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Home My WebLink AboutAQ_F_1200086_20190115_CMPL_InspRpt (4) c)C) NORTH CAROLINA DIVISION OF Asheville Regional Office AIR QUALITY Environmental Inks-A Member of the Siegwerk Group Inspection Report NC Facility ID 1200086 Date: 01/16/2019 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: 35d 42.3660m Long: 8 1 d 41.9160m 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 Donna Walters Scott Bartlett Robert Miller Plant Manager Head of Operations Health, Safety& (828)391-2310 (828)391-2383 Environmental Specialist 828-391-2314 704 400-1879 Compliance Data Comments: Inspection Date 01/15/2019 �7 Inspector's Name Bob Graves Inspector's Signature: l5 �J iC{p v Operating Status Operating Compliance Code Compliance-inspection Action Code FCE Date of Signature: '� I �—u J 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 --- Highest HAP Emitted in ounds Five Year Violation History:None Date Letter Tyne Rule Violated Violation Resolution Date Performed Stack Tests since last FCE:None Date 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. Safely Equipment: Safety glasses and safety shoes. 1. Facility Overview Discussion/Introduction On January 15,2019,I,Bob Graves met with Mr. Scott Bartlett,Head of Operations,Ms. Donna Walters,Plant Manager Water Based,and Mr.Ray Robinson,Engineering and Facilities Manager,and Mr.Robert Miller,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.Robert Miller,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 Listine Emission Emission Source IF Control Source ID Description System Notes _ P __.._ jObserved in operation. This is a small-scale ES-1 Fabatory pigment blending DC-1 one bagfilter(250 operation where pigments are blended for trial ns square feet of filter area) and/or test purposes and operates about an hour - - — — -- -- — per week —._.—._.__ ..-- ---.... -.... rarborne uilc manufacturmg DC 2 one bagfilter(960 Observed in operation with no.VE. During the ES-2 inspection,the Magnehelic gauge read ations square feet of filter area) approximately 2.0 inches H2O. _. - -- -- ---- -- DC-6 one bagfilter ES-4 dispersion manufacturing (2 480 square feet of Observed not in operation.Magnehelic gauge operations readings are documented weekly. filter area) 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. • 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 internal 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=internal inspection conducted on 12/11/18, and 1/7/2019(internal inspection/replaced filters). • DC-2=facility ID#2=internal inspection conducted on 12/27/18,and 1/7/2019((internal inspection/replaced filters). • DC-6=facility ID# 1 =internal inspection conducted on 12/3/2018, 12/27/2018,and 1/7/2019((internal inspection/replaced filters). 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. • 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 Exemption Source ID Source Regulation Notes natural gas-fired boiler(1.83 million Btu per 2Q .0102 I 1 Removed from servivice. our maximum eat input rate c 2) _ _ 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. 112f 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.