AQ_F_1800202_20210301_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Sherrill Furniture Company,Inc.
NC Facility ID 1800202
Inspection Report County/FIPS: Catawba/035
Date: 03/01/2021
Facility Data Permit Data
Sherrill Furniture Company,Inc. Permit 05049/R10
2405 Highland Avenue NE Issued 1/19/2017
Hickory,NC 28601 Expires 12/31/2024
Lat: 35d 43.9836m Long: 8ld 17.3844m Class/Status Small
SIC: 2512/Upholstered Household Furniture Permit Status Active
NAICS: 337121 /Upholstered Household Furniture Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
William Smith William Smith William Smith
Vice President of Vice President of Vice President of
Operations Operations Operations
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 03/01/2021
Inspector's Signature: e Jam J931A Inspector's Name Ryan Mills
Operating Status Operating
Date of Signature:March 1,2021 Compliance Status Compliance-inspection
Action Code FCE
Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2015 0.2800 0.0100 0.1600 11.67 0.1300 0.1600 1657.80
2011 0.2800 0.0100 0.1600 12.03 0.1300 0.1600 2315.68
*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

Sherrill Furniture Company, Inc.
March 1,2021
Page 2
Type Action: X Full Compliance _Partial Compliance _Complaint Other:
Evaluation Evaluation/Reinspection Investigation
Data Tracking: Date submitted for initial review: 3/10/2021 _IBEAM WARNING/OB,NOD,NOV,NRE
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: 3/l/2023
Directions: From MRO, travel I-77 north to 1-40 west to Hickory. Take exit 128 and turn right onto
Fairgrove Church Road. Travel to the end of the road and turn left onto Highland Avenue. Travel
approximately 1 mile and the facility is located on the right at 2405 Highland Avenue NE.
Safety Equipment: Safety glasses are required, and hearing protection and safety shoes are
recommended.
Safety Issues: None noted.
Latitude/Longitude Coordinates: A review of the"Facilities Regulated by Air Quality"on the DAQ
website indicated the facility's location is accurate and matches the facility's latitude and longitude
coordinates listed in IBEAM.No changes to the latitude and longitude coordinates of this facility are
needed in IBEAM.
Email Contacts: IBEAM email contacts were verified with no changes required.
1. The purpose of this site visit was to conduct a routine air quality inspection. This facility
manufactures upholstered furniture. The facility is currently operating 12 hours per day and 6
days per week with approximately 361 employees. Mr.William Smith,Vice-President of
Operations,accompanied me during this virtual"Go to Meeting"inspection on March 1,202 1. 1
also drove by the facility to observe the bagfilter(1) located at this facility on February 24,2021.
2. Facility Contact Information:
During the inspection I verified the facility contact information in IBEAM. No changes were
needed.
3. COVID-19Information:
Currently visitors are allowed into the facility. Masks are required. The facility states that
social distancing and teleworking of its employees and staff that are able is being highly
encouraged.A records and permit review took place via the application,"Go to Meeting"
provided by the facility on March 1,202 1. 1 took the DEQ DAQ Screening Tool survey before
going onsite for the observation of permitted equipment on February 24,2021.
4. Compliance history file review:
There have been no compliance issues in the last 5 years. The current compliance status is
discussed later in this report.

Sherrill Furniture Company, Inc.
March 1,2021
Page 3
5. Observations of permitted air emission sources and control devices:
Emission Emission Source Control Control System
Source ID Description System ID Description
WW-1 woodworking operations BH-1 bagfilter(3,255 square
feet of filter area)
Observed: This process was not observed during this inspection. This woodworking operation consists
of four(4)routers and one(1)wood hog. I observed the bagfilter during my onsite inspection on February
24,2020 with no visible emissions or accumulation of sawdust around the ducting or transfer points.
ES-1 F dip tank N/A N/A
Observed: The dip tank was not observed during this inspection.According to Mr. Smith the dip tank is
only used sporadically.
SB-1, SB-2, SB-3, SB-4 four(4)baffle-type paint
spray booths N/A N/A
Observed: The booths were not observed during this inspection.Mr. Smith sent me photographs(see
below).All baffles were in place and appeared to be in good operating condition. Mr. Smith stated that
for the year 2020 they used 3,650 gallons of coatings. (Averaging 304 gallons a month)During the last
inspection on February 12,2019 the facility was spraying approximately 350 gallons of finishing material
per month on average.
LU-1 leather upholstery N/A N/A
finishing I F
Observed: Select leather furniture is hand-wiped with a water-based solvent to clean it and then hand-
wiped with a stain. This process was not observed during this inspection. The process was not in
operation at the time of this inspection and Mr. Smith says the process is basically mothballed. (See
picture below)
6. Observations of insignificant air emission sources and control devices listed on the current permit:
Source
IES-1 -natural gas-fired boiler(8.37 million Btu per hour maximum heat input rate)
Observed: The boiler(Kewanee; 1969)was not in operation at the time of this inspection. The boiler
plate was checked during the last inspection and the rating was listed as 8369 MBh,which converts to
8.37 million Btu per hour. This boiler is only used for comfort heat,no process steam.
IES-2 -natural gas-fired boiler(5.04 million Btu per hour maximum heat input rate)
Observed: The boiler(Kewanee; 1965)was not in operation at the time of this inspection. The boiler
plate was checked during the last inspection and the rating was listed as 5040 MBh,which converts to
5.04 million Btu per hour. This boiler is only used for comfort heat,no process steam.

Sherrill Furniture Company, Inc.
March 1, 2021
Page 4
Example of one of the Four(4)Baffle-Type Spray Booths
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Leather Upholstery Finishing
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Sherrill Furniture Company, Inc.
March 1,2021
Page 5
7. Observations of air emission sources and control devices not listed on the current permit:
a. None noted.
8. Compliance with specific permit conditions and limitations:
a. Condition A.2. "Permit Renewal and Emission Inventory Requirement" states that at least
90 days prior to the expiration date of this permit,the permittee shall request permit
renewal by letter with AA application form and submit the air pollution emission
inventory report with certification sheet for 2021 calendar year to MRO DAQ.
Observed.The current permit expires on December 31,2024.No further action is
required at this time. Compliance with this permit condition is indicated.
a. Condition A.3. 15A NCAC 2D .0512, "Particulates From Wood Products Finishing
Plants". Provide adequate ductwork and properly designed collectors to control
woodworking particulates.
Observed. Wood particulate appeared to be properly controlled. No sawdust waste was
observed at exhaust points around the baghouse,and ductwork appears to be properly
maintained during my on-site visit on February 24,2020. Compliance with this permit
condition is indicated.
b. Condition A.4. 15A NCAC 21) .0515,"Particulates from Miscellaneous Industrial
Processes,"particulate matter emissions from leather upholstery finishing(ID No. LU-I)
shall not exceed allowable emission rates.
Observed.According to the permit review completed in January of 2017,the production
rate came to 2.82 lb/hr of finishing materials used on the leather upholstery finishing
process. Mr. Smith says that using this number would be on the high side since
production basically mothballed and has not been used in years. Compliance with this
permit condition is indicated.
C. Condition A.5. 15A NCAC 2D .0521, "Control of Visible Emissions". The facility is
limited to 20 percent opacity.
Observed. No visible emissions were observed at the facility. Compliance with this
permit condition is indicated.
d. Condition A.6. 15A NCAC 2D .0535,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 or his
designee of any such occurrence by 9:00 a.m. Eastern time of the Division's next business
day of becoming aware of the occurrence.
Observed. There have been no reports of excess emissions since the last inspection.
Compliance with this permit condition is indicated.

Sherrill Furniture Company, Inc.
March 1,2021
Page 6
e. Condition A.7. 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. There have been no complaints concerning the facility received by the MRO,
and no fugitive dust emissions were observed at the time of this inspection. Compliance
with this permit condition is indicated.
f. Condition A.8. Fabric Filter Requirements,conduct an annual internal inspection of the
bagfilter system. In addition, conduct periodic inspections and maintenance as
recommended by the equipment manufacturer and list corrections made and dates of
actions in a logbook.
Observed. The facility conducts weekly,monthly,and annual inspections of the
baghouse. The last four internal inspections were conducted on December 21, 2020,July
3, 2020,December 27,2019, and July 3,2019 . During the inspections in 2019 and 2020
the facility inspected the bags and checked the drive chain and gearbox oil. The chain
was lubed, and all bearings were greased.Also, all the belts on the fans were checked.
All maintenance and inspection activities are recorded in a logbook. Mr. Smith stated
that all the bags are replaced at least annually. Compliance with this permit condition is
indicated.
Example of Saghouse Internal Inspection Logbook for 2019
SHE RILL FURNITURE COMPA14Y _- v
OUSTINT SYSTEM INSPECTION AND MAENANCE
InsaP-tian of Maintenance Task Performed}
0,j o�
a hm� �—�w Coo r—.V,—
-_ �J -W,

Sherrill Furniture Company, Inc.
March 1, 2021
Page 7
Example of Baghouse Internal Inspection Logbook for 2020
SHERRILL FgANITDRECOMPANY
__...DUST SYSTEM INSPECTION AND MAINTENANCE
RATF—
-QF TASK S EA MEI -
-___ CE _T Insoprtion or
Maintenancs Task Pet{ormed)
�3 �.r c �; ,�J Grp•6,,_ �-
I
Picture of Baghouse (BH-1) taken by Ryan Mills on February 24, 2021
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Sherrill Furniture Company, Inc.
March 1,2021
Page 8
g. Condition A.9 15A NCAC 2Q .0711, "Emission Rates Requiring a Permit". The
Permittee has made a demonstration that facility-wide actual emissions do not exceed the
Toxic Permit Emission Rates(TPERs) for MIBK(methyl isobutyl ketone).
Observed. The leather upholstery finishing process is currently mothballed. The paint
used in the spray booths does not contain MIBK according to the SDS sheets that Mr.
Smith provided me. Compliance with this permit condition is indicated.
9. NSPS/NESHAP
The facility was sent an applicability letter pertaining to Subpart 000000"Hazardous Air
Pollutants for Flexible Foam Production and Fabrication Area Sources"on November 13,2007.
The facility does not conduct any type of foam gluing or fabrication and therefore is not subject.
There are no emergency generators or fire pumps on site. Therefore,this facility is not subject to
NESHAP Subpart 4Z.
There is a gasoline storage on-site that has a 3,000-gallon capacity. The facility records indicate
that the facility has a throughout of approximately 7,200 gallons a year. I did a full Stage I
inspection on the tank during the last inspection on February 12,2019. During that inspection, all
Stage I equipment was in place and all regulations for Subpart 6C were being followed.
10. Summary of changes needed to the current permit:
None.
11. Compliance assistance offered duringthe hpection:
None asked for or given during this inspection.
12. Section 112(r)applicability:
This facility does not appear to be subject to the requirements of the Chemical Accident Release
Prevention Program, Section 112(r)of the Clean Air Act.
13. Compliance determination:
Based on my observations,this facility appeared to be in compliance with the applicable air
quality regulations at the time of the inspection.
RCM:
cc:MRO File
https://ncconnect.sharepoint.com/sites/DAQ-MRO/Counties/CATAWBA/00202/INSPECT 20210301.docx