AQ_F_0900081_20190725_CMPL_CAV-Rpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Gildan Yarns,LLC Plant 71
NC Facility fD 0900081
Compliance Assurance Report County/FIPS: Bladen/017
Date: 08/07/2019
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 /Yam Mills,Except Wool Permit Status Inactive
NAICS: 313111 /Yam Spinning Mills Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Matt Moyer Randall Ferguson Randall Ferguson
Plant Manager Director of Engineering Director of Engineering
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 07/25/2019
Ar Inspector's Name Mike Thomas
Inspector's Signature: Operating Status Operating
/j Compliance Code Compliance- inspection
\If' Action Code FCE
Date of Signature: On-Site Inspection Result Compliance
67 id
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(inpounds)
Five Year Violation History:None
Date Letter Tvne Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

1)Directions:
From FRO take Highway 87 south towards Elizabethtown staying on the bypass;turn right onto
Hwy 701 south towards Clarkton;turn right onto Highway 211; facility is on the right; park in the
first lot and use the door by the flags.
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 it is
spun into 8-count thread reams. The facility produces a 50/50 polyester/cotton blend thread and a
100%cotton thread. The cotton waste is again recycled through the process,and the final wasted
matter is collected outback by a dump truck that transports it 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 particle
matter before the air is drawn through a series of water wet scrubber type spray nozzles. This wash
removes smaller particle 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:
S6Js�
. 0xtti ,u .xa'...x
I-FIRE PUMP
135 HP diesel-fired fire pump(NESHAP (SubpartZZZZ) 2Q.p102(c)(2)(B)(v)(I) Yes '� Yes
-Not
operating.
5) Inspection Conference:
On 25 July 2019, I Mike Thomas of FRO DAQ conducted a compliance assurance visit at Gildan
Yarns, LLC Plant#71. I met with Matt Moyer, Plant Manager. We discussed the following:
a) Verified FACFINDR information: no changes are needed.
b) I reviewed the maintenance records for the fire pump and found them to be complete and up
to date. The last inspection and service was conducted on 9 June 2019. The engine had
248.3 hours at the time of inspection.
c) Production:
Year Pounds of bales cotton
2018 —32,000,000
2017 —30,000,000
2016 —36,000,000
2015 40,435,096
2014 3 8,13 5,295
6)Inspection Summary:
Mr. Moyer led me on a tour of the facility which was operating. I observed the process from the
cleaning of the fibers to the spinning operation. I observed no issues in these areas. Mr. Moyer 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.
2D .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 most recent permit review based
on operating the source as described in the permit conditions. No changes have been made to
operations since that determination.

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 0.002 Ibs/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.
2D .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 2D .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. Moyer stated there have been no occurrences of excessive 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 submitted 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 Yarns,LLC Plant 71 appeared to be operating in compliance during this facility visit.
Pink Sheet:
None.
/mst