AQ_F_1200086_20200115_CMPL_InspRpt (4)

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NORTH CAROLINA DIVISION OF Asheville Regional Office
AIR QUALITY Environmental Inks-A Member of the Siegwerk
Group
Inspection Report NC Facility ID 1200086
Date: 01/17/2020 County/FIPS:Burke/023
Facility Data Permit Data
Environmental Inks-A Member of the Siegwerk Group Permit 05478/R12
1 Quality Products Road Issued 12/6/2013
Morganton,NC 28655 Expires 11/30/2021
Lat: 3 5d 42.3 660m Long: 8ld41.9160m Class/Status Small
SIC: 2893/Printing Ink Permit Status Active
NAICS: 32591 /Printing Ink Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Chad Davis Scott Bartlett Lee Kearson
UV Plant Manager Head of Operations Health,Safety&
[phone] [phone] Environmental Specialist
[phone]
Compliance Data
Comments:
Inspection Date 01/15/2020
i, Inspector's Name Bob Graves
Inspector's Signature: v Ca � � Operating Status Operating
Compliance Code Compliance-inspection
j Action Code FCE
Date of Signature: Z On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2012 0.0100 --- 0.1500 7.20 0.1200 0.0100 5.29
2007 --- 0.0000 2.90 0.0000 0.0000 ---
Five Highest HAP Emitted(in pounds)
rYcarlation History:NoneLetter Type Rule Violated Violation Resolution Date
ack Tests since last FCE:None
Test Results Test Method(s) Source(s)Tested
Directions: From Asheville, take 1-40 East to exit 103. Turn right onto Highway 64. Go less than one mile, and then turn left onto
Craftsman Drive. The facility is located approximately 200 yards on the right.
Safety E ui ment: Safety glasses and safety shoes.

1. Facility Overview
Discussion/Introduction
On January 15,2020,I,Bob Graves met with Chad Davis,Plant Manager,and Mr.Ray Robinson,Engineering and
Facilities Manager,and Mr. Lee Kearson,HSE Coordinator,to conduct an annual compliance inspection. During
the inspection, Mr.Robinson helped in the identification of the emission sources and control devices and gave
access to maintenance records. Everything appeared to be in order.
If the facility contact is not available for an inspection,ask for Mr.Ray Robinson,Engineering(cell 828-448-4966),
or Mr. Ronnie Murphy,Maintenance Supervisor(828-391-2315, or 828-448-8028),and Mr.Lee Kearson,HSE
Coordinator.
Facility Contacts
The contacts shown above are current.
Facility Description
Environmental Inks and Coatings manufactures water-based inks for use in rotogravure and flexographic printing.
These inks are made by mixing resins and water with organic pigments;the approximate percentages are 10-15%
pigment,40%resin,and 50%water. Ammonium hydroxide is added to achieve the proper pH. The inks are used
for film work,lamination(water bottles),and other printing projects. Customers are:Rock Tenn,Valdese Packing,
and the Smythe Corp., and others.The facility has been at this location since 1985 and employs approximately 60
people. They operate from 6 am to 10 pm,with the bulk of the production during the hours of 6am to 4 pm,five
days per week.
2. Emission Source and Regulatory Review
Source Listing
--- - ._._-- ---- ----._ ----. _..._.--- -- .---- .
Emission Emission Source Control
Source ID !, escri Dption System Notes
Observed not in operation. This is a small-scale
[aborat
ory pigment blending DC-1 one bagfilter(250 operation where pigments are blended for trial
ES-1
erations square feet of filter area) and/or test purposes and operates about an hour
per week.
—. — —-- _ --- ——
waterborne ink manufacturing DC-2 one bagfilter(960 Observed in operation with no VE. The facility
ES-2 ! would like to replace this baghouse in near
operations square feet of filter area) metre.
DC-6 one bagfilter
dispersion manufacturing Observed not in operation.Magnehelic gauge
ES-4 (2,480 square feet of
operations filter area) readings are documented weekly.
Permit Conditions
• Specific Condition 3: Particulate Control Requirement
An allowable particulate emissions rate is calculated based on process weight rate. The last permit review
performed this calculation and compliance was indicated.
• Specific Condition 4: Visible Emissions Control Requirement
Visible emissions from all sources are limited to 20%opacity. No visible emissions were observed from the
sources in operation.

i
i
i
• Specific Condition 6: Fugitive Dust Control Requirement
The facility is not allowed to have dust leave the property and generate complaints from the public. No fugitive
dust was observed on or beyond the property boundary.
• Specific Condition 7: Fabric Filter Requirements
The facility is required to perform,at a minimum,an annual interval inspection of the bagfilter systems, as well
as document any maintenance performed. The facility's electronic maintenance system generates work orders
to perform monthly inspections on each bagfilter. Mr. Ray Robinson gave access to the electronic logbook
inspection and maintenance(I&M)records on the bagfilters. The electronic maintenance system logbook
appears to be adequate and up to date. Compliance is indicated.
The last inspections for the bagfilter systems:
• DC-1 —facility ID#4= 12/16/19(internal inspection&replaced filters).
• DC-2=facility ID#2= 11/24/19(internal inspection&replaced filters).
• DC-6—facility ID# 1 =3/11/19 (internal inspection).
This rule does not apply to the facility.
• Specific Condition 9 and 11: NC Toxics Requirements
The facility has a modeled limit of 20.12 pounds per hour of ammonia emissions and a general condition of
limiting any NC TAPS to less than the TPERs. The highest amount of ammonium hydroxide additions above the
formula was well below the permitted limit. The facility tracks ammonia emissions. Compliance is indicated.
(see spreadsheet attached)
• Specific Condition 10: Control and Prohibition of Odorous Emissions
The facility is required to prevent objectionable odorous emissions beyond the property boundaries. Slight
odors were detected in the building,but none were detected outside. Compliance is indicated.
Record Keeping and Reporting Requirements Review
The facility has no reporting requirements. The facility is required to inspect the bagfilter systems once per
year and document the results of the inspections and any maintenance activities conducted on the bagfilter
systems. The electronic maintenance system logbook appears to be adequate and up to date(see condition No.
7 above). Compliance is indicated.
The facility is also required to keep records of additional ammonium hydroxide added to the mix above what is
in the mix. These records are kept electronically and appear adequate. Compliance is indicated.
Insignificant Sources Listing
Emission [7R7egulation
ptton
Source Notes
Source ID '
natural gas-fired boiler(1.83 million Btu per 2Q .0102 Removed from service A
I-1 pressure washer is in this
hour maximum heat input rate) (c)(2)(B)(i)(I) storage room.
3. Compliance History Review
There have been no documented violations in the past five years. One unsubstantiated dust complaint was received
on April 30,2018.

4. Stack Test Review
The facility has had no stack test requirements.
5. 112r Review
The facility is not subject to 112r.
6. Compliance Assistance
None.
7. Recommendation/Conclusion/Compliance Statement
Based on review of records and visual observations,this facility appeared to be operating in compliance with the Air
Quality standards and regulations at the time of this inspection.

Morganton Ammonia Emissions 2019
Batches with AA0600 ingredient
0.0777 168
Monthly NH3
Month Total Lbs. Number of Month Lbs. NH3 Emission Rate Average Size
Month AA0600 Usage Batches Emissions Lbs/Hr. Batch (Lbs)
January j 7,215 526 40.9 0.24! 784
February F__ 6977 378 29.40 0.17I 1,074
-- I ----I 0 I-_
March 6,769 435 33.8 0.20i 1,003
April L 6,122 360 28.0 0 17: 1,004
May — -- 5474 _ 342 26.6 0.1&s 1,055
0 I. --
June C-- 5549-- 378 294 0.17; 1;085
July 7,463 466 36.2` 0.22t 1,089_
0 . —
August � _8;6� _ 4091 318� 019 i -- 1,196
September [ 4 209 _ 340 26.4 0.16t 1,056
October f 7131 340 26.4 0.16! 1,048
— — -
November 7,523 _ 225 17:5 0 10y 1,557
December 0.0 0.00
TOTALS 73,039 4199 326.26'
Aqua Ammonia Solution (AA0600)
0.74 Water
0.26 Ammonium Hydroxide
Data comes Nom IftrIms ace Re r i 6rt CIntranet favorites for link