NC0006548_Permit Modification_20020520

NPDES DOCIMENT SCANNIN`: COVER SHEET
NC0006548
Wayne Farms / Dobson facility
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification)
Complete File
- Historical
Engineering Alternatives (EAA)
Plan of Action
Instream Assessment
(67b)
Speculative Limits
Environmental Assessment (EA)
Permit
History
Document Date:
May 20, 2002
Thins document ins printed on reuse paper - ignore any
content on the re'rerae side

Michael F. Easley, Govemor
N A T
GWilliam G. Ross Jr., Secretary
7North Carolina Department of Environment and Natural Resources
r Gregory J. Thorpe, Ph.D.
—I Gregory
Director
Division of Water Quality
Mr. Rob Poindexter
Wayne Farms, LLC
P.O. Box 383
Dobson, North Carolina
27107
May 20, 2002
Subject: Major Modification of NPDES Permit NC0006548
Wayne Farms / Dobson
Surry County
Dear Mr. Poindexter.
The subject individual NPDES permit issued on June 7, 1999 has been modified as per your request. Please find attached the
modified sections of this permit, and replace the old pages with the modified pages. This permit modification is issued pursuant
to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between North Carolina
and the U.S. Environmental Protection Agency dated May 9,1994 (and as subsequently amended).
The following modifications have been made to your permit:
• An additional effluent sheet (A.2) with a permitted flow of 0.70 MGD has been added. The facility will be subject to these
new limits after receiving an Authorization to Operate at 0.70 MGD. Until such time, the facility must continue to comply
with the 0.6 MGD effluent sheet. The Division is currently reviewing the facility's request for a re -rating of the WWTP from
0.6 to 0.7 MGD design capacity.
• Water quality based limits for ammonia and toxicity testing were recalculated for the new effluent page, based on the change
in instream waste concentration at the higher design flow. Conversely, mass -based limits for BOD, TSS, and Oil and Grease
are unchanged on both effluent pages, since there has been no change in production.
Please note that proposed revisions to the EPA Federal Effluent Guidelines for Meat and Poultry Products (40 CFR 432) were
noticed in the Federal Register on 2/25/02. The proposed revisions include new guidelines for large poultry processing
operations under Subpart K, which establish effluent limitations for ammonia, BOD5, fecal coliform, oil and grease, total
nitrogen, total phosphorus, and TSS. It is recommended that the permittee review the proposed changes, which will be
implemented (if finalized) in the next permit renewal in 2003.
If any parts, measurement frequencies or sampling requirements contained in this permit modification are unacceptable to you,
you have the right to an adjudicatory hearing upon written request within thirty (30) days following receipt of this letter. This
request must be in the form of a written petition, conforming to Chapter 150B of the North Carolina General Statutes, and filed
with the office of Administrative Hearings, 6714 Mail Service Center, Raleigh, North Carolina 27699-6714. Unless such a
demand is made, this permit shall be final and binding.
Please take notice that this permit is not transferable except after notice to the Division. The Division may require modification
or revocation and reissuance of the permit. This permit does not affect the legal requirements to obtain other permits which may
be required by the Division of Water Quality or permits required by the Division of Land Resources, Coastal Area Management
Act, or any other Federal or Local governmental permits may be required. If you have any questions or need additional
information, please contact Mr. Tom Belnick, telephone number [phone], extension 543.
Sincerely,
ORIGINAL SIGNED BY
SUSAN A. WILSON
Gregory j. Thorpe, Ph.D.
cc: Central Files
NPDES File
Winston Salem Regional Office, Water Quality
Point Source Compliance Enforcement Unit
Aquatic Toxicology Unit
p.a
N. C. Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 h 41
[phone] Customer Service 1 800 623-7748 WI)

Permit NC0006548
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards
and regulations promulgated and adopted by the North Carolina Environmental Management
Commission, and the Federal Water Pollution Control Act, as amended,
Wayne Farms, LLC
is hereby authorized to discharge wastewater from a facility located at
Wayne Farms
1018 East Atkins Street
Dobson
Surry County
to receiving waters designated as the Fisher River in the Yadkin -Pee Dee River Basin
in accordance with effluent limitations, monitoring requirements, and other
conditions set forth in Parts I, II, III and IV hereof.
This permit shall become effective July 1, 2002.
This permit and authorization to discharge shall expire at midnight on December 31, 2003.
Signed this day May 20, 2002.
ORIGINAL SIGNED BY
SUSAN A. WILSON
Gregory J. Thorpe, Ph.D., Acting Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0006548
SUPPLEMENT TO PERMIT COVER SHEET
Wayne Farms, LLC, is hereby authorized to:
1. Continue to operate an existing 0.60 MGD wastewater treatment facility with the
following components:
• Primary & secondary rotary screens
• Dissolved air floatation unit with chemical addition
• Aerated lagoon
• Biological nitrification
• Final clarifier
• Chlorination
• Dechlorination
• Sludge storage lagoon
• Continuous flow meter
The facility is located at Wayne Farms - Dobson Plant on 1018 East Atkins Street,
Dobson, in Surry County.
2. After receiving an Authorization to Operate from the Division, operate a 0.70 MGD
wastewater treatment facility; and
3. Discharge from said treatment works at the location specified on the attached map
into the Fisher River, classified C waters in the Yadkin -Pee Dee River Basin.

Permit NC0006548
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (0.60 MGD)
Beginning on the effective date of this permit and lasting until receipt of an Authorization to Operate
above 0.60 MGD or permit expiration, the Permittee is authorized to discharge treated wastewater from
Outfall 001. Such discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT
CHARACTERISTICS
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
Monthly Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample Location'
Flow
0.60 MGD
Continuous
Recording
Effluent
BOD, 5-day, 20°C
345 pounds/day
690 pounds/day
31Week
Composite
Effluent
Total Suspended Solids
465 pounds/day
930 pounds/day
3/Week
Composite
Effluent
Oil and Grease
150 pounds/day
300 pounds/day
3/Week
Grab
Effluent
NH3 as N
20.0 mg/L
30.0 mg/L
3/Week
Composite
Effluent
Total Residual Chlorine
28 pgIL
3/Week
Grab
Effluent
Fecal Coliform
(geometric mean)
200 / 100 ml
400 / 100 ml
3/Week
Grab
Effluent
Temperature
3/Week
Grab
Effluent
pH2
3/Week
Grab
Effluent
Total Nitrogen
(NO2+NO3+TKN)
Weekly
Composite
Effluent
Total Phosphorus
Weekly
Composite
Effluent
Chronic Toxicity3
Quarterly
Composite
Effluent
Temperature
Monthly
Grab
Upstream & Downstream
Dissolved Oxygen
Monthly
Grab
Upstream & Downstream
Notes:
1. Upstream = at NCSR 2258 bridge. Downstream = at NCSR 1100 bridge.
2. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
3. Chronic Toxicity (Certodaphnia) limit at 3.9% with testing in January, April, July, and October (see
Special Condition A (3)).
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0006548
A. (2) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (0.70 MGD)
Beginning upon receipt of an Authorization to Operate above 0.6 MGD and lasting until permit
expiration, the Permittee is authorized to discharge treated wastewater from Outfall 001. Such
discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT
CHARACTERISTICS
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
Monthly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample Locations
Flow
0.70 MGD
Continuous
Recording
Effluent
BOD, 5-day, 20°C
345 poundslday
690 pounds/day
31Week
Composite
Effluent
Total Suspended Solids
465 pounds/day
930 pounds/day
3/Week
Composite
Effluent
Oil and Grease
150 pounds/day
300 pounds/day
3/Week
Grab
Effluent
NH3 as N
17.5 mg/L
26.2 mg/L
31Week
Composite
Effluent
Total Residual Chlorine
28 pgl L
3IWeek
Grab
Effluent
Fecal Coliform
(geometric mean)
2001100 ml
400 / 100 ml
3NUeek
Grab
Effluent
Temperature
31Week
Grab
Effluent
pH2
31Week
Grab
Effluent
Total Nitrogen
(NO2+NO3+TKN)
Weekly
Composite
Effluent
Total Phosphorus
Weekly
Composite
Effluent
Chronic Toxiciity3
Quarterly
Composite
Effluent
Temperature
r Monthly
Grab
Upstream & Downstream
Dissolved Oxygen
Monthly
Grab
Upstream & Downstream
Notes:
1. Upstream = at NCSR 2258 bridge. Downstream = at NCSR 1100 bridge.
2. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
3. Chronic Toxicity (Ceriodaphnia) limit at 4.5% with testing in January, April, July, and October (see
Special Condition A. (4)).
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0006548
SUPPLEMENT TO EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
SPECIAL CONDITIONS
A. (3) CHRONIC TOXICITY PERMIT LIMIT (Quarterly) at 0.60 MGD
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 3.9 %.
The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in
the "North Carolina Ceriodaphnta Chronic Effluent Bioassay Procedure," Revised February 1998, or
subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions. The tests will be performed during the months of
January, April, July, and October. Effluent sampling for this testing shall be performed at the NPDES
permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the
permit limit, then multiple -concentration testing shall be performed at a minimum. in each of the two
following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the
highest concentration having no detectable impairment of reproduction or survival and the lowest
concentration that does have a detectable impairment of reproduction or survival. The definition of
"detectable impairment," collection methods. exposure regimes, and further statistical methods are
specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the parameter
code TGP3B for the pass/fail results and THP3B for the Chronic Value. Additionally, DWQ Form AT-3
(original) is to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of Water Quality
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later
than 30 days after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate
signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if
chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is
required, the permittee will complete the information located at the top of the aquatic toxicity (AT) test
form indicating the facility name, permit number, pipe number, county, and the month/year of the report
with the notation of "No Flow" in the comment area of the form. The report shall be submitted to the
Environmental Sciences Branch at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring
will be required during the following month. Should any test data from this monitoring requirement or
tests performed by the North Carolina Division of Water Quality indicate potential impacts to the receiving
stream, this permit may be re -opened and modified to include alternate monitoring requirements or
limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control
organism survival, minimum control organism reproduction, and appropriate environmental controls,
shall constitute an invalid test and will require immediate follow-up testing to be completed no later than
the last day of the month following the month of the initial monitoring.

Permit NC0006548
A. (4) CHRONIC TOXICITY PERMIT LIMIT (Quarterly) at 0.70 MGD
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 4.5 %.
The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in
the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or
subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions. The tests will be performed during the months of
January, April, July and October. Effluent sampling for this testing shall be performed at the NPDES
permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the
permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the two
following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the
highest concentration having no detectable impairment of reproduction or survival and the lowest
concentration that does have a detectable impairment of reproduction or survival. The definition of
"detectable impairment," collection methods, exposure regimes, and further statistical methods are
specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the parameter
code TGP3B for the pass/fail results and THP3B for the Chronic Value. Additionally, DWQ Form AT-3
(original) is to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of Water Quality
1621 Mail Service Center
Raleigh, North Carolina 27699-1621.
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later
than 30 days after the end of the reporting period for which the report is made.
Test data shall be complete. accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate
signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if
chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is
required, the permittee will complete the information located at the top of the aquatic toxicity (AT) test
form indicating the facility name. permit number, pipe number, county, and the month/year of the report
with the notation of "No Flow" in the comment area of the form. The report shall be submitted to the
Environmental Sciences Branch at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring
will be required during the following month. Should any test data from this monitoring requirement or
tests performed by the North Carolina Division of Water Quality indicate potential impacts to the receiving
stream, this permit may be re -opened and modified to include alternate monitoring requirements or
limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control
organism survival, minimum control organism reproduction, and appropriate environmental controls,
shall constitute an invalid test and will require immediate follow-up testing to be completed no later than
the last day of the month following the month of the initial monitoring.

NORTH CAROLINA
SURRY COUNTY
AFFIDAVIT OF PUBLICATION
Before the undersigned, a Notary Public of said County and State, duly
commissioned, qualified and authorized by law to administer oaths,
personally appeared George W. Summerlin who being first duly
sworn, deposes and says: that he (she) is Publisher
(Publisher or other officer or employee authorized to make affidavit) of
MOUNT AIRY NEWSPAPERS, INC., engaged in the publication of a
newspaper known as MOUNT AIRY NEWS, published, issued, and
entered as periodicals class mail in the city of Mount Airy in said County
and State; that he (she) is authorized to make this affidavit and sworn
statement; that the notice or other legal advertisement, a true copy of
which is attached hereto, was published in MOUNT AIRY NEWS on the
following dates:
March 10, 2002
and that the said newspaper in which such notice, paper, document or
legal advertisement was published was, at the time of each and every
such publication, a newspaper meeting all of the requirements and
qualifications of Section 1-597 of the General Statutes of North Carolina
and was a qualified newspaper within the meaning of Section 1-597 of
the General Statutes of North Carolina.
This 1 9 day of March
LC/ /
Si • nature of person making affidavit
, 2002
Sworn to and subscribed before me, this 1 9 day of
March
Notary Public
My Commission expires:
August 17, 2004
, 2002
CLIPPIN
LEGA
ADVERTISE
ATTACHED
FPUBLIC NOTICE
STATE OF NORTH
CAROLINA
ENVIRONMENTAL
MANAGEMENT COM-
MISSIONMPDES Unit
1617 Mail Service
Raleigh, NC
27699-1617
Notification of Intent
to Issue a NPDES
Wastewater Permit'
On the basis of through
staff review and appli-
cation'of NC General
Statute 143.21. Public
law 92-500 and other
lawful standards and
regulations, the North
Carolina Enyif9nntental
Manage irneni. Commis-
March 10, 2002-9B
LEGALS
sion proposes to issue
a National Pollutant
Discharge Elimination
System (NPDES)
wastewater discharge
permit to the person(s)
listed below effective
45 days from the pub-
lish date of this notice.;
Written comments re-
garding the proposed
permit will be accepted
until 30 days after the
publish date of this no-
tice. All comments re-
ceived prior to that
date are considered In
the final determinations
regarding the proposed
permit. The Director of
the NC Division of Wa
ter Quality may decide
to hold a public meet-
ing for the ' proposed
permit should the DM-
sion receive a signiff
cant degree of public
interest.
Copies of the draft per-
mit and other support-
ing information on file'
used to determine con-
_
dition$ present in the
draft pepyailaF t
ble upon t •,'no*4 and .'
;paymentvt off'
reproduction ' Mad e
comments andior re-
quests for information
to the NC Division of
Water Quality ,at the
above addressor cal
Ms. Christie Jackson at.
[phone], exten-
sion 5381. _ Plc ' e in-
clude the NPDES per -
number in y
l cmitommunication: Inteanr: .
ested persons may al-
so visit the Division of
Water Quality at 512 N.
Salisbury Street. Ra
leigh, NC 27604-1148
between the hours of
8.00 arn. and 5:00
p.m. WI review informa- '
Lion on file.
NPDES Permit Num-
ber NC0006548.
WAYNE FARMS, LLC,
P.O. BOX 383, DOB -
SON, NC 27017 has
applied tor a Modifica-
tion fora facility locat-
ed in $URFIY County
discharging; treated
wastewater into FISH-
ER RIVER in the YAD-
KIN-PEE-DEE ,River
Basin. Currently TRC
are water quality limit-
ed. This discharge may
affect future allocations
in this portion of the re-
ceiving stream.
'March10, 2002

R-c-r
NCDENR / DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
Wayne Farms, LLC
NPDES No. NC0006548
aci 'ty Information
(1.) Facility Name:
Wayne Farms
(2.) Permitted Flow,MGD:
0.60 MGD
requesting 0.70
(6.) County:
Surry
(3.) Facility Class:
III
(7.) Regional Office:
Winston-Salem
(4.) Facility Status:
Existing
(8.) USGS Topo Quad:
B16NW
(5.) Permit Status:
MajMod
(9) USGS Site:
Dobson
{ i z r r
in�i'mactrstcs
(1.) Receiving Stream:
Fisher River
(2.) Subbasin:
030702
(8.) Drainage Area (mi2):
109
(3.) Index No.:
12-63-9
(9.) Summer 7Q10 (cfs)
23
(4.) Stream Class:
C
(10.) Winter 7Q10 (cfs):
34
(5.) 303(d) Listed:
NO
(11.) 30Q2 (cfs):
48
(6.) 305(b) Status:
NA
(12.) Average Flow (cfs):
141
(7.) Use Support:
(13.) IWC (%):
3.9% @ 0.6
4.5% @ 0.7
Conditions Incorporated into Permit Modification
oposec�'Cond tions
Paameters? Affecteds
- Basis ;for 1Condit ni (s�
Add phased flow limit of 0.7
MGD to new effluent sheet A
(2).
Flow
Effluent Sheet A (2)
Per flow increase request and
flow justification.
Add phased WQ-based limit
for 0.7 MGD flow to new
Effluent Sheet A (2).
NH3
Effluent Sheet A (2)
WQ-based limits were
recalculated for new flow.
Add phased toxicity test limit
for 0.7 MGD flow to new
Effluent Sheet A(2) and add
new Special Condition A (4)..
Chronic Toxicity
Effluent Sheet A (2)
Special Condition A (4)
Effluent test concentration
was recalculated for new flow.
Renumber Special Condition
A (2) to Special Condition
A(3) .
Special Condition A (2)
Reorder based on addition of
new Effluent Sheet A (2) .

NPDES PERMIT FACT SHEET
Page 2
Wayne Farms LLC
NPDES No. NC0006548
Change language to reflect
Effluent Sheet A (1)
Facility cannot move to 0.7
this sheet will be effective
MGD phased limit until plant
until permit expiration or
re -rating is approved by
until facility receives an
Division.
Authorization to Operate at
0.7 MGD.
PROJECT NOTES
Summary
• This is a major modification request to increase permitted flow from 0.6 to 0.7 MGD for a
poultry processor. There is no current plan to increase production. The flow request is
based on recent water use increases in the processing plant in order to comply with "zero
tolerance" bacteria standards established by the USDA in 1997. To comply with USDA, the
facility has increased the water volume used to wash birds from 8.0 to 9.3 gals/bird,
resulting in additional wastewater discharge volume. At 110.000 birds/day, the additional
water generated is 143,000 gpd. The facility has implemented several water use reductions
and flow restricting devices in the processing plant. In addition, the facility has
implemented wastewater recycle procedures to reduce potable water use. Despite these
efforts, the wastewater discharge has steadily increased from annual averages of 0.42 MGD
(1999) to 0.52 MGD (2000) to 0.56 MGD (2001), and there have been a few monthly average
flow limits violations in 2001.
• The discharge is 100% industrial, with domestic wastewater piped to city sewer. The
facility is listed as a MINOR industrial. The facility discharges via Outfall 001 to Fisher
River (Class C) in .the Yadkin River Basin, which is not listed as impaired in the 2000 303(d)
list. Per 1998 Basin Plan, there are no impaired streams in this subbasin (030702). The
Basin Plan reports that sedimentation is evident in Fisher River, although water quality
generally remains good, and a Good bioclassification was assigned based on
macroinvertebrate data. There is significant flow in Fisher River (s7Q10= 23 cfs), resulting
in an instream wastewater concentration of 3.9% (at 0.6 MGD) and 4.5% (at 0.7 MGD).
Engineering Alternatives Analysis (EAA) Review
• The facility submitted an EAA with their major modification request. For the additional
flow, the facility evaluated connection to a PO'IW, land -based disposal, wastewater reuse,
as well as additional direct discharge. The direct discharge option was the most feasible.
The facility has been able to reduce wastewater discharge through water
conservation/reuse efforts, but is limited in additional wastewater reuse efforts within the
process area due to USDA restrictions. The facility has <2 acres of available land onsite for
land application, and the Town of Dobson has inadequate capacity to handle the Wayne
Farm discharge. Based on these factors, the Division concurs with the EAA conclusion.
Permitting Changes
• Flow. An additional effluent sheet (A.2) was prepared for the flow increase to 0.7 MGD. The
0.7 MGD effluent sheet will become effective after the facility receives an Authorization to
Operate at 0.7 MGD from the Division. The facility submitted a re -rating request from 0.6
to 0.7 MGD with the modification request.
• Effluent Guideline Limits. At expanded flow, leave technology -based mass limits
unchanged (BOD, TSS, O&G). Thus, there will be no increase in BOD loading to the
receiving stream. Note that these limits were based on 1977 proposed guidelines for
poultry. The EPA recently (1/30/02) signed proposed revisions to the Meat and Poultry
Products Effluent Guidelines, which will be published in Federal Guidelines as proposed
revisions. The status of these revisions will need to be considered during the next permit
renewal.
• Water Quality -Based Limits. At expanded flow, adjust water quality -based limits for NH3
and chronic toxicity to reflect new instream waste concentration.
Page 2
Version: February 20, 2002

NPDES PERMIT FACT SHEET Wayne Farms LLC
Page 3
NPDES No. NC0006548
DMR Data.
• Effluent Chemical/Physical Data. For the calendar year 2001, the facility was compliant
with mass limits for BOD, TSS, and O&G. Monthly average flow ranged from 0.46-0.66
MGD, NH3-N ranged from 0.1-4 mg/1; TN ranged from 38-299 mg/1; and TP ranged from
0.8-12 mg/1.
• Effluent Toxicity Data. The facility has passed 16 of 16 quarterly chronic toxicity tests
between 1998-2001.
• Instream Data. There were no reported exceedances of the instream dissolved oxygen
standard (5 mg/1) between 2000-01. The lowest reported downstream dissolved oxygen
values in 2000 and 2001 were 6.2 mg/land 6.3 mg/1, respectively.
• Compliance Data. The facility has had two violations of the monthly average flow limit
during 2001.
Page 3
Version: February 20, 2002

NPDES PERMIT FACT SHEET Wayne Farms LLC
Page 4 NPDES No. NC0006548
Proposed Schedule for Permit Issuance
Draft Permit to Public Notice:
Permit Scheduled to Issue:
State Contact
3/13/02
4/26/02
If you have any questions on any of the above information or on the attached
permit, please contact Tom Belnick at [phone], extension 543.
Copies of the following are attached to provide further information on the permit
development:
• Draft Modification
NPDES Recommendation by:
S :AL
ature
2-2(-O
Date
Regional Office Comments
Regional Recommendation
Signature
Reviewed and accepted by:
Date
Regional Supervisor:
Signature
Date
Signature
Date
NPDES Unit Supervisor:
Page 4
Version: February 20, 2002

03/04/2002 09
Draft Pew
permit Sche
State Cont
If you have
permit, ple
Copies of
developme
•
3367714630
FACT SHEET 1!
edule for Permit Issues
o Public Notice:
uled to Issue:
t
y questions on any of th
e contact Torn Bcinick at
following are attached t
Modification
DIV
ce
3/13/02
4/26/02
above infon
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WATER QUALiT
1
4ayne F
DirS No_ NC
ration or on ttathed
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provide further informatio
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PAGE 02/02
LLC
06548
NPDES Re
mmendation by:
, t .
Signature
IA
Date
02__
Re • ional 0
ce Comments
5,0 414s ,va Pdoaa,s4 w? 7-H 410,0 a eio ode D f c-/c"r 7747,1,
Regional 4oininen4ation
ffA-��
Sig .ature - ------
--
te___
Reviewed
ted bv:
Regional S
rvisor:
Si 9, attire
Date
NFDesS Unit
Supervisor:
Signature
Date
Page 4
V ion; February 20, 2002

Division of Water Quality Jn Ulg-e )-(AA-)
February 21, 2002
MEMORANDUM
To: Wes Hare, WSRO
Susan Wilson, NPDES Unit
Through: NA
From: Tom Belnick, NPDES Unit
Subject: Internal Draft Major Mod
Wayne Farms; NC0006548
Hello folks- Please let me know if you have any comments on this internal draft major modification.
Briefly, this is a flow increase from 0.6 to 0.7 MGD, to handle additional water usage rather than
production increases. Mass limits for BOD/TSS/O&G remain unchanged, while WQ-based limits for
NH3 and toxicity were recalculated for the new flow. The facility is also trying to get a re -rating of the
facility to 0.70 MGD, which will be handled separately. I hope to get this draft out to public notice for
March 13, so I'll need any comments back by Wednesday March 6`h. .
Thanks all.
0- - 0'04-5 40 o'J CAW-`( 714113i
(pm, (oleI0S Vou
\to, per- t (PJ 11.LAc1 CnJ - i f

Whole Effluent Toxicity Testing Self -Monitoring Summary January 18, 2002
FACILITY REQUIREMENT
YEAR JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
W.P. Ballard and Company -Durham Perm chr lim: 90% 1998 — — — — — — — — — —
NC0086720/001 Begin:2/1/2000 Frequency: Q Jan Apr Jul Oct + NonComp:Single 1999 — — — — — — — — — — —
County: Durham Region: RRO Subbasin: NEU01 2000 — — — N -- — N — — N — —
PF: 0.014 Special 2001 N — — N — — N — — N —
7Q10: 0.0 IWC(%):100 Order: 2002
Wade Hampton Club Perm chrlim: 34% 1998 — — Pass — — Fail Pass — Pass — — Pass
NC00625531001 Begin:3/1/1998 Frequency: Q P/F + Mar Jun Sep Dec + NonComp:Single 1999 — — Pass — — Pass — — Pass — — Pass
County. Jackson Region: ARO Subbasin: SAVO2 2000 — Pass — Pass — — Pass — — Pass
PF: 0.125 Special 2001 — -. Pass — — Pass -- — Pass
7Q10: 0.37 IWC(%):34 Order: 2002
Wake Forest WWTP Penn chr lim: 53%; if pf 6MGD chr lim 12% 1998 — Pass — — Pass — — Pass — Pass
NC0030759/001 Begin:12/1/2000 Frequency: Q Feb May Aug Nov + NonComp:Singlc 1999 — Pass — — Pass — — Pass Pass — NR(Pass Pass
County. Wake Region: RRO Subbasin: NEU02 2000 — Pass — — Pass — — Pass — — Pass —
PF: 2.4 Special 2001 — Pass — — Pass — — Pass — — Pass
7Q10: 67 IWC(%)5.3 Order: 2002
Wallace WWTP Penn chr lim: 27% 1998 — — Pass — -- Fall Pass — Pass -- — P355
NC0020702/001 Bcgin:9/1/1996 Frequency: Q P/F + Mar Jun Sep Dcc NonComp:Single 1999 -- Fail Fail Pass Pass — — Late Late Lale Pass
County: Duplin Region: WIRO Subbasin: CPF22 2000 — — Pass — — Pass — — Pass — — NR/Pass
PF: 1.0 Special 2001 — _. Pass — — Pass — — Pass — —
7Q10:420 IWC(%)2053 Order: 2002
Wallace WWTP Penn chr lim: 90%
NC0003450/001 Begin:11/1/1999 Frequency: Q Jan Apr Jul Oct
County: Dttplin Region: WIRO Subbasin: CPF22
PF: 4,42 Special
7Q10: 0.09 IWC(%)98.70 Order.
+ NonComp:Singlc
1998 — — — — -- — — — — —
1999 — — — — — — -- — — —.
2000 -- — — — — — I
2001 1 -- — -- ._ NR/FI
2002
Ward Transformer Co. Inc. Pcnn chr lim: 90%
NC0045608/001 Begin:811/1999 Frequency: Q P/F + Jan Apr Jul Oct
County: Wake Region: RRO Subbasin: NEU02
PF: 0.05 Special
7Q10: 0.0 IWC(%):100 Omer:
NonComp:Singlc
1998 Late Fail
1999 Pass 2000 NRILate Pass
2001 Pass --
2002
Pass
Pass — — Fail
Pass — Pass
Pass — — Pass
Pass — — Pass
Fail
Pass Pass
Pass
Pass
Pass
Warren Co. WWTP Penn chr lim: 76% 1998 — Pass
NC0020834/001 Begin:2/1/2001 Frequency: Q Mar Jun Sep Dec + NonComp: Single 1999 — — Pass
County. Warren Region: RRO Subbasin: TAR04 2000 — — Pass
PF: 2.0 Special 2001 — — NR/Pass
7Q10: 1.0 IWC(%):76.0 Orden 2002
Pass —• — Pass — Pass
— Fail Pass — Fail Pass — Pass
— — Pass — — Pass — — Pass
— — NR/Pass — — NR/Pass — —
Washington WWTP Pctm24hracp/flim: 90Y.1thd Y 1998 —
NC0020648/001 Begim5/1/2000 Frequency: Q P/F + Feb May Aug Nov + NonComp:Singlc 1999 —
County: Bcaufon Region: WARO Subbasin: TAR07 2000 —
PF: 3.2 Special 2001 —
7Q10: Tidal IWC(%):NA Order: 2002
Pass — — Pass — — Pass — — Pass
Pass — — Pass — — Pass — — Pass
Pass — — Pass — Pass -- — Pass
Pass — — Pass — Pass — — Pass
Wayne Farms -Dobson Plant Penn chr km: 3.9%
NC0006548/001 Begin:7/1/1999 Frequency. Q P/F + Jan Apr Jul Oct
County: Suny Region: WSRO Subbasin: YADO2
PF: 0.6 Special
7Q10: 23 IWC(%)3.9 Order:
+ NonComp: Single
1998 Pass — — Pass — — Pass — — Pass — —
1999 NR/Pass — — Pass — — Pass — •— Pass — —
2000 Pass — — Pass — — Pass — — Pass
2001 Pass — — Pass — Pass Pass
2002 -
Waynesville WWTP Pccm chr lim: 9e/. 1998 — Pass — — Pass — Pass — -- Pass
NC0025321/001 Begin:2/1/1997 Frequency: Q P/F + Feb May Aug Nov NonComp:Singlc 1999 — Pass — — Pass — — Pass — — Fail
County, Haywood Region: ARO Subbasin: FRB05 2000 >18 Pass — — Pass — —• Pass — — Pass
PF: 6.0 Spcial 2001 — Pass — — Pass — — Pass — — Pass
7Q10: 95.0 I WC(%):8.91 Order. 2002
>18
Weldon WWTP Perm 24hr p/f ac lim: 90%
NC0025721/001 Begin:6/1/1997 Frequency: Q + Jan Apr Jul Oct
County. Halifax Region: RRO Subbasin: ROA08
PF: 1.2 Spo i.l
7Q10: 1000 1 W C(%):0.19 Order:
+ NonComp:Single
1998 Pass — — Fail
1999 Pass — — Pass
2000 Pass — — Pass
2001 Pass — — Pass
2002
Pass
Pass — — Pass
Pass -- Pass
Pass -- — Pass
Pass — — Pass
Y Pre 1998 Data Available
LEGEND:
PERM = Permit Requirement LET = Administrative Letter - Target Frequency = Monitoring frequency: Q- Quarterly; M- Monthly; BM- Bimonthly; SA- Semiannually; A- Annually; OWD- Only when discharging; D- Discontinued monitoring requirement
Begin = First month required 7Q10 = Receiving stream low flow criterion (cfs) + = quarterly monitoring increases to monthly upon failure or NR Months that testing must occur - ex. Jan, Apr. Jul. Oct NonComp - Current Compliance Requirement
PF = Permitted flow (MOD) I C'/. = lnstream waste concentration P/F = Pass/Fail test AC = Acute CHR = Chronic
Data Notation: f - Fathead Minnow; • - Ceriodaphnia sp.; my - Mysid shrimp; ChV - Chronic value; P - Mortality of stated percentage at highest concentration; at - Performed by DWQ Aquatic Tox Unit; bt - Bad test
Reporting Notation: -- = Data not required; NR - Not reported Facility Activity Status: 1 - Inactive. N - Newly Issucd(To construct): H - Active but not discharging; t-More data available for month in question; • = ORC signature needed
48
I

DMR Review:
Facility:
NC00
Preparer:
Date:
EFFLUENT-001
Wayne Farms
6548
Tom Belnick
2/20/02
Month
Eff
AvgQ
MGD
Eff
Avg BOD
Ibs/d
Eff
AvgNH3
mg/I
Eff
AvgTSS
Ibs/d
Eff
AvgFecal
#/100m1
Eff
AvgTN
mg/I
Eff
AvgTP
mg/I
Eff
AvgO&G
Ibs/d
Dec-01
0.47
34
0.41
43
2
42
6
26
Nov-01
0.46
21
0.86
35
1
63
2
24
Oct-01
0.52
36
0.2
42
2
47
4
30
Sep-01
0.57
52
0.45
84
2
42
0.8
26
Aug-01
0.66
19
0.13
24
2
38
6
28
JuI-01
0.64
39
0.17
45
3
51
12
28
Jun-01
0.59
29
0.23
31
1
299
12
27
May-01
0.6
88
4
138
5
72
12
26
Apr-01
0.53
80
0.6
115
2
58
12
35
Mar-01
0.57
120
0.22
140
2
63
8
53
Feb-01
0.56
126
0.23
110
4
58
8
26
Jan-01
0.55
162
4
190
8
55
8
27
CurrentLimits:
0.6
345
20
465
200
NL
NL
150
ProposedLimits:
0.7
345
17.5
465
200
NL
NL
150

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U.S. EPA > Water > Water Science > ELGs > Mcat & Poultry Products
wysiwyg://13/http://www.epa.gov/ost/guide/mpi
U.S. Environmental Protection Agency
Recent Additions I Contact Us i Print Version Search:
EPA Home > Water > Water Science > Effluent Guidelines > Meat and Poultry Products
Meat and Poultry Products (MPP)
January 2002
Summary
GO
Qtioo syttloto
4,0
�U 6 r eAt vel
1h
The Meat and Poultry Products (MPP) category consists of facilities which are
engaged in the slaughter of animals and the processing of meat or poultry into
products, including meat cuts, sausage, hams, canned meats and partially cooked
products such as chicken nuggets. This industry also includes the rendering of meat
and poultry by-products into edible and inedible products such as pet or animal feed.
The meat sector includes facilities that slaughter or further process meat and includes
rendering of by-products when done on -site at the slaughtering or processing facility.
The poultry sector includes facilities that process chicken, turkey and fowl which
includes small game such as rabbit and also includes rendering when done on -site at
a slaughtering or processing facility. The MPP category also applies to stand alone
rendering facilities, also referred to a independent renderers.
The current MPP effluent guidelines regulation subdivides the meat slaughter and
processing industry into ten subcategories (including independent rendering). Four
subcategories apply to facilities that slaughter the animals and do varying amounts
rendering and further processing at the same location. Five subcategories apply to
facilities that only do further processing of meat, e.g. making sausages, hams or cuts.
One of the five further processing subcategories applies to small further processors.
Small processors are defined as facilities with production no greater than 6,000 lb/day
of finished product. EPA is not proposing to revise the requirements for this
subcategory. The tenth subcategory in the existing regulation applies to independent
rendering facilities.
EPA's proposed regulation revises the requirements for larger meat products facilities
(including independent renderers) and establishes requirements for the poultry
slaughtering and processing sector.
The proposed regulations establish requirements for large meat and poultry products
facilities to control the discharge of conventional pollutants [biochemical oxygen
demand (BOD), total suspended solids (TSS), fecal coliform, hexane extractable
material (measures oils and greases)], chemical oxygen demand (COD), and nutrient
pollutants including ammonia as nitrogen, total nitrogen and total phosphorus. EPA is
basing the proposed requirements on the application of biological treatment including
nitrification and denitrification to remove nutrients. Proposed revisions for the
independent renderers subcategory would not require independent renderers to
control nutrients but do require these facilities to comply with more stringent
limitations for ammonia. These limitations for independent renderers are based on
improved performance of the existing treatment technologies required to comply with
existing regulation.
EPA is not proposing to revise existing requirements that apply to meat slaughtering
or further processing facilities that have an annual production of 50 millions pound per
year or Tess. Also EPA is not proposing new requirements for independent rendering
facilities that render 10 million pounds of raw material per year or less. Also EPA is
proposing to establish less stringent requirements for poultry products facilities that
slaughter 10 million pounds per year or only further process 7 million pounds per year
or less. EPA estimates that these smaller MPP facilities are responsible for a small
I of 3 2/19/02 3:30 PM

U.S. EPA > Water > Water Science > ELGs > Meat & Poultry Products
wysiwyg:// 13/http://www.epa.gov/ost/guide/mpl
fraction (3 percent of the conventional pollutants and 4 percent of the nutrients) of the
overall pollutant Toad discharged from all MPP facilities.
EPA is not proposing to establish pretreatment standards for the MPP category.
Wastewater pollutants found in MPP wastewater are generally compatible with the
wastewater treatment found at Publicly Owned Treatment Works (POTWs). EPA
believes that POTWs are capable of effectively treating MPP wastewater. However,
EPA is soliciting comment on this proposal, and specifically requesting information on
POTW interferences caused by MPP discharges.
EPA estimates that today's regulation will achieve a reduction in nutrients discharged
by this industry of 53.9 million pound per year and conventionals by 32.7 million
pounds per year. EPA estimates that 246 facilities will be affected by today's proposal
and will incur costs estimated to total $80 million per year (1999 dollars). EPA
concludes that today's proposal is economically achievable.
How to obtain copies of the proposed regulation and supporting documents:
On January 30, 2002, Administrator Whitman signed the proposed revisions to the
Meat and Poultry Products Effluent Guidelines. The Federal Register will publish
these proposed revisions. You can obtain a copy by going to the EPA Effluent
Guidelines web site at: http://www.epa.gov/waterscience/quide/
How to comment on the proposed regulations:
EPA encourages all interested individuals and groups to comment on these proposed
regulations. The public comment period begins on the day the regulations are
published in the Federal Register and is open for comment for 60 days. You may
send your comments to EPA in a number of ways:
• By e-mail: [e-mail]
• By postal service:
Meat and Poultry Products Proposed Rule
US EPA, Office of Water
Engineering & Analysis Division (4303T)
1200 Pennsylvania Avenue, N.W.
Washington, D.C. 20460
• By hand delivery:
Meat and Poultry Products Proposed Rule
Engineering & Analysis Division
1201 Constitution Avenue, N.W.
Room 6233L, Connecting Wing
Washington, D.C. 20460
Please submit any references cited in your comments. Please submit an original and
three copies of your written comments and enclosures.
EPA Home I Privacy and Security Notice 1 Contact Us
Last updated on Friday, February 1st, 2002
URL: http://www.epa.gov/ost/guide/mpp/
2 of 3
2/19/02 3:30 PM

proposed revisions for meat&poultry- 40 CFR 432
Subject: proposed revisions for meat&poultry- 40 CFR 432
Date: Thu, 28 Feb 2002 16:46:14 -0500
From: Tom Belnick <[e-mail]>
To: Dave Goodrich <[e-mail]>,
Susan A Wilson <[e-mail]>
FYI- I know Susan was going to check out the new proposed regs, but
since I have Wayne Farms in for a mod I took a quick look at just the
proposed poultry changes. For large poultry processors, the proposed
regs would reduce monthly average permitted BOD and TSS loading by 88%
and 92%, respectively. For Wayne Farms, this equates to monthly average
concentrations of 8.5 mg/1 (BOD) and 7 mg/1 (TSS). They can't do this
right now. The reg also adds mass limits for TN (equivalent to 13.8
mg/1 for Wayne, which currently averages 35-70 mg/1) and TP (equivalent
to 12.6 mg/1 for Wayne- generally not a problem). BIG changes.
Mailto:[e-mail]
N.0 DENR-DWQ/NPDES Unit
1617 Mail Service Center, Raleigh NC 27699-1617
Work: [phone] ext. 543
Fax: [phone]
Key 10
49-e(1414- Afe—
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1 of 1 2/28/02 4:47 PM

ed
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01344 419, P"Pj p,\j‘Mifrx
1" Ih-N 03510 • ih
M . osot • / 10
0�6- 33 l^3 /
TS -0Y67 •060
�N aC12.) a2.23q
TP .013 13 0 /760
(' r. : #Y6
t-
.10 cf'''R:11:: Tf:vir
ft) 2_ 5 Ai')
r ‘f) g/Dekv
1 e,,,41-v,I,q6L-
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T 7Ctix ttd
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r 4
600-, 7S-Zx 421
Ts� i)1x .0'1677_ 35.c lcl
TA 11 .7.70A 6g #a
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1
Table 23. Recommended Effluent Limitations for July 1, 1977
Industry
Subcategory
Effluent Parameters
BOD5, kg/kkg LWK*
SS, kg/kkg LWK
Grease, kg/kkg LWK
Fecal Coliform,
Max. .Count/100 ml
Chickens
0.46
0.20
400
0.62 1
0.39
0.57
0.14
400
Turkeys
Fowl
0.61
0.72
0.15
400
Ducks
0.77
0.90
0.26
400
Further Processing
Only
0.30 kg/kkg FP
0.35 kg/kkg FP
0.10 kg/kkg FP
400
*kg/k'-g LWK is equivalent to lb/1000 lb LWK
0

WAYNE POULTRY NC0006548
FOR APPROPRIATE DISCHARGERS, LIST COMPLETE GUIDELINE LIMITATIONS BELOW
Effluent Characteristics
Monthly
Average
Daily
Maximum
Comments
BOD5
276.0/345.0
552.0/690.0
original production limit/increased limit
TSS
372.0/465.0
744.0/930.0
original production limit/increased limit
Oil & Grease
120.0/150.0
240.0/300.0
original production limit/increased limit
Fecal Coliform
200
400
NH3
Type of Product Produced
Lbs/Day Produced
Effluent Guideline Reference
Processed chicken
Z 600,000
Proposed 40 CFR Part 432 subpart 112
;750,000 roposed increase
Proposed 40 CFR Part 432 subpart 112

IWC Calculations
Wayne Farms
NC0006548
Prepared By: Tom Belnick, NPDES Unit
Enter Design Flow (MGD):
Enter s7Q10(cfs):
Enter w7Q10 (cfs):
0.6
23
34
Residual Chlorine
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (UG/L)
UPS BACKGROUND LEVEL (I
IWC (%)
Allowable Conc. (ug/I)
Fecal Limit
(If DF >331; Monitor)
(If DF <331; Limit)
Dilution Factor (DF)
NPDES Servor/Current Versions/IWC
Ammonia (NH3 as N)
(summer)
23 7Q10 (CFS)
0.6 DESIGN FLOW (MGD)
0.93 DESIGN FLOW (CFS)
17.0 STREAM STD (MG/L)
0 UPS BACKGROUND LEVEL
3.89 IWC (%)
437 Allowable Conc. (mg/I)
200/100mI
25.73
Ammonia (NH3 as N)
(winter)
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL
IWC (%)
Allowable Conc. (mg/I)
23
0.6
0.93
1.0
0.22
3.89
20.3
34
0.6
0.93
1.8
0.22
2.66
59.6
2/20/02

IWC Calculations
Wayne Farms
N C0006548
Prepared By: Tom Belnick, NPDES Unit
Enter Design Flow (MGD):
Enter s7Q10(cfs):
Enter w7Q10 (cfs):
0.7
23
34
Residual Chlorine
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (UG/L)
UPS BACKGROUND LEVEL (I
IWC (%)
Allowable Conc. (ug/l)
Fecal Limit
(If DF >331; Monitor)
(If DF <331; Limit)
Dilution Factor (DF)
NPDES Servor/Current Versions/IWC
Ammonia (NH3 as N)
(summer)
23 7Q10 (CFS)
0.7 DESIGN FLOW (MGD)
1.085 DESIGN FLOW (CFS)
17.0 STREAM STD (MG/L)
0 UPS BACKGROUND LEVEL
4.50 IWC (%)
377 Allowable Conc. (mg/I)
200/100m1
22.20
Ammonia (NH3 as N)
(winter)
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL
IWC (%)
Allowable Conc. (mg/I)
23
0.7
1.085
1.0
0.22
4.50
17.5
34
0.7
1.085
1.8
0.22
3.09
51.3
2/19/02

e c r.✓1 120 em /o/sA)✓
�ht
ar;k c tnr Go
ReidEngineering Company, Inc.
i;r
Reid2Jngineering Company, Inc.
Consulting Environmental Engineers
Specializing in the Design and Operation of Water Pollution Control Systems
October 1, 2001
Mr. Tom Belnick
State of North Carolina
Department of Environment and Natural Resources
Division of Water Quality
P. O. Box 29535
Raleigh, NC 27626-0535
SUBJECT: WAYNE FARMS, LLC, DOBSON, NC
WASTEWATER TREATMENT SYSTEM
NPDES #NC0006548
Dear Mr. Belnick,
1r�
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rr,
C LC
G
-4
n>
CLL
rd Li
This letter and attached information is provided to follow up our
phone conversation on Tuesday, September 26, 2001.
Wayne Farms in Dobson, North Carolina desires to increase the flow
limit in their existing NPDES from the present limit = 0.60 MGD to a new
limit = 0.70 MGD. This facility is presently discharging over 0.60 MGD and
has incurred permit flow violations due to the increase in wastewater
discharge flow volume resulting from the additional water usage in the
processing plant required to comply with "zero tolerance" bacteria
standards established by the USDA.
To comply with new product standards the volume of potable water
used for bird washing has increased resulting in a jump in the volume of
water used per bird from 8.0 to 9.3 gallons/bird. This increase in water
usage has resulted in a corresponding increase in wastewater discharge
r 7 �. G r l o Tro io t i64
,i3,6U1
volume.
byd
adlhPA
ff
1210 Princess Anne Street • Fredericksburg, Virginia 22401 • 540-371-8500 • FAX [phone]
Registered Professional Engineers in Alabama, Arkansas, California, Delaware, Florida, Georgia, Idaho, Illinois, Indiana, Iowa, Kansas, Kentucky, Louisiana, Maine, Maryland, Michigan, Minnesota,
Mississippi, Missouri, Nebraska, New Jersey, New York, North Carolina, Ohio, Oklahoma, Pennsylvania, South Carolina, Tennessee, Texas, Virginia, Washington, West Virginia

Mr. Tom Belnick
Department of Environment and Natural Resources
October 1, 2001
Page 2
No expansion in production capacity has occurred at the Dobson
plant. The production capacity is still approximately 110,000 birds/day, 5
days/week. Wayne Farms has dropped plans which were under
consideration in 1999 to expand the production capacity of the processing
plant from 110,000 birds/day up to 140,000 birds/day. To increase the
permitted wastewater discharge flow volume from 0.60 MGD up to 0.70
MGD, no modifications of the wastewater treatment plant are required.
To avoid future permit flow limit violations, Wayne Farms desires the
current wastewater treatment facility to be re -rated for 0.70 MGD capacity
and for the monthly average flow limit in the existing NPDES permit to be
changed from 0.60 to 0.70 MGD.
A revised Engineering Alternatives Analysis (EAA) has been
prepared by Reid Engineering Company and is submitted with this letter to
the NC-DENR for re -rating the flow capacity of the wastewater treatment
facility and the flow limit in the NPDES permit.
If you have questions or need additional information please advise.
Sincerely;
RE! ENGINE ING COMPANY, INC.
John H. Reid, P.E.
President
cka
cc: Rob Poindexter

Michael F. Easley
Governor
\' V1ATFRQ
'G
v
Rob Poindexter
Wayne Farms, LLC
P.O. Box 383
Dobson, North Carolina 27017
Dear Mr. Poindexter:
NCDENR
William G. Ross, Secretary
North Carolina Department of Environment and Natural Resources
Kerr T. Stevens, Director
Division of Water Quality
June 19, 2001
Subject: NPDES No. NC0006548
Wayne Farms
Surry County
Return # 2121
The Division is returning your NPDES permit modification request for an increase in permitted flow
from 0.6 MGD to 0.8 MGD. Based on our phone conversation on 6/14/01, the anticipated facility
expansion has been put on hold, therefore the request for additional flow due to anticipated production
increases is no longer warranted. If the facility decides to implement the facility expansion at a later date, you
will need to resubmit a major modification request letter, a fee of $215, and the Engineering Alternatives
Analysis. If you have any questions, feel free to contact me at [phone], extension 543.
erely,
011
rom Belnick
NPDES Unit
cc: NPDES File
Winston-Salem Regional Office, Water Quality
!1(0.1( iv P''i Gr/�,� — Th'i Ma) o,- 1/1t11, l/PJ T
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N. C. Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
Internet: h2o.enr.state.nc.us
Phone: [phone], extension 511 Fax: [phone]
DENR Customer Service Center 1 800 623-7748
e-mail: [e-mail]

mA'°a°-e
May 25, 2001
Mr. Dave Goodrich, NPDES Unit Supervisor
NCDEHNR
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Acres International's Poultry Processing Wastewater Recovery
Pilot -Test
Location: Wayne Farms Processing Facility, Dobson, North Carolina
Dear Mr. Goodrich,
Enclosed is Acres International's Poultry Processing Wastewater Recovery System
Pilot -Test Protocol. The objective of this pilot -test is to determine if Acres International's
state-of-the-art wastewater recovery technology can cost-effectively treat poultry/meat
processing wastewaters to a level that exceeds EPA's National Drinking Water Standards.
This pilot -test will be performed at Wayne Farms Poultry Processing Facility in Dobson,
North Carolina beginning the first week of July 2001 and should conclude the final weeks
of August 2001.
Ultimately our goal is to treat poultry/meat process wastewaters to a level that exceeds
Drinking Water Standards and to reuse this treated water in poultry/meat processing
operations only. Under no circumstances shall Acres International treated wastewaters be
used in applications that require "potable/drinking water". We believe if Acres
International Poultry Processing Wastewater Recovery Technologies consistently
meets/exceeds EPA's National Drinking Water Standards and we are granted permission
to reuse this treated wastewater in poultry/meat processing operations; our water recycling
technology could reduce water use within the meat processing industry by billions
(possibly hundreds of billions) of gallons per year.
Wayne Farms is requesting your involvement in this pilot -test to ensure that we are
operating, sampling, and analyzing this process in accordance with standards set forth in
EPA's National Drinking Water Standards.
Please review the enclosed pilot -test protocol and provide comments/suggestions to
improve our project. We also look forward to meeting with you or your colleagues in the
near future to discuss your involvement with this pilot -test and involvement with future
full-scale systems that we hope to install at our Wayne Farms Poultry Processing Facility
in Albertville, Alabama.
340 Jesse Jewel Parkway
Sum: 20(1
Gatnesville. GA 30501
770' 538_2132
770 333 1
pha.wdlis,r!.? •apttedyh.uo
Page I of 2

I will be contacting you within the next few days to discuss your project involvement. If
you have questions or would like to discuss details of this pilot -test you can reach me at
[phone] or [phone]. You can also contact Dale Stolzfus, Wayne Farms,
Engineering Manager, at [phone] or David Brady with Acres International at (905)
496-3400 with questions or concerns.
Thanks for your time and consideration and I will be contacting you within the next few
days to discuss your participation in this project.
Sincerely,
Phil Willis
enc: Protocol for Advanced Water Recovery System
cc: Dale Stolzfus, Mike Robach, Rob Poindexter - Wayne Farms
David Brady, Dale Morris - Acres Int
Dave Goodrich- NCDEHNR NPDES Unit Supervisor
Les Behrends - Tennessee Valley Authority, Mussel Shoals, AL
Bob Freeman, David Parker - EPA Region 4 Water Division
Tom Stevens - NSF
Jeff Adams - Environmental Technology Verification
Page 2 of 2

05/09/01 14:52 WAYNE FRRMS 4 919 733 0719
NO.971 P01
WAYNE FAR M
Division of Continental Grain Company
Mr. Tom Belnick
State of North Carolina
Department of Environment and Natural Resources
Division of Water Quality
P.O. Box 29535
Raleigh, NC 27626-0535
Dear Mr. Rolnick,
April 20, 2001
Per our conversation today, Wayne Farms Dobson, NC requests the permitted discharge flow of 0.600
MGD be increased to 0.800 MGD. As mentioned, the EAA has been completed and submitted by Reid
Engineering on our behalf, as well as, the $215 processing fee.
Additionally, concerning your inquiry about the amount of available land on site which could be used for
spray irrigation, the Wayne Farms plant currently has <2 acres of available land on site for this active,
which is well short of the acres required to dispose of the additional 200,000 GPD. Also, this land exists in
a low lying area of the site adjacent to a unnamed tributary ofthe Fisher River.
thank you for the consideration of this permitting change and if I can be of any further assistance, please
advise. I can be reached at [phone]or my email address is "r,poindextergwaynedgh.corn
Thank you,
Rob Poindecter
ACCoUNTIN© oPFICE & PROgeSSIIG PLAINT P•O, Box 383 Dobson, NC 27017 Phone [phone] Fax [phone]
FEED MILL 3005 N.C. Highway 25$ Elkin, NC 28821 prior% (91Q) 386-4471 HATCHERY Phone [phone]aa UVE Priooucnow Phoaka [phone]

MP"
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NCDENR
JAMES B. HUNT JR.
GOVERNOR
BILL HOLMAN
SECRETARY
*Id
NORTH CAROLINA DEPARTMENT OF' ,
ENVIRONMENT AND NATURAL RESOURCES
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DIVISION OF WATER QUALITY
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1617 MAIL SERVICE CENTER, RALEIGH, NORTH CAROLINA 27699-1617
website: h2o.enr.state.nc.us PHONE [phone] FAX [phone]
AN EQUAL OPPORTUNITY / AFFIRMATIVE ACTION EMPLOYER - 50% RECYCLED/1O% POST -CONSUMER PAPER

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Permit Number
NC0003344
NC0005I26
NC0006548
NC0028835
NC0072575
Facility Name
SWIFT -EC KRI C H/B UTTE RBAL L
TYSON FOODS, INC. - I-IARMONY
County
DUPLIN
IREDELL
WAYNE POULTRY OF N.C.-DOBSON SUIZRY
PERDUE FARMS, INC./LEWISTON BERTIE
GOLDEN POULTRY/GOLD-KIST LEE
_ship ,t Brto?O4/1,kbJ i h-� 33 " 38 a 3 /S/
The Vi egi-ed FC rep 1/44,•/ yr0
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06/29/00 THU 09:59 FAX [phone] REID ENGINEERING
YJb/et/ww WHYMt 541i3716576
a002
NO.59 Doi
• ��
D1vlolon 41 Confirm/dal Oraln Company
Tuesday, kale 27, 2000
John. Reid
Reid Engineering
Mums Anne St.
Fredricksbtrrg, VA
Dear John,
Pertaining to the possibly of spray ixrigs,ting all or a portion alto wastewater from Ways
Farms, there is currently not enough land available in proximity to the plat for this type of
disposal. The processing plant is located within the city limits of the town of Dobson. By being
within the city limits and within a commercial sector, Wayne Farms is basically land locked. if I
can be of any further help, please advise.
Rob Poindcxter
Technical Services iiau,ager
Wayne Farms
ACCt3UlJ1h114 OFRCE & PROCESSING GIANT P.O. sat an onn.:nn, NC a7n17 Phnnn Mien 389-3191 Fai 01171 waft.
FEED MILL. 3095 NZ, HIGInvc Y 268 Elkin, NC R8Q21 nano (914j 3864471 HATCHERY Mena 19101 366.2268 LIVE PA04UCT1ON Phone (910133&4413

06/29/00 THU 09:59 FAX [phone]
REID ENGINEERING 13J001
REID ENGINEERING COMPANY, INC.
1210 Princess Anne Street
Fredericksburg, Virginia 22401
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]
DATE:►
Fax
to:
fax #:
Reiff Ei g iieering Company, Iris,
110111081111111,
c1q 153` 0119
from: ,xck
Subject:
pages:
Message:
0-_
THIS TRANSMITTAL 1S: ( ) FOR APPROVAL
( ) FOR YOUR ACTION
( ) FOR YOUR INFORMATION
( ) A5 REQUESTED
( )FOR YOUR USE

C Ic���rlJl t ✓t
Reid Engineering Company, Inc.
fs
ReidEngincerirtg Company, Inc.
Consulting Environmental Engineers
Specializing in the Design and Operation of Water Pollution Control Systems
July 22, 1999
Mr. Tom Belnick
State of North Carolina
Department of Environment and Natural Resources
Division of Water Quality
P. O. Box 29535
Raleigh, NC 27626-0535
/f4) p /I01)
6 677
tZ/5:©!4
Tele: 919/733-5083 (543)
SUBJECT: WAYNE FARMS WASTEWATER TREATMENT SYSTEM
EXPANSION, DOBSON, NC
NPDES PERMIT #NC0006548
Dear Mr. Belnick,
Wayne Farms in Dobson, NC is requesting a permit modification due to a
proposed increase in flow from .60 MGD to .80 MGD. As required by the NC-
DEHNR, we are submitting an Engineering Alternatives Analysis with this
request for a permit modification. The $215 fee is also attached.
Wayne Farms would appreciate your review of this information as soon as
possible to confirm that the document is satisfactory so that a draft NPDES
permit can be prepared for Wayne Farms for public notice. If you have
questions please call.
r-
,Ili2 3
JUL 8 1 99
DENR - WATER QUALITY
POINT SOURCE BRANCH
0
JHR/ca
cc: Rob Poindexter, Wayne Farms
Sincerely,
R ENGINEERING COMPANY, INC.
I
hn H. Reid, P.E.
resident
1210 Princess Anne Street • Fredericksburg, Virginia 22401 • 540-371-8500 • FAX [phone]
Registered Professional Engineers in Alabama, Arkansas, California, Delaware, Florida, Georgia, Idaho, Illinois, Indiana, Iowa, Kansas, Kentucky, Louisiana, Maine, Maryland, Michigan, Minnesota,
Mississippi, Missouri, Nebraska, New Jersey, New York, North Carolina, Ohio, Oklahoma, Pennsylvania, South Carolina, Tennessee, Texas, Virginia, Washington, West Virginia

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
Kerr T. Stevens, Director
July 29, 1999
Mr. Rob Poindexter
Wayne Poultry of N.C.
P.O. Box 383
Dobson, North Carolina 27017
A7rA
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: NPDES Permit Modification
Permit NC0006548
Wayne Farms - Dobson
Surry County
Dear Mr. Poindexter:
The Division received your permit modification request and fee of $215.00 (paid
by check # 6897) on July 28, 1999. Thank you for submitting this package.
Tom Belnick of the NPDES Unit staff will review this application. Mr. Belnick will
contact you if further information is needed to complete the application.
If you have any additional questions concerning the subject application, please
contact Mr. Belnick at [phone], extension 543.
Sincerely,
Charles H. Weaver, Jr.
NPDES Unit
cc: Central Files
Winston-Salem Regional Office, Water Quality Section
NPDES File
John H. Reid / Reid Engineering
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 919 733-5083, extension 511 (fax) 919 733-0719
An Equal Opportunity Affirmative Action Employer
[e-mail]

TELEPHONE RECORD YDate: ProjJect: f"C 000 �� e
( Time:
tikyle 1Yn1 11-C
❑ Retum MrJ Mrs. Representing:
❑ Call to Address
❑ Cali from
Subject:
Telephone:
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FAX:
NOTES/ SUMMARY
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NEEDED FOLLOW-UP ACTION(S)
1.
2.
3.
4.
5.
BY WHOM/WHEN
1.
2.
3.
4.
5.
cc:
Signed

IWC Calculations
Wayne Farms, LLC (Expansion request from 0.6 to 0.8 MGD)
NC0006548
Prepared By: Tom Belnick, NPDES Unit
Enter Design Flow (MGD):
Enter s7Q10(cfs):
Enter w7Q10 (cfs):
0.8
23
34
Residual Chlorine
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (UG/L)
UPS BACKGROUND LEVEL (I
IWC (%)
Allowable Conc. (ug/I)
Fecal Limit
(If DF >331; Monitor)
(If DF <331; Limit)
Dilution Factor (DF)
NPDES Servor/Current Versions/IWC
Ammonia (NH3 as N)
(summer)
23 7Q10 (CFS)
0.8 DESIGN FLOW (MGD)
1.24 DESIGN FLOW (CFS)
17.0 STREAM STD (MG/L)
0 UPS BACKGROUND LEVEL
5.12 IWC (%)
332 Allowable Conc. (mg/I)
200/100mI
19.55
Ammonia (NH3 as N)
(winter)
7Q10 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL
IWC (%)
Allowable Conc. (mg/I)
23
0.8
1.24
1.0
0.22
5.12
L15.5 )
34
0.8
1.24
1.8
0.22
3.52
45.1
6/14/00

NCDENR / DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
Wayne Farms, LLC
NPDES No. NC0006548
Facility Information
(1.) Facility Name:
Wayne Farms
(2.) Permitted Flow (MGD):
0.60 MGD:
requesting 0.80
(6.) County:
Surry
(3.) Facility Class:
III
(7.) Regional Office:
Winston-Salem
(4.) Facility Status:
(New or existing)
Existing
(8.) USGS Topo Quad:
B 16NW
(Dobson)
(5.) Permit Status:
(i.e., New, Modification,
or Renewal)
Modification-
expansion
Stream Characteristics
(1.) Receiving Stream:
Fisher River
(2.) Subbasin:
030702
(8.) Drainage Area (mi2):
109.00
(3.) Index No.:
12-63-(9)
(9.) Summer 7010 (cfs)
23.08
(4.) Stream Classification:
C
(10.) Winter 7Q10 (cfs):
34
(5.) 303(d) Listed:
NO
(11.) 30Q2 (cfs):
48.74
(6.) 305(b) Status:
NA
(12.) Average Flow (cfs):
___14,1-7p�
3.9% @0.6 '
.-0.8 i
(7.) Use Support:
(13.) IWC (%):
,_fj,
Conditions Incorporated into Permit Major Modification
Proposed Conditions
Parameters Affected
Basis for Condition(s)
Add phased flow limit of 0.8
MGD.
Flow
Per expansion request and flow
justification.
Add phased monthly average
limit of 15,mg/I.
NH3
This parameter is water quality
based for amm toxicity,
using 1WC o 0 at 0.8 MGD.
Delete daily max limit of 30
mg/I at 0.6 MGD
NH3
NPDES policy or limits based
on NH3 toxicit is to use
monthly avera e only.
Add phased chronic toxicity test
with 1WC 3.5:7t
Chronic toxicity test
Per toxicity p licy for complex
wastewaters
e 0. >l1

NPDES PERMIT FACT SHEET
Page 2
Wayne Farms LLC
NPDES No. NC0006548
Change tox language for both
Chronic toxicity test
Per new tox language effective
flows to reflect updated follow-
up procedures.
July 1999.
Proiect Notes
Summary. This is a major modification request to increase permitted flow from 0.6 to 0.8 MGD for a
poultry processor. The discharge is 100% industrial, with domestic wastewater piped to city sewer.
Facility discharges via Outfall 001 to Fisher River (Class C), which is not listed in the Draft 2000 303(d)
list. Per 1998 Basin Plan, there are no impaired streams in this subbasin (030702). The Basin Plan
reports that sedimentation is evident in Fisher River, although water quality generally remains good, and
a Good bioclassification was assigned based on macroin - - . ate data. There i ' • t flow in
Fisher River (s7Q10= 23 cfs), resulting in IWC of onl 3.9% (at 1.6 MGD) an 3.5% (at 0.: GD).
EAA Review. The facility has requested an increase in permitted flow from 0.6 to i.: ' P, based on
increasing production rate from 110,000 birds killed per day (bpd) to 140,000 bpd. Based on the present
wastewater generation rate of 8 gal per bird killed, an increase in wastewater of 240,000 gpd (30,000 bpd
x 8) is projected. Facility is requesting increase of 200,000 gpd, since wastewater recycle will handle
some of the projected increase. Conclusion- additional flows appear justified.
The facility evaluated several wastewater disposal alternatives. Connection to POTW is unfeasible
(letter provided by Town of Dobson POTW). Land based disposal options are constrained by available
land. Facility presently reuses a portion of the treated wastewater, but cannot reuse all of it due to USDA
restrictions against reuse as a potable water source. Conclusion- direct discharge appears justified.
Permit Limits. Add phased effluent sheet with flow limit of 0.8 MGD. At expanded flow, leave
technology -based limits unchanged (BOD, TSS, O&G), and adjust water -quality based limit for NH3 to
reflect new IWC. Also adjust phased flow toxicity test to reflect new IWC.
DMRs-Effluent Data. In 1998, flow averaged between 0.39-0.57 MGD (0.60 MGD limit). Effluent -
limited parameters were well below mass -based limits. Monthly averages (lbs/d) ranged from 9-34 for
BOD (versus 345 #/d limit); 0.5-3.3 for NH3 (versus 100 #/d limit); 20-79 for TSS (versus 465 #/d limit);
18-34 for O&G (versus 150 #/d limit). All NH3 values were < 1 mg/1 (versus 20 mg/1 limit). Violations
were noted for fecals in 1998- one monthly average, and 14 daily max (due to broken chlorinator and
faulty oxygen meter in AS basin) but problem does not appear to be chronic. Facility has passed 11/12
tox tests between 96-98. TN concentrations (mg/1) reported in 1998 were: 76, 56, 22. TP concentrations
(mg/1) reported in 1998 were: 12, 7,7.
DMRs-Instream Data. In 1998/97, some summer data indicated DO sag below outfall:
Date Upstream DO Downstream DO
8/98 4.0 mg/1 2.0 mg/1
9/98 9.2 mg/I 7.4 mg/1
10/98 8.6 mg/1 7.1 mg/1
7/97 9.0 mg/1 7.5 mg/1
In light of expansion request, there is justification to maintain no net increase in oxygen -consuming
waste loading based on 8/98 data. Based on DMR effluent data, the proposed limits should still provide
sufficient buffer for facility to comply with.
Page 2
Version: June 15, 2000

Wayne Farms
NC0006548
Qeff=0.80 MGD
Residual Chlorine
7010 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (UG/L)
UPS BACKGROUND LEVEL (I
IWC (%)
Allowable Conc. (ug/I)
Fecal Limit
(If DF >331; Monitor)
(If DF <331; Limit)
Dilution Factor (DF)
IWC Calculations
Prepared By: Tom Belnick, NPDES
Ammonia (NH3 as N)
(summer)
23.08 7Q10 (CFS)
0.8 DESIGN FLOW (MGD)
1.24 DESIGN FLOW (CFS)
17.0 STREAM STD (MG/L)
0 UPS BACKGROUND LEVEL
5.10 IWC (%)
333 Allowable Conc. (mg/1)
Ammonia (NH3 as N)
(winter)
7Q10 (CFS)
200/100m1 DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
19.61 UPS BACKGROUND LEVEL
IWC (%)
Allowable Conc. (mg/I)
23.08
0.8
1.24
1.0
0.22
5.10
15.5
34
0.8
1.24
1.8
0.22
3.52
45.1
4/18/01