AQ_F_0900081_20201123_CMPL_CAV-Rpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Gildan Yarns,LLC Plant 71
NC Facility ID 0900081
Compliance Assurance Visit Report County/FIPS:Bladen/017
Date: 11/25/2020
Facility Data Permit Data
Gildan Yarns,LLC Plant 71 Permit . n/a
820 West Highway 211 Issued n/a
Clarkton,NC 28433 Expires n/a
Lat: 34d 29.6060m Long: 78d 40.1260m Class/Status Permit Exempt
SIC: 2281 /Yarn Mills,Except Wool Permit Status Inactive
NAICS: 313111 /Yam Spinning Mills Current Permit Applications)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SEP
Matt Moyer Randall Ferguson Randall Ferguson
Plant Manager Director of Engineering Director of Engineering
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 11/23/2020
Inspector's Name Denise Bruce
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
Action Code FCE
Date of Signature: O_ 0,-0 On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2013 0.3300 --- --- --- --- 0.1426 ---
2008 0.2100 --- --- --- --- 0.0900 ---
*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

1)Directions:
Head South on Green St toward Maiden Ln(0.1 mi)At the traffic circle,take the 2nd exit onto
Gillespie St (1.2 mi)Turn right onto the ramp Hwy 87 S to Elizabethtown (0.2 mi)Merge onto NC-
87 S (33.5 mi)Continue onto NC-87 Bypass S (4.2 mi)Use the right lane to take the US-701/NC-242
ramp to Elizabethtown/White Lake/Whiteville(0.3 mi)Turn right onto NC-242 S/US-701 S (8.3 mi)
Turn right onto NC-211 N/W Green St(0.5 mi)
2) Safety Equipment:
All standard FRO DAQ safety gear. Be aware of various machinery operating;be aware of noise,
pinches, and scratches because of air pressure-driven doors.
3)Process/Facility Description:
This is a cotton and cotton-blend spinning mill. It is necessary for the plant process to maintain the
air temperature and relative humidity in the plant,respectively at 75 to 78 degrees F and 63 percent.
The facility has two sections of cotton thread machines: Side A with 18 machines and Side B with 28
machines.
Bales of ginned cotton are processed using several cleaner blender-mats to remove the cotton waste
from the usable fibers. The fibers go through multi-mixer CVT guard machines and are drawn to
frames machines where the fibers are spun into continuous loose strands that are barely held together
in thick appearing rope type strands. These spun fiber strands are accumulated through a special
computerized process, into large barrels that are fed to the open-end spinner machines where they are
spun into 8-count thread reams. The facility produces a 50/50 polyester/cotton blend thread and a
100% cotton thread. Cotton waste from the process is recycled back to the process. Waste matter
from the process is collected and transported off site for agricultural use
Air Filtration Systems:
There are 4 fabric filter house units and 3 air wash scrubber units with associated fabric filter lined
rotating drums,which all remove particle matter. The fabric filters are used to remove larger
particulate matter before the air is drawn through a series of water wet scrubber type spray nozzles.
This wash removes smaller particulate matter and aids in the needed control of the facility
temperature and humidity levels. The large amount of water used for the scrubber system is filtered
through a special screen and reused for the wet scrubber control device. Winter months require less
water use,whereas the summer months require a greater usage of water. From the air wash units,the
air is put through a fabric filter lined rotating drum and then exhausted back into the plant. Exhausts
from these control devices are not released into the atmosphere but re-enter back into the plant.
Fire pump engine:
The facility has a 135-brake horsepower engine manufactured in CY1989 with non-resettable hour
meter that is exercised—30 minutes each week and only used for facility emergency reasons.

4)Equipment List:
The facility rescinded their air permit on 4 October 2016. The following equipment is on site.
- Emission sources associated with the air filtration system(s)utilized in the yarn spinning
process (Standard Industrial Classification Code(SIC)2281,2282, and 2284);
-Operating at—4300 pounds of thread per hour;^0% opacity.
Insignificant/Exempt Activities:
I-FIRE PUMP
135 HP diesel-fired fire pump(NESHAP 2Q.0102(c)(2)(B)(v)(I) Yes Yes
Subpart ZZZZ)
-Not operating
5) Compliance Assurance Visit:
On 23 November 2020,I Denise Bruce of FRO DAQ conducted a compliance assurance visit at
Gildan Yarns, LLC Plant#71. I met with Daniel Alguire, Plant Manager and Steve Bedsole Plant
Engineer. We discussed the following:
a) Verified FACFINDR information: updates to the Facility Contact information were needed
and were updated in IBEAM before this inspection report was made.
b) I reviewed the maintenance records for the fire pump and found them to be complete and up
to date. Inspections are completed weekly. The engine had 265.1 hours at the time of
inspection.
c) Production:
Year Pounds of bales cotton
2019 —30,000,000
2018 —32,000,000
2017 30,000,000
2016 —36,000,000
2015 40,435,096
2014 38,135,295
6)Inspection Summary:
Mr.Aligure led me on a tour of the outside of the facility. I was able to observe the emission points
for the air wash filters. I observed no visible emissions. Mr. Bedsole took me to the outlying
building that contains the facility's fire pump. He showed me the logbook for maintenance and test
runs. The log appeared to be complete and up to date.
7)Applicable Air Quality Regulations:
2D .0503—'Particulates from Fuel Burning Heat from Fuel Burning Indirect Heat
Exchangers"—Particulate matter emissions from the fuel burning indirect heat exchangers shall not
exceed the allowable emission rates.
Appeared in Compliance-The facility has no fuel burning indirect heat exchangers on site.

21) .0515"Particulates from Miscellaneous Industrial Processes"—Particulate matter emissions
from the emission sources shall not exceed allowable emission rates.
Appeared in Compliance- Compliance was determined during the previous permit review based on
operating the source as described in those permit conditions. No changes have been made to
operations since the permit recission.
2D .0516"Sulfur Dioxide Emissions from Combustion Sources"—Sulfur dioxide emissions from
the emission sources shall not exceed 2.3 pounds per million Btu heat input.
Appeared in Compliance-The fire pump engine combusts ULSD. The AP-42 emission factor for
this fuel is 0.0021bs/mmBtu.
2D .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 over a six-
minute period.
Appeared in Compliance—No visible emissions were observed during this inspection.
21).0521 "Control of Visible Emissions"—Visible emissions from the emission sources,
manufactured prior to July 1, 1971, shall not be more than 40 percent opacity when averaged over a
six-minute period.
Appeared in Compliance—Facility does not have equipment manufactured prior to 1 July 1971.
A.8 21) .0535 Notification Requirement,-Facility is required to notify the DAQ of excess
emissions that last for more than four hours resulting from malfunction,breakdown, or abnormal
conditions.
Appeared in Compliance—Mr.Bedsole stated there have been no occurrences of excess emissions
since the last inspection.
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.
Appeared in Compliance—No fugitive dust emissions were observed. Facility grounds are paved
and landscaped. Mr.Moyer stated that he has not received any dust complaints. FRO DAQ has not
received any dust complaints regarding this facility.
8) 112r Status:
The facility does not store any of the listed chemicals above a threshold quantity,and therefore is not
required to maintain a written Risk Management Plan(RMP).
9)Non-Compliance History since CY2010:
On 11 September 2015, an NOD was issued due to record-keeping of Air Filtration System and Fire
Pump,I-FIRE PUMP. Response was received on 28 September 2015.
10) Comments/Compliance Statement:
Gildan Yam,LLC Plant#71 appeared to be I7V COMPLIANCE with the applicable air quality rules
and appears to still meet the permit exemption requirements as production and processes have
remained the same since the permit recission.
Pink Sheet:
None.
/adb