6034_Kamps_ApprovedPermitApplication_DIN26860_2016

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Kamps Inc.
Graham St. Main Plant
OPERATIONS PLAN
August 29, 2016
Prepared by:
Kamps Inc.
5104 N. Graham Street
Charlotte, North Carolina
Phone: [phone]
Fax: [phone]
DIN 26860
Approved by SW Section
10/13/2016
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TABLE OF CONTENTS

Section 1 Page
1.0 Introduction 3
Section 2
2.0 Standard Facility Operations 3
2.1 Drainage and Erosion Control 3
2.2 Site Access 4
2.3 Dust Control 4
2.4 Fires 4
2.5 Products 4
2.6 Hours of Operation 4
2.7 Process Flow 5
Figure A – Process Flow Diagram 5
2.7.1 Processing Equipment 5
2.7.2 Receiving and Inspection 5
2.7.3 Stockpiling 6
2.7.4 Sortation 6
2.7.5 Grinding 6
2.7.6 Screening 6
3.0 General 6
3.1 Personal Hygiene 6
3.2 Staffing 7
3.3 Personal Protective Equipment (PPE) 7
3.4 Mechanical Equipment Hazard Prevention 7
3.5 Employee Health and Safety 7
3.5.1 Physical Exposure 8
3.5.2 Fire Extinguishers 8
3.6 Facility Emergency Phone Numbers 8

APPENDICIES
Appendix A – Zoning Letter 10
Appendix B – Site Footprint 12
Appendix C – Site Signage 14
Appendix D – Manufacturer Information Sheets 15
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1.0 – Introduction

Kamps Pallets owns and operates a solid waste processing plant in Charlotte, North Carolina.
The facility processes clean wood, painted wood and engineered wood, both new and
recycled materials. This operational plan details the activities at this facility. The site is
zoned I-1 and has been verified by the City of Charlotte Zoning Office to be in compliance
with city ordinances. A letter from the City of Charlotte Zoning Office is included in
Appendix A.

2.1 – Standard Facility Operations

Facility Name: Custom Pallet & Crating
Division of Kamps Inc.
5104 N Graham St.
Charlotte, NC 28269
704-921-1100

Facility Manager: Michael Szczepanski
704-921-1100 // 704-252-4003

Facility Operator Kamps Inc.
2900 Peach Ridge NW
Grand Rapids, Michigan 49534
800-759-8100

The facility accepts various types of wood waste to include broken pallets and crates, process
wood drops and end trims. The materials may be composed of clean wood waste, painted
wood, engineered wood, or a combination. Engineered and painted wood are separated from
clean wood waste prior to processing. The materials are processed so that recycled and
marketable products are produced. The following sections outline the standard operating
procedures for the facility.

2.2 – Drainage and Erosion Control

The process is controlled by maintaining wood waste storage and grinding activities in
paved areas. Drainage is controlled into two outfall areas and are managed according to the
Division of Water Quality General Permit NCG210000.
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2.3 – Site Access

Site access is controlled by a full perimeter fence with a gate that is locked when the facility
is closed to prevent illegal dumping. The dump area is staffed and loads are reviewed prior
to their dumping. Contamination charges are applied if illegal materials are found in loads
already dumped and unacceptable materials are removed and disposed of.

2.4 – Dust Control

Dust in the grinding process is controlled by water spray nozzles on the grinder.

2.5 – Fires

To prevent fires, dust and chip piles are minimized. Water spray is applied to the chip
grinding stream to minimize risk of fires due to sparks and hot spots. Water is available and a
loader can be used to push burning materials away from non-involved materials. A fire
station is located within one mile of the facility in case of an emergency.

2.6 – Products

Finished products in the form of industrial fiber is sold to particle board and MDF mills for
conversion into industrial products. This material is processed in bulk form onto trailers and
shipped within 72 hours off of the site. No open piles of wood chips are stored on the
ground.

In addition, clean wood waste will be ground into chips for use as ground mulch. Raw
materials are picked and controlled so that painted and engineered wood are not permitted
into the stream used to make the mulch. All painted and engineered materials are used to
produce the industrial fiber product.

2.7 – Hours of Operation

Hours of operation will be 7:00 am until 5:00 pm, Monday through Saturday. These hours
vary, depending on level of business needs. Posted hours for incoming material is Monday
through Friday, 8:00 am until 3:30 pm.
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2.8 – Process Flow

Figure A shows the generic process flow of the grinding operation.

2.8.1 – Processing Equipment

Equipment used on site include conveyors, a horizontal grinder, a shaker screen, a rubber
tire loader, forklifts and an excavator. The appendix contains information sheets on this
equipment.

The grinder is a Rotochopper EC-266 with a throughput capacity of approximately 75
cubic yards per hour, depending on screen size and material moisture content. Assuming
an 8-hour processing time the planned capacity of the one-shift operation will be 600
cubic yards per day.

2.8.2 – Receiving and Inspection

After check-in at the office, the drivers are directed to the dumping area where an
inspector will approve the load for dumping. Clean woodwaste is dumped in one area
and painted/engineered materials in another according to the daily plan. Unapproved
materials may be cause for a load rejection. After dumping, the load will be reviewed for
hidden contamination, and fees charged as appropriate.

Unacceptable materials dumped will be sorted with improper materials placed in
containers and hauled away.
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2.8.3 – Stockpiling

Material is stored in piles in preparation of processing. The maximum amount of
material stored on site will not exceed the amount that could be ground in 30 days.
After grinding, material is directly loaded on trailers and hauled away. Materials
containing engineered and painted wood will not be allowed to exceed 5 days grinding
capacity.

2.8.4 – Sortation

Materials are fed into the system by an excavator. Material is placed on a shaker
conveyor which spreads and feeds the material past pick stations where hidden
contaminants are removed. This includes both non-wood contaminants like plastic, metal
and non-wood organics.

2.8.5 – Grinding

After passing the pick stations material is conveyed into the grinder. Material is ground
to specific sizes based on customer specifications. Internal screens and feed settings can
be changed to modify the material in process.

2.8.6 – Screening

After grinding the material is passed through a shaker screen to remove material
considered too fine or too coarse based on specifications. Internal screens can be
changed to modify these sortations. Oversized material is returned to the grinder for
repeat processing and fines are collected on a trailer and sold as boiler fuel.

3.1 – General

The wood waste processed contains minimal pathogenic organisms. Despite this fact
general worker health and safety is a priority and special procedures must be followed.
Some of these procedures are listed in this section.

3.2 – Personal Hygiene

The following personal hygiene practices are required and stressed to all operators.
 Wash hands before eating, drinking or smoking
 Wash and dress any cut, no matter how small. Any cut could be the source of
infection.
 Keep fingernails clean and trimmed to limit potential sources of pathogens.

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3.3 – Staffing

Individuals that are highly debilitated or have severe allergies will not be assigned to
work around the wood processing equipment.

All assigned individuals will be trained and monitored to assure safe practices.

3.4 – Personal Protective Equipment (PPE)

Depending on area of assignment PPE is designated and/or provided to operators.
Typical items required are listed below:
 Safety Shoes
 Noise protection equipment
 Dust protection
 Foul weather gear
 Protective gloves
 High visibility outerwear

3.5 – Mechanical Equipment Hazard Prevention

All equipment is to be operated with care and caution. Operators are trained in safe
usage and all equipment is inspected daily for safety defects and are promptly repaired.

Use of loaders, excavators, switchers and forklifts require certified operators only.

3.6 – Employee Health and Safety

Some general safety rules:

 Make sure you understand the job and the safe way to do it. Read and understand
the documentation provided.
 Use common sense, ask questions when something seems impractical or unsafe.
 Never work alone. Have someone aware of your activity in case of trouble.
 Always follow Lockout Tagout (LOTO) rules when doing mechanical repairs.
 Maintain a positive attitude towards safety. Don’t take shortcuts. Look out for
each other.
 Report any accidents or injuries, including near misses. Even small occurrences
can lead to big problems. Get first aid in office as needed.
 Know where the fire extinguishers are.
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3.5.1 – Physical Exposure

Employees are subject to potential exposures to fluids, solids and airborne
contaminants. Employees are trained how to limit these exposures and what to do if
they are exposed. Excessive dust can occur when conditions are extremely dry. This
dust can be a hazard as a result of the irritating effect on eyes and mucous membranes.
Proper PPE can resolve these concerns if used when needed. These include dust
masks, respirators and goggles. In addition, dusty areas can be sprayed down with
water to improve these dusty conditions.

3.5.2 – Fire Extinguishers

Potential fire hazards exist in any wood products processing area. This can be
especially critical when fine dust is allowed to accumulate. Good housekeeping must
be practiced to minimize these exposures.

The regular review and maintenance of fire extinguishers is necessary to minimize
these risks. Each unit is to be inspected monthly and replaced as needed. All units are
to be serviced annually by a certified fire extinguisher service.

3.6 – Facility Emergency Phone Numbers
Main Office: Custom Pallet & Crating Division of Kamps
Division of Kamps, Inc.
 5104 N Graham St.
Charlotte, NC 28269
Phone: [phone]
Fax: [phone]

Facility Manager: Jake Greer
704-921-1100 // 980-214-6699

Plant Manager: Mike Szczepanski
704-921-1100 // 704-252-4003

Facility Operator: Kamps Inc.
2900 Peach Ridge NW
Grand Rapids, Michigan 49534
800-759-8100
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APPENDIX A

Zoning Letter
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APPENDIX B

Site Footprint

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APPENDIX C

Site Signage
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CUSTOM PALLET & CRATING
Division of Kamps Inc.
Facility Operator
Permit Number #xx-xx-xx
Woodwaste Processing Facility
Acceptable Materials
 Wood Packaging
 Processed Wood Scrap and Drops
 Clean Untreated Woodwaste
 Painted or Unpainted Woodwaste

EMERGENCY PHONE NUMBERS
OPERATOR: 704-921-1100 Normal Hours
AFTER HOURS : 704-252-4003
: 980-214-6699
EMERGENCY DIAL: 911

HOURS OF OPERATION:
Monday – Friday 8:00am – 3:30pm
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APPENDIX D

Manufacturers Information
Sheets

Rotochopper Grinder

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Cat 926 G Loader

The Caterpillar 928G wheel loader was introduced in 1996 in the USA
and England as the replacement for the Caterpillar 928F.
[edit] Features

The 928G has a 3116 turbo engine producing 125 flywheel horsepower
(FWHP). It has a four speeds forward, three reverse autoshift countershaft
transmission with a kickdown switch. It comes standard with full hydraulic
brakes, G-Series two-door cab, gull-wing service doors, a serviceable cooling
system with swing-out fan, as well as increased reach, dump clearance,
breakout force, fuel tank and bucket capacity, lift and tilt, and back drag
capability.
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Cat 312 E Excavator
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