NC0002305_Permit Issuance_19960916

NPDES DOCUMENT SCANNING% COVER SHEET
NPDES Permit:
NC0002305
Guilford Mills WWTP
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
September 16, 1996
This document is printed ora. areuse paper - ignore any
content on the rejrerse side

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
September 1 6. 1996
Mr. Jimmy Summers
Corporate Environmental & Energy Manager
Guilford Mills, Inc.
P.O. Box 26969
Greensboro. North Carolina 27419-6969
Arn
EDEI--IN F
Subject: NPDES Permit Issuance
Permit No. NC0002305
Guilford East Facility
Duplin County
Dear Mr. Summers:
In accordance with the application for discharge permit received on January 26, 1996, the Division is
forwarding herewith the subject state - NPDES 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 December 6. 1983.
Several changes have been made to the DRAFT permit in preparing this final permit. The sample type for
BOD. COD. TSS. chromium. zinc, copper, chloride, chronic toxicity, total nitrogen and total phosphorus has been
changed from grab to composite. The fecal coliform monitoring has been changed from 3/week to weekly. The
upstream and downstream monitoring requirements have been changed to reflect the NCAC Title 15A 2B .0500
regulations. The daily maximum concentrations for chromium and TRC remain unchanged, however it is the
Division's understanding that pending the result of the flow study to be performed under the SOC, these limits may
change based on a change in IWC. The Division accepts the comment letter received on August 20, 1996 as
notification that antimony was detected at levels above 1.0 mg/L. The Division should be notified if significant
levels of antimony continue to be detected.
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 redeipt 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, Post Office Drawer 27447, Raleigh,
North Carolina 27611-7447. Unless such a demand is made, this permit shall be final and binding.
Please take notice that this permit is not transferable. Part II. E.4. addresses the requirements to be
followed in case of change in ownership or control of this discharge.
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.
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

If you have any questions or need additional information. please contact Mr. Mark McIntire. telephone
number [phone]. extension 553.
Sincerely,
Original Signed By
David A. Goodrich
A. Preston Howard. Jr.. P.E.
cc: Central Files
Mr. Roosevelt Childress, EPA
Wilmington Regional Office, Water Quality
Permits and Engineering Unit
Facility Assessment Unit
Aquatic Survey and Toxicology Unit

Permit No. NC0002305
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, 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,
Guilford Mills, Incorporated
is hereby authorized to discharge wastewater from a facility located at
Guilford East Division
N.C. Highway 11
North of Kenansville
Duplin County
to receiving waters designated as the Northeast Cape Fear 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 November 1, 1996
This permit and authorization to discharge shall expire at midnight on July 31, 2001
Signed this day September 16, 1996
Original Signed By
David A. Goodrich
A. Preston Howard, Jr., P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit No. NC0002305
SUPPLEMENT TO PERMIT COVER SHEET
Guilford Mills, Inc.
is hereby authorized to:
1. Continue to operate an existing 1.5 MGD wastewater treatment facility consisting of
a bar screen, parshall flume, a continuous recording flow meter, a mechanical lint
screen, an aerated flow equalization basin with three floating aerators, a pump
station, an aeration basin with eight floating aerators, a square aeration basin with
four floating aerators, one round aeration basin with one floating aerator, a splitter
box, two clarifiers, a chlorination / dechlorination facility, a reaeration basin with
one floating aerator, twelve sludge drying beds, an effluent pump station and an
effluent recording flow meter and sampler located at Guilford East Division, N.C.
Highway 11, North of Kenansville, Duplin County (See Part III of this Permit),
and
2. Discharge from said treatment works at the location specified on the attached map
into the Northeast Cape Fear River which is classified Class C-Swamp waters in
the Cape Fear River Basin.

- ~ Heaona'
ROAD CLASSIFICATION
PRIMARY HIGHWAY
HARD SURFACE
SECONDARY HIGHWAY
HARD SURFACE
LIGHT -DUTY ROAD. HARD OR
IMPROVED SURFACE
UNIMPROVED ROAD
Latitude 35°01'00" Longitude 74°1'05"
Map # K27NW Sub -basin 03-06-22
Stream Class C-Swamp
Discharge Class Industrial / Domestic
Receiving Stream Northeast Cape Fear River
Design 0 0.15 MGD Permit expires 7/31/01
SCALE 1:24 000
0
1 MILE
.o: t'.14.:ucdy::':r.:caea
0
7000 FEET
1
0
1 KILOMETER
CONTOUR INTERVAL 5 FEET
Guilford East
NC0002305
Duplin County
WWTP

A. ( ). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
Permit No. NC0002305
During the period beginning on the effective date of this permit and lasting until expiration, the Permittee is authorized to discharge
from outfall(s) serial number 001. Such discharges shall be limited and monitored by the Permittee as specified below:
Effluent Characteristics Discharge Limitations
Lbs/day Units
Mon. Avg. Daily Max. Mon. Avg.
Flow 1.50 MGD
BOD, 5 Day, 20°C 83.4 125.1
1301), 5 Day, 20°C
COD 3000 6000
Total Suspended Solids 1035 2071
pFI2
Dissolved Oxygen3
Fecal Col i form
Sulfide 1 1.2 24.0
Phenols 5.6 12.0
Chromium
Total Residual Chlorine4
Zinc
Copper
Oil and Grease
Chloride
Temperature (°C)
Conductivity
Chronic Toxicity5
Total Nitrogen
Total Phosphorus
200/ 100m1 400/ 100m1
56.0 µg/1
19.0 WI
Monitoring
(specify) Measurement
Daily Max. Frequency
Continous
3/Week
10.0 mg/1 3/Week
3/Week
3/Week
3/Week
3/Week
Weekly
Weekly
Weekly
Weekly
3/Week
2/Month
2/Month
2/Month
2/Month
3/Week
3/Week
Quarterly
Quarterly
Quarterly
Requirements
Sample
Type Location
Recording
Composite
Composite
Composite
Composite
Grab
Grab
Grab
Grab
Grab
Composite
Grab
Composite
Composite
Grab
Composite
Grab
Grab
Composite
Composite
Composite
1 or E
E
E
E
E
E
E,U,D
E
E
E
E
E
E
E
E
E
E,U,D
E,U,D
E
E
E
1
Notes:
I Sample Locations: E - Effluent, I - Influent, U - Upstream in Goshen Swamp at Highway II Bridge, D - Downstream in NE Cape Fear River at
Sarecta Bridge; Instream sampling shall be performed three times per week during June thru September and once per week during the rest of the year.
2 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
3 The daily average dissolved oxygen effluent concentration shall not be less than 6.0 mg/1.
4 Limit applies only if chlorine is added to the wastestream.
5 Chronic (Ceriodaphnia), 24 hour, P/F at 90%; January, April, July and October; See Part III, Condition E.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Part III.- NC0002305
E. CHRONIC TOXICITY PASS/FAIL PERMIT LIMIT (QRTRLY)
The effluent discharge shall at no time exhibit chronic toxicity using test procedures outlined in:
The North Carolina Ceriodaphnia chronic effluent bioassay procedure (North Carolina Chronic Bioassay
Procedure - Revised *September 1989) or subsequent versions.
The effluent concentration at which there may be no observable inhibition of reproduction or significant mortality
is 90% (defined as treatment two in the North Carolina procedure document). The permit holder shall perform
quarterly monitoring using this procedure to establish compliance with the permit condition. The first test will be
performed after thirty days from the effective date of this permit 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.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge
Monitoring Form (MR-1) for the month in which it was performed, using the parameter code TGP3B.
Additionally, DWQ Form AT-1 (original) is to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Water Quality
4401 Reedy Creek Road
Raleigh, N.C. 27607
Test data shall be complete and accurate and include all supporting chemical/physical measurements performed in
association with the toxicity tests. as well as all dose/response data. Total residual chlorine of the effluent toxicity
sample must be measured and reported if chlorine is employed for disinfection of the waste stream.
Should any single quarterly monitoring indicate a failure to meet specified limits, then monthly monitoring will
begin immediately until such time that a single test is passed. Upon passing, this monthly test requirement will
revert to quarterly in the months specified above.
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 and appropriate environmental controls, shall constitute an invalid test and will require immediate
retesting(within 30 days of initial monitoring event). Failure to submit suitable test results will constitute
noncompliance with monitoring requirements.

NPDES WASTE LOAD ALLOCATION
PERMIT NO.: NC0002305
PERMI I EE NAME:
FACILITY NAME:
Guilford Mills, Inc.
Guilford East Division
Facility Status: Existing
Permit Status: Modification
Major �!
Pipe No.: 001
Minor
Design Capacity: 0.965 MGD r
Domestic (% of Flow): 2.0 %
Industrial (% of Flow): 98.0 %
Comments:
With this renewal, GM is requesting a flow increase from 1.25 IvIGD to
1.5 MGD.
RECEIVING STREAM: the Northeast Cape Fear River
Class: C-Swamp
Sub -Basin: 03-06-22
Reference USGS Quad: G27SE
County: Duplin
Regional Office: Wilmington Regional Office
(please attach)
Previous Exp. Date: 7/31/96 Treatment Plant Class: class 111 ?
Classification changes within three miles:
No Change within three miles.
Requested by:
Prepared by:
Reviewed by:
Mark McIntire
PLO
ED
Date: 2/22/96
Date: ?
Date:
7a
Modeler
Date Rec.
#
cb
7_ 2zHt
u
st
Drainage Area (ini2 ) Avg. Streamflow (cfs): j9
7Q10 (cfs) , . S Winter 7Q10 (cfs) 30Q2 (cfs)
Toxicity Limits: IWC q0 % Acut. Chronic
Instream Monitoring: 4`'`d On te,ev..4-771,5-/lM €. fa ''0 ->7a,ag: , rex-J.4 )j SArn y &SO req, ono/ s�6�7T•
Parameters T n O ./ )Q O,, �o ;Lit Cold . VI
Upstreain yes Location Go.Aer 64.", JI,,ay l /
Downstream ye Location/U�G�,P ct
Recommended Limits
Flow (MGD):
BOD5 (lbs/day):
BOD5 (mg/1):
COD (lbs/day):
TSS (lbs/day):
DO (mg/1):
pH (SU):
Fecal Col. (/100 ml):
Sulfide (lbs/day):
Phenols (lbs/day):
Chromium (14/1):
Residual Chlorine (µg/1):
Zinc (p.g/1):
Copper (1.tg/1):
Oil & Grease (mg/I):
Chloride (mg/1):
TN (mg/1):
TP (mg/1):
* Limit applies only if chlorine is added to the wastestream.
1.25 MGD
Mnthly Avg. Daily Max.
1.25
83.4
125.1
12.0
3000 6000
1035 2071
6.0
6.0-9.0
200 400
10.0 20.0
5.0 10.0
56.0
19*
monitor
monitor
monitor
monitor
monitor
monitor
1.5 MGD
Mnthly Avg. Daily Max.
1.5
83.4
125.1
10.0
3000 6000
1035 2071
6.0
6.0-9.0
200 400
11.2 24.0
5.6 12.0
56.0
19*
monitor
monitor
monitor
monitor
monitor
monitor
comments: �Sc.l r 4-6 l,f fiNrrc 'Jy( *D Sloe Cftanv1 YJ 1,1
�ira:v1co arc-4 l.Ja,h�fiJG� . pP Con7ta�/l
(Go/Je rnt f 141.175,joie-�o�„t5t' 4� rapf�� /t %rntiifS cc.
*s,L
an0( 71ax.can„„.e. Al rna, or-- otIS l Ci�fty atrr�nnycrhrrs7c )S
scl`��- by Gwit rd M-lls. ✓ J

Facility Name:
NPDES No.:
Type of Waste:
Facility Status:
Permit Status:
Receiving Stream:
Stream Classification:
Subbasin:
County:
Regional Office:
Requestor:
Date of Request:
Topo Quad:
FACT SHEET FOR WASTELOAD ALLOCATION
Guilford Mills, Inc.
NC0002305
98% Industrial, 2% Domestic
Existing
Renewal w/ Modification
Northeast Cape Fear River
C-Swamp
03-06-22
Duplin
Wilmington
Mark McIntire
2/22/96
G27SE
JUL 01 1996 U
Request # 8451
Stream Characteristic:
USGS #
Date:
Drainage Area (mi2):
Summer 7Q10 (cfs):
Winter 7Q10 (cfs):
Average Flow (cfs):
IWC (%):
Ci
021076813.0
1988 .v
326 -,-.
6.5
18
Wasteload Allocation Summary
(approach taken, correspondence with region, EPA, etc.)
* The discharge is to side stream at the edge of a swampy area of the river where the channel is
highly braided. Preliminary observations by regional office staff indicate that minimal positive
flow exists at the outfall point. The facility has applied for an SOC that will entail a flow study and
development of a survey transect for the outfall vicinity. After study results are available, a course
of action (such as outfall relocation) can be determined by the permittee. The permit should contain
the appropriate reopener clause to allow for the adjustment of limits for whole effluent toxicity and
individual toxicants according to t}}e alternative selected by Guilford Mills. Limits in this WLA are
recommended on the basis of an assumed IWC of 90% based on DEM staff observations of the
discharge location.
Permittee has applied for a flow increase to 1.5 MGD to accommodate an expansion of plant
production, and the attached limits for the projected production levels were developed according to
40 CFR 410.52 Subpart E (Knit Fabric Finishing). However, due to the uncertainty of the impact
of this discharge on the receiving swamp and some low DO levels recorded instream by the
permittee, past expansions have been permitted with no increase in loading of oxygen demanding
wastes, as is recommended in this WLA. Federal guideline limits for BOD, COD and TSS should
be superseded by the water quality limits reflecting no increase in pollutant loading. The monthly
average limit for BOD5 is still recommended in mass only, so as not to discourage water
conservation measures at the facility. However, the daily maximum concentration limit for BOD5
has been retained and reduced to reflect no increase in load upon expansion to 1.5 MGD.
Special Schedule Requirements and additional comments from Reviewers:
T� CliCKY Pic ' G atoms f atv 9v err-ocrive yr
rbfmtr, 71j4 Nt ' 65‘-- 411/0,1 w/a ce 1PL-O - * 'ut .
Nor ..s u14) ran/r41141 A• 5c11-6N1Le•
WILL- !INC; 5r K647 ' P67

' JUL-09-1996 11:26 FROM DEM WATER QUALITY SECTION TO bJIRO P.02/03
2
Recommended by: Date:
Reviewed by
Jnstream Assessment: Date:
Regional Supervisor l� i✓ t �� r Date:
Permits & Engineering: &Al Date: -1//4f �G
RETURN TO TECHNICAL SUPPORT BY:
TOXICS/METALS/CONVENTIONAL PARAMETERS
Toxicity Test:
Existing Limit:
Recommended Limit:
Monitoring Schedule:
Existing Limit
Flow (MGD):
BOD5 (ibs/day):
BOD5 (mil):
COD abs/day):
TSS (lbs/day):
DO (mg(1):
pH (SU):
Fecal Col_ (%100 nal):
Sulfide (lbs/day):
Phenols (lbs/day):
Chromium (141):
Residual Chlorine (µg/1):
Zinc ().1gtl): monitor
Copper (.Lg/1): monitor
Oil & Grease (mil): monitor
Chloride (mg/1): monitor
TN (mg/1): monitor monitor
TP (mg/1): monitor monitor
* Limit applies only if chlorine is added to the wastestream.
Chronic (Ceriodaphnia) 24 hr., Quarterly P/F
P/F @ 19% (0.965 MGD). P/F @ 23% (1.25 MGD)
P/F @ 90% (all flows)
Jan., Apr., Jul., Oct.
0.965 MGD
Monthly Avg. Daily Max.
0.965
132.8
11.0 16.5
4750 9500
1035 2071
5.0
6.0-9.0
9.5 18.0
4.75 9.5
266
1.25 MGD
Monthly Avg. Daily Max.
1.25
83.4 125.1
12.0
3000 6000
1035 2071
6.0
6.0-9.0
200 400
10.0 20.0
5,0 10.0
217
28*
monitor
monitor
monitor
monitor

; JUL-09-1996 11:26 FROM DEM WATER QUALITY SECTION TO
WIRO P.03/03
KwammralmiLimita
3
JtQQ
Monthly Avg. Daily Max.
1.25
83.4 125.1
12.0
3000 6000
1035 2071
6.0
200 6.0
4009.0
10.0 20.0
5.0 10.0
56.0
19*
monitor monitor
Copper monitor monitor
011 & Grease (lug/1); monitor monitor
Chloride zng/1, monitor monitor
TN (mg/1): monitor monitor
TP (mg/1): monitor monitor
* Limit applies only if chlorine is added to the wastestream.
Flow (MGD):
BOD5 (lbsklay):
BOD5 (mg/1):
COD (lbs/day):
TSS (lbs/day):
DO (mg/I):
pH (SU):
Fecal CoL (j100 mi):
Sulfide (lbs/day):
Phenols (lbs/day):
Chromium (µgjl):
Residual Chlorine (g/1):
Zinc (µ):
Limits Chauges_Due To:
Change in 1WC
Change in stream classification
Relocation of discharge
Increased wasteflow for production expansion
New pretreatment information
Other (onsite toxicity study, interaction, etc.)
a.S MGD
Monthly Avg. Daily Max.
1.5
83.4
3000
1035
200
11.2
5.6
125.1
10.0
6000
2071
6.0
6.0-9.0
24.0
12.0
56.0
19*
Eara=cds) Affected
X WET test, Cr, TRC
x BOD, sulfide, phenols
WQ or EL
SS Pt t'l PI VI,Sg•ISS
X Parameter(s) are water quality limited. For some parameters, the available load capacity of
the immediate receiving water will be consumed. This may affect future water quality based
effluent limitations for additional dischargers within this portion of the watershed.
OR
No parameters are water quality limited, but this discharge may affect future allocations.
Upstream Location:
Downstream Location:
Parameters:
1NSTREAM MONITORING REQUIREMENTS
Goshen Swamp @ Hwy 11 bridge
NE Cape Fear River @ Sarvcta bridge
Temp., DO, pH, Conductivity
Special instream monitoring locations or monitoring frequencies:
Note that BOD5 and COD have been dropped from instream monitoring requirements
TOTAL P.03

4
MISCELLANEOUS INFORMATION & SPECIAL CONDITIONS
Adequacy of Existing Treatment
Has the facility demonstrated the ability to meet the proposed new limits with existing treatment
facilities? Yes No
If no, which parameters cannot be met?
Would a "phasing in" of the new limits be appropriate? Yes No
If yes, please provide a schedule (and basis for that schedule) with the regional
office recommendations:
If no, why not?
Special Instructions or Conditions
Wasteload sent to EPA? (Major) Y (Y or N)
(If yes, then attach updated evaluation of facility, including to)ics analysis, modeling analysis if
modeled at renewal, and description of how it fits into basinwide plan)
Additional Information attached? Y (Y or N) If yes, explain with attachments.
1. Federal effluent guideline limits
2. Toxicity test fact sheets
3. Map of vicinity

Guilford Mills, NCO0O23O5
Effluent Guideline Limitations - 40 CFR 410.52 (Subpart E)
Type of Product Produced
1000 Ibs/day prod. mon. avg
1000 Ibs/day daily max
Knit Fabric Finishing
1 12
120
Summary
410.52(a) (BPT)
Effluent Parameter
EPA Limitations in 40 CFR
(Ibs/1000 Ibs of product)
Effluent Limits
(Ibs/day)
Comments
Daily Max.
30 day avg.
Daily Max,
30 day avg.
BOD5
5.0
2.5
600
280
BPT
COD
60.0
30.0
7,200
3,360
BPT
TSS
21.8
10.9
2,616
1,221
BPT
Sulfide
0.20
0.10
24.0
11.2
BPT
Phenols
0.10
0.05
12.0
5.6
BPT
Total Chromiur
0.10
0.05
12.0
5.6 BPT
6.0-9.0�
pH
6.0-9.0
6.0-9.0
6.0-9.0
Production numbers are based on a conversation with Jimmy Summers on 6/25/96.
Daily max (120,000 Ibs/day)
Monthly avg. (112,000 Ibs/day)

Facility Name 6/Jrd A9E/i6/ 5t ,)1t/ sJoyt Permit # /JGOOa 305 Pipe # 00 /
CHRONIC TOXICITY PASS/FAIL PERMIT LIMIT (QRTRLY)
The effluent discharge shall at no time exhibit chronic toxicity using test procedures outlined in:
1.) The North Carolina Ceriodaphnia chronic effluent bioassay procedure (North Carolina Chronic Bioassay
Procedure - Revised *September 1989) or subsequent versions.
The effluent concentration at which there may be no observable inhibition of reproduction or significant mortality
is qn % (defined as treatment two in the North Carolina procedure document). The permit holder shall perform
guarterLv monitoring using this procedure to establish compliance with the permit condition. The firtt test will be
performed after thirty days from the effective date of this permit during the months of
/4pr., O I. Off'. . Effluent sampling for this testing shall be performed at the NPDES
muttefl final effluent discharge below all treatment processes.
Pe g
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge
Monitoring Form (MR-1) for the month in which it was performed, using the parameter code TGP3B.
Additionally, DEM Form AT-1 (original) is to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Road
Raleigh, N.C. 27607
Test data shall be complete and accurate and include all supporting chemical/physical measurements performed in
association with the toxicity tests, as well as all dose/response data. Total residual chlorine of the effluent toxicity
sample must be measured and reported if chlorine is employed for disinfection of the waste stream.
Should any single quarterly monitoring indicate a failure to meet specified limits, then monthly monitoring will
begin immediately until such time that a single test is passed. Upon passing, this monthly test requirement will
revert to quarterly in the months specified above.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of
Environmental Management 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 and appropriate environmental controls, shall constitute an invalid test and will require immediate
retesting(within 30 days of initial monitoring event). Failure to submit suitable test results will constitute
noncompliance with monitoring requirements.
7Q10 G. S cfs
Permitted Flow S MGD Recommended by:
IWC '70 A m4.e % i Ie ( duo, ne,1
Basin & Sub -basin 03-06-47 e •
Receiving Stream Ai reAr Rs je r'
County ,Q14/Apt Date G !o &
QCL PIF Version 9/91

Facility Name (9u i l Pord / II S / s+ a, v, Sso1 Permit # NG0O0230 S Pipe # DO (
CHRONIC TOXICITY PASS/FAIL PERMIT LIMIT (QRTRLY)
The effluent discharge shall at no time exhibit chronic toxicity using test procedures outlined in:
1.) The North Carolina Ceriodaphnia chronic effluent bioassay procedure (North Carolina Chronic Bioassay
Procedure - Revised *September 1989) or subsequent versions.
The effluent concentration at which there may be no observable inhibition of reproduction or significant mortality
is qD % (defined as treatment two in the North Carolina procedure document). The permit holder shall perform
quarterly monitoring using this procedure to establish compliance with the permit condition. The first test will be
performed after thirty days from the effective date of this permit during the months of
.-J`c�. , 4pr.,074r. ,. or.%: . Effluent sampling for this testing shall be performed at the NPDES
permitted final effluent discharge below all treatment processes.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge
Monitoring Form (MR-1) for the month in which it was performed, using the parameter code TGP3B.
Additionally, DEM Form AT-1 (original) is to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Road
Raleigh, N.C. 27607
Test data shall be complete and accurate and include all supporting chemical/physical measurements performed in
association with the toxicity tests, as well as all dose/response data. Total residual chlorine of the effluent toxicity
sample must be measured and reported if chlorine is employed for disinfection of the waste stream.
Should any single quarterly monitoring indicate a failure to meet specified limits, then monthly monitoring will
begin immediately until such time that a single test is passed. Upon passing, this monthly test requirement will
revert to quarterly in the months specified above.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of
Environmental Management 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 and appropriate environmental controls, shall constitute an invalid test and will require immediate
retesting(within 30 days of initial monitoring event). Failure to submit suitable test results will constitute
noncompliance with monitoring requirements.
7Q10 (.. S cfs
Permitted Flow 1. a•S MGD Recommended by:
d) IWC 90 C-S4;1n4 % dr.►..44 ch ,1,141
Basin & Sub -basin 03-06- ..
Receiving Stream /lily Cape. .4 r i .Vc
County Orlin
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Wasteflow (MGD):
BODS (mg/1):
COD (lbs/day):
DO (mg/1):
TSS (lbs/day):
Total Chromium (l.tg/1): dyx,si *,<
pH (SU): 41 , '' •,;�
T (°C): rtr�► r�:�.
TP (mg/1): (us-
TN (mg/I):
Sulfide (lbs/day):
Chronic Toxicity:
Fecal (/100 ml):
Chlorine (p.g/1):
Phenols (lbs/day):
Zinc (1.1.g/1):
Chloride (mg/1):
Copper (µgn):
Oil and Grease (mg/1):
Temperature (°C):
132.5 ibsid
Pre -expansion
Monthly Daily Max.
Avg.
0.965
11
4750
5.0
5 & 4 1035
6 0-9.0
monitor
monitor
monitor
9.5 18.0
P/F @19% (Jan, Apr,
Jul, Oct)
4.75
monitor
monitor
monitor
monitor
monitor
16.5
9500
5.0
2071
• 266
6.0-9.0
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monitor
monitor
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Monthly
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8
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6.0
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monitor
monitor
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6000
6.0
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217
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monitor
monitor
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Oct)
200
28.0*
5.0 10.0
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monitor
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monitor
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*Total residual chlorine shouldonly be limited/monitored if added to the wastestream.

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WHOLE EFFLUENT TOXICITY TESTING OISELF-MONITORING SUMMARY) Thu, Jun 13, 1996
V Pm 1992 Data Available
ACII 1'fY kl'O1IIRI?MI'NT YP
A(P(1
INN
n
Golden Poultry PERM CIIK LIM: 9.1% (New penis 611N36)
NC0072575/00I Begin:6/1/93 frequency: Q PAr A Jan Apr Jul Oct No8CompSINGL E
County: Lae Regioa:RRO Subbuia:CPFII
PF:1.0 Spcclal
7Q10: 17.0 IWC(%):9.I Order:
92 Pass
93 Pass
94 Pass
95 Pass
• 98 Pass
-•
—
—
—
—
---
—
—
—
—
Pass
Pass
Pass
Pass
Pass
r_r-1-a
---
—
—
—
-• •
—
—
—
„1,
Pass
Pass
Pass
Pass
r], a
--
—
—
—
.,l'.r
---
•-
-•
—
,n I
Pass
Pass
Pass
Peas
Pass
NIIV
--
—
-
(llf(-
—
--
._
Goldsboro 1VWVTP I'EKM CIIR LIM: 4%;6% WHEN I3XP
NC0023949/001 Begin:4/I/94 Fn,qu8nry: Q PA, A Jan Apr Jul Oct NonConsp:SINGI.I:
County:Wayne Region: WAIN) Subbuin:NEUOS
PP:6.375 Special
7Q10: 271.1 IWC(%):3.79 Oran:
92 Pass
93 al
94 Late•Latat
05 Pass
96 Pass
—
—
—
—
—
—
—
—
•-
—
Nil
Pass
Pass
Pass
Pass
—
—
--
--
--
--
—
—
Pass
Pass
Pass
Pass
--
--
--
—
—
—
—
Pass
Pass
Pass
Pass
--•
--
---
—
--
-.
--
—
Graham 11' mine Penn du lirn: 14%
NC0021211/001 Begin:3/1/96 Frequency: Q PA' A Ma Jun Sep Dec
County:Absiuox Region:WSRO Subbuin:CP1,02
PP:3.5 Special
7Q10:34 IWC(%):14 Older:
•NonComp:Singlc
1
92 --
93 —
04 —
OS —
96 —
—
—
—
—
—
Pass
Pass
Pass
Pass
Late
--
—
—
--
Pass
•-
--
—
--
Pass
Pass
Pass
Lino
---
•-----
--
Pass
•-•
---
-••
Fed
Pass
NEVI ate
Fail
Pass
---
Pass
Pass
—
--
•--
--
Pass
Pass
Pass
Pass
Granite Fells 1VW7'I' PERM CIIR LIM: I I%
NC0021890/001
NonCongs:SINGLE
92 --
93 --
94 —
95 —
06 --
--
--
—
—
--
Pass
Pass
Pass
NR/Pass
Pass
—
—
—
—
--
—
--
—
—
Pass
Pass
Pass
Pass
—
—
—
—
--
.-
—
--
Pass
Pass
Pass
Pass
-•-
--
—
---
—
—
—
—
Pass
Pass
Pass
Pass
Oegia: I2/1193 Frequency. Q PA: A Marian Sep Dec
Comity:Caldwell Regioa:ARO Subbasio:CTB32
PF:0.75 Special
7Q10:9.3 IWC(%):11 Order:
Greensboro N Buffalo Crk WWTP Perm chi lim: 90%
NC00232
NunComp:Single
92 Pass
93 Fait
04 Pass
95 NFtFa1
96 Fail
.-
Pass
—
Fall
Puss
--
•-
—
Fad
--
Pass
Pass
Pass
Pass
Pass
—
—
—
—
—
—
— -
—
,
Fad
Pass
Pass
Fad
Fail
—
—
Pass
Pass(s)
--
—
—
Pass(s)
Pass
Pass
Fad
--
--
—
Pass
--
—
--
--
45/001 Begin:4/1/96 Frequency: Q PAj A Jan Apr Jul Oct
Coumy:Guilford Region:WSRO Subbaaia: CP1432
PP: 16.0 Special
7Q10.0.90 IWC(%):96.50 Older
1; ' ssuora Osborne WWTP fend chrlim: 907E
NC(X147384A(0I Regis:1/1/96 fiap¢asy: Q WV A 1411 Apr Jul Oct
County:(iuilford Regina:WSRO Subbasio:Cl'F02
PF:20.0 Special
7Q10: 2.1 IWC'(%):93.7 Order
NoaConlp:Singlc
V D2 Pass
93 Fail
04 Pass
05 NFI/Pass
96 Fail
---
Pass
—
—
Fes
---
--
—
—
Pass
Fut
Pass
Pass
Pass
Pass
Pass
---
--
--
---
---
--
--
Pass
Pass
Pass
Fad
---
--
—
Pass
---
—
—
-•
Pass(s)
Pass
Pass
Pass
—
•-
—
—
...
—
—
—
Greenville WWTP Penn chi lim: 13%; upon cap 17.5MGD clw lim 20%
NC0023931/001 Begin:6/6/95 Frequency: Q('n7 A Mar Jun Sep Ike NonCmtlp:Siugle
County:Pitt Regioa:WAKO Subbasia: TAROS
PF: 10.50 special
166.0 IWC(%):8.91 Onla:
V 92 --
D3 --
04 —
05 —
96 —
--
--
—
--.
---
Pass(s)
Pass(s)
Pass(s)
Pass(s)
Pass(s)
—
—
•-
—
—
--
--
---
Pass(s)
Pass,Pass
Pass(s)
Pass s
I)
---
--
--
---
---
--
—
—
Pass(s)
Pass(s)
Pass
Fail
--
--
—
Ptlrsd(a)Pass(s)
--
—
—
—7Q10:
Pass(s)
Pass(a)
Pass(s)
G Industries, Inc. PERM CIIR LIM: 6%
NC000(391AN1( Begin:4/1/94 Frequency: Q P/P A Feb May Aug Nov
Coualy:l'olk Region:ARO Subbasin:BK1)06
PF:0.45 Special
7Q10: 10.8 1WC(%):6.07 Order
NunConip:SIN(illi
92 ---
03 --
04 —
05 —
06 Pass
Pass
fuss
fuss
Pass
Pass
---
-•
--
---
—
---
—
--
—
—
Pass
Pass
Pass
Pass
--
---
—
---
---
---
•-•
—
Pass
Pass
Pass
Pass
--
--
--
—
—
—
--
Pass
Pass
Pass
Fag
—
--
Fad
G laduxlrieo. Inc. PERM CIIR LIM: 1.8%
NC00113984/1911 Begin:9/1/94 Frequency: Q PAr A Marius Sep Dec
Couay:C•leveLod Region: MHO Subbasin: BRDO5
P11:.38 Special
7Q10: 32 IWC(%):1.8 laden.
NonComp:SINGLI3
92 --
93 —
94 —
05 —
96 --
---
•••
--
---
...
.--
.-.
--
_-.
Puss
—
—
—
--
—
»-
—
.-
.-
--
—
.-
---
-_
--
._
._
--
--
_-
..-
_-
...
-_
---
—
-
-••
—
—
—
. -
Pass
Guilford Mills Bass PI(RM Lint LIM: 19%t WIII•N >0.965
NC0002305J001 Begin:
(:IIH 1.IM 23%
- . NuuCorup:SIN LE
02 Fu1
93 Pass
04 Fug
95 Fad
06 Pass
- Fad
--
Pass
Fed
---
Fail
--•
—
Pass
—
Fag
Fad
Pass
Pass
Pass
Fad
Pass
—
—
Pass
---
—
---
Pass
Fad
Puss
Pass
---
M
--
---
--•
Pass
--
---
Pass
Fail
pass
Pass
---
fat
---
---
Puss
---
I1/1194 - Frequency: Q PAr -A Jan Apr Jul Oct. -
Couoly:Duplia Region:WINO Subbasin:CPF22
PP:0965 Special
7Q10:6.500 1WC(%):18.68 Onkr.
Halifax WWTP I'EKM CIIR LIM: 14%
NC0066192/001 Begin:1/12/93 Frequency: Q ('Ar A Jai Apr Jul Oct
Cauaty:H alifax Region: HRO Sabb.uin: KOA08
P12:0.075 Special
7Q10: 0.70 IWC(6.):14.0 ONcr:
NoaCompSING1.E
92 -•-
93 •--
94 Pass
05 Puss
96 Fad
—
Pass
—
—
Pass
—
—
—
—
—
--
NR/Pass
Pass
Pass
Puss
—
—
—
—
--
_--
--
•-•
—
Pass
Pass
Pass
.-.
---
---
---
...
•--
--
•••
.--
Pass
Fad
Pass
...
---
Pass
•--
-.
-"
•••
0 2 cooucwivc failures = significant noncompliance
I.F.GFNI)-.
PI•:KM . Perin' Kerpiircmeal LET = Administrative Leiter - Target Frequency = Monitoring frequency: Q- Qsanealy; M- Monthly:DM- Bimonthly; SA• Sc ':uu,ually: A. Annually; OWD- ()My when discharging;1)- Discontinu d uonnoring requircnala;
Drain = Hsu month asiuiral 7Q10 = Kocciviog sucanl low flow criterion (c(s) A = o uanedsc y monitoring Mersas to moodily
upon single failure Malu dui lrsiiuu:uN• g must ur - cm.. IAAPK,1(11-•OCE Nw(orup = Cwuut Cungdi,une Itrquireosw,
PF=Permittedflow (MGD) IWC%=luslrwmwutecuncenualion P/F=11us/Fadchronic Ia1 AC=Acute (:IIK=Chronic
❑au Notation: f - Fauirad Minnow; • - Ceriodaplmia sn.: my - Mvsid shrimp: CIIV - Chronic value;1' - Mortality of stated percentace sr hiellesl concentration: at - Podomed 4v 1)I9d Tom. Eva! (iroupt Is1 - Dad teat
Kcloning Nw:uioo: -- = Data WI required; NR - Nol reported; ( ) - Beginning of Quarter Facility Activity Status: I - Inactive, N - Newly Issucd(lo construct); 11 • Active: bur uoi discharging; 1-More data available for month in 1(uestlan f=111tCsir:o'a"'"
24

Joo
State of North Carolina
Department of Environment, Health, and Natural Resources
Wilmington Regional Office
MEMORANDUM
DATE:
TO:
THROUGH:
FROM:
SUBJECT:
DIVISION OF ENVIRONMENTAL MANAGEMENT
May 23, 1996
Dianne Williams Wilb -n
Dave A
Mike Williams
REU ED
MAY 2 6 1996
EA(,ILMES ASSESSMENT( 1131T
Staff Repo and Recommendations SOC WQ No. 96-14
Guilford Mills, Inc.
NPDES Permit NC0002305
Duplin County
1.0
A)
Please fmd attached a staff report for an SOC for Guilford Mills, Inc. EMC WQ 96-14. The
Cuaipany requests the SOC until final compliance date of October 30, 1998. Your review and comment
on the proposed draft is requested by June 7, 1996. The Company has reviewed the SOC as it appears
and is satisfied, and ready to sign the document.
If you have any questions concerning this report, please contact me at [phone].
MW: GUILES OC.AP6
cc: Wilmington Regional Office
-1

9) Comply with final effluent limitations contained in NPDES Permit NC0002305 on
or before October 30, 1998.
c. During the time in which this Special Order by Consent is effective, comply with the
interim effluent limitations contained in Attachments A, B, and C. The following
reflects only the requirements that have been modified from previous NPDES
requirements:
Parameter
Toxicity
Permit Limitation
No observable inhibition of
reproduction or significant
mortality at an effluent
concentration of 23 %
Parameter Permit Monitoring Requirements
Fecal Coliform Weekly Composite @ effluent
Conductivity 3/Week Composite @ U, and D
Annual Pollutant None as Required by previous
Analysis permit.
SOC Limitation
Full range chronic toxicity
monitoring at serial dilutions of
60%, 46%, 23%, 11.5%, and
6.5%
SOC Requirements
Weekly Grab @ effluent
3/Week Grab @ U, and D
Annual sampling
@ effluent (See attachment C)
d. No later than fourteen (14) calendar days after any date identified for accomplishment
of any activity listed in 2b. above, submit to the Director of DEM written notice of
compliance or noncompliance therewith. In the case of noncompliance the notice
shall include a statement of the reason(s) for noncompliance, remedial action(s) taken.
and a statement identifying the extent to which subsequent dates or times for
accomplishment of listed activities may be affected.
3. Guilford Mills agrees that unless excused under paragraph 4, Guilford Mills will pay the
Director of DEM, by check payable to the North Carolina Department of Environment,
Health and Natural Resources, stipulated penalties according to the following schedule for
failure to meet the deadlines set out in paragraphs 2b. and 2d., or failure to comply with the
effluent limitations/monitoring requirements contained in Attachments A, B, and C.

Failure to meet a schedule date $100/day for the first 7 days; $500/day
thereafter
Failure to maintain compliance with
any modified limit contained in the
SOC.
Failure to achieve compliance with
effluent limits at final compliance
deadline of October 30, 1998 and beyond.
Failure to monitor chronic toxicity
in accordance with the schedule
contained in attachments A and/or B.
$1, 000 per violation
$10,000 per month
$5,000 per omitted value
4. Guilford Mills and the Commission agree that the stipulated penalties are not due if the
company satisfies DEM that noncompliance was caused solely by:
a. An act of God;
b. An act of war;
c. An intentional act or omission of a third party but this defense shall not be available if
the act or omission is that of an employee or agent of the defendant or if the act or
omission occurs in connection with a contractual relationship with the permittee;
d. An extraordinary event beyond the permittees control. Contractor delays or failure to
obtain funding will not be considered as events beyond the permittees control; or
e. Any combination of the above causes.
Failure within thirty (30) days of receipt of written demand to pay the penalties, or challenge
them by a contested case petition pursuant to G.S. 150B-23, will be grounds for a collection
action, which the Attorney General is hereby authorized to initiate. The only issue in such an
action will be whether the thirty (30) days has elapsed.

5. This Special Order by Consent and any terms, conditions and interim effluent limitations
contained herein, hereby supersede any and all previous Special Orders, Enforcement
Compliance Schedule Letters, terms, conditions, and limitations contained therein issued in
connection with NPDES Permit No. NC0002305.
6. Noncompliance with the terms of this Special Order by Consent is subject to enforcement
action in addition to the above stipulated penalties, including injunctive relief pursuant to
G.S. 143-215.6C.
7. The permittee, upon signature of the Special Order by Consent, will be expected to comply
with all schedule dates, terms, and conditions of this document.
8. This Special Order by Consent shall expire oOctober 30. 1998`__ ____
ci,w_ -31
For Guilford Mills, Inc.:
Date
John Emrich, Chief Operating Officer
Guilford Mills, Incorporated
For the North Carolina Environmental Management Commission:
Date
Chair of the Commission

EMC WQ No. 96-14
ATTACHMENT A
Guilford Mills, Inc: NPDES Permit NC0002305
A(1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - Interim
During the period beginning on the effective date of this Special Order and lasting until October 30, 1998.
001. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristics
Flow
BOD, 5 day, 20 degrees C (lbs/day)
BOD, 5 Day, 20 degrees C (mg/1)
COD
Total Suspended Solids
Sulfide
Phenols
Fecal Coliform (Geometric Mean)
Total Chromium
Total Residual Chlorine
Dissolved Oxygen **
Temperature
Chloride
Copper
Oil and Grease
Zinc
Total Phosphorous
Total Nitrogen (NO2 +NO3 +TKN)
Chronic Toxicity *
Conductivity
Annual Pollutant Analysis (APAM)
Permittee is authorized to discharge from outfall serial number
Discharge Limitations
Units as Specified Measurement
Monthly Average Daily Max, Frequency
1.25 MGD
83.4 lbs/day
3000.0 lbslday
1035.0 lbs/day
10 lbs/day
5.0 lbs/day
200/100 ml
(Attachment B)
(Attachment C)
125.1 lbs/day
12.0 mg/1
6000.0 lbs/day
2071.0 lbs/day
20.0 lbs/day
10.0 lbs/day
400/100 nil
217.0 ug/1
28.0 ug/1
* Toxicity monitoring shall be conducted as required in Attachment B.
Sample Location: I - Influent, E - Effluent, U - Upstream at nearest accessible point, D - Immediately downstream at the Sarecta Bridge.
The daily average effluent dissolved oxygen concentration shall not be less than 6.0 mg/1.
Total residual chlorine should only be limited if added to the wastestream.
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be by grab sample three times per week at the effluent.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
The permittee may also be required to monitor for other parameters as deemed necessary by the permit or Administrative letters.
**
***
***
Continuous
3/Week
3/Week
Weekly
3/Week
Weekly
Weekly
Weekly
Weekly
Weekly
3/Week
3/Week
2/Month
2/Month
2/Month
2/Month
Monthly
Monthly
Quarterly
3/Week
Annually
Monitoring Requirements
Sample **Sample
Type Location
Recording
Composite
Composite
Composite
Composite
Grab
Grab
Grab
Composite
Grab
Grab
Grab
Composite
Conposite
Composite
Grab
Composite
Composite
Composite
Grab
I or E
E
E
E
E
E
E
E
E
E
E,U,D
E,U,D
E
E
E
E
E
E
E
U,D
E

ATTACHMENT B
CHRONIC TOXICITY MONITORING (QUARTERLY)
Guilford Mills, Inc.
NPDES Permit NC0002305
EMC SOC WQ 96-14
Duplin County
The Permittee shall conduct chronic toxicity tests using test procedures outlined in:
The North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure (September, 1994) or
subsequent versions.
The effluent concentration defined as the Instream Waste Concentration (IWC) shall be 23 %
Recommended effluent serial dilutions for the full range test are 60%, 46 %, 23 %, 11.5 %, and 6.5 %
(these concentrations may be modified upon prior approval from the Environmental Sciences Branch
provided that Phase II methodology is adhered to). The chronic value for the analysis will be
determined using the geometric mean of the highest concentration having no statistically detectable
impairment of reproduction or survival and the lowest concentration that does have a statistically
detectable impairment of reproduction or survival. The presence of 48 hour acute toxicity will be
determined using Fishers Exact Test at 48 hours from test initiation. Collection methods, exposure
regimes, and further statistical methods are described by the document referenced above.
The permit holder shall perform at a minimum, quarterly monitoring using these procedures to
establish compliance with the Order condition. Full range toxicity monitoring is to be conducted 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.
All toxicity testing results required as part of this Order condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the
appropriate parameter code TEIP3B for the chronic value and TGA3B for the 48 hour Acute Toxicity
measure (Pass/Fail). Additionally, DEM Form AT-3 (original) is to be sent to the following address:
Attention:
Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Road
Raleigh, NC 27607
Test data shall be complete and accurate and include all supporting chemical/physical measurements
performed in association with the toxicity tests, as well as all dose/response data. Total residual
chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the waste stream.
Should any test data from this monitoring requirement or tests performed by the North Carolina
Division of Environmental Management indicate potential impacts to the receiving stream, this Special
Order by Consent 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 and appropriate environmental controls, shall constitute an invalid test and will
require immediate retesting (within thirty (30) days of initial monitoring event). Failure to submit
suitable test results will constitute noncompliance with monitoring requirements.

STAFF REPORT
Special Order by Consent
Guilford Mills, Inc.
EMC WQ No. 96-14
I. Discussion
Guilford Mills, Inc., Guilford East Division, holds NPDES Permit No. NC0002305
for the operation of an existing biological activated sludge wastewater treatment plant
for textile dyeing and finishing industry, and authorizes the discharge of treated
wastewater to the Northeast Cape Fear River, classified "C-Swampwater" waters of
the State, in the Cape Fear River Basin. During permit reissuance dated September
26, 1994, DEM stated that since the outfall did not extend into the main channel of
the river at this location, future allocations of limits could be affected as 7Q10
information is based on the main channel flow data. Toxicity limitations became more
stringent as flows were increased during this period. The chronic toxicity limitation of
19 % was based on a permitted flow of 0.965 MGD. The limit became 23 % as flow
was increased to 1.25 MGD. During the past year, the Company has reformulated and
substituted dyes in an effort to reduce toxicity. Recent full range chronic toxicity tests
have indicated that the effluent is not chronically toxic in effluent concentrations of
44 % . It is anticipated that at the present outfall location, the 7Q10 will be 0 CFS, and
therefore require a 90% chronic limit, which will not be attainable. Other chemical
parameter limitations will likely be affected as a result of this change. The Company
is requesting a Special Order by Consent for a two year period. During this time, the
Company proposes to study outfall location strategies, make necessary operational
changes and/or construct necessary treatment plant improvements to attain compliance
with final permit limits on or before October 30, 1998.
II. Additional Information
a. Current MP screen -
b. Funding source - Guilford Mills, Inc.
c. Instream assessment - None known
d. Additional flows - None
e. Facility improvements required by this Order - Possible relocation of outfall,
and/or construction of additional in -plant treatment processes
f. Is facility monitoring according to current NPDES Permit or SOC? NPDES
Permit NC0002305

g.
Does toxicity need to be included? Yes, it is recommended that full range
chronic toxicity monitoring be required on a quarterly basis for the duration of
the SOC. See Attachment B.
h. Does pretreatment need to be addressed? No
i. Facility type and design flow? Activated sludge 1.25 MGD
j. Is facility properly operated and maintained? Yes
k. Is NPDES Permit under adjudication? No
1. Are there special circumstances concerning issuance of the SOC? The outfall
pipe is at the same location as was constructed 20 years ago. During 1994 it
was discovered that limits were based on 7Q10 of the main channel, while the
outfall was actually located along the fringe of one of the channels of the
swamp.
m. Expiration date should be listed on Attachment A. The date to achieve
compliance with final effluent limitations is October 30, 1998, and is listed on
Attachment A.
n. Are current NPDES parameters listed on the SOC limits/monitoring page? Yes
o. Discuss downstream water quality impacts. Impacts to the Northeast Cape Fear
River downstream of this location have not been documented.
p.
Explain mechanisms for arriving at interim limits and compliance schedule. The
interim limitations were determined by reviewing the past twelve (12) months
self monitoring data from the plant. The compliance schedule was submitted by
Guilford Mills based on recommendations from its consultant, Grey
Engineering, anticipated completion of instream modeling studies, and a
proposed schedule of construction activities for waste treatment units and/or
outfall relocation. The schedule, as submitted, is reasonable.
III. Recommendations
It is recommended that Guilford Mills, Inc., be granted the SOC as proposed. It is
also recommended that stipulated penalties be imposed in the amount of $10,000.00
for failure by the Company to meet the final compliance date of October 30, 1998.
MW:GUILFSOC.AP6

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMIVIISSION
COUNTY OF DUPLIN
IN THE MATTER OF )
NORTH CAROLINA )
NPDES PERMIT )
NO. NC0002305 )
HELD BY GUILFORD MILLS )
INCORPORATED )
SPECIAL ORDER BY CONSENT
EMC WQ NO. 96-14
Pursuant to provisions of North Carolina General Statutes (G.S.) 143-215.2 and 143-215.67, this
Special Order by Consent is entered into by Guilford Mills, Inc., hereinafter referred to as Guilford
Mills, and the North Carolina Environmental Management Commission, an agency of the State of
North Carolina created by G.S. 143B-282, and hereinafter referred to as the Commission:
1. Guilford Mills and the Commission hereby stipulate the following:
a. That Guilford Mills holds North Carolina NPDES Permit No. NC0002305, . for
operation of an existing wastewater treatment works and for making an outlet
therefrom for treated wastewater to the Northeast Cape Fear River, Class "C-Swamp"
waters of this State in the Cape Fear River Basin, but will be unable to consistently
comply with the final effluent limitations anticipated in the renewal of Permit No.
NC0002305 to be issued effective July 31, 1996. Compliance may require preparation
of plans and specifications for construction and operation of additional treatment
works, and/or relocation of the outfall pipe 001.
b. That noncompliance with fmal effluent limitations will constitute a cause and
contribution to pollution of the waters of this State named above, and Guilford Mills
is within the jurisdiction of the Commission as set forth in G.S. Chapter 143, Article
21.
c. Since this Special Order is by Consent, neither party will file a petition for a
contested case or for judicial review concerning its terms.
~' d. That no ext - - 'on o order be rant - : • eyo • - fmal om ice . z •
Octo , 19 plic44 "mi3O ruL,catte
2. Guilford Mills desiring to comply with the permit identified in paragraph la. above, hereby
agrees to do the following:

a. Comply with all terms and conditions of the permit except those effluent limitations
identified in paragraph la. above. See Attachments A, B, and C for all monitoring
requirements and effluent limitations. The permittee may also be required to monitor
for other parameters as deemed necessary by the Director in future permits or
administrative letters.
b. Undertake the following activities in accordance with the indicated time schedule:
1) Continue implementation of the Toxicity Reduction Evaluation and submit detailed
quarterly TRE progress reports in triplicate to the Wilmington Regional Office no
later than the 30th day of each March, June, September and December for the
duration of the SOC. Quarterly TRE progress reports will contain TRE activities
undertaken during the quarter, and activities proposed for the upcoming quarter. The
TRE should consider but is not limited to effluent characterization and identification
of suspected toxicants, evaluation of point source contributions of toxicity,
engineering evaluation of the WWTP, activated sludge treatability/refractory studies,
evaluation of chemical usage and product substitution, and WWTP/Production
changes which may affect toxicity.
2) Conduct a study of the Northeast Cape Fear River system in the vicinity of
Guilford Mills, Inc. and study alternatives to meet new NPDES permit limitations.
The study will model the flow regime of the River/swamp system adjacent to the
plant, include a surveyed transect of the River/swamp system from the area of the
present outfall area, and will suggest alternatives for meeting new permit limits. The
study will be completed and three (3) copies of the report of the findings will be
submitted to DEM on or before June 30, 1997.
3) Meet with DEM to determine course of action based on study, and select
alternative for meeting new permit limits on or before July 31, 1997.
4) Submit application for modified NPDES Permit, if needed on or before August 31,
1997.
5) Submit application for authorization to construct for selected alternative on or
before September 30, 1997.
6) Receive approval for authorization to construct November 30, 1997.
7) Begin construction of necessary improvements to achieve compliance on or before
December 15, 1997.
8) Complete construction of necessary improvements to achieve compliance on or
before September 30, 1998.

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§410.44
tions representing the degree of efflu-
ent reduction attainable by the appli-
cation of the best available technology
economically achievable (BAT):
Pollutant or pollutant property
BAT limitations
Maximum for
any 1 day
Average of
daily values
for 30 con-
secutive days
COD
Sulfide
Phenols » ..
Total Chromium
Kg/kkg (or pound per 1,000
Ib) of product
60.0
020
0.10
0.10
30.0
0.10
0.05
0.05
(b) Except as provided in paragraph
(e) of this section for commission fin-
ishing operations, the following limita-
tions establish the quantity or quality
of pollutants or pollutant properties,
controlled by this section and attrib-
utable to the finishing of woven fabrics
through simple manufacturing oper-
ations employing a synthetic fiber or
through complex manufacturing oper-
ations employing a natural fiber, which
may be discharged by a point source
subject to the provisions of this sub-
part, in addition to the discharge al-
lowed by paragraph (a) of this section.
Pollutant or pollutant property
BAT timtations
Maximum for
any 1 day
Average of
daily values
for 30 con-
secutive days
COD
K9Adcg (or pounds per 1,000
lb) of product
20.0
10.0
(c) Except as provided in paragraph
(e) of this section for commission fin-
ishing operations, the following limita-
tions establish the quantity or quality
of pollutants or pollutant properties,
controlled by this section and attrib-
utable to the finishing of woven fabrics
through simple manufacturing oper-
ations employing a natural and syn-
thetic fiber blend or through complex
manufacturing operations employing a
synthetic fiber, which may be dis-
charged by a point source subject to
the provisions of this subpart, in addi-
tion to the discharge allowed by para-
graph (a) of this section.
40 CFR Ch. 1 (7-1-93 Edition)
Pollutant or pollutant property
BAT limitations
Maximum for
any 1 day
Average of
daily values
for 30 con-
secutive days
COD
Kglkkg (or pounds per 1,000
lb) 01 product
40.0
20.0
(d) Except as provided in paragraph
(e) of this section for commission fin-
ishing operations, the following limita-
tions establish the quantity or quality
of pollutants or pollutant properties,
controlled by this section and attrib--'•
utable to the finishing of woven fabrics
through complex manufacturing oper-
ations employing a natural and syn-
thetic fiber blend, which may be dis-
charged by a point source subject to
the provisions of this subpart, in addi-
tion to the discharge allowed by para-
graph (a) of this subpart.
Pollutant or pollutant property
BAT limitations
Maximum
for any 1
day
Average of
daily values
for 30 con-
secutive
days
COD
Kg/kkg (or pounds per
1,000 D) of product
60.0 I 30.0
(e) Additional allocations equal to
the effluent limitations established in
paragraphs (a), (b), (c), and (d) of this
section are allowed any existing point
source subject to such effluent limita-
tions that finishes woven fabrics
through "commission finishing" as de-
fined in §410.01.
(47 FR 38819, Sept. 2, 1982. as amended at 48
FR 39629, Sept. 1. 1983]
§ 410.44 Pretreatment standards for
existing sources (PSES).
Any existing source subject to this
subpart that introduces process
wastewater pollutants into a publicly
owned treatment works must complY
with 40 CFR part 403.
Environmental Protection Agency
*410.45 New standardssource performance
(NSPS).
Any new source subject to this sub-
part must achieve the following new
source performance standards (NSPS):
SIMPLE MANUFACTURING OPERATIONS
Pollutant or pollutant property
NSPS
Maximum for
any 1 day
Average of
daily values
for 30 con-
secutive days
BOD5
COD
TSS
Sulfide
Phenols
Total Chromium
pH'
Kglkkg (or pounds per 1.000
Ib) of product
3.3
41.7
8.8
0.20
0.10
0.10
(')
1.7
26.9
3.9
0.10
0.05
0.05
(')
' Within the range 6.0 to 9.0 al all times.
NOTE: Additional allocations for "commission finishers" are
not available to new sources.
COMPLEX MANUFACTURING OPERATIONS •
Pollutant or pollutant property
NSPS
Maximum for
any 1 day
Average of
daily values
for 30 con-
secutive days
B0D5
COD
TSS
Sulfide
Phenols
Total Chromium
PH'
Kglkkg (or pounds per 1.000
Ib) o1 product
3.7
68.7
14.4
0.20
0.10
0.10
(1)
1.9
442
6.4
0.10
0.05
0.05
(' )
Within the range 6.0 to 9.0 at all times.
NOTE: Additional allocations for "commission finishers" we
not available to new sources.
DESIZING
Pollutant or pollutant property
NSPS
Maximum for
any 1 day
Average of
daily values
for 30 con-
secutive days
8005
COD
TSS
Sulfide
Phenols
Total Chromium
PH
Kglkkg (or pounds per 1,000
lb) of product
5.5
59.5
15.6
0.20
0.10
0.10
(')
2.8
38.3
6.9
0.10
0.05
0.05
(' )
'Within the range 6.0 to 9.0
NOTE: Additional allocations
not available to new sources.
at all times.
for "commission finishers" are
§ 410.51
§ 410.46 Pretreatment standards for
new sources (PSNS).
Any new source subject to this sub-
part that introduces process
wastewater pollutants into a publicly
owned treatment works must comply
with 40 CFR part 403.
1)410.47 Effluent limitations represent-
ing the degree of effluent reduction
attainable by the application of the
best conventional pollutant control
technology (BCT). [Reserved]
Subpart E-Knit Fabric Finishing
Subcategory
§ 410.50 Applicability; description of
the knit fabric finishing sub-
category.
The provisions of this subpart are ap-
plicable to process wastewater dis-
charges resulting from the following
types of textile mills: knit fabric fin-
ishers, which may include any or all of
the following unit operations: Bleach-
ing, mercerizing, dyeing, printing,
resin treatment, water proofing, flame
proofing, soil repellency application
and a special finish application.
§ 410.51 Specialized definitions.
In addition to the definitions set
forth in 40 CFR part 401 and §410.01 of
this part, the following definitions
apply to this subpart:
(a) The term simple manufacturing op-
eration shall mean all the following
unit processes: desizing, fiber prepara-
tion and dyeing.
(b) The term complex manufacturing
operation shall mean "simple" unit
processes (desizing, fiber preparation
and dyeing) plus any additional manu-
facturing operations such as printing,
water proofing, or applying stain re-
sistance or other functional fabric fin-
ishes.
(c) For NSPS (§410.55) the term ho-
siery products shall mean the internal
subdivision of the knit fabric finishing
subcategory for facilities that are en-
gaged primarily in dyeing or finishing
hosiery of any type.

r
§410.52
* 410.62 Effluent limitations represent-
ing the degree of effluent reduction
attainable by the application of the
best practicable control technology
currently available (BPT).
(a) Except as provided in 40 CFR
125.30 through 125.32, any existing point
source subject to this subpart must
achieve the following effluent limita-
tions representing the degree of efflu-
ent reduction attainable by the appli-
cation of the best practicable control
technology currently available (BPT):
Pollutant or pollutant property
BOD5
COD
TSS
Sulfide
Phenols
Total chromium
PH
BPT limitations
Maximum for
any 1 day
Average of
daily values
for 30 con-
secutive days
K99 (or pounds per 1,000
lb) of product
5.0
60.0
21.8
020
0.10
0.10
(' )
2.5
30.0
10.9
0.10
0.05
0.05
()
+Within the range 6.0 to 9.0 al eta times.
(b) Except as provided in paragraph
(d) of this section for commission fin-
ishing operations, the following limita-
tions establish the quantity or quality
of pollutants or pollutant properties,
controlled by this section and attrib-
utable to the finishing of knit fabrics
through simple manufacturing oper-
ations employing a natural and syn-
thetic fiber or through complex manu-
facturing operations employing a syn-
thetic fiber, which may be discharged
by a point source subject to the provi-
sions of this subpart, in addition to the
discharge allowed by paragraph (a) of
this section.
Pollutant or pollutant
BPT limitations
Maximum
for any 1
day
Average of
daily values
for 30 con-
secutive
days
COD
Ktildcg (or pounds per
1,000 b) of product
20.0 I 10.0
(c) Except as provided in paragraph
(d) of this section for commission fin-
ishing operations, the following limita-
40 CFR Ch. I (7-1-93 Edition)
tions establish the quantity or quality
of pollutants or pollutant properties,
controlled by this section and attrib-
utable to the finishing of knit fabrics
through complex manufacturing oper-
ations employing a natural and syn-
thetic fiber blend, which may be dis-
charged by a point source subject to
the provisions of this subpart, in addi-
tion to the discharge allowed by para-
graph (a) of this section.
Pollutant or pollutant property
coo
I3PT limitations
Maximum
for any 1
day
Average of
daily values
lor.30 con-
secutive
days
Kglkkg (or pounds per
1,000 b) of product
40.0 20.0
(d) Additional allocations equal to
the effluent limitations established in
paragraphs (a), (b), and (c) of this sec-
tion are allowed any existing point
source subject to such effluent limita-
tions that finishes knit fabrics through
"commission finishing" as defined in
§ 410.01.
[47 FR 38819, Sept. 2, 1982, as amended at 48
FR 39624, Sept. 1, 1983]
*410.53 Effluent limitations represent-
ing the degree of effluent reduction
attainable by the application of the
best available technology economi-
cally achievable (BAT).
(a) Except as provided in 40 CFR
125.30 through 125.32, any existing point
source subject to this subpart must
achieve the following effluent limita-
tions representing the degree of efflu-
ent reduction attainable by the appli-
cation of the best available technology
economically achievable (BAT):
Pollutant or pollutant property
COD
Sulfide
Phenols
Total Chromium
BAT limitations
Average 0
daily values
for 30 con-
secutive arr
Maximum for
any 1 day
Kgikkg (or pounds per 1,000
Ib) of product
60.0
020
0.10
0.10
300
0.10
0.06
aos
Environmental Protection Agency
(b) Except as provided in paragraph
(d) of this section for commission fin-
ishing operations, the following limita-
tions establish the quantity or quality
of pollutants or pollutant properties,
controlled by this section and attrib-
utable to the finishing of knit fabrics
through simple manufacturing oper-
ations employing a natural and syn-
thetic fiber or through complex manu-
facturing operations employing a syn-
thetic fiber, which may be discharged
by a point source subject to the provi-
sions of this subpart, in addition to the
discharge allowed by paragraph (a) of
this section.
Pollutant or pollutant property
BAT limitations
Maximum
for any 1
day
Average of
daily values
for 30 con-
secutive
days
COD
Kgikkg (or pounds per
1.000 Ib) of product
20,0 I 10.0
(c) Except as provided in paragraph
(d) of this section for commission fin-
ishing operations, the following limita-
tions establish the quantity or quality
of pollutants or pollutant properties,
controlled by this section and attrib-
utable to the finishing of knit fabrics
through complex manufacturing oper-
ations employing a natural and syn-
thetic fiber blend, which may be dis-
charged by a point source subject to
the provisions of this subpart, in addi-
tion to the discharge allowed by para-
graph (a) of this section.
Pollutant or pollutant property
CAD
BAT limitations
Maximum for I dalvy vaallues
any 1 day for 30 con-
secutive days
Kghckg (or pounds per 1,000
Ib) of product
40.0 I 20.0
(d) Additional allocations equal to
the effluent limitations established in
paragraphs (a), (b), and (c) of this sec-
tion are allowed any existing point
source subject to such effluent limita-
tions that finishes knit fabrics through
§ 410.55
"commission finishing" as defined in
§ 410.01.
[47 FR 38819, Sept. 2, 1982, as amended at 48
FR 39624, Sept. 1, 1983]
§ 410.54 Pretreatment standards for
existing sources (PSES).
Any existing source subject to this
subpart that introduces process waste-
water pollutants into a publicly owned
treatment works must comply with 40
CFR part 403.
§ 410.55 New source performance
standards (NSPS).
Any new source subject to this sub-
part must achieve the following new
source performance standards (NSPS):
SIMPLE MANUFACTURING OPERATIONS
NSPS
Pollutant or pollutant property
BOD5
COD
TSS
Sulfide
Phenols
Total chromium
pH
Maximum for I dAailjyrvaallues
any 1 day 11 for 30 con-
secutive days
Kg/kkg (or pounds per 1,000
Ib) of product
3.6
48.1
13.2
0.20
0.10
0.10
(')
1.9
31.0
5.9
0.10
0.05
0.05
(')
1 Within the range 6.0 to 9.0 at all times.
NOTE: Additional allocations for "commission finishers" are
not available to new sources.
COMPLEX MANUFACTURING OPERATIONS
Pollutant or pollutant property
SODS
COD
TSS
Sulfide
Phenols
Total Chromium
PH
NSPS
Maximum for 1 daily verage
any 1 day for 30 con-
secutive days
Kg/kkg (or pounds per 1,000
lb) of product
4.8 2.5
51.0 32.9
122 5.4
020 0.10
0.10 0.05
0.10 0.05
('-) ('-)
' wrt In the range 6.0 to 9.0 at all times.
NOTE: Additional allocations for "commission finishers" are
not available to new sources.

SOC PRIORITY PROJECT: YES NO X
If Yes, SOC No.
To: Permits and Engineering Unit
Water Quality Section
Attention: Mark McIntire
(Review Engineer)
Date: May 8, 1996
NPDES STAFF REPORT AND RECOMMENDATION
County: Duplin
Permit No. NO0002305
PART I - GENERAL INFORMATION
1. Facility and Address:
Guilford East
Post Office Box 498
Kenansville, North Carolina 28349
2. Date of Investigation: May 3, 1996
3. Report Prepared by: Edward Beck
4. Persons Contacted and Telephone Number:
Jimmy Summers, Corporate Environmental Manager
[phone]
5. Directions to Site: The site is located on the east side of
NC Highway 903/11 north of Kenansville, approximately 0.1 mile
south of the junction of NCSR 1300.
6. Discharge Point(s), List for all discharge points:
Latitude: 35° 01' 00" Longitude: 74° 51' 05"
Attach a USGS map extract and indicate treatment facility site and
discharge point on map.
U.S.G.S. Quad No: G27SE U.S.G.S. Quad Name: Albertson
7. Site size and expansion area consistent with application ?
X Yes No If No, explain:
8. Topography (relationship to flood plain included): The
elevation of the plant site is approximately 30 meters msl
which is probably above the 100 year flood plane.

9. Location of nearest dwelling: No dwellings in the vicinity.
10. Receiving stream or affected surface waters:
Northeast Cape Fear River
a. Classification: Class C Swampwater
b. River Basin and Subbasin No.: 03-06-22
c. Describe receiving stream features and pertinent
downstream uses:
Rural swamp with multiple stream channels in the vicinity
of the outfall.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater to be permitted:
1.25 MGD and 1.5 MGD
b. What is the current permitted flow limit? 1.25 MGD
c. Actual treatment capacity of the current facility?
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two
years: February, 1995, an authorization was given for
construction of fine and coarse screening devises at the
head of the plant.
e. Please provide a description of existing or substantially
constructed wastewater treatment facilities: The system
consists of an automatic cleaning bar screen, a parshall
flume, a continuous recording flow meter, fine and coarse
screening devises, a flow equalization basin with three
floating aerators, a two million gallon aeration basin
with eight floating aerators, a one million gallon
aeration basin with four floating aerators, two aeration
basins of one half million gallon capacity each with one
floating aerator each, two clarifiers with mechanical
skimmers and sludge scrapers and enzyme addition, an
aerobic sludge digester with one floating aerator, a
reaeration basin with one floating aerator, a flow meter,
a composite sampler, twelve sludge drying beds.
f. Please provide a description of proposed wastewater
treatment facilities: A proposal is currently being
reviewed for improvements in several areas of the
treatment facility. One of the small aeration basins is
to be converted to a chlorine contact and dechlorination
facility. The two clarifiers are to be improved with the
addition of perimeter baffles. A new effluent pump
station is to be installed and the final reaeration basin
and effluent weir are to be abandoned.
g. Possible toxic impacts to surface waters: The facility is
currently passing toxicity tests required by the permit.

h. Pretreatment Program (POTWs only):
in development approved
should be required not needed X
2. Residuals handling and utilization/disposal scheme:
a. If residuals are being land applied, please specify DEM
Permit No. WQ0006816
Residuals Contractor: McGill Environmental Systems, Inc
Telephone No.: [phone]
b. Residuals stabilization: PSRP PFRP X
Residuals are digested and dewatered at the treatment plant
site and then digested at the McGill facility.
3. Treatment plant classification (attach completed rating
sheet) : Class III
4. SIC Code(s): 2259
Wastewater Code(s) Primary: 55 Secondary: 02, 14
Main Treatment Unit Code: 050 5
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant
Funds or are any public monies involved? NA
2. Special monitoring or limitations (including toxicity)
requests: See recommendations
3. Important SOC, JOC or Compliance Schedule dates:
A SOC has been drafted which contains current effluent limits
for a period of two years. This is in anticipation of more
stringent limits which more accurately reflect the outfall
location.
4. Alternative Analysis Evaluation: Has the facility evaluated
all of the non -discharge options available? Please provide
regional perspective for each option evaluated.
Nondischarge alternatives are not practical due to the volume
of wastewater and poor soils in the vicinity. A municipal or
regional system is not available.
5. Other Special Items:
PART IV - EVALUATION AND RECOMMENDATIONS

Effluent limits for the facility have historically been
generated with the consideration that the outfall is directly into
the main channel of the receiving stream. The outfall actually
discharges to the edge of the swamp which borders the river and
flows into a channel which appears to be dry upstream of the
outfall. It appears that the receiving stream at the point of
discharge has a zero flow during 7Q10 conditions. In anticipation
of more stringent effluent limits, the permittee has requested
entrance into a Special Order by Consent which will allow time to
evaluate alternative discharge points. A consultant has been
commissioned to prepare a topographic transect of the river to
determine if is practical to extend the outfall pipe to the main
channel of the river. Other potential outfall points upstream and
downstream on the river will also be evaluated.
Plant upgrades and operational improvements instituted
approximately one year ago have resulted in consistent compliance
with current effluent limits. The permittee has now requested that
the flow limit be increased to 1.5 MGD due to anticipated
production increases. A proposal is currently being reviewed for
modifications which should allow the facility to treat the
increased flow and meet fecal coliform limits.
As previously stated, it appears that the existing outfall
enters a stream channel with zero flow at 7Q10 conditions. It is,
therefor, recommended that the effluent limits be reevaluated.
Several errors exist in the current permit. Fecal Coliform
effluent monitoring and conductivity instream monitoring are both
required to be composite samples. These should both be grab
samples.
It is recommended that a permit be drafted and placed at
public notice. If no significant adverse comments are received, it
is recommended that the permit be reissued for a period of five
years in accordance with the basinwide permitting program.
Signature of Report Preparer
ater Quality Regional Supervisor
EB: NC2305.056
cc: Wilmington Regional Office
Technical Support Branch
Central Files
Date
/7T

UPSTREAM
date temp
DO
GUILFORD MILLS
% sat BOD5
temp
DOWNSTREAM
DO % sat
BOD5
DO
DEF
mg/1
5/1/95
22.0
6.8
77.8
3.8
22.0
7.3
83.5
3.6
-0.5
5/8/95
21.0
6.9
77.4
4.0
21.0
7.2
80.8
4.4
-0.3
5/15/95
23.0
6.8
79.3
4.6
23.0
7.2
84.0
4.2
-0.4
5/22/95
23.0
7.0
81.6
4.3
23.0
7.2
84.0
3.9
-0.2
5/29/95
24.0
7.0
83.2
4.2
24.0
7.4
87.9
3.7
-0.4
6/5/95
22.0
7.0
80.1
22.0
7.4
84.7
-0.4
6/7/95
24.0
7.0
83.2
24.0
7.8
92.7
-0.8
• 6/9/95
25.0
7.1
85.9
25.0
7.8
94.4
-0.7
6/12/95
24.0
6.8
80.8
3.6
24.0
7.4
87.9
3.6
-0.6
6/14/95
24.0
7.0
83.2
24.0
7.4
87.9
-0.4
6/16/95
24.0
7.0
83.2
24.0
7.4
87.9
-0.4
6/19/95
22.0
7.0
80.1
3.6
22.0
7.4
84.7
3.8
-0.4
6/21/95
24.0
7.1
84.4
24.0
7.4
87.9
-0.3
6/23/95
24.0
7.2
85.6
24.0
7.6
90.3
-0.4
6/26/95
24.0
7.2
85.6
3.3
24.0
7.5
89.1
3.5
-0.3
6/28/95
24.0
7.2
85.6
24.0
7.8
92.7
-0.6
6/30/95
24.0
7.0
83.2
24.0
7.6
90.3
-0.6
7/10/95
24.0
6.2
73.7
24.0
6.8
80.8
-0.6
7/12/95
26.0
6.4
78.9
3.6
26.0
7.2
88.8
3.4
-0.8
7/14/95
27.0
6.6
82.9
27.0
7.0
87.9
-0.4
7/17/95
28.0
6.4
81.8
3.8
28.0
7.2
92.0
3.6
-0.8
7/19/95
26.0
6.5
80.1
26.0
7.0
86.3
-0.5
7/21/95
27.0
6.6
82.9
27.0
7.0
87.9
-0.4
7/24/95
27.0
6.5
81.6
3.6
27.0
7.2
90.4
3.6
-0.7
7/26/95
27.0
6.6
82.9
27.0
7.0
87.9
-0.4
7/28/96
25.0
6.5
78.7
25.0
7.0
84.7
-0.5
7/31/95
26.0
6.5
80.1
26.0
7.2
88.8
-0.7
8/2/95
27.0
6.4
80.3
27.0
7.2
90.4
-0.8
8/4/95
27.0
6.6
82.9
27.0
7.0
87.9
-0.4
8/7/95
26.0
6.2
76.4
3.6
26.0
7.4
91.2
3.0
-1.2
8/9/95
24.0
6.1
72.5
24.0
7.4
87.9
-1.3
8/11/95
25.0
6.1
73.8
25.0
7.6
92.0
-1.5
8/14/95
27.0
6.0
75.3
3.9
27.0
7.2
90.4
3.9
-1.2
8/16/95
25.0
6.0
72.6
25.0
7.2
87.2
-1.2
8/18/95
25.0
5.9
71.4
26.0
7.4
91.2
-1.5
8/21/95
24.0
6.0
71.3
24.0
7.1
84.4
-1.1
8/23/95
23.0
5.9
68.8
23.0
7.4
86.3
-1.5
8/25/95
25.0
5.8
70.2
25.0
7.5
90.8
-1.7
8/28/95
23.0
6.0
70.0
3.2
23.0
7.4
86.3
2.9
-1.4
8/30/96
23.0
5.9
68.8
23.0
7.4
86.3
-1.5
9/5/95
22.0
5.9
67.5
22.0
7.2
82.4
-1.3
9/6/95
22.0
5.8
66.4
3.5
22.0
7.4
84.7
2.9
-1.6
9/8/95
21.0
6.2
69.6
22.0
7.2
82.4
-1.0
9/13/95
23.0
4.4
51.3
23.0
7.5
87.5
-3.1
9/14/95
24.0
4.5
53.5
24.0
7.4
87.9
-2.9
9/15/95
25.0
4.4
53.3
25.0
7.5
90.8
-3.1
9/18/95
21.0
4.3
48.2
2.0
22.0
7.4
84.7
2.3
-3.1
9/20/95
23.0
5.0
58.3
23.0
7.5
87.5
-2.5
9/22/95
23.0
5.0
58.3
23.0
7.5
87.5
-2.5
9/25/95
22.0
5.0
57.2
22.0
7.3
83.5
-2.3
9/27/95
23.0
6.0
70.0
23.0
7.4
86.3
-1.4
9/29/95
23.0
5.8
67.6
23.0
7.5
87.5
-1.7
10/4/95
22.0
6.2
70.9
23.0
7.2
84.0
-1.0
10/11/95
22.0
6.5
74.4
22.0
7.5
85.8
-1.0
10/18/95
21.0
6.4
71.8
21.0
7.2
80.8
-0.8
10/25/95
23.0
6.5
75.8
23.0
7.4
86.3
-0.9

GUILFORD
F
A
B
c
GUILFORD MILLS, I N C. • G R E E N S B O R O, NC
P.O. Box 26969 • Greensboro, NC 27419-6969 • [phone]
January 24, 1996
Mr. David A. Goodrich
Permits and Engineering Unit
DEM, Water Quality Section
P. O. Box 29535
Raleigh, NC
27626-0535
Subject: Renewal of NPDES Permit No. NC0002305
Duplin County
Dear Mr. Goodrich:
CFN
J �'nceo
co-ji
o/6sog ,
/11/L(
With this letter, Guilford Mills is requesting renewal of the referenced NPDES
permit at its Guilford East Plant in Duplin County. Enclosed please find a check
for $400 and a completed NPDES permit application. Also find enclosed a
narrative description of the sludge management plan for the plant and a
description of water conservation measures which are on -going at the plant.
Guilford Mills is requesting a flow limitation increase from 1.25 MGD to 1.5
MGD with this permit application. The purpose for this request is increased
production. Maximum production rates at the plant are expected to increase
from 100,000 lbs per day to 120,000 lbs per day in the near future. At the
average water usage of 12.5 gallons per pound processed, the plant will need to
treat and discharge an average of 1,500,000 gallons per day. Guilford Mills
desires to remain at the current permitted flow rate until improvements have
been made, then go to the higher permitted flow rate.
Since the textile industry is a primary industry as described in Appendix A of 40
CFR 122, Guilford Mills is required to submit a priority pollutant analysis
(PPA) with this permit application. The results of the PPA are not available at
this time. However, the results should be ready by the second week in
February. Guilford Mills will forward the results of the PPA to your attention
as soon as they are available.

Page 2
Mr. Goodrich
Please call me at [phone] if you have any questions or need any
additional information.
Sincerely,
Jimmy Summers
Corporate Environmental and Energy Manager
cc: Brent Turner, Guilford East
Dave Adkins, WiRO, DEM

Guilford East Sludge Management Plan
Activated sludge is wasted from the Guilford East Wastewater Treatment
Plant (WWTP) on a regular basis. The sludge is aerobically digested and then
placed on drying beds. After the sludge has dried to about 10 % solids, the
sludge is hauled to McGill Environmental Systems of NC near Rose Hill, NC.
At McGill, the sludge is mixed with chicken manure and other wastes and is
composted. The resulting compost is. sold or given away as a fill material or soil
amendment.
Guilford East Water Conservation Program
Plant management at Guilford East has actively reduced water
consumption per pound of production over the past several years. Water
consumption per pound of production has dropped from 14.3 gallons per pound
in fiscal 1993 to about 11.2 gallons per pound in fiscal 1995. Guilford East
continues to seek out and identify water use reduction opportunities. This effort
will continue as part of Guilford Mills' overall water reduction program.

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Mr. Jimmy Summers, Corporate Environmental
Guilford Mills, Inc./Corporate Headquarters
4925 West Market Street
Greensboro, North Carolina 27407
Dear Mr. Summers:
AVA
ED E I--1 N FR.
August 7, 1995
and Energy Manager
/ Cc
Subject: Future Permit Limits
NPDES #NC0002305
Guilford East Division
Duplin County
I apologize for the tardiness of this response to your May 8, 1995 letter. I can appreciate your concern
regarding future limits at this facility, especially in light of the timing of expanded production and
modifications to your wastewater treatment facilities.
As you mentioned in your letter, the outfall does not extend into the main channel of the Northeast Cape
Fear River, but to the edge of a swamp that borders the plant property. As stated in the cover letter to the
issuance of your NPDES permit, this discharge location could affect future allocations of limits for
chemical -specific parameters, and the whole -effluent toxicity test limit. The chemical -specific parameters m
which are most likely to be affected are those toxicants which are based on the assumption of the receiving&
stream containing 6.5 cubic feet per second under low -flow (summer 7Q10) conditions. Currently, al a,
residual.chlorine and chromium would be affected. Limits for oxygen -consuming wastes will not if,'
affected unless there is specific documentation of decreased dissolved oxygen levels downstream oche
outfall which can be attributed to this discharge. As a result of the uncertainty of swamp systems, ibis
likely, however, that any future increase in wastewater flow, beyond the expansion already underWity,
may result in no increase in mass loading permitted for oxygen -consuming wastes.
If you have any questions concerning this permit, please contact Mr. David Goodrich, NPDES
.7^1:�1G1 Y1V1, GL LC1Gk:i1C.Gllv ',umbel �7i7 f / JJ-J083 , c7.1. 517.
Sincerely,
Steve W. Tedder, Chief
Water Quality Section
cc: Wilmington Regional Office
Technical Support Branch
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper