NC0035211_Renewal (Application)_20200409

RECEN
April 9, 2020 APR 2 0 2020
NDDE0IDWRINPDES
Wren Thedford
NC DENR/DWR/NPDES Unit
1617 Mail Service Center
Raleigh,NC 27699-1617
Subject: Renewal Request for NPDES No.NC0035211
Shuford Yarns, LLC
Caldwell County
Dear Mr.Thedford:
Please find attached a completed renewal application for the subject facility. By submittal
of this application, Shuford Yarns, LLC is formally requesting to renew NPDES Permit No.
NC0035211 with a flow of 5,400 GPD. Please be advised that Shuford Yarns wishes to maintain
the current permitted levels of flow in order to respond to future manufacturing opportunities that
would require an increase in employment.
Upon review of this renewal application, should your or your staff have any questions or
concerns,please contact me at(828) 838-1682 or via email at igobble cr,shufordyarns.com
Sincerely,
411.
Jonathan S. o sole, CSP
Director of Environment and Safety
Attachments

Sludge Management Plan
Shuford Yarns, Dudley Shoals Facility
Sanitary Wastewater Treatment System
The Sanitary Wastewater Treatment System at the referenced facility, consisting of septic tank, dosing
facilities, distribution box, and surface sand filter treatment, generates a minimal amount of sludge.
When necessary, a contract sanitary waste hauler will be contacted to pump out the solids, and dispose
of them at a permitted waste treatment facility.
011709/2,02n
Name Date

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
Mail the complete application to:
N. C. DEQ / Division of Water Resources / NPDES
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit Number NC003521I
Please print or type.
1. Contact Information:
Owner Name Shuford Yarns LLC
Facility Name Dudley Shoals
Mailing Address 2815 1st Ave SW
City Hickory
State / Zip Code NC 28602
Telephone Number 828-838-1682 Main Contact: Jonathan Gobble
Fax Number
e-mail Address [e-mail]
2. Location of facility producing discharge:
Check here if same as above ❑ RECEIVE®
Street Address or State Road 5100 Burns Rd APR 2 0 2020
City Granite Falls NCDEQIDWRINPDES
State / Zip Code NC / 28630
County Caldwell
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name Water Tech Laboratories, Inc.
Mailing Address 5 Pinewood Plaza Dr.
City Granite Falls
State / Zip Code NC / 28630
Telephone Number 828-396-4444
Fax Number
4. Ownership Status:
Federal ❑ State ❑ Private ® Public ❑
Page 1 of 5 C-MI 6/17

' NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
5. Standard Industrial Classification (SIC) code(s): 3131
6. Number of employees: 80
7. Describe the treatment system List all installed waste treatment components with capacities,
describe the processes that generate wastewaters. If the space provided is not sufficient attach a
separate sheet of paper with the system description.
Facility consists of a septic tank, dosing, distribution box, and surface sand filter
treatment system, discharging directly to the river. Wastewater is primarily sanitary
sewage (domestic) from the facility. The only process water is a small amount of
blowdown from the facility's air compressors. Facility has a contract Operator in
Responsible Charge (ORC).
8. Is facility covered under federal effluent limitation guidelines? No ® Yes ❑
If yes, specify the category?
9. Principal product(s) produced: Yarn Manufacturing
Principal raw material(s) consumed: Polyester Fiber
Briefly describe the manufacturing process(es):
The Facility processes synthetic fiber, via the processes of carding, drawing, spinning, and
twisting, to create yarn.
Page 2 of 5 C-MI 6/17

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
10. Amount of principal product produced or raw material consumed
(List specific amounts consumed and/or units of production over the last three years)
Product Produced or Raw Material Product Produced or Raw Material
Consumed Consumed
(AVERAGE) (PEAK)
N/A-Facility's wastewater is sanitary
per Day sewage. No process waste.
per Month
per Year
11. Frequency of discharge: Continuous ❑ Intermittent
If intermittent:
Days per week discharge occurs: 5 Duration: 24 hrs/day (typical)
12. Types of wastewater discharged to surface waters only
Discharge Flow
(GALLONS PER DAY)
Sanitary - monthly average 80 employees x 25 gpd/e = 3,000 GPD
Utility water, etc. - monthly average Approximately 100 gpd (air compressor blowdown)
Process water - monthly average N/A
Stormwater-monthly average N/A-covered under a different permit, not
discharged to treatment system
Other-monthly average Cooling Towers/Air Washes discharge under a
Explain: different permit, not discharged to treatment system
Monthly Average 2,000 gpd to treatment system
total discharge (all types)
13. Number of separate discharge points: 1 Outfall Identification number(s) 001
14. Name of receiving stream(s) (Provide a map showing the exact location of each outfall, including
latitude and longitude):
Upper Little River- Catawba River Basin
Page 3 of 5 C-MI 6/17

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
15. Effluent Data [for new or proposed discharges]
Provide data for the parameters listed. Temperature and pH shall be grab samples,for all other parameters 24-hour
composite sampling shall be used. If more than one analysis is reported, report daily maximum and monthly average.
If only one analysis is reported, report as daily maximum.
NOTE:Permittees requesting renewal should complete the table ONLY for the parameters
currently monitored. Summarize the past 3 years of effluent data.
Parameter Daily Monthly Units of
Maximum Average Measurement
Biochemical Oxygen Demand (BOD5) 21.4 2.4 mg/L
Chemical Oxygen Demand (COD) N/A N/A
Total Organic Carbon N/A N/A
Total Suspended Solids 11.7 1.7 mg/L
Ammonia as N N/A N/A
Temperature (Summer) 26.0 21.5 Celsius
Temperature (Winter) 17.1 11.2 Celsius
pH 7.6 6.5 su's
Fecal Coliform (If sanitary waste is N/A N/A
present)
Total Residual Chlorine (if chlorine is N/A N/A
used)
16. List all permits, construction approvals and/or applications (check all that apply and provide permit
numbers or check none if not applicable):
Type Permit Number Type Permit Number
Hazardous Waste (RCRA) NESHAPS (CAA)
UIC (SDWA) Ocean Dumping (MPRSA)
NCG500321;
NPDES NCG 170225 Dredge or fill (Section 404 or CWA)
PSD (CAA) Other Air:7392G03
Non-attainment program (CAA)
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Discharge is sanitary sewage. No additional chemicals are added.
Page 4 of 5 C-MI 6/17

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
18. Is this facility located on Indian country? (check one)
Yes ❑ No
19. Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Jonathan S. Gobble Director-Environmental Health & Safety
Printed name of Person Signing Title
Id
°q0 94f -e)
Mylicant Dat
North Carolina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false
statement representation, or certification in any application, record, report, plan, or other document files or
required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or
monitoring device or method required to be operated or maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable
by a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section
1001 provides a punishment by a fine of not more than$25,000 or imprisonment not more than 5 years, or both,
for a similar offense.)
Page 5 of 5 C-MI 6/17