NC0000639_Permit (Issuance)_20020118

NPDES DOCUMENT SCANNING: COVER SHEET
NPDES Permit:
NC0000639
Sapona Manufacturing Company
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Instream Assessment
(67b)
Speculative Limits
Environmental Assessment (EA)
Permit
History
Document Date:
January 18, 2002
This document is printed on reuse paper - igrnore any
content on the reYerse side

OF \N A 7-9
ATA
NCDENR
Mr. Dean Lail
Sapona Manufacturing Company, Inc.
P.O. Box 128
Cedar Falls, North Carolina 27230
Dear Mr. Lail:
Michael F. Easley
Governor
William G. Ross, Jr., Secretary
North Carolina Department of Environment and Natural Resources
Gregory J. Thorpe, Ph.D., Acting Director
Division of Water Quality
January 18, 2002
Subject: Issuance of NPDES Permit NC0000639
Sapona Manufacturing Company
Randolph County
Division personnel have reviewed and approved your application for renewal of the subject permit.
Accordingly, we are forwarding the attached NPDES discharge permit. This permit 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 (or as subsequently amended).
This final permit includes no major changes from the draft permit sent to you on November 14, 2001. While
outfall 003 has been deleted from this permit, be certain that all groundwater cleanup requirements have been met.
Contact the Division's Groundwater Section at [phone] if you need assistance with groundwater
contamination issues.
If any parts, measurement frequencies or sampling requirements contained in this permit 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 demand is made, this decision shall be final and binding.
Please note 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, the Coastal Area Management Act or any other Federal or Local governmental permit that may be
required.
If you have any questions concerning this permit, please contact Charles Weaver at telephone number (919)
733-5083, extension 511.
cc: Central Files
Winston-Salem Regional Office/Water Quality Section
Technical Assistance & Certification Unit
NPDES Unit
N. C. Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
Internet: h2o.enr.state.nc.us
Sincerely,
ORIGINAL SIGNED BY
SUSAN A.INILSON
Gregory J. Thorpe, Ph.D.
Phone: [phone]
fax: [phone]
DENR Customer Service Center..1 800 623-7748

M
Permit NC0000639
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,
Sapona Manufacturing Company, Inc.
is hereby authorized to discharge wastewater from a facility located at
Sapona Manufacturing Company
2478 Riverside Drive
Cedar Falls
Randolph County
to receiving waters designated as the Deep River in the Cape Fear 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 March 1, 2002.
This permit and authorization to discharge shall expire at midnight on September 30, 2006.
Signed this day January 18, 2002.
ORIGINAL SIGNED BY
SUSAN A. WIlILSON
Gregory]. Thorpe, Ph.D., Acting Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0000639
SUPPLEMENT TO PERMIT COVER SHEET
Sapona Manufacturing Company, Inc., is hereby authorized to:
1. Continue operation of a 0.01 MGD wastewater treatment facility with the following
components:
❖ Aeration basin with diffused aeration
❖ Clarifier with sludge return
••• Effluent chlorination
This system discharges via outfall 001 from a facility located at 2478 Riverside Drive in
Cedar Falls, Randolph County.
2. Continue to discharge boiler blowdown, cooling tower blowdown, and air washer
wastewater via outfall 002.
3. Discharge from said treatment works at the locations specified on the attached map into
the Deep River, classified C waters in the Cape Fear River Basin.

iA Sapona Manufacturing Company
•• Randolph County
• � y :NPDES Permit No. NC0000639
a 7 -----
=USGS Quad No. E-20NW
USGS Quad Name Ramseur
ii•-.42,/,-E.-7•:. i---~>j<'...
-ii j -;',..g---ki.',/.''
Quad: Ramseur, N.C.
Latitude: 35°44'51 "(001);
35°44'50" (002)
Longitude: 79°43'33" (001);
78°43'34" (002)
Stream Class: C Subbasin: 30609
Receiving Stream: Deep River
NC0000639
Sapona Manufacturing
Company
North
SCALE 1:2'4000

Permit NC0000639
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (001)
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge from outfall 001 (Domestic Waste). Such discharges shall be limited and monitored
by the Permittee as specified below:
EFFLUENT
CHARACTERISTICS
DISCHARGE LIMITATIONS
Monitoring Requirements
Monthly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample Location
Flow (MGD)
0.01
Weekly
Instantaneous
Influent or Effluent
BOD, 5-day, 20°C
30.0 mg/L
45.0 mg/L
Weekly
Grab
Effluent
Total Suspended Solids
30.0 mg/L
45.0 mg/L
Weekly
Grab
Effluent
NH3-N
,
,
2/Month
Grab
Effluent
Fecal Coliform
(geometric mean)
200 / 100 ml
400 / 100 ml
Weekly
Grab
Effluent
Total Residual Chlorine
2/Week
Grab
Effluent
Temperature
Weekly
Grab
Effluent
pH'
2/Month
Grab
Effluent
NOTES:
1. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS.
A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (002)
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge from outfall 002 (Boiler Blowdown, Cooling Tower Blowdown, Air Wash
Wastewater). Such discharges shall be limited and monitored by the Permittee as specified below:
DISCHARGE
LIMITATIONS
Monitoring Requirements
EFFLUENT
CHARACTERISTICS
Monthly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample Location
Flow (MGD)
Semi-annually
Estimate
Effluent
Temperature'
Semi-annually
Grab
Effluent
Total Residual Chlorinez
Semi-annually
Grab
Effluent
pH3
Semi-annually
Grab
Effluent
NOTES:
1. The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving waters of
more than 2.8oC and in no case cause the ambient water temperature to exceed 32oC.
2. This monitoring requirement only applies if chlorine is added to the cooling water.
3. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS.
(continued on next page)

Permit NC0000639
A. (3.) BIOCIDE CONDITION
There shall be no chromium, zinc or copper added to the treatment system except as pre -approved
additives to biocidal compounds.
The permittee shall obtain approval from the Division's Aquatic Toxicology Unit prior to the use of any biocide (not
previously approved by the Division) in -the effluent discharged under this permit. Approval for use of any biocide
not previously approved should be requested at least 90 days in advance of any planned usage.
Contact the Aquatic Toxicology Unit for detailed instructions on requesting approval of biocides:
NC DENR / DWQ / Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Concentrations of chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or
action levels in the receiving stream.

NORTH CAROLINA-
RANDOLPH 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
MARIA PAYNE
who being first duly sworn, deposes and says, that he
(she) is
BUSINESS MANAGER
of The Courier -Tribune, engaged in the publication of
a newspaper known as The Courier -Tribune,
published, issued, and entered as second class mail
in the City of Asheboro, in said County and State; and
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 The Courier -Tribune on the
following dates:
November 16, 2001
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, 1943, as
amended, and was a qualified newspaper within the
meaning of Section 1-597 of the General Statutes of
North Carolina.
This 16th day of November, 2001
aiuft; g
Sworn to and subscribed before me the 16th day of
November, 2001
Larrucc/ Mimryktru
Notary Public
My commission expires: 6/19/06
lou 44AY War Tb Pu T
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Public m.rrrt-o
STATE OF NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT
• COMMISSIONMPDES UNIT
1617 MAIL SERVICE CENTER
• RALEIGH, NC 27699-1617
NOTIFICATION OF INTENT TO
m , ISSUE A NPDES
w ,WASTEWASTER PERMIT
Ona bs basis of thorough staff review
anA tpplication of NC General Stat-
utelf113.21 Public law 92-500 and
ott{�lawful standards and regula-
tio the North Carolina Environ-
meptal Management Commission
pr cues to issue a National Pollu-
te Discharge Elimination System
(N S) wastewater discharge per-
mit gthe person(s) listed below ef-
fective 45 days from the publish date
of Mis notice.
Wrrfen comments regarding the pro -
pone ' permit will be accepted until
30 Rays after the publish date of this
notices All comments received prior
to that date are considered in the fi-
nal -determinations regarding the pro-
posed permit. The Director of the NC
Division of Water Quality may decide
to hold a public meeting for the pro-
posedRpermit should the Division re-
ceiNe a significant degree of public
Interest.
Copies of the draft permit and other
supporting information on rile used to
determine conditions present in the
draft permit are available upon re-
queVand payment of the cost of re-
production. Mail comments and/or
regl est for information to the NC Df-
visibrtbf Water Quality at the above
ad is' or call Ms. Christie Jackson
at 16) 733.5083, extension 538.
Plepse include the NPDES permit
nurbber (attached) in any communi-
catlbrr. Interested persons may atso
visir the Division of Water Quality at
51aN. Salisbury Street. Raleigh, NC
27604-1148 between the hours of
8:00 am and 5:00 pm to review intor-
mafion on filo.
NPDES permit Number NC0000839,
Sappna Manufacturing Company,
Inci.P.0 Box 128 Cedar Falls, NC
27230 has applied for a permit re-
neval for a facility located in RAN-
D PH County discharging treated
watftewater into the Deep River in
theiCape Fear River Basin. Curentry
no rameters are water quality limit-
ed.,, "is discharge may affect future
ailopalions in this portion of the re-
ceiving stream.
11 19/16/01
a.
pEONNt SOURCE BRpNCN

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0000639
Facility Information
Applicant/Facility Name:
Sapona Manufacturing Company, Inc.
Applicant Address:
P.O. Box 128, Cedar Falls, North Carolina, 27230
Facility Address:
2478 Cedar Falls Rd, Cedar Falls, NC 27230
Permitted Flow
0.01 MGD (outfall 001), Outfalls 002, and 003 not limited
Type of Waste:
100% Domestic (outfall 001); Blowdown (002); Remediation (003)
Facility/Permit Status:
Renewal
County:
Randolph
Miscellaneous
Receiving Stream:
Deep River
Regional Office:
Winston-Salem
Stream Classification:
C
USGS Topo Quad:
E2ONW
303(d) Listed?:
No
Permit Writer:
Mark McIntire
Subbasin:
03-06-09
Date:
November 13, 2001
Drainage Area (mi2):
250
Summer 7Q 10 (cfs)
11
Winter 7Q10 (cfs):
Average Flow (cfs):
290
IWC (%) ® 0.01 MGD:
0.03
SUMMARY OF FACILITY AND WASTELOAD ALLOCATION
Sapona Manufacturing operates this facility in Randolph County. The facility manufactures textured synthetic
filament yarn and covered spandex from nylon, polyester, and spandex. The manufacturing process consists of
texturing, covering, twisting, and winding. A dry process, no wastewater is generated during manufacturing.
The facility operates three outfalls. Outfall 001 is the domestic outfall permitted to discharge up to 0.01 MGD. This
outfall averages approximately 0.03 MGD. Outfall 002 discharges boiler and cooling tower blowdown and air wash
water. Flow from this outfall is quite variable, ranging from 0 MGD to 0.013 MGD. Outfall 003 is the discharge
from a fuel oil #2 remediation site.
TOXICITY TESTING:
Current Requirement: None
COMPLIANCE SUMMARY:
There have been no apparent compliance issues for at least that last three years. Operation appears quite good with
average effluent levels well below permit requirements.
INSTREAM MONITORING:
This facility is not required to conduct instream monitoring and none is proposed.
PROPOSED CHANGES:
None
PROPOSED SCHEDULE FOR PERMIT ISSUANCE:
Draft Permit to Public Notice: November 14, 2001
STATE CONTACT:
If you have any questions on any of the above information or on the attached permit, please contact Charles Weaver
at [phone] ext. 511.
Sapona Manufacturing Fact Sheet
NPDES Renewal
Page 1

SAPONA
MANUFACTURING COMPANY, INC.
Quality Yarns Since 1836
3/27/01
Ms. Valery Stephens
NC DENR / Water Quality / Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
�r�ll�;lllY�
Re: Cover Letter for renewal of NPDES Permit NC0000639
Dear Ms. Stephen:
Please renew our permit for wastewater discharge. The application is enclosed.
There have been no significant changes to our system since issuance of the last permit, however, we do
plan to rescind our permit for outflow 003 only. This was a groundwater remediation system to treat
groundwater contaminated with number 2 fuel oil in 1994. There has been no flow from this outfall since
1996 and the system has been dismantled.
Also, please note that we have hired a contractor to help manage our system. The contractor is Danny Hill
& Associates, PO Box 1052, Greensboro, NC 27402.
The physical address has also changed from the previous permit. The address street name was changed
from Riverside Drive to Cedar Falls Road.
Thank you,
002,1f,-9
Dean F. Lail
President
Sapona Manufacturing Company, Inc.
cc: Danny Hill
Submitting one signed original and two copies
Enclosed:
Completed application
Sludge management plan narrative description
Schematic diagrams of wastewater and cooling water
Email: [e-mail] Web: www.saponamfg.com
P.O. Box 128 • 2478 Cedar Falls Road • Cedar Falls, NC 27230 • Ph. 336-625-2727 • Fax [phone]

SAP ONA
MANUFACTURING COMPANY, INC.
Quality Yarns Since 1836
3/27/01
Sludge Management Plan narrative description for renewal of NPDES Permit NC0000639
Sludge is pumped out periodically and hauled to the local public wastewater treatment facility in Asheboro.
This service is currently performed by Van Boys Septic Tank Hauling at the direction of Danny Hill.
Dean F. Lail
President
Sapona Manufacturing Company, Inc.
41, -4;40
Email: [e-mail] Web: www.saponamfg.com
P.O. Box 128.2478 Cedar Falls Road • Cedar Falls, NC 27230 • Ph. 336-625-2727 • Fax [phone]

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Sapona Manufacturing Company Inc.
Evacuation Routes
Pink - Primary Exit Route
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Red - You are here
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