. Steve Hannah,was
replaced with the new technical contact,Ms. Zenaida Camacho,EHS Manager.
COVID-19 Information:
• Who did you speak with regarding the facility's COVID-19 inspection procedures?
Candy Duffey—Plant Manager
• Does the facility allow on-site inside the facility buildings, on-site but outside only or virtual only
inspections?
On-site inspections are allowed
• Does the facility follow social distancing, mask wearing and hand washing procedures in the
facility? (list other procedures the facility follows)
Yes, on-site personnel were wearing masks and following social distancing as much as
possible.
• Are there any COVID-related requirements of inspectors before entering the facility?
(temperature check, sign health form,etc)
There were no COVID related requirements aside from wearing a mask/social distancing.
1. General: The purpose of this site visit was to conduct a routine air quality inspection. This facility cuts and
glues pieces of foam into cushions, etc.,for the furniture and medical industry. The facility is currently
operating five days per week(Monday through Friday) from 7:OOAM to 3:30PM with approximately 62
employees. I arrived at the facility at approximately 9:00 AM. Ms. Candy Duffey,Plant manager,
accompanied me during this inspection.

Hickory Springs Hiddenite
August 18,2021
Page 3
2. Facility Contact Information: During the inspection I verified the facility contact information in IBEAM. The
technical contact was updated to Ms.Zenaida Camacho,EHS Manager.
3. Compliance history file review: No problems have been noted in the last five years by DAQ,prior to this
inspection. The current compliance status is discussed in the following sections.
4. Observations of permitted air emission sources and control devices:
Emission Emission Source Control Control System
Source ID Description System ID Description
ES-F-01 (NESHAP) flexible polyurethane
foam gluing operation N/A N/A
Observed.The operation consists of two parts: the first is a spray conveyor,used to glue together large
sheets of foam, guided by an electronic eye and a gang sprayer system;the second is a group of eight
gluing stations with a low pressure,high volume spray gun at each station. The facility now has nine
spray stations.Each station is covered with brown paper, and it is changed every week. Eight spray
stations and the conveyor were in operation with no issues noted.
5. Observations of insignificant air emission sources and control devices listed on the current permit:
a. None.
6. Observations of air emission sources and control devices not listed on the current permit:
a. None.
7. Compliance with specific permit conditions and limitations:
a. Condition A.2. 15A NCAC 2D .0202, "Permit Renewal and Emissions Inventory Requirement"-The
Permittee, at least 90 days prior to the expiration date of this permit, shall request permit renewal by
letter.
Observed.The current permit does not expire until March 31,2024. Compliance with this stipulation is
indicated.
b. Condition A.3. 15A NCAC 21) .0521, "Control of Visible Emissions"-Visible emissions from
the emission sources,manufactured after July 1, 1971, shall not be more than 20 percent opacity
when averaged.
Observed.No visible emissions were observed at the time of the inspection. Compliance with
this stipulation is indicated.
c. Condition A.4. 15A NCAC 21) .0535, "Notification Requirement"-The Permittee of a source of excess
emissions that last for more than four hours and that results from a malfunction, a breakdown of process
or control equipment or any other abnormal conditions, shall notify the Director.

Hickory Springs Hiddenite
August 18,2021
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Observed.No excess emissions have been reported since the last inspection. Conversation with Ms.
Duffey indicated that the facility has not had any excess emissions since the last inspection. Compliance
with this stipulation is indicated.
d. Condition A.5. 15A NCAC 2D .0540, "Particulates from Fugitive Dust Emission Sources"-The
Permittee shall not cause or allow fugitive dust emissions to cause or contribute to substantive complaints
or excess visible emissions beyond the property boundary.
Observed.No fugitive dust emissions were observed at the time of the inspection. Compliance with this
stipulation is indicated.
e. Condition A.6. 15A NCAC 2D .0958(c), "Work Practices for Sources of Volatile Organic Compounds"-
For all sources at facilities that use volatile organic compounds (VOC) as solvents, carriers,material
processing media, or industrial chemical reactants,or in similar uses that mix,blend,or manufacture
volatile organic compounds, or emit volatile organic compounds as a product of chemical reactions;the
Permittee shall adhere to the required work practices.
Observed.The facility appears to be following the required work practices. However,this condition no
longer applies to counties designated as attainment for ozone. These changes have been listed on the
electronic yellow-sheet. Compliance with this stipulation is indicated.
f. Condition A.7. 15A NCAC 21) .1111, "Maximum Available Control Technology 40 CFR 63 Subpart
000000)" -The Permittee shall comply with all applicable provisions of 40 CFR 63, Subpart
000000 "National Emission Standards for Hazardous Air Pollutants for Flexible Polyurethane Foam
Production and Fabrication Area Sources",including Subpart A "General Provisions."
Standards and Compliance
a. For foam fabrication operations with loop slitters,the Permittee shall retain on site a statement
signed and dated by a responsible official stating that the facility does not use any adhesive
containing methylene chloride in a flexible polyurethane foam fabrication process.
b. Permittee shall not use any adhesive containing methylene chloride in a flexible polyurethane
foam fabrication process.
Recordkeeping Requirements
a. The Permittee shall demonstrate compliance using adhesive usage records,Material Safety Data
Sheets or engineering calculations.
Observed.The facility uses spray guns to add the glue to the foam.No loop slitters are used in the
process. According to the MSDS the adhesive is a foam solvent-based adhesive from Worthen Industries,
Inc. The MSDS also indicated that this adhesive does not contain methylene chloride. Compliance for
this condition is indicated.
g. Condition A.8. 15A NCAC 21) .1806, "Control and Prohibition of Odorous Emissions"-The Permittee
shall not operate the facility without implementing management practices or installing and operating odor
control equipment sufficient to prevent odorous emissions from the facility from causing or contributing
to objectionable odors beyond the facility's boundary.

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August 18,2021
Page 5
Observed.No odors were observed at the time of the inspection.No odor complaints have been filed
against the facility. Compliance with this stipulation is indicated.
8. NSPS/NESHAP Review:
There are no generators or fire pumps at the facility, so the facility is not subject to NESHAP Subpart 4Z.
There are no boilers at the facility, so the facility is not subject to NESHAP Subpart W.
There are no gasoline storage tanks at the facility, so the facility is not subject to NESHAP Subpart 6C.
9. Summary of changes needed to the current permit:
Condition A.6. (15A NCAC 2D .0958(c))can be removed because the rule no longer applies to counties
designated as attainment for ozone. This information is listed on the yellowsheet in the facility file.
10. Compliance assistance offered duringtpectiow.
None.
11. Section 112(r)applicability
The facility does not appear to be subject to this regulation.
12. Compliance determination:
Based on my observations,the facility appeared to be in compliance with all applicable Air Quality
regulations at the time of the inspection.
EJS:
c: MRO file
https://neconnect.sharepoint.com/sites/DAQ-MRO/Counties/ALEXANDER/00083/INSPECT 20210818.doex