SW_F_6022-COMPOST-_10-13-2014_SP_AO

Wallace Farm Inc.
Large, Type 3 Compost Facility
Huntersville Site

Permitting Report

October 2014

1100 Crescent Green, Suite 208, Cary, North Carolina 27518
• O: 919-792-1900 • F: 866-311-7206
Firm No. C-2910

10/13/14
October 13, 2014
Ms. Donna Wilson
North Carolina Department of Environment and Natural Resources
Division of Waste Management Solid Waste Section 1646 Mail Service Center
Raleigh, North Carolina 27699-1646
RE: Permit Number SWC-60-22 – Dated 4/22/2010 Wallace Farm Inc. Large, Type 3 Compost Facility
Mecklenburg County, North Carolina
Dear Ms. Wilson:
On behalf of Wallace Farm Inc., we are pleased to submit the enclosed permit application for
renewal of the current permit for the Large, Type 3 Compost Facility located in Mecklenburg County, North Carolina.
If you have any questions or need additional information, please call.
Sincerely,
GARRETT & MOORE, INC.

Bernie Garrett P.E.

Cc: Eric Wallace
1100 Crescent Green Drive, Suite 208, Cary, North Carolina 27518 • O: 919-792-1900 • F: 866-311-7206
PERMIT APPLICATION DEMONSTRATING
COMPLIANCE WITH SOLID WASTE SECTION RULE
.1400-SOLID WASTE COMPOST FACILITIES
FOR
WALLACE FARM, INC.
LARGE, TYPE 3 COMPOST FACILITY

OWNER:
Wallace Farm, Inc.
14410 Eastfield Road
Huntersville, NC 28078
Phone: [phone]

ENGINEER:
Garrett & Moore, Inc.
1100 Crescent Green Drive
Suite 208
Cary, NC 27518
Phone: [phone]

October 2014

CONTENTS

CONTENTS Page
Section 1
1.0 - GENERAL .................................................................................................................... 1

Section 2
2.0 - APPLICATION REQUIREMENTS ............................................................................. 1
2.1 – PERMIT DRAWINGS ................................................................................................. 1
2.2 - ZONING ........................................................................................................................ 2
2.3 - SITING AND DESIGN STANDARDS ........................................................................ 2
2.3.1 - Floodplain .......................................................................................................... 2
2.3.2 - Property Line Buffer .......................................................................................... 2
2.3.3 - Residences Buffer .............................................................................................. 2
2.3.4 - Well Buffer ........................................................................................................ 2
2.3.5 - Perennial Streams/Rivers Buffer ....................................................................... 3
2.3.6 - Surface Water Quality Standards ....................................................................... 3
2.3.7 - Closed-Out Disposal Area ................................................................................. 3
2.3.8 - Adequate Access ................................................................................................ 3
2.3.9 - Surface Water Requirements ............................................................................. 4
2.3.10 - Groundwater Requirements ............................................................................. 4
2.3.11 - Public Access ................................................................................................... 4
2.3.12 - Sedimentation Pollution Control Law ............................................................. 4
2.3.13 - Air Pollution Control Requirements ................................................................ 5
2.4 - FEEDSTOCK AND MATERIAL TYPES .................................................................... 5
2.4.1 Design (or maximum throughput) capacity ......................................................... 8
2.4.2 Soils .................................................................................................................... 8
2.5 - SITE PLAN ................................................................................................................... 8
2.6 - OPERATION DESCRIPTION ...................................................................................... 8
2.7 - PROCESS FLOW .......................................................................................................... 14
Process Flow Fact Sheet ............................................................................................... 16
2.7.1 - Materials Receiving/Processing ......................................................................... 19
2.7.2 - Mixing ............................................................................................................... 19
2.7.3 - Composting ........................................................................................................ 19
2.7.4 - Curing and Storage ............................................................................................ 19
2.7.5 - Screening ........................................................................................................... 20
2.7.6 - Air Emissions and Control Technologies .......................................................... 20
2.7.7 - Leachate Treatment............................................................................................ 21
2.8 - PRODUCT LABEL ....................................................................................................... 21
2.9 - ENGINEERING PLANS AND SPECIFICATIONS ..................................................... 21

Wallace Farm Type 3 Compost Facility
Huntersville Site

CONTENTS, Continued
Section 3 3.0 - REQUIRED INFORMATION FOR OPERATING PERMIT ...................................... 21
3.1 - CONTINGENCY PLANS ............................................................................................. 21
3.1.1 - Equipment Breakdown ...................................................................................... 21
3.1.2 - Air Pollution/Odors ........................................................................................... 22
3.1.3 - Non-Conforming Materials ............................................................................... 22
3.1.4 - Spills .................................................................................................................. 22
3.1.5 - Fires ................................................................................................................... 22
3.1.6 - Particulates ......................................................................................................... 22
3.1.7 - Noise .................................................................................................................. 23
3.1.8 - Vectors ............................................................................................................... 23
3.1.9 - Unusual Traffic Conditions ............................................................................... 23
3.1.10 - Adverse Weather Conditions ........................................................................... 23

3.2 - OPERATION AND MAINTENANCE MANUAL ...................................................... 24
3.3 - QUALITY ASSURANCE PLAN ................................................................................. 24
3.4 - PROCESS FLOW .......................................................................................................... 25
3.5 - PERMITS AND APPROVALS .................................................................................... 25
3.6 - PRODUCT MARKETING AND DISTRIBUTION PLANS ........................................ 25
References ............................................................................................................................. 26
Permit Drawings
See Attached Permit Drawings
Appendices
Appendix A – Zoning Verification
Appendix B – Report on Wetland & Stream Designations
Appendix C – Construction Specifications
Appendix D– Manufacturers’ Equipment Information
Appendix E – Product Label and Analytical Information

Wallace Farm Type 3 Compost Facility
Huntersville Site

1.0 - GENERAL
Wallace Farm, Inc. (herein also referred to as Wallace Farm) operates a Large Type 3
Compost Facility on Eastfield Road, Huntersville, Mecklenburg County, North Carolina. The facility
processes various types of feedstocks, including animal manures, yard waste, wood waste, land
clearing debris, waste water treatment residuals, cotton and tobacco materials, food and/or animal
processing residuals, and food waste. All of the feedstocks used at the facility are non-hazardous.
(Further details on materials for composting operations are detailed below.) These operations offer
environmentally friendly options to landfills, help ease environmental and energy burdens on the
state, and produce useful end-products, while helping meet the state’s recycling goals.

General Statute 130A-309.04 calls for reducing the public’s use of, and reliance upon,
landfills. Composting is a key, preferred method for achieving this goal. With its green operations,
Wallace Farm enhances and promotes this critically important goal for all citizens of North Carolina.

The accompanying permit documents have been compiled to meet requirements of the North
Carolina Department of Environment and Natural Resources (NC DENR) Division of Waste
Management - Solid Waste Section as outlined in the North Carolina Solid Waste Compost Rules -
Section .1400 - Solid Waste Compost Facilities.

2.0 - APPLICATION REQUIREMENTS
This application addresses requirements for a Large, Type 3 Solid Waste Compost Facility, as
detailed in the North Carolina Solid Waste Compost Rules - Section .1400. These materials were
prepared under the supervision and direction of a professional engineer duly registered in the State of
North Carolina.

2.1 – PERMIT DRAWINGS
A permit drawing, which includes a one-fourth mile map and site plan are included as an
attachment to this report.

Wallace Farm Type 3 Compost Facility
Huntersville Site 1

2.2 - ZONING
Documents from the unit of government having zoning jurisdiction over the site is included
in Appendix A.

2.3 - SITING AND DESIGN STANDARDS
The following sections include description of how the solid waste composting operations
comply with siting and design standards in Rule .1404 of the North Carolina Solid Waste Compost
Rules.

2.3.1 - Floodplain
The solid waste composting operations are not within the 100 year floodplain.

2.3.2 - Property Line Buffer
Wallace Farm will operate such that the minimum 100 foot buffer from the property line to
the solid waste composting area will be maintained. The permit drawings demonstrate compliance
with the property line buffer.

2.3.3 - Residences Buffer
This facility was permitted by NCDENR and has been in operation based on a 100 foot buffer
from compost operations to the property line. A 500 foot buffer from residences is not applicable for
this site because the facility was permitted prior to the existence of residences.

2.3.4 - Well Buffer
There are two water wells located on the Wallace Farm property. The wells are greater than
100 feet from the composting areas. There are also seven groundwater monitoring wells, as shown
on the site plan.

Wallace Farm Type 3 Compost Facility
Huntersville Site 2

2.3.5 - Perennial Streams/Rivers Buffer
A minimum 50 foot buffer will be maintained between perennial streams/rivers and solid
waste composting areas. The permit drawings demonstrate compliance with perennial stream/river
buffers.

2.3.6 - Surface Water Quality Standards
Surface water is addressed through a number of means. Stormwater from compost areas is
directed to a collection pond, which has a storage volume of approximately 2,000,000 cubic feet.
Charlotte-Mecklenburg Utilities (CMU) has issued Wallace Farm a permit for routing water from
this pond to the CMU wastewater system via a sewer line which traverses the Wallace Farm
property. A copy of the renewed permit (effective on August 22, 2012) is provided in Appendix B.
All details regarding flow rates, sampling and testing regimens, and reporting requirements, are
stipulated in the CMU permit and other Appendix B information.

Wallace Farm has been issued a storm water permit (a copy is included, in Appendix C) by
the Division of Water Quality. Underground pipes, shown on the site plan, divert non-process
stormwater runoff off-site. Passive treatment methods (including grassy areas) are in place. No
known violations of water quality standards have ever occurred.

2.3.7 - Closed-Out Disposal Area
The composting facility is not located over a closed-out disposal area.

2.3.8 - Adequate Access
A 25 foot minimum distance will be maintained around the periphery of the composting areas
to allow adequate access by fire fighting equipment. The permit drawings demonstrate compliance
with adequate access.

2.3.9 - Surface Water Requirements
The site shall meet the following surface water requirements:

Wallace Farm Type 3 Compost Facility
Huntersville Site 3

(A) A site shall not cause a discharge of materials or fill materials into waters or wetlands of the
state that is in violation of Section 404 of the Clean Water Act; No waters or wetlands of the
state will be filled to construct or operate the proposed facility.
(B) A site shall not cause a discharge of pollutants into waters of the state that is in violation of
the requirements of the National Pollutant Discharge Elimination System (NPDES), under
Section 402 of the Clean Water Act. Stormwater discharges for operations of the proposed
facility are permitted in accordance with NPDES General Permit No. NCG 240000.
(C) A site shall not cause non-point source pollution of waters of the state that violates assigned
water quality standards. Stormwater discharges for operations of the proposed facility are
permitted in accordance with NPDES General Permit No. NCG 240000.

2.3.10 - Groundwater Requirements
The facility utilizes natural soils for pads. Wallace Farm installed groundwater monitoring
wells. Locations of these wells are shown on the site plan, and tabulated well designations and
testing results are included in Appendix D.
Appendix D also includes an April 26, 2000 letter from the Division of Water Quality
indicating that the composting operation has not been a factor affecting ground water quality. The
Aquifer Protection Section's summary of groundwater requirements for the site is summarized in a
letter dated March 7, 2005 (also included in Appendix D). The seasonal high water table has been
determined by Wallace Farm's geologist to be greater than two feet from the surface (see the May 9,
2008 letter in Appendix D). Wallace Farm is working with the Aquifer Protection Section,
Moorseville Regional Office on all ground water matters, and that office reported recently that all
requirements for monitoring and reporting are up-to-date.

2.3.11 - Public Access
The facility will not allow uncontrolled public access. A fence surrounds the proposed
facility on all sides and trespassing has never been an issue. Members of the public can onle visit the
facility operations when accompanied by a Wallace Farm employee.

Wallace Farm Type 3 Compost Facility
Huntersville Site 4

2.3.12 - Sedimentation Pollution Control Law
Stormwater discharges for operations of the facility are permitted in accordance with NPDES
General Permit No. NCG 240000.

2.3.13 - Air Pollution Control Requirements
The facility will be operated to meet air pollution control requirements to minimize fugitive
odorous emissions and to minimize odors at the property boundary. Minimize means to reduce to the
smallest amount, extent, or degree reasonably possible. Operational procedures for maintaining
aerobic conditions within the compost piles will be applied to minimize odor generation. These
procedures include adjusting the porosity, moisture content and pH of mixes. Additionally, the
carbon to nitrogen (C:N) ratio of the initial mix will be greater than 20:1 to minimize the release of
nitrogen based compounds such as ammonia.
An additional step that will be utilized, when necessary, is covering windrows with
carbonaceous materials, as described in Section 2.6 and in the O&M Manual. Conveyors have been
added to two spreaders to apply a layer of carbonaceous materials to windrows after formation, and
following turning.

2.4 – FEEDSTOCK AND MATERIAL TYPES
Feedstocks to be composted under this permit include animal manures, wood materials, yard
waste, cotton materials, food and/or animal processing residuals, food waste, waste water treatment
residuals, grease trap residuals, US domestic tobacco material, wood ash, cardboard, bleaching clay,
cosmetics production materials, virgin gypsum board, lime, and starch water. Wood materials to be
composted at the facility under this permit include land clearing debris, yard waste, wood shavings,
sawdust, and pallets. Wood materials are from ground and unground land clearing debris and pallets.
Ground and unground yard waste is generated by local municipalities and the general public. The
wood shavings are generated from sawmill and furniture manufacturing operations. No wood
materials will have been painted, stained, glued, or treated. The ash is from facilities that have
received approval from NCDENR or DWQ for ash distribution.

Wallace Farm Type 3 Compost Facility
Huntersville Site 5

The food processing residuals result from biological treatment of animal and/or food
processing wastewater (with no human components) and the food waste comes from vegetable,
dairy, meat, and bakery products. No domestic wastewater is included in the food residuals, food
waste, the cosmetic, or starch water waste streams. New waste streams will not be received until
approval by the Division of Waste Management.

The only feedstocks that are expected to have seasonal variations in availability are leaves,
yard waste, and mulch. Leaves are seasonal and arrive in the fall and winter. Ground mulch
typically arrives during the drier months of the year when land clearing jobs are undertaken. These
factors vary depending upon the economy and the extent of construction activities. It is very
important for Wallace Farm to stockpile this material when it is available to help make it through
times when it is not.

Estimated annual quantities of feedstocks are summarized in Table 1. Please note that, as can
be shown in annual reports submitted by Wallace Farm, exact quantities received will vary from year
to year and from feedstock to feedstock, and in some years certain feedstocks might not be available
at all.
Note also that approximately 26,000 to 40,000 tons per year of wood materials are estimated
as going into Wallace Farm’s mulch business. This business component involves grinding, coloring,
and/or blending mulch products to be distributed in bulk or packaged form.

Wallace Farm Type 3 Compost Facility
Huntersville Site 6

Table 1. Estimated1 Annual Feedstock Quantities

Feedstock Estimated Annual
Range (Tons)
Estimated
Density2,
lb/ cubic yard
Estimated
Annual Range
(cubic yards)
Ground Wood Debris 35000 - 60000 700 100000 – 171400
Yard Waste 8000 – 18000 600 26700 – 60700
Food Processing Residuals 35000 - 45000 1650 42400 - 54500
Cotton 500 - 1000 400 2500 - 5000
Sawdust/Shavings 500 - 1000 440 2300 - 4500
Food Waste
1000 - 2500 1400 1400 - 3600
Animal Manures 1000 - 1500 750 2700 - 4000
Tobacco 500 - 1000 400 2500 - 5000
Wood Ash/Lime 1500 - 6000 1100 2700 - 10900
Cardboard 100 - 1000 260 800 - 7700
Virgin Gypsum Board 100 - 1000 1485 100 - 1300
Bleaching Clay 2000 - 4000 685 5800 - 11700
Cosmetic Production Residuals 500 - 1000 1500 700 - 1300
Starch Water 7000 - 8000 1685 8300 - 9500
Vegetable Waste 12000 – 50000 550 43600 - 181800
Unground Wood 1000 - 4000 850 2400 - 9400
1Quantity estimates are for years when feedstocks are available. Not all feedstocks are available each year The estimated values are subject to change.
2Densities are field measurements, or estimated from various references.

Wallace Farm Type 3 Compost Facility
Huntersville Site 7

2.4.1 Design (or maximum throughput) capacity
The design capacity (or maximum throughput rate) of a windrow-based facility is a function
of a number of factors, including composting, curing, and storage times. These factors can vary
depending on operations approaches (composting has minimum time and temperature requirements,
for example, but longer times may be used), market conditions, and sales outlets’ timing and needs.
One means of estimating the design capacity is to consider product mixing rates.
Wallace Farm will not receive for composting more than 100,000 tons per year of material.
Further, it is expected that the facility will receive approximately 40,000 tons of additional wood
materials per year to be used for the mulching component of the facility.

2.4.2 Soils
Refer to Section 2.3.1

2.5 - SITE PLAN
The facility site plan is included in the permit drawings.

2.6 - OPERATION DESCRIPTION
Facility Operators are:

Eric Wallace 704-875-2975 ext. 17
Dale Cagle 704-875-2975 ext. 20
Dean Lentz 704-875-2975 ext. 19

The following describes facility operations. Dry carbonaceous materials (including wood
materials, yard waste, sawdust, wood shavings, and cotton materials) are delivered to the facility and
off loaded in the receiving area. A 1564 Hogzilla tub grinder, multiple Volvo, John Deere, and Cat
wheel loaders, and a 320 Cat excavator are used for regrinding land clearing debris and for grinding
unground land clearing debris, yard waste, and pallets. Materials with significant water content
(including food and/or animal processing residuals, waste water treatment residuals, manures, US
domestic, tobacco waste, food wastes, cosmetics waste, and starch water) are unloaded directly into
the concrete receiving/mixing pit for preparing compost mixes. The mixing pit can hold

Wallace Farm Type 3 Compost Facility
Huntersville Site 8

approximately 900 cubic yards of dry materials and approximately 120 tons of material with
significant water content.
The facility utilizes three cone-bottom 15,000 gallon vertical tanks. These tanks are used for
off-loading shipments of high-water content feedstocks that arrive when the mixing pit is in use
and/or filled to capacity. Use of the tanks help maximize operations efficiency. (More detail on
these tanks is provided in Section 2.7.)
The receiving pit is concrete, 60’ x 60’ with 8” thick floors. The walls are 8’ high and 10”
thick. A concrete unloading and washout area is located above the pit. This area is 60’ x 30’ with 8”
thick floors. (See the Concrete Pit Construction Specifications, Appendix E).
Materials are blended in the mixing pit by thorough mixing using one or two Volvo, John
Deere or Cat front end loaders at a rate of 300-400 yards per hour, targeting a homogenous mixture
with a C:N ratio of 20:1 to 30:1 and a moisture content of 40-60%. After the last mixture is
prepared and removed for further processing, the walls and dump areas are washed down with a high
pressure hose. The wash water is directed into the pit, to which fresh bulking material is added on
the bottom to absorb the moisture.
Analytical laboratory results for incoming feedstocks are used to determine the quantity of
each feedstock to use in each compost mix. The feedstocks will be sampled annually and such
analytical results will be updated and provided to the Division.
Parameters for each feedstock (%C, %N, moisture content, and bulk density) are entered into
standard mass-balance equations for composting—those in use were originally acquired by Wallace
Farm at one of the national composting schools. In addition, a standard computer spreadsheet is on-
hand for verifying product mix ratios. Quantities of feedstocks used in mixtures are measured using
two approaches: mass measurements of each feedstock load (known using tare readings), and by
using the volume of the front end-loader buckets. When liquid wastes are stored, volumes routed to
the mixing pit are measured from knowledge of the fraction of tank capacity utilized.
Within two hours of blending, the mix is transported to the composting pad using dump
trucks and placed into windrows. A front end loader is used to improve the shape of the windrows as
necessary. Windrows are constructed approximately 14 - 16 feet wide, 5 - 7 feet high, and several
hundred feet long. The windrows are turned periodically using a Backhus windrow turner to maintain

Wallace Farm Type 3 Compost Facility
Huntersville Site 9

aerobic conditions within the pile and to invert and fluff the windrow. The composting areas slope
with the natural lay of the land to facilitate drainage and allow access during any weather conditions.
Material generally remains in the turned windrows for approximately eight to sixteen weeks,
followed by placement in a static pile for a minimum of six months. The material achieves the
process to further reduce pathogens (PFRP) requirements (as well as Vector Attraction Reduction
requirements) in the windrows by maintaining pile temperatures at or above 131°F for at least 15
consecutive days. Windrows are turned at least five times during the period when temperatures are ≥
131ºF. During the PFRP period, temperatures are measured one time per week until requirements
have been met. An oxygen meter is used to measure oxygen content of compost pile pore space, and
usually is applied at the same time that temperatures are checked. Current process durations for the
various steps are shown in Table 2.
Working windrows vary from 5 - 7 feet in height by 14 - 16 feet in width. Cross-sections
vary depending upon initial size at set-up, and due to shrinkage. Windrow lengths may vary. Other
windrow sizes may be used, depending upon equipment settings, and other factors.

Wallace Farm Type 3 Compost Facility
Huntersville Site 10

Table 2. Process durations at Wallace Farm.
Step Process duration
Receiving • 0.5 hours for weighing and removal
• Storage of feedstocks and bulking agents up to
180 Days
• Storage of high water content feedstocks up to
72 hours
Preparation • 1 hour for each mixing pit loading
• 2 days for each windrow
Composting 8 to 16 weeks
Curing 6 to 18 months
Distribution • 36 months of onsite storage
• Occurs all year, with increases in distribution
occurring in the Spring and Fall.

In the event that a batch of compost does not meet state or facility requirements for
distribution, the material can be added to a new compost mix for reprocessing or applied to farm
land. (Land application of compost not meeting state requirements must be pre-approved by DENR.)
If land is not available for land application, then an approved municipal solid waste landfill will be
used as a last resort for disposal.
After composting, the material is screened to approximately ½-3/8 inch to prepare for
marketing. The compost is marketed as Composted Cow Manure, Grade A Compost Plus, and
Mushroom Compost. In addition, the compost is mixed with other materials to create a variety of
products. These products include items such as Blended Top Soil, Planting Soils, and Potting Soils.
These products are marketed in both bulk and bagged form. Many professional landscape
organizations and retail outlets utilize the final products. In the event material cannot be marketed, it
will be applied to pasture or farmland to supplement commercial fertilization practices.
Personnel at Wallace Farm are trained to perform various work tasks on the farm and in
conjunction with the composting operation. There is not a precise routine at the composting facility.
Different personnel will work together to perform various operations on a given day. For example,

Wallace Farm Type 3 Compost Facility
Huntersville Site 11

moving material off of the composting pad to the static pile may be the priority one week, whereas
screening the material in preparation for marketing may be the priority the next week.
Listed below are some general operations typically performed by personnel at the facility:

General Manager - Manage all operations and direct work efforts
Office Manager - Coordinates all billings and administrative activities
Fleet Manager - Coordinates all deliveries and trucking operations
Tractor Trailer and Dump Truck Drivers - Haul feedstocks and finished materials
Front End Loader Operator - Mixes feedstocks/shapes windrows/loads product/mixes and
screens finished products
Compost Turner Operator - Turns windrows/monitors compost piles
Bagging Line Operator - Bags finished products

The operation schedule varies as for other farm operations. Operations procedures may be
performed seven days per week depending on the work to be accomplished.
There are few routine tasks performed at the start of each day. Other than unlocking the
buildings, work is resumed from the previous evening. For example, bagging lines are restarted, and
compost mixing recommences.
Activities performed at the end of each day include: washing down the concrete receiving
area and mixing pit, removing keys from all trucks and equipment, locking fuel tanks and buildings.
Airborne particulates are generally associated with dry compost. The initial mix solids
content can be varied during mixing to prevent over drying of the piles during composting. In
addition, water from the collection pond, or water from an on-site farm pond may be used to add
moisture, if necessary. A tractor driven PTO (power take-off) pump is used to fill a 4,000 gallon
Hydroforce water tank that is mounted on an International truck, and/or a 5,000 gallon Hydroforce
water tank mounted on a Volvo, off-road truck. The water trucks are equipped with spray nozzles
for applying water to travel areas and are equipped with specially designed nozzles for applying
water to the top of compost windrows.
Wallace Farm reports the following operational approach for meeting PFRP. During the first
month following windrow formation, Wallace Farm targets turning windrows every 5-10 days. If
necessary, water from the collection or a farm pond is added to windrows during this time, which is
prior to the start of PFRP. PFRP is typically met during the second month of active composting. (As
stated in the Rules (.1406 (12) (A)), for meeting PFRP, “Aerobic conditions shall be maintained

Wallace Farm Type 3 Compost Facility
Huntersville Site 12

during the compost process. A temperature of 131 degrees F (55 degrees Celsius) or greater shall be
maintained in the windrow for at least 15 days. During the high temperature period, the windrow
shall be turned at least five times.” As noted above, Vector Attraction Reduction is accomplished by
meeting PFRP requirements.) If additional water is needed during this PFRP period, well water is
used. After PFRP has been met, turning frequency is reduced to approximately every 10 days.
Household wastes are not part of the Wallace Farm feedstocks, such that household
hazardous wastes (nor any type of hazardous wastes) are not expected. If household hazardous
wastes were delivered, they would be seen during unloading and/or during product mixing, and they
would be removed and disposed of in an approved facility.

Wallace Farm Type 3 Compost Facility
Huntersville Site 13

2.7 - PROCESS FLOW
The process flow is depicted in Figure 3, with further details in the Process Flow Fact Sheet
which follows. Processing steps are described in following sections. The tonnage values are
estimates only and are subject to change. The total annual quantity received for composting will not
exceed 100,000 tons.

Wallace Farm Type 3 Compost Facility
Huntersville Site 14

RECEIVING
CONCRETE
MIXING
PIT
WINDROW COMPOSTING
8 - 16 WEEKS
CURING
STATIC PILE
> 12 MONTHS
SCREENING
PRODUCT
MIXES COMPOST STORAGE MARKET
WOOD MATERIALS (35,000 - 60,000)
MANURE (1,000 - 1,500)FOOD WASTE (1,000 - 2,500)
FOOD RESIDUALS (35,000 - 45,000)
TOBACCO MATERIALS (500 - 1,000)
FRONT END LOADERDUMP TRUCK
CARBONACEOUS
MIXTURES &
H20 AS NEEDED
LOADER
SPREADER
PRODUCT
MIX
PRODUCT
STORAGE
FRONT ENDLOADER
LOADER
RECYCLED
BULKINGAGENT
Figure 3. Wallace Farm Solid Waste Composting Facility Process Flow Diagram (see
text for further details). All values are in tons/year, unless otherwise indicated.
LOADER
DUMP TRUCKS
LOADER
LOADER
LOADER
YARD MATERIALS (8,000 - 18,000)
GRINDING
COTTON MATERIALS (500 - 1,000)VIRGIN GYPSUM BOARD (100 - 1,000)
SAWDUST/SHAVINGS (500 - 1,000)WOOD ASH/LIME (1,500 - 6,000)UNGROUND WOOD (1,000 - 4,000)CARDBOARD (100 - 1,000)
BLEACHING CLAY (2,000 - 4,000)COSMETICS MATERIALS (500 - 1,000)
STARCH WATER (7,000 - 8,000)
(40,000 cubic yards)
(100,000 cubic yards)
VEGETABLE WASTE (12,000 - 50,000)

Wallace Farm Type 3 Compost Facility
Huntersville Site 15

Process Flow Fact Sheet
This Fact Sheet information summarizes the processing steps and equipment at the facility.
Note that aeration capacity is not cited because passive aeration is the method in use.

Grinding
• A 1564 Hogzilla tub grinder is used to grind and regrind incoming wood and
yard materials at 240 cu yds/hr.
Volvo 150, Cat 962, John Deere 644 or 724 loaders and a Cat 320 excavator
are also used when the grinder is in operation. Bucket sizes are 6 and 2 cubic
yard, respectively.

Mixing Pit
• Volume: approximately 1500 cubic yards
• The detention time when mixing is performed is from 1 to 3 hours
• Equipment Used at Mixing Pit:
• (1-2) Volvo 150 wheel loaders (6 cubic yard bucket)
• Caterpillar 962 wheel loader (5 cubic yard bucket)
• John Deere 724 wheel loader (5 cubic yard bucket)
• (3) John Deere 250 articulated dump trucks (18 cubic yard capacity
each)
• (4) Ford 8000 tandem dump trucks. (18 cubic yard capacity each)
• The equipment listed above is capable of mixing and hauling
approximately 300 cubic yards per hour.

Windrow Composting
• Bachkus self-propelled compost turner on tracks. The Bachkus turner is
capable of turning a windrow 5-7 feet tall and 14-16 feet wide at
approximately 1200 cubic yards per hour.
• A 4055 or 4455 John Deere tractor and Knight manure spreaders that have
been modified with a custom side discharge conveyers will be used to apply
carbonaceous materials to the top of windrows. The Knight spreader has a
capacity of approximately 18 cubic yards which will adequately cover one
windrow.
• An International water truck and a Volvo off-road truck is used to apply
water to windrows as needed. The water trucks are equipped with 4000 and
5000 gallon Hydroforce tanks, respectively. Each truck is capable of
applying approximately 8000 gallons of water per hour.

Windrow Composting to Static Pile
• Equipment Used to Transport Compost from Windrow to Static Pile
• Volvo 150 wheel loader (6 cubic yard bucket)

Wallace Farm Type 3 Compost Facility
Huntersville Site 16

• Caterpillar 962 wheel loader (5 cubic yard bucket)
• John Deere 644 and 724 wheel loaders (4.25-5 cubic yard
buckets)
• (3) John Deere 250 articulated dump trucks (18 cubic yard cap.)
• (4) Ford 8000 tandem dump trucks (18 cubic yard capacity)

• Equipment Used to Construct Static Piles
• Caterpillar D6 bulldozer
• Caterpillar 963 track loader

• Equipment Used to Add 3” to 6” of Finished Compost or other
Carbonaceous Material to Windrows
• John Deere 4055 and 4455 4WD Tractors
• (2) Knight 8000 Series spreaders with custom built side
conveyer

Static Pile to Product Mix Area
1. Equipment Used to Move Compost from Static Pile to Mixing Area
• Volvo 150 Wheel loaders
• Cat 962 wheel loader
• John Deere 644 and 724 wheel loaders
• Cat 320 excavators
• (3) John Deere 250 articulated dump trucks as needed
• (4) Tandem dump trucks as needed

Finished Product Mixing
1. Equipment Used in Product Mixing
• Volvo 150 wheel loaders (6 cubic yard bucket)
• John Deere 644 or 724 wheel loaders (4.25-5 cubic yard buckets)
• Backhus compost turner

Product Screening
Equipment Used for Screening:
• (2) Powerscreen 2100 Phoenix trommel screens with a screening
capacity of 225 cubic yards per hour per machine.

Storage capacity
• Feedstocks with high water content: 45,000 gallons total storage.
• Feedstocks with low water content: Receiving and storage areas
shown on the Site Plan
• Storage for finished Product
• A 200’ x 80’ building for product ready to be marketed.

Wallace Farm Type 3 Compost Facility
Huntersville Site 17

• An additional 200’ x 80’ building includes three packaging lines
used to package and palletize products for distribution.
• Outdoor storage: 100,000 cubic yards; pallet storage noted below

Bulking agent:
Only wood materials are accumulated, and quantities vary with local
construction practices. The stored quantities can range from zero to
approximately 75,000 cubic yards; and are on site from zero to 365 days.

Quantities and timing summary

Active compost
Approximately 40,000 cubic yards, composting for 8 to 16 weeks.

Compost in curing stage
Approximately 100,000 cubic yards for 1 year to 18 months.

Compost finished and ready for bagging after curing
Approximately 50,000 cubic yards, for up to 12 months

Products bagged and ready to go to market
Approximately 12,000 pallets, on-site up to 5 months, with ongoing
production and shipping throughout the year

Topsoil
Approximately 75,000 cubic yards, 365 days

Wallace Farm Type 3 Compost Facility
Huntersville Site 18

2.7.1 - Materials Receiving/Processing
Wood materials, yard waste, sawdust, wood shavings and cotton materials are delivered by
truck to the site and unloaded in the receiving and bulking agent storage area. Grinding of wood
materials will be performed with a 1564 Hogzilla Tub Grinder. Any contaminants such as metal or
trash that are inadvertently mixed with the wood material are disposed of at a landfill. Manure, food
processing residuals, and other feedstocks with high water content are delivered to the concrete
receiving/mixing pit shown on the site plan for immediate processing.

2.7.2 - Mixing
Mixing is accomplished by a front end loader as described in Section 2.6. The mix is then
moved by front end loader and dump trucks to a composting area.

2.7.3 - Composting
The mix is placed into windrows. A front end loader is used to shape the windrows, as
required. Carbonaceous materials may be placed on top of the windrows to increase solids content to
adjust the C:N ratio, or to minimize compost smells. The windrows are periodically turned with the
Bachkus compost turner. Windrows are constructed approximately 14-16 feet wide at the base and
5-7 feet high and several hundred feet long. The temperatures are measured in each windrow once
per week until PFRP is achieved by maintaining temperatures above or equal to 131°F for a
minimum of 15 consecutive days. Windrows are turned at least five times during this period in which
temperatures are ≥ 131 ºF. (Vector attraction reduction is met by having temperatures higher than
104 Fahrenheit with an average temperature higher than 113 degrees for 14 days or longer.) Material
remains in windrows for approximately eight to sixteen weeks during the active composting period.

2.7.4 - Curing and Storage
After active composting, material is stored in a static pile for approximately six to twelve
months prior to screening. Compost will be stored in the compost storage shed, or in large piles or
windrows outdoors. The piles and windrows may be covered with vented plastic covers to keep the
compost dry during wet weather. Final curing and storage capacity for approximately thirty six

Wallace Farm Type 3 Compost Facility
Huntersville Site 19

months of compost production is available outdoors. Additionally, approximately twelve months of
storage capacity is provided under a roof.

2.7.5 - Screening
The material is screened to approximately ½-3/8 inch to produce a more marketable compost
product. The overs (material greater than 3/8 inch in nominal size) are recycled and stored in the
receiving area until being mixed with incoming feedstocks.

2.7.6 - Air Emissions and Control Technologies
Operational procedures as specified in the operation and maintenance manual, such as
maintaining aerobic conditions within the composting process (through control of porosity, moisture
content, oxygen levels, and proper turning), maintaining a neutral pH, and increasing the C:N ratio
will be followed. In addition, nitrogen-containing materials will be handled promptly, helping
prevent formation of nitrogenous compounds such as ammonia. All reasonable efforts will be made
to avoid turning windrows during unfavorable weather conditions, such as inversion conditions and
undesirable wind directions, to minimize odors beyond the facility boundary. Data from an onsite
weather station will be monitored on a daily basis. Windrows will be covered with carbonaceous
materials (taking care not to reduce air flow), if offensive odors are observed.
Airborne particulates are generally associated with dry, dusty compost piles. The initial mix
solids content can be varied during mixing to prevent over drying of the piles during composting. In
addition, the water collected in the collection pond, or water from an on-site well and/or farm ponds
may be used to add moisture back to the piles, if necessary. A tractor driven PTO pump is used to
fill 4000 or 5000 gallon truck mounted Hydroforce water tanks. The water trucks are equipped with
spray nozzles for applying water to travel areas and are equipped with specially designed nozzles for
applying water to the top of compost windrows. Water from the collection pond and the farm pond
is not added to windrows after the start of the PFRP period.

Wallace Farm Type 3 Compost Facility
Huntersville Site 20

2.7.7 - Leachate Treatment
Stormwater from composting areas is routed using natural contours and installed diversion
berms to the stormwater pond. Water from the stormwater pond is used on windrows that require
additional moisture for dust suppression (but not during or after PRFP), and may be used for
compost mixes.

2.8 - PRODUCT LABEL
A copy of the Wallace Farm product information sheets and product labels and compost (and
feedstock) analytical data is included in Appendix G. The Grade A composted cow manure is
registered with the NCDA as a fertilizer. The material is required to meet a minimum N-P-K value
of .5-.5-.5. It is routinely tested by the NCDA Agronomic Division. Grade A compost plus and
mushroom compost are registered with NCDA as a soil amendment.

2.9 - ENGINEERING PLANS AND SPECIFICATIONS
No additional site modifications are planned at present. Manufacturers’ performance data for
equipment utilized at the facility is included in Appendix F.

3.0 - REQUIRED INFORMATION FOR OPERATING PERMIT
The following section describes the information required for reviewing an application for a
permit to operate the composting facility.

3.1 - CONTINGENCY PLANS
Contingency plans for unusual and adverse conditions are as follows:

3.1.1 - Equipment Breakdown
Wallace Farm has a full time mechanic on staff, who routinely conducts regular equipment
maintenance. Sufficient storage of the feedstocks is provided to allow for routine maintenance
problems. If the compost turner breaks down, loaders can be used while it is under repair. Wallace

Wallace Farm Type 3 Compost Facility
Huntersville Site 21

Farm also maintains a good relationship with its vendors and can get equipment repaired quickly.
However, equipment can be rented as necessary to maintain operations.

3.1.2 - Air Pollution/Odors
These approaches are described in Section 2.7.6.

3.1.3 - Non-Conforming Materials
Incoming feedstocks will be inspected upon arrival. Non-conforming materials are not
allowed on the site and visual inspection prevents this from being a problem. Any rocks found in
shipments are removed. Plastics are not a factor; however these would be separated out, by hand, if
present and placed in the on-site dumpster.

3.1.4 - Spills
Spills of non-composted material will be cleaned up by a front end loader and added to active
compost piles.

3.1.5 - Fires
The local fire department will be called if needed in the event of any fire at the facility. If
piles of material catch on fire, a bulldozer and loaders will be used to separate the unburned material
from the burning material and prevent the fire from spreading.

3.1.6 - Particulates
Particulates are generally associated with overly dry compost piles. Water from on-site farm
ponds, from the collection pond, or from an on-site well can be used to increase moisture content and
reduce particulates. As noted above, addition of water from on-site ponds will not be performed
after the start of PRFP.

Wallace Farm Type 3 Compost Facility
Huntersville Site 22

3.1.7 - Noise
Equipment normally associated with farm operations and grading operations has been used at
this location for many decades and will continue to be used on the site. Reasonable levels of noise
are expected

3.1.8 – Vectors
Vector attraction reduction takes place during composting. To meet vector attraction
reduction, materials are to be treated in an aerobic process for 14 days or longer, during which time
the temperature of compost shall be higher than 40 degrees Celsius (104 degrees F) and the average
temperature shall be higher than 45 degrees Celsius (113 degrees F). Periodic turning occurs
throughout the composting process, as discussed above and in the O&M Manual. This approach is
considered very effective at controlling vectors. Nevertheless, Wallace Farm staff makes visual
observations for vectors. The attraction of birds has never been an issue on the site.
Process modifications will be made, if required, to ensure these vector attraction reduction
requirements are met. This may include increasing the amount of wood material and cotton material
in the initial mix. Mixing of incoming wet materials and bulking agents occurs is outlined in Section
2.6. Periodic turning occurs throughout the composting process, as discussed above and in the O&M
Manual.

3.1.9 - Unusual Traffic Conditions
Delivery schedules may be modified, if required, to prevent traffic impacts.

3.1.10 – Adverse Weather Conditions
Operations will be curtailed as necessary during wind, heavy rain, snow, freezing or other
adverse weather conditions. If conditions are very severe, feedstock delivery will be stopped, and
operations will cease. The compost turner, which runs on tracks, permits operations under all but the
most severe conditions. Delivery and other operations will also be reduced to match staff absences
due to inclement weather.

Wallace Farm Type 3 Compost Facility
Huntersville Site 23

3.2 - OPERATIONS AND MAINTENANCE MANUAL
A separate operations and maintenance (O&M) manual for the facility has been prepared and
is included with this permit application.

3.3 - QUALITY ASSURANCE PLAN
Detailed records, including quantity and type of incoming materials, outgoing products, pile
temperatures, moisture and oxygen levels, turning frequency, and product testing will be maintained
at the facility. Composite compost samples will be taken quarterly and compared to the standards
shown in Table 4. Wallace Farm uses certified laboratories, and their testing procedures are noted on
each lab analysis. Wallace Farm will test or obtain test data on the cotton material, food processing
residuals, and other incoming feedstocks annually to ensure metals are below Solid Waste standards
as shown in Section .1407.
Non-compostable materials are not allowed on the site. Wallace Farm receives feedstocks of
very consistent quality from known suppliers. This feedstock does not contain any sort of non-
compostable materials. Should non-compostable materials be delivered, they will be sent back to
those that sent them, if allowable by law. If hazardous materials are received, Wallace Farm will
report to the Division of Waste Management immediately to seek solutions with them and determine
proper removal and disposal procedures to follow. If non-compostable materials are screened from
initial delivery, they will be separated and processed according to law. If they are non-hazardous,
they will be routed to a landfill. If hazardous, Wallace Farm will follow directions of experts at the
Division of Waste Management.

Wallace Farm Type 3 Compost Facility
Huntersville Site 24

Table 4. Quarterly monitoring for Class A compost requirements.
Parameter Unit Limit Foreign Matter % < or = 6 Cadmium mg/kg dry wt. 39 Copper mg/kg dry wt. 1500 Lead mg/kg dry wt. 300 Nickel mg/kg dry wt. 420 Zinc mg/kg dry wt. 2800
Selenium mg/kg dry wt 36
Arsenic mg/kg dry wt 41
Mercury mg/kg dry wt 17 Pathogens (fecal coliform) MPN/g dry wt. < 1000 per g Total N % None Phosphorous % None Potassium % None

3.4 - PROCESS FLOW
The process flow is described in Section 2.7.

3.5 - PERMITS AND APPROVALS
A copy of the local zoning authority approval to operate the composting facility is included in
Appendix A

3.6 - PRODUCT MARKETING AND DISTRIBUTION PLANS

Wallace Farm successfully markets the final compost in both bag and bulk form to large
chain retail outlets, area landscapers, and homeowners.

Wallace Farm Type 3 Compost Facility
Huntersville Site 25

REFERENCES

Epstein 1997. The Science of Composting. Technomic Publishing Co., Inc., Lancaster, Pennsylvania
p. 340.

Radcliffe, D.E., K.A. McVay, and D.E. Brune, 1997. "Nitrogenous and Phosphorus Losses from
Dairy Loafing Areas and Lagoons." From the Proceedings of the Southeastern Sustainable Animal
Waste Management Workshop. February 11 - 13, 1997, Tifton, Georgia, p. 25.

Wallace Farm Type 3 Compost Facility
Huntersville Site 26
WALLACE FARM, INC.

SOLID WASTE COMPOSTING FACILITY
OPERATION AND MAINTENANCE MANUAL

October 2014

Prepared for:
Wallace Farm, Inc.
14410 Eastfield Road
Huntersville, NC 28078
Phone: [phone]

Prepared by:
Garrett & Moore Inc.
1100 Crescent Green Drive
Suite 208
Cary, NC 27518
Phone: [phone]

CONTENTS

Page
Chapter 1
1.0 - Introduction ................................................................................................................... 1
1.1 - Composting Process Description .................................................................................. 1
1.2 - Facility Overview .......................................................................................................... 1

Chapter 2
2.0 - Standard Facility Operations ......................................................................................... 3
2.1 - Erosion Control ............................................................................................................. 3
2.2 - Leachate Management................................................................................................... 3
2.3 - Site Access .................................................................................................................... 3
2.4 - Signage .......................................................................................................................... 3
2.4A – Safety Requirements .................................................................................................. 4
2.5 - Materials Receiving ...................................................................................................... 4
2.6 - Mixing ........................................................................................................................... 5
2.7 - Composting ................................................................................................................... 6
2.8 - Compost Curing/Storage ............................................................................................... 8
2.9 - Screening ....................................................................................................................... 8
2.10 - Product Distribution .................................................................................................... 8
2.11 - Equipment Maintenance and Storage.......................................................................... 9
2.12 - Operator Checklist ...................................................................................................... 9
2.13 - Troubleshooting .......................................................................................................... 11
2.13.1 - Procedures For Responding To Odor Complaints .................................................. 13
2.13.2 – Neighborhood Relations .......................................................................................... 13

Chapter 3
3.0 - Sampling, Testing, and Record Keeping ....................................................................... 15
3.1 - Sampling and Testing Schedule .................................................................................... 15
3.1.1 - Grab Sample Definition ............................................................................................. 15
3.1.2 - Grab Sampling Procedure .......................................................................................... 16
3.1.3 - Composite Sample Definition .................................................................................... 16
3.1.4 - Composite Sampling Procedure ................................................................................. 16
3.1.5 - Pathogen Samples ...................................................................................................... 17
3.1.6 - Metals and Foreign Matter ......................................................................................... 17
3.2 - Operational Record Keeping Procedures ...................................................................... 18
3.2.1 – Material Receiving and Mixing Records ………………………………………… .. 18
3.2.2 - Compost Windrow Data ............................................................................................ 18
3.2.3 – Row (Windrow) Data ................................................................................................ 19
3.2.4 - Laboratory Data .......................................................................................................... 19
Table 3-1. Semi-Annual Monitoring for Grade A Compost Requirements ................. 20

Wallace Farm O&M Manual
Huntersville Site
CONTENTS, Continued

Chapter 4
4.0 - General .......................................................................................................................... 21
4.1 - Personal Hygiene .......................................................................................................... 21
4.2 - Personal Protective Equipment ..................................................................................... 21
4.3 - Mechanical Equipment Hazard Prevention ................................................................... 22
4.4 - Employee Health and Safety ......................................................................................... 22
4.4.1 - Fire Extinguisher ........................................................................................................ 22
4.4.2 - Physical Exposure ...................................................................................................... 23
4.4.2.1 - Bioaerosols .............................................................................................................. 23
4.4.2.2. - Dust ........................................................................................................................ 23
4.5 - Facility Emergency Phone Numbers ............................................................................. 24

Chapter 5
5.0 - Contingency Plans ......................................................................................................... 25
5.1 - Equipment Breakdown .................................................................................................. 25
5.2 - Air Pollution/Odors ....................................................................................................... 25
5.3 - Non-Conforming Materials ........................................................................................... 26
5.4 - Spills ............................................................................................................................. 26
5.5 - Fires ............................................................................................................................... 26
5.6 - Particulates .................................................................................................................... 27
5.7 - Noise ............................................................................................................................. 27
5.8 - Vectors .......................................................................................................................... 27
5.9 - Unusual Traffic Conditions ........................................................................................... 27

Chapter 6
6.0 - Reporting ....................................................................................................................... 28
7.0 - Product Marketing And Distribution Plan .................................................................... 29

References ............................................................................................................................ 30

Wallace Farm O&M Manual
Huntersville Site
CONTENTS, Continued

Figures
Figure 1. Odor complaint response sequence

Appendices

Appendix A
- Site Plan
Appendix B
- Site Signage
Appendix C
- Sample Row Data Record
- Sample Windrow Data Recording Sheet
- Sample Pit Mix Recording Sheet
Appendix D
- Compost Product Information
Appendix E
- Concrete Pit Construction Specifications
Appendix F - New Compost Turner and New Grinder
Appendix G
- Odor Response Form

Wallace Farm O&M Manual
Huntersville Site
1.0 - INTRODUCTION
This Operation and Maintenance (O&M) Manual was developed for Wallace Farm, Inc. The
objective of the manual is to provide guidance for operators and outline required activities so that the
facility: (1) operates in accordance with state regulations, (2) minimizes external impacts, and (3)
composting is undertaken with proper regard for the health and safety of the facility’s operators and
neighbors.

1.1 - COMPOSTING PROCESS DESCRIPTION
Composting is the controlled aerobic (oxygen rich), thermophilic (temperature range 105 °F
to 165 °F), biological conversion of organic materials into a stable end product (compost). This
conversion is accomplished by microorganisms (bacteria, actinomycetes, and fungi) normally present
in organic materials within the composting mass. By optimizing the environment for the
microorganisms, the process of decomposition is accelerated.
There are three major objectives in composting. The first is to destroy disease-causing
organisms (pathogens) that may be present, by following state requirements for PFRP (Process to
Further Reduce Pathogens) which meets Vector Attraction Reduction requirements. The second
objective is to stabilize the product so that it does not putresce. The final objective is to produce a
stable, manageable product for beneficial use in landscaping and other applications.
The method of composting used at Wallace Farm is the turned windrow method. This
method achieves the objectives outlined above, while processing feedstocks efficiently.

1.2 - FACILITY OVERVIEW
The Composting Facility is in Mecklenburg County. Wallace Farm is a family owned and
operated facility. There is not a precise routine; each employee is trained to perform various tasks.
Depending on specific operations on any given day, several people may work together to accomplish
the tasks. Operating schedules vary depending on the priorities of the day.
Staff and operations each typically performs are listed below.
• General Manager - Manage all operations and direct work efforts
• Office Manager - Coordinates all billings and administrative activities
• Fleet Manager - Coordinates all deliveries and trucking operations
• Tractor Trailer and Dump Truck Drivers - Haul feedstocks and finished materials

Wallace Farm O&M Manual
Huntersville Site
1
• Front End Loader Operator - Mixes feedstocks/shapes windrows/loads product/mix
and screen finished product
• Compost Turner Operator - Turns windrows/monitors compost piles
• Bagging Line Operator - Bags finished products
• Grinder Operator – Grinds yard waste, pallets, and other mulch products.

Wallace Farm O&M Manual
Huntersville Site
2
2.0 STANDARD FACILITY OPERATIONS
The following sections cover standard operating procedures for the facility.

2.1 EROSION CONTROL

Stormwater and erosion control measured are installed and shown on the permit drawings.
Stormwater discharges for operations of the facility are permitted in accordance with NPDES
General Permit No. NCG 240000.

2.2 LEACHATE MANAGEMENT

The compost windrows will be constructed to facilitate drainage between windrows.
Stormwater discharges for operations of the proposed facility are permitted in accordance with
NPDES General Permit No. NCG 240000.
Passive treatment of storm water from compost areas occurs as the water is routed through
rip rap, silt fencing, over grassy areas, and to sedimentation catch basins. Water from composting
areas is routed using natural contours and diversion berms to the stormwater ponds shown in the
site plan. Water from the stormwater ponds may also be used on windrows for dust suppression
(but not during or after PFRP), and in compost mixes.
.
2.3 SITE ACCESS
Public access is not allowed, except when accompanied by a Wallace Farm employee. A
fence along the property boundary reasonably limits unauthorized access onto the site. An operator
is on duty at the site when the facility is open. The road to the site is maintained to allow all-
weather access.

2.4 SIGNAGE

A sign stating that “No hazardous waste, asbestos containing material, or medical waste is
allowed on site” is prominently posted at the site entrance, along with signage providing
information on materials that are acceptable. Copies of site signage are included in Appendix B.

Wallace Farm O&M Manual
Huntersville Site
3

2.4A SAFETY REQUIREMENTS

Safety requirements include the following:

• Open burning of solid waste is prohibited.

• As discussed in Section 4.4 and 4.4.1, equipment is provided to control accidental
fires; arrangements have been made with the local fire protection agency to
immediately provide fire-fighting services when needed (see Section 5.5).

• Personnel training is provided to insure that all employees are trained in site
specific safety, remedial, and corrective action procedures. Training is discussed
in Sections 4.2 and 4.4.

• In addition, all new employees complete an orientation program covering, at a
minimum, the following: all aspects of job safety, including fire; general physical
facility orientation; and job orientation, emphasizing duties of the employee,
including composting procedures.

2.5 MATERIALS RECEIVING
Only permitted materials can be accepted. Hazardous materials are not allowed on the site.
Incoming materials are inspected, and any unacceptable materials are to be loaded on the truck that
brought them and transported to a permitted landfill. Feedstocks to be composted under this permit
include animal manures, wood materials, yard waste, cotton materials, food and/or animal processing
residuals, food waste, waste water treatment residuals, grease trap residuals, US domestic tobacco
material, wood ash, cardboard, bleaching clay , cosmetics production materials, virgin gypsum board,
lime, and starch water. Wood materials to be composted at the facility under this permit include land
clearing debris, yard waste, wood shavings, sawdust, and pallets.
Materials are received and recorded on a weight (per ton) or volume (per gallon) basis. For
materials recorded on a volumetric basis, a gallon of material is weighed. Then the resulting
conversion factor (pounds per gallon) is multiplied by the total number of gallons received to convert
to total pounds. Total pounds are converted to tons by dividing by 2000. USDA certified scales on
site will be used to weigh incoming feedstocks. The dry carbonaceous materials such as the wood

Wallace Farm O&M Manual
Huntersville Site
4
materials and cotton materials, are unloaded in the receiving and storage area. A tub grinder is used
to adjust the size of wood material products for composting, as described below.
Materials with significant water content (including food and/or animal processing residuals,
waste water treatment residuals, manures, US domestic tobacco material, food waste, bleaching clay,
starch water, and cosmetic production material, will be unloaded directly into the concrete
receiving/mixing pit for preparing compost mixes. In addition, temporary storage for high-water
content materials is being developed for the operations. If the mixing pit is filled to capacity or if it
is in use when a load of high-water content material arrives, these materials can be off-loaded to the
frac tank(s). Use of the tanks will help achieve maximum efficiency in the mixing pit. At a
minimum, the tanks are to be emptied every 36 hours.
The scales, receiving areas, storage areas, and concrete receiving/mixing pit are shown on the
site plan.
The receiving/mixing pit is cleaned out daily. After the last mixture is prepared and removed
for further processing, the walls and dump areas are washed down with a high pressure hose. The
wash water is directed into the pit, to which fresh bulking material is added on the bottom to absorb
the moisture.
Prior to accepting a new waste material not included in this O&M manual, Wallace Farm,
Inc. will thoroughly assess the material and the facility producing it to determine its composition and
suitability for composting. NCDENR will be contacted for assistance with these evaluations.
Samples will be obtained and tested, and lab results will be forwarded to NCDENR as part of the
request for approval for adding the material to the list of allowable feedstocks. New waste materials
will not be received without approval by the Division of Waste Management.
As discussed in the Application component of the Application/O&M Manual submittal,
quantities received will vary from year to year and from feedstock to feedstock, and in some years
certain feedstocks are not available at all.

2.6 MIXING

Dry carbonaceous materials (including wood materials; land clearing debris; yard waste;
wood shavings; sawdust, virgin gypsum board, and cotton material), are delivered to the facility and
off-loaded in the receiving/storage area. Wood materials, including land clearing debris, yard waste,

Wallace Farm O&M Manual
Huntersville Site
5
and pallets, are ground as necessary. Materials with significant water content (including food and/or
animal processing residuals, waste water treatment residuals, manures, US domestic tobacco
material, food waste, starch water, and cosmetic production materials) are unloaded directly into the
concrete receiving/mixing pit for preparing compost mixes. These materials are blended with front
end loaders in the mixing pit upon arrival. Materials are mixed to obtain a homogenous mix with a
C:N ratio of 20:1 to 30:1.
A feedstock database that includes results of laboratory analyses is used to calculate the
appropriate mix ratios to obtain a homogenous mix with a C:N ratio of 20-30:1 and target moisture
contents of 40 to 60%. The calculations are performed by hand with a calculator using the standard
compost mix mass balance equations, obtained by Wallace Farm at a national compost school.
Computer spreadsheets are also available for verifying the hand calculations (see, for example,
http://compost.css.cornell.edu/download.html).
Within two hours of blending, the mix is transported to the composting pad via dump
trucks and placed into windrows. A front end loader is used to improve the shape of the windrows as
necessary. The new windrows are turned immediately if favorable climatic conditions exist. If
weather conditions are unfavorable, various procedures can be followed, as described in Sections 2.7
and 5.2.

2.7 COMPOSTING

Windrow composting at the facility is accomplished by placing the mix in windrows
approximately 5 - 7 feet in height by 14 - 16 feet wide, and up to several hundred feet long. The
windrows are periodically turned to break up clumps, to expose more surface area to active
microorganisms, and to expose all materials to temperatures ensuring pathogen destruction and
vector attraction reduction.
The facility uses a self-propelled, track driven Backhus compost turner and a, state-of-the-art,
grinder (this equipment is described in Appendix F). The compost turner performs well during all
weather conditions, and will improve mixing and aeration of compost windrows. The grinder will
help optimize admixture and compost particle sizes. These machines improve composting
efficiency.

Wallace Farm O&M Manual
Huntersville Site
6
To ensure pathogen destruction and vector attraction reduction, the pile temperatures are
maintained at or above 131 °F for at least 15 consecutive days. Windrows are turned at least five
times during this PFRP (Processes to Further Reduce Pathogens) period during which temperatures
are ≥ 131 ºF and temperatures are measured at least one time per week during this period.
Temperatures are taken in each windrow at 50-foot intervals down the length of the windrow using a
three-foot long dial type or digital thermometer. The probe is inserted approximately one to two feet
into the pile from the pile surface. Temperatures are recorded as illustrated in the recording sheet
shown in Appendix C. Temperatures are measured at least one time per week until the 131 °F for 15
consecutive days has been met. An oxygen meter will be used to measure oxygen content of compost
pile pore space, usually at the same time that temperatures are checked. Windrows are turned based
on temperature measurements and atmospheric conditions. Material generally remains in the turned
windrows for approximately eight to sixteen weeks, the exact time being a function of windrow
performance and temperature readings. Following this windrow processing period, the compost is
placed in a static pile for a minimum of six months for curing.
If temperatures exceed 160 °F, the windrow requires turning to cool the composting material.
If temperatures during the active composting period are less than 120 °F, the windrow requires
turning as well. Low temperatures may indicate insufficient oxygen, and pile turning will provide the
needed oxygen to the microorganisms. Temperatures determining when the compost pile requires
turning are guides and may be adjusted based on long-term pile temperature trends and composting
times. If material begins to dry significantly, thereby inhibiting microbial activity, and dusty
conditions are prevalent, water will be added to the top of the windrows. This water can come from
the potable supply, or, if added prior to the start of PFRP, can be from an on-site farm pond or the
collection pond. After adding water, the pile is turned to distribute the moisture. Vector attraction
reduction is met by maintaining pile temperatures above 104 °F for 14 days or longer, during which
time the average temperature is greater than 113 °F.
Within two hours of blending, the mix is transported to the composting pad using dump
trucks and placed into windrows. A front end loader is used to improve the shape of the windrows as
necessary. The windrows are turned periodically using the Bachkus windrow turner to maintain
aerobic conditions within the pile and to invert and fluff the windrow.

Wallace Farm O&M Manual
Huntersville Site
7
2.8 COMPOST CURING/STORAGE

The primary purpose of the curing/storage pile is to provide volume equalization. Multiple
compost rows, once the compost material is stable, are moved to the curing/storage pile and then the
compost material is moved out to the bagging operations and to other finished product storage areas.
Wallace Farm is a member of the US Composting Council (USCC). Compost rows are
sampled regularly and tested by the USCC for stability. Wallace Farm consistently receives a rating
of “very stable” from the USCC. The compost material moved from the compost rows to the
curing/storage pile is considered to be stable and is ready for finished product uses at that time.
Two beneficial processes occur in the curing/storage. First, the material color darkens giving it
a blacker hue, which is more desirable from an aesthetic standpoint. Also, the storage time in the
curing/storage pile helps balance the moisture content of the finished product. Temperature of the
curing/storage pile is typically around 110o F.

2.8.1 Compost Curing/Storage Pile Construction

Curing/storage is an important step in the operation by Wallace Farm and must be performed in
a manner to prevent loss of finished product. There are two primary concerns associated with the
curing/storage pile:
1. Loss of finished product due to absorption of water, which results in excessive
moisture content and an unusable product.
2. Loss of finished product due to fire.
To minimize the potential for loss of product due to excessive moisture and loss of product due
to fire, the following procedures will be implemented during construction of the curing/storage pile:
1. Finished compost will be hauled from the compost piles to the curing/storage area.
2. Compost will be spread in an approximate 1-foot lift and compacted with a dozer. No
loose material will be allowed to remain in place.
3. Additional lifts will be spread and compacted resulting a “constructed” curing/storage
pile with a relative high density of material with minimized voids.
4. Curing/storage pile side slopes will be constructed in a manner that allows equipment
to perform compaction on side slopes.

Wallace Farm O&M Manual
Huntersville Site
8
5. Typical curing/storage piles will be 100 to 200 feet wide.
6. Maximum curing/storage pile height will be 60 feet.
7. All procedures used in constructing the curing/storage pile should focus on
minimizing the intrusion of air into the pile and minimizing infiltration of water into
the pile.
8. Vehicular access will be maintained around the entire perimeter of the curing/storage
pile.

2.8.2 Compost Curing/Storage Pile Monitoring

Daily visual monitoring for vents and cracks will be performed. Any vents or cracks identified
will be immediately remedied using the construction procedures described above.
Operators are trained to identify any hot areas in curing/storage pile. If temperatures in the
curing/storage pile rise above the typical 110o F, the operators can feel the heat being generated and
the operators take the corrective actions described below.
Visual inspections for smoke are continuously performed by the operators during daily
operation and if smoke is identified the operators take the corrective actions described below

2.8.3 Compost Curing/Storage Pile Corrective Action

If hot areas are encountered or if smoke is identified, the material generating the heat or smoke
is immediately removed from the curing/storage pile, mixed with compost material having a
relatively higher moisture content, and moved to product packaging.
A 5,000 gallon water tanker is used on site at all times. The water tanker is a 6-wheel drive off
road truck and is equipped with a water cannon capable of spraying water about 50 to 75 feet. The
water tanker truck can drive on the curing/storage pile to access excessively hot or smoking areas.
If excessively hot or smoking areas are encountered, the Fire Department will be notified. An
all-weather (aggregate base course) access road provides access from the public road through the site
and directly to the curing/storage pile. Vehicular access will be maintained around the entire
perimeter of the curing/storage pile.

Wallace Farm O&M Manual
Huntersville Site
9
2.9 SCREENING

Screening is conducted after curing. The screen size is 3/8-1/2” or as required by the market.
The compost (< 1/2”) is stored on site prior to distribution. The overs (> 1/2”) are returned to the
receiving/storage area and added to other feedstocks in amounts determined by experience and using
Wallace Farm’s feedstock information database.

2.10 PRODUCT DISTRIBUTION
The finished product is distributed in bags and in bulk. Records are maintained of material
purchasers. The compost products are registered with the NCDA as a fertilizer and/or soil
amendment. Compost marketed as a fertilizer must meet a minimum N-P-K value of .5-.5-.5.
(Product information is included in Appendix D.)
If product fails to meet state regulatory or facility requirements or is otherwise unmarketable,
it can be applied per regulations and with NCDENR pre-approval to land or taken to an approved
municipal solid waste landfill. Otherwise, poor quality compost, as well as compost not meeting all
regulatory requirements, will be returned to the receiving/processing area and fully reprocessed
following the treatment and monitoring steps described above.

2.11 EQUIPMENT MAINTENANCE AND STORAGE

Regular equipment maintenance is required to ensure a marketable product is produced.
Refer to specific equipment O&M manuals for equipment maintenance schedules. Small equipment,
such as temperature probes, will be stored inside the bagging line building or in the office.

2.12 OPERATOR CHECKLIST
The following chart is a quick reference for operators to ensure performance of proper
procedures.

Wallace Farm O&M Manual
Huntersville Site
10
Operator Checklist
As
Required
Daily Weekly Monthly Semi-Annually
Annually
Inspect Incoming Materials
 Turn Windrows
 Perform Equipment
Maintenance


Screen Compost
 Measure Windrow
Temperatures
one time
per week


Clean-up Spills
 Prepare/Update Windrow
Data Sheets


Record Information on
Windrow Data Sheet


Prepare Monthly Information
Sheet


Sample/Analyze Compost
Product


Inspect Grass Areas
 Reseed Grass Areas1
 Wash Mixing Pit
 Inspect/Repair Access Road
 Submit Report to NCDENR


1Reseed at least semi-annually or more frequently, if required.

Wallace Farm O&M Manual
Huntersville Site
11

2.13 TROUBLESHOOTING

This section presents commonly encountered problems at composting facilities. The
following is a guide to potential problem areas, and accompanying corrective action.
Problem/Condition Corrective Action
Pile temperature too high (>160 °F) Increase turning frequency and/or decrease pile
size.
Pile temperature too low (<110 °F) Increase turning frequency and/or increase pile
size. Check pile moisture content, pH, and C:N
Dry piles Check pile moisture content. Add water.
Dusty conditions at site Spray water on windrows to suppress dust.
Odors around compost pad, or off-site odors -Check for/clean up spills. Cover odorous
windrows with compost or carbonaceous blend.
-Do not disturb odorous windrow for
approximately 10 days following initial turning.
-Check incoming feedstocks.
Odors during pile turning

-Adjust as necessary the initial mix C:N ratio,
pH, porosity and/or water content of mix.
-Avoid turning during adverse atmospheric
conditions, if possible.

Odor complaint from neighbor Follow procedures noted below and in the
next section, including:
1. Respond immediately
2. Complete Odor Response Form (see
Appendix G)
3. Determine whether corrective action is
needed.
4. If needed, perform immediate corrective
action to address odors
5. Cover odorous windrows with a layer of
carbonaceous materials.
6. Check incoming feedstocks.
7. Consult on-site weather station.
Proposal for processing new material Contact NCDENR.

Odor complaints are addressed by following the procedures described in the next section.

Wallace Farm O&M Manual
Huntersville Site
12
2.13.1 PROCEDURES FOR RESPONDING TO ODOR COMPLAINTS

Procedures for responding to odor complaints are detailed in this section. Odor complaints
can be called in or e-mailed to the Wallace Farm office. If a complaint is received, the following
steps are taken:

1. A member of Wallace Farm office staff promptly visits the complaint location.
2. Upon arrival, Wallace Farm staff member completes an Odor Response Form.
3. The Wallace Farm staff member determines if complaint is verifiable.
4. If the complaint is not verifiable, the staff member returns to the office and files the
completed Odor Response Form.
5. If the complaint is verifiable, the Wallace Farm staff member immediately contacts the
compost facility manager.
6. The compost facility manager promptly investigates to identify the odor source.
7. Corrective Action is implemented immediately.
8. A weather data sheet is attached to the odor response form and filed.

These procedures are presented graphically in Figure 1.

2.13.2 NEIGHBORHOOD RELATIONS

Wallace Farm routinely invites neighbors who are curious or interested or who have
experienced odors to tour the facility and to learn about the process to minimize any impacts.

Wallace Farm O&M Manual
Huntersville Site
13

Wallace Farm O&M Manual
Huntersville Site
14
3.0 SAMPLING, TESTING, AND RECORD KEEPING

Sampling and testing at the composting facility is necessary to:

• Monitor process efficiency
• Provide data to regulatory agencies
• Provide data for trouble-shooting
• Verify quality of materials for composting

It is extremely important that all sampling and testing be done at representative points in the
process and in a consistent manner. The data resulting from any sampling and testing program is
only as good as the sample taken. Sampling should be done consistently, on a regular basis, and
using specific techniques. This section outlines the sampling schedule and sampling procedures
required for a successful sampling and testing program. The operator should make every effort to
follow a consistent routine, according to these guidelines.
Parameter testing includes pathogen indicators, regulated metals, nutrients, and foreign
matter. Sampling and handling requirements are discussed in following sections.

3.1 SAMPLING AND TESTING SCHEDULE
Final product sampling is conducted every six months or 20,000 tons, whichever comes first.
At Wallace Farm’s option, compost samples are taken monthly to comply with the STA (Seal of
Testing Assurance) Certification of the US Composting Council. The following sections outline
sampling types and procedures.

3.1.1 Grab Sample Definition

Grab samples are collected at a specified time, in a specified location of a certain process.
Analysis of a grab sample provides results from a random part of the process stream. To achieve a
more representative analysis of a given process stream, many grab samples can be collected at
various times and analyzed individually, or these grab samples can be combined to produce a
composite sample.

Wallace Farm O&M Manual
Huntersville Site
15
3.1.2 Grab Sampling Procedure

Grab samples are collected using a plastic shovel and a clean, dry sampling jar (one-pint glass
or plastic bag). The sample is collected at a point in the material approximately two feet into the
storage pile from the outside of the surface and representative of the compost pile which is being
sampled. Grab sample volumes should be consistent. Grab samples should be taken monthly and
stored in refrigeration until needed to produce a six month (semi-annual) composite sample for
analysis.

3.1.3 Composite Sample Definition

Composite samples are a mixture of grab samples collected individually at various times at
the same location in a certain process, or a mixture of samples that are collected individually at
various locations in a certain process. The grab samples are immediately transferred to a composite
sample container for storage. Composite samples generally are more representative than grab
samples.

3.1.4 Composite Sampling Procedure

Composite samples are stored in a clean, dry sampling jar (one gallon or larger) with an
airtight, screw-on lid. The sampling container is labeled with data indicating time and location of the
sample and stored in a cool, dry place, out of direct sunlight, preferably a refrigerator. At the end of
the sampling period, the composite sample is well mixed and a representative portion placed in a
smaller sampling jar (one pint) for analysis. The sampling jar is airtight and stored in a refrigerator
until it is delivered to the laboratory for analysis. Analysis should be performed as quickly as
possible, preferably within 24 hours after collection. The sample jar is adequately labeled with
sample name, date of collection, and the operator’s name. Composite samples can also be taken at
random from the screened material (immediately after screening or in the product storage pile)
approximately two feet from the pile surface. Several grab samples can be taken from the pile and
combined and thoroughly mixed to create the composite sample.

Wallace Farm O&M Manual
Huntersville Site
16
3.1.5 Pathogen Samples

Pathogen samples will be grab samples. The pile will be broken apart using a front-end
loader. A shovel will be cleaned with hot soapy water and then sterilized by pouring alcohol on the
shovel and lighting it on fire. The sterile shovel will then be utilized to dig approximately two feet
into the open face of the pile that was broken apart. A sterile scoop is then used to obtain a sample
and place it in a sterile jar. The person sampling will also be wearing sterile gloves during the
sampling event. Pathogen samples will be taken at least semi-annually. Once pathogen samples have
been taken, they are stored on ice and sent to the lab immediately.

3.1.6 Metals and Foreign Matter

A composite sample of the compost is analyzed after every 20,000 tons of compost
produced or every six months, whichever comes first, for regulated metals and foreign matter listed
in Table 3.1
Sampling equipment (including coring devices, shovels, trowels, and containers) must be
made of materials that will not contaminate or react with compost constituents. Suitable sampling
equipment materials include glass, stainless steel and plastic (teflon, polyethylene, polypropylene).
Any steel equipment used must not be galvanized or zinc coated because it can contaminate samples.
All sampling equipment must be kept clean to avoid contamination.
Sample containers for metals (and all other analytes) are to be obtained from the certified
laboratory doing the analyses. For metals these containers shall be plastic or glass, the minimum
sample volume sent to the laboratory is 300 mL. Samples for metals analyses are to be stored at 4
°C, and can be held up to six months prior to analysis.
Foreign matter content is determined by passing a dried, weighed sample of the compost
product through a one-quarter inch screen. EPA Method 160.3 is used to dry the sample. The
material remaining on the screen is visually inspected, and the foreign matter that can be clearly
identified is separated and weighed. The weight of the separated foreign matter divided by the
weight of the total sample is determined and multiplied by 100. The result is the percent dry weight
of foreign matter content.

Wallace Farm O&M Manual
Huntersville Site
17
3.2 OPERATIONAL RECORD KEEPING PROCEDURES

Keeping accurate records is an important part of the operation of any modern composting
facility. Proper records are necessary to monitor the performance of the facility and to make
operational decisions. Of great importance is the establishment of a reliable continuing record for
proof of performance, thus justifying operational decisions, expenditures, and recommendations.
Daily operational records also provide information useful in process adjustments required due to
climatic or seasonal changes or other recurring problems of a specific nature. Accurate records also
provide the basis for planning future expansion, planning future modifications, establishing and
adjusting operating budgets, and providing evidence of performance in compliance with regulations.

The NC DENR Division of Waste Management requires record keeping sufficient for
determining facility efficiency and the effectiveness of treatment in meeting standards. Personnel
from NC DENR Division of Waste Management will make periodic visits to the facility. During
these inspections, a review of operational and other records may be requested. Records must be
retained for five years.

The following sections outline data to be maintained at the facility.

3.2.1 Material Receiving and Mixing Records
The type and quantity of materials received are recorded daily. Daily records are also kept
documenting feedstock mix ratios and row placement on compost pads. A sample “Pit Mix
Recording Sheet” is included in Appendix C.

3.2.2 Compost Windrow Data

Compost windrow data are maintained by the operator for each windrow built at the facility.
Each windrow is defined as the mix placed on the composting area that is contained in one windrow.
Data will include information as to the day the pile was built, along with monitoring data. A sample
Windrow Data Sheet is attached in Appendix C. The P1, P2…Pl0 indicates the same relative
location in a windrow. Each point is approximately 50 feet from the next. Temperatures are

Wallace Farm O&M Manual
Huntersville Site
18
measured at least one time per week until the time and temperature requirements are met. The day a
pile is turned or sampled is also noted. The date pile construction began and date completed is when
material is first placed in the windrow and when the last material is placed in the windrow,
respectively. Windrow numbers start with 1 and increase throughout the composting pad as new
windrows are constructed. Additional data is to be collected to record performance over periods
greater than 30 days, as necessary. The operator also maintains a log to document the exact day and
time the turner is in operation.

3.2.3 Row (Windrow) Data

Compost row data are summarized in a database for record-keeping and to evaluate the
overall materials processing operation. Data should be recorded in the database as it becomes
available, thus keeping records current. A sample Row Data Record Sheet is included in Appendix
C.

Any material not meeting the time and temperature requirements, which fails pathogen or
other testing, or is otherwise unmarketable, is identified in the database and appropriately segregated.
Approaches for handling these materials are re-composting, land application with prior NCDENR
approval, and transporting them to a Municipal Solid Waste landfill.

3.2.4 Laboratory Data

Laboratory data include bacteriological, heavy metal, and nutrient concentrations. Compost
samples are taken at least every six months as outlined in Section 3.1. These samples are used to
verify that the product meets the requirements listed in Table 3-1. Certified laboratories are used
and testing procedures are noted on each analytical report.

Wallace Farm O&M Manual
Huntersville Site
19
Table 3-1. Semi-Annual Monitoring for Grade A Compost Requirements1
Parameter Unit Limit Foreign Matter % < or = to 6 Cadmium mg/kg dry wt. 39 Copper mg/kg dry wt. 1500 Lead mg/kg dry wt. 300 Nickel mg/kg dry wt. 420 Zinc mg/kg dry wt. 2800
Selenium mg/kg dry wt 36
Arsenic mg/kg dry wt 41
Mercury mg/kg dry wt 17 Pathogens (fecal coliform) MPN/g dry wt. < 1000 per g Total N % None Phosphorous % None Potassium % None
1NC DENR Solid Waste Compost Rules

Wallace Farm O&M Manual
Huntersville Site
20
4.0 GENERAL

Some feedstocks may contain pathogens, which composting, if carried out properly, will
destroy. The following are some general recommendations for the health and safety of workers at
Wallace Farm.

4.1 PERSONAL HYGIENE
The following personal hygiene recommendations will be stressed as common practices
to all operators.

• Wash hands before eating, drinking, or smoking.

• If heavily contacted with feedstocks such as food processing residuals or manure,
immediately take a hot shower and put on clean clothing.

• Wash, disinfect, and bandage ANY cut, no matter how small it is. Any break in the
skin can become a source of infection. Change bandages frequently and wear
protective clothing or equipment over the wound.

• Keep fingernails closely trimmed and clean (dirty nails can harbor pathogens).

Individuals who are more susceptible to diseases or have severe allergies or asthma
should not be employed to work at compost facilities.

4.2 PERSONAL PROTECTIVE EQUIPMENT

Personal Protective Equipment (PPE) must be evaluated as to the level of protection
necessary for particular operating conditions and then made available to facility employees. The list
below includes the PPE typically used and/or required in a compost facility workplace.

• Leather shoes with hard soles

• Noise reduction protection is required in areas where extended exposure to
continuous high decibel levels are expected

• Disposable rubber latex or chemical resistant gloves for appropriate protection

Wallace Farm O&M Manual
Huntersville Site
21
• Dust filter masks

Following use, PPEs should be disposed or adequately cleaned, dried, and readied for
reuse.

4.3 MECHANICAL EQUIPMENT HAZARD PREVENTION

The loaders, bulldozer, dump trucks, grinder, screen, and windrow turner should be operated
with care, taking all necessary precautions. All safety equipment such as horns and lights should be
functional.

4.4 EMPLOYEE HEALTH AND SAFETY
Some general safety rules are as follows:

• Make sure that you understand the job that has to be done. Review the equipment
O&M Manual prior to attempting repairs/changes.

• Use common sense when attempting a job. Use the safest way to get the work done,
including using the proper equipment and tools.

• Use the buddy system in case of repair of mechanical equipment (have a co-worker
stand by).

• Keep the right attitude towards safety. Lack of awareness or a careless attitude can
lead to accidents.

• Make sure you know the locations of the first aid kit and fire extinguishers.
Understand how to use them.

4.4.1 Fire Extinguisher

Potential fire hazards at a compost facility are created from the build-up of fine dry dust
particles on and around operational motors and control panels. These build-ups can cause
overheating and potential fire if periodic equipment cleaning and maintenance are not practiced.
Portable fire extinguishers should be maintained in a state of readiness at the screen locations and on
each piece of moving equipment.

Wallace Farm O&M Manual
Huntersville Site
22

4.4.2 Physical Exposure
Facility personnel who may be physically exposed on-site should be kept aware of the health
aspects associated with the fluids, solids, and airborne constituents found at composting facilities.
Training concerning safe work practices around these potential exposures should include all
equipment, and proper disposal procedures for contaminated materials.

4.4.2.1 Bioaerosols

Bioaerosols are small particles containing microorganisms, and are of concern as are any
materials that may contain pathogens. Bioaerosols can be created during many facility operations,
including mixing, turning, and screening of composted materials. Once airborne, bioaerosols may
be inhaled or contact the eyes. Dirty hands also may result in inadvertent transmission to the mouth
or eyes.

Facility employees should refer to Sections 4.1 Personal Hygiene and 4.2 Personal Protective
Equipment for reminder information on Health and Safety.

4.4.2.2 Dust
Excessive dust can have an irritating effect on eyes and mucous membranes if proper PPE,
such as eye protective goggles and dust filter masks, are not worn by facility personnel in affected
areas. As discussed in Section 2.2, water can be placed on windrows for dust suppression. Goggles
and dust masks should be worn by staff regardless in “dusty” conditions.

Wallace Farm O&M Manual
Huntersville Site
23

4.5 - FACILITY EMERGENCY PHONE NUMBERS

EMERGENCY MEDICAL/FIRE
POLICE SERVICES: 911

FACILITY OWNER: Wallace Farm, Inc.
14410 Eastfield Road
Huntersville, NC 28078
Phone: [phone] Ext 17
Cell: [phone]

OPERATORS: Dale Cagle
Phone: [phone] Ext 20

Dean Lentx
Phone: [phone] Ext 19

Wallace Farm O&M Manual
Huntersville Site
24
5.0 CONTINGENCY PLANS

Contingency plans for unusual and adverse conditions are as follows:

5.1 EQUIPMENT BREAKDOWN

Wallace Farm has a full-time mechanic on staff who conducts regular equipment
maintenance. Sufficient storage of the feedstocks is provided to allow for routine maintenance
problems.
If the compost turner breaks down, loaders can be used while it is under repair. Wallace
Farm also maintains a good relationship with its vendors and can get equipment repaired quickly.
However, equipment can be rented as necessary to maintain operations.

5.2 AIR POLLUTION/ODORS

Composting is a controlled and constantly monitored process. Steps for minimizing odors
during composting and on the site are described below. Minimize means to reduce to the smallest
amount, extent, or degree reasonably possible.
One important operational procedure is maintaining aerobic conditions within the compost
piles through adjusting the porosity and moisture content. Oxygen levels will be monitored using an
oxygen meter to assure aerobic conditions exist.
Moisture levels in the compost windrows will be maintained in the 40 - 60% range for newly
created compost windrows and compost windrows within the PFRP period. Moisture will be tested
with a hand squeeze test when monitoring temperatures. Test results will be recorded with the
temperature results, on the same form, in parentheses. It also is important to keep temperature levels
between appropriate levels, maintaining PFRP temperatures as described in Section 2.7.
Temperatures must not be allowed to get above 160o F, which can slow down the composting
process and lead to odors.
Additionally, the carbon to nitrogen (C:N) ratio of initial mixes is to be greater than 20:1 to
minimize the release of nitrogen based odorous compounds such as ammonia. This ratio is achieved
through use of standard mass balance calculations using analytical data for feedstocks, as described
in Section 2.6. All feedstock constituent data should be updated periodically through laboratory

Wallace Farm O&M Manual
Huntersville Site
25
analyses, to assure the accuracy of these calculations. Nevertheless, mix samples should be pulled
periodically for carbon and nitrogen measurements by a lab, to verify that calculations are correct.
Additional steps will be taken to minimize odors include covering odorous windrows with a
layer of carbonaceous materials and placing potentially odorous materials in the center of windrows
during their construction.

5.3 NON-CONFORMING MATERIALS

Incoming feedstocks will be inspected upon arrival. Any non-conforming materials will be
rejected, or removed and disposed of following state regulations, including disposal in a permitted
landfill.

5.4 SPILLS

Spills of non-composted material will be cleaned up using a front-end loader and added to
active compost piles before beginning the PFRP treatment regimen.

5.5 FIRES

The local fire department will be called if buildings catch fire. If piles of material catch on
fire, the local fire department will be contacted, and a bulldozer will be used to separate the unburned
material from the burning material to prevent the fire from spreading. In case of fire anywhere at the
facility, the following must be contacted immediately, as follows:

Local fire department: call 911.

NCDENR Regional Environmental Senior Specialist
Currently: Hugh Jernigan 336-771-5093

Arrangements should be made with the fire department to provide immediate fire-fighting
service when needed.

Wallace Farm O&M Manual
Huntersville Site
26
5.6 PARTICULATES

Particulates are generally associated with overly dry compost piles. Potable water or water
from ponds on site can be used to increase moisture content and reduce particulates, as discussed in
Section 2.2.

5.7 NOISE

Equipment normally associated with farm operations and land clearing has been used on this
site for many decades and will continue to be used on the site. Reasonable levels of noise are
expected.

5.8 VECTORS
Vector attraction reduction takes place during composting. To meet vector attraction
reduction, materials are to be treated in an aerobic process for 14 days or longer, during which time
the temperature of compost shall be higher than 40 degrees Celsius (104 degrees F) and the average
temperature shall be higher than 45 degrees Celsius (113 degrees F). This approach is considered
very effective at controlling vectors.
Process modifications will be made, if required, to ensure these vector attraction reduction
requirements are met. This may include increasing the amount of wood material and cotton material
in the initial mix.
Further, Wallace Farm staff are to make visual observations for vectors.

5.9 UNUSUAL TRAFFIC CONDITIONS
Delivery schedules may be modified, as necessary, to minimize traffic impacts.

Wallace Farm O&M Manual
Huntersville Site
27
6.0 REPORTING

An annual report for the period July 1 to June 30 is submitted by August 1 of each year, using
the form provided by NC DENR. In addition, all windrow and monthly data sheets and semi-annual
product test data is submitted with the report. The following records will be maintained and available
for inspection by Mecklenburg County and the Division of Waste Management:

• Type and tons of materials received at the facility (dry weight)
• Origin of the materials
• Total tons of compost produced
• Total tons of compost used or disposed from the facility
• Monthly temperature monitoring sheets
• Product test results showing compliance with the Class A compost requirements

The monitoring requirements for Class A compost are as follows:
Parameter Unit Limit Foreign Matter % < or = to 6 Cadmium mg/kg dry wt. 39 Copper mg/kg dry wt. 1500 Lead mg/kg dry wt. 300 Nickel mg/kg dry wt. 420 Zinc mg/kg dry wt. 2800
Selenium mg/kg dry wt 36
Arsenic mg/kg dry wt 41
Mercury mg/kg dry wt 17 Pathogens (fecal coliform) MPN/g dry wt. < 1000 per g Total N % None Phosphorous % None Potassium % None

Wallace Farm O&M Manual
Huntersville Site
28
In addition to the above information, daily processing data, including temperature data
and quantity of material processed, will be maintained and available for inspection by the
Division of Waste Management.

7.0 PRODUCT MARKETING AND DISTRIBUTION PLAN
Wallace Farm is an established composting company, having been operating for many
years. As such, the marketing and distribution plan is to continue marketing and distributing
compost products as currently done, maintaining business practices, while modifying them from
time to time as circumstances warrant.

Wallace Farm O&M Manual
Huntersville Site
29

REFERENCES

Epstein (1997). The Science of Composting. Technomic Publishing Co., Inc., Lancaster,
Pennsylvania p. 340.

Wallace Farm O&M Manual
Huntersville Site
30

APPENDICES

Appendix A - Site Plan

Appendix B
- Site Signage

Appendix C - Row Data Record
- Windrow Data Recording Sheet
- Pit Mix Recording Sheet

Appendix D
- Compost Product Information

Appendix E
- Concrete Pit Construction Specifications

Appendix F
- New Compost Turner and New Grinder

Appendix G
- Odor Response Form

704-875-2975
Product Name:WFCO
Sample Date:9/8/14 12:00 PM
Receive Date:9/9/14
A & L Lab Number:74269
A & L Report Number:F14252-6012
Compost Parameters Method Reported as (units of measure)Test Results Test Results
Plant Nutrients:%, weight basis %, wet weight basis %, dry weight basis
Nitrogen TMECC 04.02-D Total N 0.79 1.04
Phosphorus TMECC 04.03-A P2O5 0.35 0.46
Potassium TMECC 04.04-A K2O 0.42 0.55
Calcium TMECC 04.05-CA Ca 1.22 1.61
Magnesium TMECC 04.05-MG Mg 0.35 0.46
Moisture Content TMECC 03.09-A %, wet weight basis
Organic Matter Content TMECC 05.07-A %, dry weight basis
pH TMECC 04.11-A pH units
Soluble Salts (electrical
conductivity EC 5 )TMECC 04.10-A dS/m (mmhos/cm)
Particle Size TMECC 02.02-B % < 9.5 mm (3/8 in.), dw basis
Stability Indicator (respirometry) Stability Rating:
CO2 Evolution TMECC 05.08-B mg CO2-C/g OM/day 1
mg CO2-C/g TS/day 1
Maturity Indicator (bioassay)
Percent Emergence TMECC 05.05-A average % of control
Relative Seedling Vigor TMECC 05.05-A average % of control
TMECC 07.01-B Fecal Coliform
TMECC 04.06 As, Cd, Pb, Hg,
Mo, Ni, Se, Zn
COMPOST TECHNICAL DATA SHEET
Wallace Farm LLC
Eric Wallace
14410 Eastfield Rd
Huntersville NC 28078-6636
PASS/FAIL: per US EPA Class A
standard, 40 CFR § 503.32(a) PASS
A & L Great Lakes Laboratories, Inc. 3505 Conestoga Drive Fort Wayne IN 46808
24.10
35.72
7.1
0.90
98.40
Select Pathogens
Very Stable
97
94
Trace Metals PASS/FAIL: per US EPA Class A
standard, 40 CFR § 503.13,
Tables 1 and 3.
PASS
Participants in the US Composting Council’s Seal of Testing Assurance Program have shown the commitment to test their compost
products on a prescribed basis and provide this data, along with compost end use instructions, as a means to better serve the needs of
their compost customers.
704-875-2975
Product Name:WFCO
Sample Date:9/8/14 12:00 PM
Receive Date:9/9/14
A & L Lab Number:74269
A & L Report Number:F14252-6012
Compost Parameters Method Reported as (units of measure)
Plant Nutrients:%, weight basis
Moisture Content TMECC 03.09-A %, wet weight basis
Organic Matter Content TMECC 05.07-A %, dry weight basis
pH TMECC 04.11-A pH units
Soluble Salts (electrical
conductivity EC 5 )TMECC 04.10-A dS/m (mmhos/cm)
Particle Size TMECC 02.02-B % < 9.5 mm (3/8 in.), dw basis
Stability Indicator (respirometry) Stability Rating:
CO2 Evolution TMECC 05.08-B mg CO2-C/g OM/day 1
mg CO2-C/g TS/day 1
Maturity Indicator (bioassay)
Percent Emergence TMECC 05.05-A average % of control
Relative Seedling Vigor TMECC 05.05-A average % of control
TMECC 07.01-B Fecal Coliform
TMECC 04.06 As, Cd, Pb, Hg,
Mo, Ni, Se, Zn
COMPOST TECHNICAL DATA SHEET
Wallace Farm LLC
Eric Wallace
14410 Eastfield Rd
Huntersville NC 28078-6636
24.10
A & L Great Lakes Laboratories, Inc. 3505 Conestoga Drive Fort Wayne IN 46808
Test Results
Not Reported
97
94
35.72
7.1
0.90
98.40
Very Stable
Select Pathogens PASS/FAIL: per US EPA Class A
standard, 40 CFR § 503.32(a) PASS
Trace Metals PASS/FAIL: per US EPA Class A
standard, 40 CFR § 503.13,
Tbl 1 d3
PASS
Participants in the US Composting Council’s Seal of Testing Assurance Program have shown the commitment to test their compost
products on a prescribed basis and provide this data, along with compost end use instructions, as a means to better serve the needs of
their compost customers.
704-875-2975
Product Name:WFCO
Sample Date:9/8/14 12:00 PM
Receive Date:9/9/14
A & L Lab Number:74269
A & L Report Number:F14252-6012
Compost Parameters Method Specification Requirements
pH TMECC 04.11-A Minimum 5.0 Maximum 8.5
Soluble Salts TMECC 04.10-A Maximum 5.0 dS/m (mmho/cm)
Moisture Content TMECC 03.09-A 30 - 60%, wet weight basis
Organic Matter Content TMECC 05.07-A 25 - 65 %, dry weight basis
Sieve Size (aggregate size)TMECC 02.02-B % dry weight passing through
3" Sieve 100%
1" Sieve minimum 90%
3/4" Sieve minimum 65%
1/4 " Sieve maximum 50%
Stability
Carbon Dioxide Evolution TMECC 05.08-B < 8 mg CO2-C / gram OM / Day
Maturity
Seed Germination TMECC 05.05-A > / = 80% (compared to control)
Trace Elements /
Heavy Metals TMECC 04.06 Meets US EPA Class A Standard
40 CFR § 503.13 PASS/FAIL
Pathogens TMECC 07.01-B
Fecal Coliform
< 1000 MPN / gram total solids
PASS / FAIL
Man-made Inerts TMECC 02.02-C < 1.0% Total Inerts (dry basis)
Laboratory Report Number: F14252-6012
Laboratory Sample Number 74269
Approved by: Gregory T. Neyman - Vice-President / COO
0.90
7.1
24.10
Wallace Farm LLC
Eric Wallace
14410 Eastfield Rd
Huntersville NC 28078-6636
COMPOST TECHNICAL DATA SHEET for NORTH CAROLINA DOT
A & L Great Lakes Laboratories, Inc. 3505 Conestoga Drive Fort Wayne IN 46808
Test Results
35.72
100.00
100.00
98.40
92.26
0.00
Participants in the US Composting Council’s Seal of Testing Assurance Program have shown the commitment to test their compost
products on a prescribed basis and provide this data, along with compost end use instructions, as a means to better serve the needs of
their compost customers.
1
97
PASS
PASS