AQ_F_1800517_20200127_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Carolina Pelleting and Extrusion,Inc.
NC Facility ID 1800517
Inspection Report County/FIPS:'Catawba/035
Date: 01/14/2020
Facility Data Permit Data
Carolina Pelleting and Extrusion,Inc. Permit 09188/R03
1694 Fisher Court Issued 3/3/2016
Newton,NC 28658 Expires 2/29/2024
Lat: 35d 38.6020m Long: 81d 12.1660m Class/Status Small
SIC: 3087/Custom Compound Purchased Resins Permit Status Active
NAILS: 325991 /Custom Compounding of Purchased Resins Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Douglas Hicks Douglas Hicks Douglas Hicks
President President President
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 01/14/2020
Inspector's Name Sandra Sherer
Inspector's Signatu . Operating,Status Operating
Compliance Code Compliance-inspection
Action Code FCE
Date of Signature: �_�;7 2,d!, On-.Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2015 0.0156 --- 0.0200 --- 0.0200 0.0156 0.8480
2010 0.0900 --- --- --- --- 0.0800 ---
Highest HAP Emitted inpounds)
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

Carolina Pelleting and.Extrusion,Inc.
January 14,2020
Page 2
Type Action: X Full Compliance _Partial Compliance Complaint Other:
Evaluation Evaluation/Reinspection Investigation
Data Date submitted for initial review 1/17/2020 IBEAM WARN/OB or NOD or r NOV or NOWNRE
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 1/l/2022
Directions: From MRO,travel Hwy. 150 west to Hwy. 16 north toward Newton. Travel approximately
10 miles and turn left onto East P ext. (across from Dale.Earnhardt Chevrolet),then left onto Fisher
Court. The facility is located on the left at 1694 Fisher Court.
Safety'Equipment. Safety glasses are required and safety shoes are recommended.
Safety Issues: None.
La&Long Coordinates: A review of"Maps of DAQ Regulated Facilities" website indicates the facility's
location is,correct. The latitude and longitude coordinates in IBEAM are accurate.
Emai[Contacts: The facility contacts were verified with no changes needed.
1. The purpose of this site visit was to conduct a routine air quality inspection.This facility_ processes
powders into "non-dusting, free flowing pellets"which are used as extrusion additives by various
industries. The facility is currently operating eight hours per day, five days per week.
Approximately three people work at the facility. Mr. Douglas Hicks, President, accompanied me
during the inspection.
2. Facility Contact.Information:
During the inspection, I verified the facility contact information in IBEAM. No changes were
needed.
3. Compliance-history file review:
No compliance issues in the last five years.
4. Observations of permitted air emission sources and control devices:
[Emissij Emission Source_ Control Control
Source Description System ID System
Description
ES-01, bulk bag unloader(ID No.ES-01, 10,000 lb/hr CD-01 bagfilter
ES-02, maximum process rate); (1716 square'
ES-03, feet of filter
ES-04, mixer(ID No.ES-02, 10,500 lb/hr maximum process area)

Carolina Pelleting and Extrusion,Inc.
January 14,2020
Page 3
Emissi f Emission Source Control Control
on
Source Description System ID System
- _ Descrip_tion
- _
ES-05, rate);
ES-06,
ES-07, :feeder(1D No. ES-03, 1500 lb/hr maximum process
ES-08, rate);
ES-09
extruder(ID No. ES-04, 1500 lb/hr maximum process
rate);
dryer/cooler(ID No. ES-05, 1500 lb/hr maximum
process rate);
r
conveyor(ID No. ES-06, 1000 lb/hr maximum process
rate);
Classifier(ID No. ES-07, 1000 lb/hr maximum process
E rate);
product hopper(ID No. ES-08, 1.5 tons/hr maximum
unloading rate);
packaging operation(ID No. ES-09, 3000 lb/hr
maximum process rate)
Observed. Various fine powders (packaged in 450 pound bags up to 1500 pound bags) are
unloaded into the mixer and mixed (dry or wet, according to the "recipe"). The fine powders are
mixed with various additives such as antioxidants(to stabilize the final plastics from UV radiation).
The product is then fed into the extruder,where rollers force the powder into holes in a large metal
plate to form the pellets. The product is then fed into the dryer/cooler, which either dries or cools
the product depending on the moisture content(most of the emissions come from the dryer/cooler
process). The pellets are then conveyed to a classifier(screener),which uses two screens to remove
any pellets that are too small or too big. The product is then packaged either into bags or fifty-five
gallon drums for shipment. Waste is recycled back into the process. Emissions from all processes
are controlled by the bagfilter located inside the facility,which vents to the atmosphere. Depending
on the product, the facility can process 300 to 1000 pounds of product per hour. The facility was
not operating at the time of the inspection.
5. Observations of insignificant air emission sources and control devices listed on the current permit:
Source Exemption Source of ` Source of Title V
Regulation TAPS? a Pollutants?
_F_IES-10 -natural gas-fired boiler(6.12 2Q .0102
Yes­_F Yes
mmBtu/hr max. heat input) (c)(2)(B)(ii)
Observed. The Cleaver Brooks boiler provides process steam for the extrusion process and was
not in operation at the time of this inspection.

Carolina Pelleting and Extrusion,Inc.
January 14,2020
Page 4
IES-11 -natural gas-fired process hot water 2Q .0102 yes Yes
heater(1.79 mmBtu/hr max. heat input) (c)(2)(B)(ii) �,
Observed. The heater is used for comfort heat and was in operation at the time of this inspection.
2Q .0102-
IES-12-lab mixer(50 pounds/batch) No No
E
- _... (c)(1)(C)OV) ; .
Observed. The mixer was not operating at the time of the inspection.
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. EMISSION INVENTORY REQUIREMENT - At least 90 days prior to
the expiration date of this permit, the Permittee shall submit the air pollution emission
inventory report for the 2015 calendar year.
Observed. The facility's air permit does not expire until February 29,2024. Compliance
is indicated.
b. Condition A.3. PARTICULATE CONTROL REQUIREMENT - As required by 15A
NCAC 2D.0515 "Particulates from Miscellaneous Industrial Processes,"particulate matter
emissions from the emission sources shall not exceed allowable emission rates.
Observed. Compliance was demonstrated in the permit application and permit review.
C. Condition A.4. 15A NCAC 2D .0521, "Control of Visible Emissions". The facility is
limited to 20 percent opacity.
Observed. The facility was not operating during the time of inspection. Compliance with
this stipulation is indicated.
d. Condition A.5.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 or any such occurrence
by 9:00 a.m. Eastern time of the Division's next business day of becoming aware of the
occurrence.
Observed. Based on conversation with Mr.Hicks,there have been no instances of excess
emissions. Compliance is indicated for this condition.
•c. Condition A.6. FUGITIVE DUST CONTROL REQUIREMENT - As required by 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.

Carolina Pelleting and Extrusion,Inc.
January 14, 2020
Page 5
Observed. No fugitive dust complaints have been received for this facility. Compliance
with this stipulation is indicated.
d. Condition A.7. BAGFILTER REQUIREMENTS. Conduct an annual internal inspection
of the bagfilter system. In addition, the Permittee shall perform periodic inspections and
maintenance as recommended by the equipment manufacturer and list corrections made
and dates of actions in a fabric filter log book.
Observed. The facility is conducting the required inspections and is maintaining the
required bagfilter logbook. Since the last inspection, internal baghouse inspections were
performed on March 16, 2018, August 14, 2018 and August 8, 2019. Compliance is
indicated.
8. NSPS/NESHAP Review:
This facility is exempt from the boiler NESHAP Subpart 6J due to the size and fuel type of the
boiler. The facility has no generators or diesel fire pumps and therefore is not subject to the
NESHAP Subpart 4Z GACT. The facility does not have any gasoline storage tanks and therefore
is not subject to NESHAP Subpart 6C.
9. Summary of changes needed to the current permit:
None.
10. Compliance assistance offered duringthe he inspection:
Mr.Hicks is planning on adding another extrusion process that will have its own separate bag filter.
I told Mr. Hicks to notify this office when he knows what control device he plans on purchasing
because this addition will probably require a permit modification. This extrusion line has been
added to the yellowsheet.
11. Section 112(r)qpplicability:
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.
12. 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.
SLS:Ihe
cc:MRO File
https://neconnect.sharepoint.com/sites/DAQ-MRO/Counties/CATAWBA/00517/INSPECT 20200114.docx