AQ_F_1200107_20210811_CMPL_InspRpt (4)

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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: 08/12/2021
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 Carson Copeland Scott McLaughlin NSPS: Subpart Dc
Facility Engineer Chief Operating Officer Facility Engineer
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 08/11/2021
Inspector's Name Mamie Colburn
Inspector's Signature: dNI&Ct 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
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
X 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

Directions
Take I-40E to Exit 113 (Rutherford College). Turn left. Go approximately 2 miles and turn left onto
Lovelady Road. Proceed approximately one mile, and the facility will be located on the right. Inspectors
may need to check in or meet at the Plant No. 1 at 1000 Perkins Road, S.E.first.
Safety
Safety Equipment: Hearing Protection and Safety Shoes
Safety Issue: Forklifts travel throughout the facility;vision of forklift drivers may be limited due to
equipment and storage of items. Care should be taken when touring the facility. The roof of the facility
can be accessed by stairs.
COVED-19 Safety: Due to COVID concerns, DAQ staff was instructed to contact facilities to check on
their current COVID protocols and safety plans prior to arrival. On Wednesday August 11, 2021 I called
Mr. Scott McLaughlin to let him know I was planning to inspect their facility in the immediate future. Mr.
McLaughlin let me know that masks were required,they had no current known COVID outbreaks, and he
volunteered information that he and Mr. Eller who would be meeting with me, were vaccinated. He said
that Valdese Weavers' had brought the Burke County Health Department on site to give vaccinations to
staff if they chose to receive one. After speaking to Mr. McLaughlin I let him know that I would be at the
facility at 1 pm that afternoon.
Contact Information
I reviewed the contact information with Mr. Scott McLaughlin from the IBEAM FacFinder report. Mr.
McLaughlin is now the facility contact and technical contact. Mr. Atkinson is no longer with the
company. It should be noted that Mr. McLaughlin's office is located at Valdese Weavers Perkins Road
facility, not at this facility. Mr. Laughlin's direct line is [phone] and cell phone is 828-289-9426.
Mr. Phil Eller,Plant Engineer for the Lovelady and Cresent Street plants is the back-up contact for this
site should Mr. McLaughlin not be available. He can be reached at(828)432-4244.
Facility Description
Valdese Weavers, Inc. has three permitted facilities in Burke County, along with one unpermitted
weaving plant in Hildebran. The company makes upholstered material for the furniture industry. The
Lovelady Road plant is the company's finishing and distribution center. The Crescent Street plant is
considered the"Prep Plant",where all warping and slashing will be done. The Perkins Road facility
conducts weaving and dyeing. As part of its process,this facility has the following permitted equipment:
three natural gas/No. 2 fuel oil-fired boilers,and three natural gas-fired tenter frames. The facility
operates 3 shifts,24 hours per day, Monday-Friday, with an occasional Saturday or Sunday. This site
has approximately 260 employees including office staff.
Inspection Narrative
On Wednesday August 11'9 20211 met with Mr. Scott McLaughlin and Mr. Phil Eller at the Perkins
Road Plant No. 1.After discussing the permit requirements of Plant No. 1 we discussed the Lovelady Rd.
facility. We spoke about the plant for 30 minutes and then I followed Mr. Eller to tour the Loveland
facility without Mr. McLaughlin. Mr. Eller and I were on site at the Loveland facility for 45 minutes.
Mr.McLaughlin and Mr. Eller and I discussed if there were any recent changes and/or planned changes at
the facility. They told me that they had added a new Biancalani natural gas/electric dryer(to soften fabric)
to replace similar less efficient dryers on site. The original dryers were non-permitted sources. The new
equipment was given a new stack. In 2020 Angela Hopper of DAQ requested that Mr. Atkinson contact
Mr.Michael Koershner of the ARO DAQ, concerning the softening equipment once the facility has more
detailed information on the equipment and installation. There are no notes in the Sharepoint file or

il3eam regarding communication with DAQ regarding this new equipment. The new dryer was seen
in operation during the inspection on August 11 ch
The following permitted equipment was observed during inspection:
Emission Emission Source
Notes
Source ID Description
B 1 (NSPS), B2 (NSPS), 'three natural gas/No. 2 Only one boiler(B 1)was operating during the
And B3 (NSPS) fuel oil-fired boilers inspection, firing on natural gas with no visible
(33.5 million Btu per emissions. Although there are three boilers on-site
hour maximum heat (from the old Carolina Mills plant),the facility does
,input rate, each) not operate B2 or B3. It was previously reported to
DAQ personnel that the facility has no intentions of
burning fuel oil at this site. B2 and B3 are currently'
.being used for spare parts and looked partially
disassembled.
TF 1, TF2 and TF3 three natural gas-fired
The tenter frames were observed in operation with
tenter frames (8.4, 6.0
no visible emissions. VE release points were
and 7.0 million Btu per
viewed from the front parking lot. Each of the
'hour maximum heat
tenter frames has 2 stacks.
input rate, respectively)
Tenter Frames Zones and Temperature Observations:
Each of the Tenter Frames have a series of zones. Each of the zones have a different operating
temperature. These temperatures vary depending on the fabric and the product being applied to the fabric.
• TF #3 was viewed first. It was in operation with temperatures ranging from 232- 260 degrees F.
TF 3 has 8 zones.
• TF 42 was viewed second. It was in operation with temperatures ranging from 178-240 degrees F.
TF 2 has 6 zones.
• TF#1 was viewed last. It was in operation with temperatures ranging from 141-23 8 degrees F.
TF 1 has 10 zones.
Compliance with specific permit conditions and limitations
• Specific Condition 6: Visible Emissions Control Requirement
All equipment at this facility has a 20% opacity limitation. No visible emissions were observed
at the time our visit. The facility has previously had visible emission issues from the Tenter
Frames. After receiving an Informational Letter concerning visible emissions from TF 1 in 2018,
the facility has increased the frequency of cleaning all the TF stacks from bi-monthly to weekly.
• Specific Condition 7: New Source Performance Standards
The three permitted boilers at this facility are subject to NSPS Subpart Dc. As such,the facility is
required to keep track of each fuel combusted in the boilers, along with fuel supplier certifications
that show sulfur content of the fuel oil to be less than 0.5% by weight. The fuel records (natural
gas)were reviewed. No fuel oil has been received nor combusted by the facility. Compliance is
indicated. According to Mr. Eller, no fuel oil has been burned at the facility since Valdese
Weavers bought it in 2007.

• Specific Conditions 8: Excess Emissions Notification Requirement
The facility is required to report excessive emissions that last for four hours and that result from a
malfunction, breakdown of process or control equipment or any other abnormal conditions. The
facility has not had an excessive emissions event. Compliance is indicated.
• Specific Conditions 9: Fugitive Dust Control Requirement
The facility cannot cause or allow fugitive dust emissions to cause or contribute to substantive
complaints or excess visible emissions beyond the property boundary. During inspection, no
fugitive dust emissions were observed. All lots are paved. Compliance is indicated.
• Specific Conditions 10: Toxic Air Pollutant Emissions and Reporting Requirement
Valdese Weavers LLC-Lovelady Road Plant has facility wide hourly emissions limits for
ammonia(as NH3)and formaldehyde. The DAQ approved modeling, submitted by the facility,
on September 22, 2008. The facility is required to be constructed and operated in a manner
consistent with the approved computer modeling. The facility appears to operating consistent
with the approved modeling Compliance is indicated.
• Specific Condition 12: 40 CFR 63 Subpart JJJJJJ-National Emission Standards for
Hazardous Air Pollutants for Area Sources: Industrial, Commercial,and Institutional
Boilers
The facility has indicated the primary operating scenarios(POS) for the affected sources is firing
natural gas (ID Nos. B1, B2, and B3). The facility is not required to comply with most of the
JJJJJJ requirements if they continue to burn natural gas. Once the facility begins to burn fuel oil
they will be required to comply with the JJJJJJ requirement. The facility has no plans to burn
fuel oil, only natural gas. There is currently no fuel oil stored on site. Compliance is indicated at
this time.
• General Condition 15: Permit Retention Requirement
This condition requires the facility to retain a current copy of the air permit at the site. It must be
made available to personnel of the DAQ, upon request. The facility keeps a copy of their current
air permit on site. Air permit was seen in the Air Quality records book on site in the maintenance
area.
Recordkeeping Requirements:
The facility is required to record monthly and total annually the gallons of fuel oil combusted and
a fuel supplier's certification shall be kept on-site and made available to DAQ personnel on
request. The facility is not currently burning No. 2 fuel oil. There is no No.2 fuel oil stored on
site. The facility has not burned any No.2 fuel oil since 2007.
Reporting Requirements:
The facility is required to submit an annual report to the DAQ by January 30 of each year
regardless of actual emissions. The report should contain the following information:
A. amount of fuel oil combusted, facility-wide
B. a copy of the fuel supplier certification with the highest sulfur content delivered to the facility
within the previous calendar year.

The July 1, 2020—Dec. 31, 2020 NSPS semi-annual report was delinquent but complete. I
discussed this delinquency with Mr. McLaughlin by email before this inspection and during
the inspection.
The facility is required to submit a semi-annual report to the DAQ. The report should contain
the following information:
A. the name of the oil supplier
B. a statement from the oil supplier that the oil complies with the specification under the
definition of distillate oil and
C. a certified statement signed by the owner or operator of an affected source that the records of
fuel supplier certification submitted represent all of the fuel combusted during the reporting
period.
Insignificant/Exempt Activities
Source Notes
I-Cal -one natural gas-fired calendar process This item has been removed from the facility. It is
(0.19 mmBtu/hour maximum heat input rate) no longer on site.
One dryer was observed not in operation.
I-Dry- five natural gas-fired dryers (2.81 According to facility personnel,the dryers are
currently not used very often. Some will be sold.
mmBtu/hour maximum heat input rate, **A new large Biancalani natural gas-fired
combined)
dryer was added to the floor to replace the other
dryers.
The storage and mixing room was not observed. I-
Mix was added to the insignificant/exempt
I-Mix—one chemical storage and mixing room activities list during the recent permit renewal. The
facility now has a designated storage and mixing
room for all the chemicals used on site. The
facility calls this room the Finishing Drug Room.
Other Equipment
The facility operates a large natural gas Biancalani dryer. This dryer was updated with a newer Biancalani
dryer since the last inspection. This dryer has 10 zones and is similar to a tumble dyer. The other natural
gas turbine dryers on site are still on site but have been unhooked from gas and power. They will be sold.
Stack Test Review
Valdese Weavers, LLC-Lovelady Road Plant currently does not have a stack test requirement in their air
permit. No stack test has been performed since the last inspection.
112r Review
This facility is not subject to 112r.
Five-Year Compliance History
The facility has had no documented violations in the past five-years.

Recommendations at this time
This table of Insignificant/Exempt Activities from the permit needs to be updated. There is 1 large NEW
Biancalani natural gas dryer with 10 zones. There at 3 other dryers on site that are used occasionally.
Compliance Statement
At the time of inspection, Valdese Weavers—Lovelady Road facility appeared to be in compliance with
Air Permit 09762R03.