HomeMy WebLinkAboutAQ_F_2100044_20170719_CMPL_InspRpt NORTH CAROLINA DIVISION OF Washington Regional Office
AIR QUALITY Seabrook Ingredients Inc
NC Facility ID 2100044 ✓
Inspection Report County/FIPS: Chowan/041
Date: 07/21/2017
Facility Data Permit Data
F
ngredients Inc Permit 05410/R09
Drive Issued 9/19/2012
C 27932 Expires 8/31/2017
7460m Long: 76d 35.2170m Classification Small
/Salted And Roasted Nuts And Seeds Permit Status Active
NAICS: 311911 /Roasted Nuts and Peanut Butter Manufacturing Current Permit Application(s)Renewal
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Steve Markoya `/ Anne Craig Kate Hern
Maintenance Manager Plant Manager
(252)482-5014 (252)482-2112 (404)751-0254
Compliance Data
Comments: The facility appeared to operate in compliance with all applicable air V
quality regulations and permit conditions at the time of inspection. Inspection Date 07/19/2017
Inspector's Name Doug Byrd
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
Action Code FCE V/
Date of Signature: � � // 7 On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR: j
TSP S02 NOX VOC CO PM10 *HAP
2011 25.10 --- 2.00 0,1000 1.70 12.70 ---
2006 47.00 2.00 --- 12.00 ---
Highest HAP Emitted(inpounds)
Five Year Violation History:None
E
med Stack Tests since last FCE:None
Location:
From WaRO,take Hwy 17 North to Edenton and exit at Hwy 32 (Exit 227). Turn right at the end of the exit ramp and
go about 0.54 miles turn left onto Broad St. The facility is located at the intersection of Broad St. and Peanut Drive, a
small distance after making a left on Broad Street.
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Safety:
Safety shoes and hearing protection should be used at a minimum. The facility will require you to wear a hair
net. Also,with salmonella at a high probability on the outside of peanut shells,when you walk from one area
to another, they will spray the souls of your shoes with a solvent/alcohol solution. Safety glasses are not
required,but recommended. No phones,rings, or loose materials are allowed on the factory floor. They will
require you to sign a food safety form, stating you don't have any diseases, etc. Use caution when filling out
the entry forms; do not sign any confidentiality agreements or liability waivers.
Facility Summary:
Seabrook Ingredients receives shelled peanuts and removes the skins through blanching and cutting
operations. They press peanuts for oil & fat reduction and bulk package peanuts &peanut butter.
List of Permitted Sources:
The following table lists out the sources at the facility. Some corrections need to be made during the next
renewal.
• 1-S needs to be described as the ROCA separator
• 5-S is actually 15,000 pounds per hour, not 8,000 lbs/hr
• 8-S has been removed from the facility
Emission Emission Source Control Control System
tion Sys Y p
Source ID Description stem ID Description
�-----
1-S gravity separator---------- 1-C cyclone(60 inches in diameter)
(7,500 pounds per hour maximum processing 2-C cyclone(60 inches in diameter)
capacity)
2-S gravity separator 3-C cyclone(60 inches in diameter)
(7,500 pounds per hour maximum processing 4-C cyclone(60 inches in diameter)
capacity)
-- —3-S peanut blancher F5Z-- cyclone(84 inches in diameter)
(15,000 pounds per hour maximum processing
capacity) _ _ _
5-S `peanut blancher i 7-C cyclone(60 inches in diameter)
(8,000 pounds per hour maximum processing rate)
6-S f ut re-blancher(8,000 pounds per hour 8-C cyclone(60
pean nches in diameter)
maximum processing capacity)
— --------- --— - ---- - --- e ------ _ - -
8-S de-stoner operation 9-C cyclone(60 inches in diameter)
(8,000 pounds per hour maximum processing 10-C cyclone(60 inches in diameter)
capacity) ----- ---- li
ES-ROAST [natural gas-fired peanut roaster(14 million BTUer hour maximum heat input and 25,000 pounds /A N/Aer hour maximum processing capacity) _J
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Inspection Comments:
I, Doug Byrd, Environmental Specialist, performed a compliance inspection for Olam Edible Nuts (Seabrook
Ingredients, Inc.)on 7/19/2017 with the assistance of Mr. Steve Markoya, Maintenance Manager
Mr. Markoya and I viewed all sources on the permit and we then walked back to his office where he showed
me their database that tracks all maintenance activities. He printed off a few copies of their cyclone
inspections, they split the cyclone inspections by parts, airlocks, augers, and cyclone blowers. The airlocks
are performed every two months, the augers every three months, and the cyclone blowers every two months.
This is more stringent than the minimum of an annual internal inspection. All cyclones appeared to be well
maintained,and were in operation. No VE was observed from the cyclones. VE of approx. 15%was observed
from the roaster exhaust stacks and an accumulation of peanut skins were on the ground around the stacks. I
pointed out permit condition A.5 which requires that no source emit more than 20% opacity and advised Mr.
Markoya to keep an eye on the operation of the roaster to avoid any complaints. I also suggested that the
sweeping up of the peanut skins around the roaster stacks be more frequent than the current once a week
scheduled. No fugitive dust problems were noticed. The cyclones are inspected and results are recorded at
least once per shift, which equates to checking the blowers three times a day.
Mr. Markoya informed me that the facility name is still Olam Edible Nuts but the company legal department
decided that it was going to keep the air permit under Seabrook Ingredients Inc. and no name change will be
requested.
All processes were in operation during the inspection. All equipment appeared to be in good condition and
no problems were noted. Mr. Markoya stated the facility operates using only natural gas. The facility only
handles peanuts; they clean, shell, roast, and make peanut butter. All cashew operations have been removed
from the facility and were removed from the permit during the last permit renewal.
Regulatory Review:
2D.0202 - "Registration of Air Pollution Sources"
This Rule gives the Director the authority to require the registration of air pollution sources, and require
them to submit information about the source. It is under this Rule that the Division is requiring facilities
to submit an emissions inventory 90 days before a Permit expires. Compliance is indicated.
2D. 0515- "Particulates from Miscellaneous Industrial Processes"
Compliance with this rule under normal operating conditions was determined in the Permit Review even
without considering controls. Proper use and maintenance of control devices should ensure compliance.
Control devices appeared to be in good condition. All of the permitted sources were in use at the time of
the inspection and no emissions were noted. Compliance is indicated.
2D.0516- "Sulfur Dioxide Emissions from Combustion Sources"
Sulfur dioxide emissions from the plant shall not exceed 2.3 pounds per million Btu heat input. The
• facility uses natural gas exclusively. Natural gas combustion produces negligible sulfur dioxide and
compliance with this rule should easily occur. Compliance is indicated.
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2D.0521 - "Control of Visible Emissions"
Visible emissions from the processes shall not be more than 20 percent opacity when averaged over a six-
minute period, except that six-minute periods averaging not more than 87 percent opacity may occur not
more than once in any hour nor more than four (4) times in any 24-hour period. VE of approx. 15%
opacity was observed from the roasters and permit condition A.5 was pointed out to management to avoid
a complaint. No VE was observed from the cyclones. Compliance is indicated.
2D.0535- "Excess Emissions Reporting and Malfunctions"
The facility is required to report excess emissions which last for more than four hours that result from a
malfunction, a breakdown of process or control equipment or any other abnormal conditions. A
notification condition is included in the permit. No excess emissions for periods greater than 4 hours were
reported and none are assumed to have occurred. Compliance is indicated.
2D.0540 - "Particulates from Fugitive Non-Process Dust Emission Sources"
The facility shall not cause or allow fugitive dust emissions to cause or contribute to substantive
complaints or excess visible emissions beyond the property boundary. If substantive complaints or
excessive fugitive dust emissions from the facility are observed beyond the property boundaries for six
minutes in any one hour,the owner or operator may be required to submit a fugitive dust plan as described
in 21) .0540(f). No fugitive dust emissions were noted at the facility during inspection and no fugitive dust
complaints have been issued against the facility. Compliance is indicated.
2D.0611 - "Monitoring Emissions from Other Sources"
It is under this rule that the control device inspection and maintenance requirements are implemented.
Electronic records indicated cyclone inspections and maintenance were current. Compliance is
indicated.
2D.1806- "Control and Prohibition of Odorous Emissions"
The owner or operator of a facility subject to this rule shall not operate the facility without implementing
management practices sufficient to prevent odorous emissions from the facility from causing or
contributing to objectionable odors beyond the facility boundary. Although the processing operation emits
odors, no objectionable odors were noted during inspection. Compliance is indicated.
Compliance History (5-Year):
The facility has not had any compliance violations in the last five years.
Comments. Conclusions, and Recommendations:
The facility appeared to operate in compliance with all applicable air quality regulations and permit conditions
at the time of inspection.
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