NC0040797_Plan of Action_20040528

NPDES DOCUMENT ! CANNINO COVER :SHEET
NPDES Permit:
NC0040797
Henry Fork WWTP
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
(744 D( 7_f0
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
May 28, 2004
This document is printed on reuse paper - ignore any
content on the reirerse side

ilickory
Where Bus ness and Pieosure Grow Together -
May 28, 2004
Alan Klimek, P • erector
Division of . ter Quality
NCDE
1617 ail Service Center
eigh, NC 27699-1617
Subject: NPDES NC0040797 A. (3.)
Color Reduction Study
Dear Mr. Klimek:
Public Utilities
Pretreatment
City of Hickory
4014 River Road
Hickory, NC 28602
Telephone [phone]
Fax [phone]
[e-mail]
JO i 200!
D/V. OF V►,
Dl� �TFR QUALITY
Y
Enclosed you will find the Color Reduction Study and cost estimates for the Henry Fork
Wastewater Treatment Plant.
The evaluation performed by Degussa/Stockhausen Inc, estimates cost for reducing color
by 75% and 90% using Praestol 193k (see enclosure). Also included, is data from fiscal
years 2002-2003 and thru April of 2003-2004 for color monitoring and removal from the
normal treatment processes (see enclosures). The Henry Fork WWTP was able to reach
these removal percentages without incurring additional expenditures.
In order to reach the 75% and 90% thresholds, chemical addition would be required.
These levels could be reached at significant additional cost the City of Hickory. These
costs would increase/decrease with variations in flow and color level of the influent. The
enclosed charts give increasing cost estimates for 75% and 90% as the plant influent flow
increases.
Sincerely,
-7,c/t-vq
Robert Shaver,
HF WWTP ORC
City of Hickory
Cc: Dave Goodrich, NPDES Unit
GREATER
HICKORY
METRO

♦ `•
min
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Pollution Prevention and Environmental Assistance
Michael F. Easley, Govemor William G. Ross Jr., Secretary
Gary Hunt, Director
May 17, 2004
Dear Mrs. McNeely:
Please find the attached color reduction reports for those facilities identified by the City of
Hickory as having color discharge. DPPEA visited Crystal Dyeing and Finishing on May 10th
but a power outage during the dyeing process disrupted the sampling program. Since the facility
only dyes two days every other week a color reduction report will not be available by the
reporting deadline with the State of North Carolina. DPPEA will complete this color reduction
visit and send the results to the City of Hickory. If you have any questions please contact me at
336-249-1480.
Sincerely
ohn Burke
1639 Mail Service Center, Raleigh, North Carolina 27699-1639
Phone: [phone] FAX: [phone] Internet: www.p2pays.org
An Equal Opportunity 1 Affirmative Action Employer — 100% Recycled 1 100% Post Consumer Paper

May 17, 2004
Bob Shaver
Plant Supervisor
Henry Fork WWTP
4014 River Road
Hickory, NC 28602
Re: ADMI Color Removal Evaluation
Dear Bob,
Thank you, on behalf of Stockhausen, Inc. and myself, for the opportunity to evaluate our Praestol line of
flocculants and coagulants at your facility. Your staff was extremely helpful; please extend my thanks to
them.
As you are aware, on April 28, 2004 I performed chemical treatment on your MLSS. The purpose was to
select a product to reduce the ADMI color increments of your final effluent. Testing entailed addition of
Dimdac and Polyamine products @15 & 3OPPM. After a five minute settling period, the supernatant was
drawn off and analyzed. The instrument of choice was a Milton Roy Spectronics Genesys 5. See attached
tables.
From the test results, our Praestol 193K achieved the results necessary to meet your discharge
requirements. The Praestol 193K is a high molecular weight Polyamine. It is available in drums, totes or
bulk quantities. Based on a flow of 2MGD, you would need 30gallons/day for an average daily dosage of
15PPM. This of course is dependent on the production of color waste into your system.
In conclusion, feel free to phone [phone] for any concerns.
Sincerely,
Degussa. / Stockhausen, Inc.
W. Patrick Matthews
Senior Sales Representative
Water Chemicals Division
PC: Ron Jones
Neal Powell

4/29/2004 10:31 Hrvi
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LLE WASTEWATER TREATMENT PLANT
CITY OF MARTINSVI
Dilution Factor
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41:Z9l2004
82.70
85.60
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64.70
83.40
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92.00
79.10
97.30
92.50
80.00
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98.00
99.10
541.4
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544.3
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561.9
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96.70
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0.086
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we
310 110
Date of Calibration Curve
Slope
X intercept
R2 value
913/2003
1395.261963
-9.52333164
0.999957502
ANALYST
22

- FORM 403c
rev 3/99
4/29/2004 10:41 AM
E
2
CD
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1
CITY OF MARTINSVILLE WASTEWATER TREATMENT PLANT
188K 30ppm
193K 15ppm
193K 30ppm�
SamTie Name
50 STD
300 STD
188K l5ppm
1
1
1
1
1
Dilution Factor
1
4/28/2004
Sample Date
4/29/2004
4/29/2004
4/28/2004
4/28/2004
4128/2004
96.80
422.2
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82.70
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432
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95.00
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97.40
438.6
97.20
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95.30
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95.50
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97.60
444.4
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95.80
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489.5
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551.8
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577.4
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600.8
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5109
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99.60
99.10
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99.20
99.60
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49
302
51
36
51
28
Date of Calibration Curve 9/312003
Slope 1395,261963
X intercept -9.52333164
R2 value 0.999957502
ANALYST
AOMf

$300,000.00
$250, 000.00
$200,000.00
$150,000.00
$100,000.00
$50, 000.00
$-
COST PER YEAR FOR 75 PERCENT REMOVAL
$246,572.1
$232,873.65
S205.476.75
S178,079.85
$150,682.95
$123,286.05
$95,889.15
$68,492.25
S54,793.80
2.0MGD 2.5MGD 3.5MGD 4.5MGD 5.5MGD 6.5MGD 7.5MGD 8.5MGD 9.0MGD
0
L❑ COST PER YEAR FOR 75 PERCENT
REMOVAL

$600,000.00
$500,000.00
S400,000.00
S300,000.00
$200,000.00
$100,000.00
$-
COST PER YEAR FOR 90 PERCENT REMOVAL
$493,144.2
$465,747.30
$410,953.50
$356,159.40
S301,365.70
$246,572.10
$191,778,30
$136,984.50
109,587.60
2.0MGD 2.5MGD 3.5MGD 4.5MGD 5.5MGD 6.5MGD 7.5MGD 8.5MGD 9.0MGD
0
❑ COST PER YEAR FOR 90 PERCENT
REMOVAL

ADMI COLOR ANALYSIS
1400
1200
1000
800
600
400
200
0
COLOR MONITORING 2002-2003
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100
90
80
70
60
50
40
30
20
10
0
PERCENT REMOVAL 20002-2003
28
63
0
86
76 -
94
81
73 73
68
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COLOR MONITORING-2003-2004
JULY AUG SEPT OCT NOV DEC JAN FEB MARCH APRIL MAY JUNE
MONTH
❑ INFLUENT El EFFLUENT ❑ UPSTREAM ❑ DOWNSTREAM

PERCENT REMOVAL
100
90 -
80 -
70 -
60 -
50 -
40 -
30 -
20 -
10-
0
PERCENT REMOVAL 2003-2004
86
81
36
78
87
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52
55
62
74
g O
MONTH
El PERCENT REMOVAL

Division of Pollution Prevention and
Environmental Assistance
North Carolina Department of Environment and Natural Resources
Color Reduction Assessment
Longview Yarns
Hickory, North Carolina
DPPEA
John Burke
April 13, 2004
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]: FAX: [phone]
Longview Yarns - 1 - April 28, 2004

Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. All references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.
Longview Yarns 2 April 28, 2004

Longview Yarns: Color Reduction Assessment
1.0 Introduction
The City of Hickory and Longview Yarns requested assistance from the Division of Pollution Prevention
and Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent color. The City
of Hickory was required by the North Carolina Division of Water Quality to perform a color reduction
assessment to identify best management practices for the major sources of color in its wastewater.
Longview Yarns was identified by the City of Hickory as a source of color. Color testing of Longview
Yarns' effluent was 175 ADMI 2"d half of 2002, 104 ADMI 1 S` half 2003, and 458 2"d half of 2003.
On April 13th, John Burke, of DPPEA, met with Russ Perkins, Owner, to discuss current operations and
sample selected dyebath discharges. The following report provides information on the generation of
color from the Longview Yarns' operations and options for potentially reducing the level of color.
2.0 Facility Background and Color Analysis
Longview Yarns dyes and finishes rayon blended yarns (70%
rayon 30% cotton) and some nylon yarns. Direct dyes are used
for dyeing the rayon/cotton yarn and acids are used for dyeing the
nylon. The facility operates 1 shift 5 days per week. 100% of
production is dyed goods.
The dyehouse is equipped with 1 — 600 pound, 1 — 220 pound, 1
—150 pound, and 1 — 100 pound skein dyeing machines that
operate at a 20:1 liquor ratio. Machines are typically operated at
90% of full load. The facility currently produces an average of
1,500 pounds per day of finished yarn and discharges
approximately 16,000 gallons per day of wastewater.
DPPEA targeted the darker shade dyeings for color analysis due
to relative large impact these shades have on effluent color.
DPPEA sampled two dyebaths to estimate the percent exhaustion
of dye on the yarn for a khaki shade (direct) and green shade
(acid). Figure 1 provides the procedure used for the green shade
and Figure 2 shows the procedure for the khaki shade.
DPPEA performed a visual determination of the exhaustion for
these shades by comparing the spent bath color to a series of
diluted samples of the initial dyebath. The dilutions for the khaki
and green shades were 80%, 90% and 95%.
Based on this analysis, the khaki and green were estimated at
+90% dye exhaustion. Final fixation of dyestuff will be impacted
by additional processing steps and was not evaluated through this
analysis.
3.0 Color Reduction Options
Based on the dyebath exhaustion samples study, Longview Yarns
appears to be getting high exhaustion. DPPEA does not have any
suggestions related to these dyeing operations.
Figure 1 Green Shade
130 lbs in 150 Ibs Package
Procedure
Fill tub
Add leveler
Add oxalic acid
Add Dye
Heat to 130°F at 1 ° rise
Hold 10 minutes
Heat to 160°F at 1 ° rise
Hold 10 minutes
Heat to 190°F at 2° rise
Hold 10 minutes
Drain
0.5%
1.5%
0.1%
Figure 2 Khaki Shade
75 Ibs in 100 lbs Package
Procedure
Fill tub
Add leveler
Add scour
0.2%
0.2%
Add Dye 1.0%
Add Salt 2.5%
Heat to 190°F 2° rise
Hold 15 minutes
Drain
Longview Yarns - 3 April 28, 2004

Division of Pollution Prevention and
Environmental Assistance
North Carolina Department of Environment and Natural Resources
Color Reduction Assessment
Kentucky Derby Hosiery
Hickory, North Carolina
DPPEA
John Burke
March 10, 2004
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]: FAX: [phone]
Kentucky Derby Hosiery - 1 - April 28, 2004

Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. All references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.
Kentucky Derby Hosiery - 2 April 28, 2004

Kentucky Derby Hosiery: Color Reduction Assessment
1.0 Introduction
The City of Hickory and Kentucky Derby Hosiery requested assistance from the Division of Pollution
Prevention and Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent
color. The City of Hickory was required by the North Carolina Division of Water Quality to perform a
color reduction assessment to identify best management practices for the major sources of color in its
wastewater. Kentucky Derby Hosiery was identified by the City of Hickory as a source of color. Color
testing of Kentucky Derby Hosiery' effluent was <35 ADM12"d half of 2002, <59 ADMI 1st half 2003,
and <111 2"d half of 2003.
On March 22"d, John Burke, of DPPEA, met with Mike Waller, Dyehouse Manager, to discuss current
operations and sample selected dyebath discharges. The following report provides information on the
generation of color from the Kentucky Derby Hosiery' operations and options for potentially reducing
the level of color.
2.0 Facility Background and Color Analysis
Kentucky Derby Hosiery bleaches, dyes and finishes hosiery blends of cotton and nylon. Direct and acid
dyes are used for dyeing the hosiery. The facility operates 2 shifts 5 days per week. Currently, 90% of
production is white goods and 10% dyeing. Approximately 20% of the dyeing is dark shades.
The dyehouse is equipped with 3 — 200 pound, 3 —150 pound, 1 — 100 pound, 1 — 75 pound, 1 — 60
pound, 1 — 50 pound, and 1 — 25 pound paddle dye machines that operate at a 25:1 liquor ratio. Machines
are typically operated at 100% full Toad or more. The facility currently produces an average of 7,400
pounds per day of finished hosiery and discharges approximately 75,000 gallons per day of wastewater.
DPPEA targeted dark shade dyeing of the hosiery for color analysis
due to relative large impact these shades have on effluent color.
DPPEA sampled one dyebath to estimate the percent exhaustion of
dye on the hosiery for a black shade using direct and acid dyes.
Figure 1 provides the procedure used for the black shade.
DPPEA performed a visual determination of the exhaustion for
these shades by comparing the spent bath color to a series of
diluted samples of the initial dyebath. The dilutions for the black
shade were 60%, 70%, 80%, and 90%.
Based on this analysis, the black shade was estimated at 80% dye
exhaustion. Final fixation of dyestuff will be impacted by
additional processing steps and was not evaluated through this
analysis. Fixation of direct dyes on cotton goods is typically in the
range of 70 to 95% and acid dyes on nylon is 80 to 93%'. The final
fixation of dye for the black would probably be within this range
for the respective dye types utilized.
Figure 1 Black Shade
210 lbs in 200 lbs Paddle
Procedure
Fill tub
Add oil
Add lubricant
Add acid dyes
Add direct dyes
Heat to 90°F 5 min
Heat to 160°F at 8° per min
Heat to 200°F at 3° per min
Hold 10 minutes
Add Salt
Hold 20 minutes
Drop bath
2.0%
1.0%
0.5%
3.3%
40.0%
Best Management Practices for Pollution Prevention in the Textile industry, EPA/625/R-96/004
Kentucky Derby Hosiery - 3 - April 28, 2004

3.0 Color Reduction Options
Based on the dyebath exhaustion samples study, Kentucky appears to be getting average exhaustion on
the darker shades. Some practices that can assist in increasing exhaustion include:
> Maintain lowest achievable liquor ratio. Underloading machines will increase liquor ratios and may
result in reduced exhaustion. If feasible smaller lots should be matched to smaller tubs. Larger tubs
could be marked for a lower fill level for smaller loads that maintain the lowest achievable liquor
ratio while still allowing circulation of goods in the tub.
> Optimize time -temperature profile scheme to achieve maximum exhaustion of dye. Work with dye
supplier to identify most appropriate profile for darker shades. Rate of temperature rise, final hold
temperature and length of exhaustion phase will impact final exhaustion.
> The facility may want to consider adding salt in 3 stages of increase load with a 10-minute interval
instead of loading at one time.
> The facility may want to evaluate the use of both oil and lubricant in the dybath.
Kentucky Derby Hosiery - 4 - April 28, 2004

Division of Pollution Prevention and
Environmental Assistance
North Carolina Department of Environment and Natural Resources
Color Reduction Assessment
Ward Hosiery
Hickory, North Carolina
DPPEA
John Burke
April 22, 2004
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]; FAX: [phone]
Ward Hosiery - I - April 28, 2004

Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. All references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.
Ward Hosiery 2 April 28, 2004

Ward Hosiery: Color Reduction Assessment
1.0 Introduction
The City of Hickory and Ward Hosiery requested assistance from the Division of Pollution Prevention
and Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent color. The City
of Hickory was required by the North Carolina Division of Water Quality to perform a color reduction
assessment to identify best management practices for the major sources of color in its wastewater. Ward
Hosiery was identified by the City of Hickory as a source of color. Color testing of Ward Hosiery's
effluent was <195 ADMI 2"d half of 2002, <378 ADMI 1st half 2003, and <513 2"d half of 2003.
On April 22"d, John Burke, of DPPEA, met with Rick Ward, Owner, to discuss current operations and
sample selected dyebath discharges. The following report provides information on the generation of
color from the Ward Hosiery's operations and options for potentially reducing the level of color.
2.0 Facility Background and Color Analysis
Ward Hosiery dyes and finishes cotton, nylon and wool blends. Direct dyes are used for dyeing the
cotton and acids are used for dyeing the nylon and wool. The
facility operates 1 shift 5 days per week.
The dyehouse is equipped with 2 — 300 pound, 2 — 200 pound, 5
—150 pound, 1 —100 pound, 1 — 50 pound, and 1-10 pound
paddle dye machines that operate at a 25:1 liquor ratio. Machines
are typically operated at full load. The facility currently produces
an average of 1,600 pounds per day of hosiery and discharges
approximately 28,000 gallons per day of wastewater.
DPPEA targeted the darker shade dyeings for color analysis due
to relative large impact these shades have on effluent color.
DPPEA sampled one dyebath to estimate the percent exhaustion
of dye on the hosiery for a black shade. Figure 1 provides the
procedure used for the black shade.
DPPEA performed a visual determination of the exhaustion for
this shade by comparing the spent bath color to a series of diluted
samples of the initial dyebath. The dilutions for the black shade were 80%, 90% and 95%.
Based on this analysis, the black shade was estimated at just below 90% dye exhaustion. Fixation of
direct dyes on cotton goods is typically in the range of 70 to 95% and acid dyes on nylon is 80 to 93%'.
Final fixation of dyestuff will be impacted by additional processing steps and was not evaluated through
this analysis.
Figure 1 Black Shade
150 lbs in 150 lbs Paddle
Procedure
Fill tub
Add leveler 2.0%
Raise to 100°F
Add Dye 5.2%
Add salt 80%
Raise to 200oF
Hold 25 min
Add acid 0.5%
Hold 10 min
Drain
3.0 Color Reduction Options
Based on the dyebath exhaustion samples study, Ward Hosiery appears to be getting high exhaustion.
DPPEA does not have any suggestions related to these dyeing operations.
Best Management Practices for Pollution Prevention in the Textile Industry, EPA/625/R-96/004
Ward Hosiery - 3 - April 28, 2004

Division of Pollution Prevention and
Environmental Assistance
North Carolina Department of Environment and Natural Resources
Color Reduction Assessment
Johnson Hosiery Mills
Hickory, North Carolina
DPPEA
John Burke
January 29, 2004
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]: FAX: [phone]
Johnson Hosiery Mills - i - April 28, 2004

Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. An references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.
Johnson Hosiery Mills 2 April 28, 2004

Johnson Hosiery Mills: Color Reduction Assessment
1.0 Introduction
The City of Hickory and Johnson Hosiery Mills requested assistance from the Division of Pollution
Prevention and Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent
color. The City of Hickory was required by the North Carolina Division of Water Quality to perform a
color reduction assessment to identify best management practices for the major sources of color in its
wastewater. Johnson Hosiery Mills was identified by the City of Hickory as a source of color. Color
testing of Johnson Hosiery Mills' effluent was 634 ADMI 2nd half of 2002, <562 ADMI 1' half 2003,
and <245 2nd half of 2003.
On January 29th, John Burke, of DPPEA, met with Scott Wilson, Dyehouse Manager, to discuss current
operations and sample selected dyebath discharges. The following report provides information on the
generation of color from the Johnson Hosiery Mills' operations and options for potentially reducing the
level of effluent color.
2.0 Facility Background and Color Analysis
Johnson Hosiery Mills bleaches, dyes and finishes hosiery blends
of cotton, nylon, and acrylic. Reactive, acid and basic dyes are
used for dyeing the hosiery. The facility operates 1 shift 5 days
per week. Currently, 50% of production is washouts and 50% is
dyed goods.
The dyehouse is equipped with 1 — 600 pound Braun and 2 — 240
pound, 1 — 200 pound, 2 —100 pound, and 2 — 40 pound paddle
tubs operating at 30:1 liquor ratio. The facility currently produces
an average of 3,000 pounds per day of finished hosiery and
discharges approximately 80,000 gallons per day of wastewater.
DPPEA targeted dark shade dyeing of the hosiery for color
analysis due to relative large impact these shades have on effluent
color. DPPEA sampled one two-step dyeing to estimate the
percent exhaustion of dye on the hosiery for a black shade (cotton
with reactive and nylon with acid). Figure 1 provides the
procedure used for the black shade.
DPPEA performed a visual determination of the exhaustion for
this shade by comparing the spent bath color to a series of diluted
samples of the initial dyebath. The dilutions for the acid dyeing
were 30%, 40%, 50%, 60%, and 70% and they were 50%, 60%,
70%, and 80% for the reactive dyeing.
Based on this analysis, the acid dye was estimated lower than
40% exhaustion and the reactive dye was estimated at 55%
exhaustion. Final fixation of dyestuff will be impacted by
additional processing steps and was not evaluated through this
analysis. Fixation of reactive dyes on cotton goods is typically in
Figure 1 Black Shade
243 lbs in 240 lbs Paddle
Procedure
Add leveler 1.0%
Add Ammonium sulfate2.0%
Add acid dye 2.2%
Heat to 205°F (3°F rate of rise)
Run 20 minutes
Drop
Fill and Heat to 90°F
Add lubricant
Add leveler
Add wetter
Add salt
4.0%
1.0%
1.0%
296.2%
Add reactive dye 6.6%
Two 5 minute increments
Heat to 140°F (3°f rate of rise)
Run 5 minutes (leveling)
Add alkali 1.8%
Wait 10 minutes
Add alkali
Wait 10 minutes
Add alkali (split)
Wait 5 minutes
Add alkali aid
Maintain 140°F
Run for 50 minutes
Drop bath
5.3%
10.6%
2.9%
Johnson Hosiery Mills - 3 April 28, 2004

the range of 50 to 80% and acid dyes on nylon is 80 to 93%1. The final fixation of dye for both of these
dye types would probably be below these levels and in the case of the acid dye well below.
3.0 Color Reduction Options
Based on the dyebath exhaustion samples study Johnson appears to getting below average exhaustion
rates for the dye types used. There may be some opportunities to reduce color discharge through
increasing exhaustion and final fixation on these dark shade dyeings. Johnson Hosiery Mills should
consider some of the following practices to increase dye exhaustion. The mill may already be doing
some of these things.
Dyeing
➢ Maintain lowest achievable liquor ratio. Paddle tubs inherently require higher liquor ratios that
result in larger salt requirements and more auxiliary chemical usage as well as poor exhaustion and
shade repeatability. Johnson may want to consider increasing the use of the Braun dyeing machine
for dark shades due to the ability to operate this machine at liquor ratios as low as 10:1. Another
option for Johnson would be to reduce the upper fill level of the paddle tubs so that a 20:1 liquor
ratio could be obtained (as long as the paddles will still circulate goods effectively).
> Optimize time -temperature profile scheme to achieve maximum exhaustion of dye. Based on the dye
samples the exhaustion for both dye types is poor. The cause of this is not clear, but increasing the
time of dyeing for the acid dye may improve exhaustion. Increasing dye time prior to alkali addition
or dropping temperature to 120°F for 15 minutes prior to alkali addition may increase exhaustion of
reactive dyes.
> Johnson should work with its dye suppliers to optimize the dyeing procedure. The excessive amount
of salt use does not appear to be aiding in dye exhaustion.
> Reduce dependence on auxiliaries like dye levelers that impede exhaustion. Make sure that excess
leveler is not being added beyond the specified amount in the dye formula. Both a leveling agent and
sulfate, used for leveling of acid dye, is being used in this formula.
➢ Evaluate need for high percentage of lubricant in reactive dyebath.
➢ Johnson may want to consider utilizing direct dyes in place of reactive dyes if the markets are open
to these dyestuffs. Johnson could reduce run time and salt consumption with the use of Direct dyes
over neutral reactive dyes. Acid and direct dyes can be dye together significantly reducing run time
as compared to the neutral reactive dyes. Or, consider use of bi-functional reactive dyes that required
less salt and typically have a higher exhaustion. If Johnson's customers are not open to other
dyestuffs then the facility should work with its current supplier for opportunities to improve dye
exhaustion.
Best Management Practices for Pollution Prevention in the Textile Industry, EPA/625/R-96/004
Johnson Hosiery Mills - 4 - April 28, 2004

Division of Pollution Prevention and
Environmental Assistance
North Carolina Department of Environment and Natural Resources
Color Reduction Assessment
Ellis Hosiery Mills
Hickory, North Carolina
DPPEA
John Burke
February 20, 2004
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]; FAX: [phone]
Ellis Hosiery Mills - 1 - April 28, 2004

Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. All references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.
Ellis Hosiery Mills 2 April 28, 2004

Ellis Hosiery Mills: Color Reduction Assessment
1.0 Introduction
The City of Hickory and Ellis Hosiery Mills requested assistance from the Division of Pollution
Prevention and Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent
color. The City of Hickory was required by the North Carolina Division of Water Quality to perform a
color reduction assessment to identify best management practices for the major sources of color in its
wastewater. Ellis Hosiery Mills was identified by the City of Hickory as a source of color. Color testing
of Ellis Hosiery Mills' effluent was 1332 ADMI 2°d half of 2002, 2974 ADMI 1 ' half 2003, and 1815 2nd
half of 2003. Based on these color samples and the typical effluent flow, Ellis is on of the larger
contributors of color.
On January 21 S', John Burke, of DPPEA, met with Karl Powell, Dyehouse Manager, to discuss current
operations and sample selected dyebath discharges. The following report provides information on the
generation of color from the Ellis Hosiery Mills' operations and options for potentially reducing the level
of color.
2.0 Facility Background and Color Analysis
Ellis Hosiery Mills bleaches, dyes and finishes hosiery blends of cotton, nylon, and acrylic. Direct,
reactive, acid and basic dyes are used for dyeing the hosiery. The facility operates 3 shifts 3-4 days per
week. Currently, 15% of production is white goods (bleach and optical), 15% acid dyeing, 14% direct
dyeing, 30% reactive dyeing, and 25% basic dyeing. Some goods are dyed with more than one dye type.
A majority of dyed goods are dark shades.
The dyehouse is equipped with 6 — 600 pound, 4 — 400 pound, 3 - 200 pound Braun dye machine that
operates at a 10:1 liquor ratio for reactive dyeing and 15:1 for basic dyeing. Machines are typically
operated at 60% full load. The facility currently produces an average of 20,000 pounds per day of
finished hosiery and discharges approximately 140,000 gallons per day of wastewater.
DPPEA targeted dark shade dyeing of the hosiery for color analysis
due to relative large impact these shades have on effluent color.
DPPEA sampled two dyebaths to estimate the percent exhaustion of
dye on the hosiery for a black shade (86% cotton with reactive and
14% nylon with acid) and navy shade (80% acrylic with basic and
20% nylon with acid). Figure 1 provides the procedure used for the
black shade and Figure 2 provides the procedure used for the navy
shade.
DPPEA performed a visual determination of the exhaustion for
these shades by comparing the spent bath color to a series of
diluted samples of the initial dyebath. The dilutions for the black
shade were 60%, 70%, 80%, and 90% and for the navy shade 70%,
80%, and 90%. The black shade was sampled twice before the
drop once when the color sample was taken and once after a 15-
minute extension on the bath.
Based on this analysis, the black shade was estimated at 75% dye
exhaustion at the time the shade sample was taken and it had dropped below 70% after the additional 15
minutes prior to the actual drop. The navy shade was 85% exhaustion. Final fixation of dyestuff will be
impacted by additional processing steps and was not evaluated through this analysis. Fixation of reactive
Figure 1 Black Shade
360 lbs in 600 lbs Braun
Procedure
Heat 100°F
Add salt
Add soap
Run 10 minutes
Heat 140°F
Add dye assist
Add reactive dyes
Run 15 minutes
Add alkali
Run 45 minutes
Drop bath
100%
1.0%
2.0%
7.9%
10.0%
Ellis Hosiery Mills - 3 - April 28, 2004

dyes on cotton goods is typically in the range of 50 to 80%, acid dyes on nylon is 80 to 93%, and basic
dyes on acrylic is 97-981. The final fixation of dye for both the
black and navy dyeing would probably be within these ranges for
the respective dye types utilized.
3.0 Color Reduction Options
Based on the dyebath exhaustion samples study, Ellis appears to be
getting average exhaustion rates for the dye types used. The
facility may want to consider the following options for increasing
exhaustion and reducing the volume of color discharged:
> Consider increasing the percentage of full load dyeing.
Currently, Ellis dyes all loads at 60% full load. Increasing the •
percent of full load should decrease the liquor ratio and
increase exhaustion. There may be other issues that limit the
facility's ability to increase loads.
➢ Based on the reactive dyebath samples it appears that extending
the dye time after alkali addition had a negative affect on dye
exhaustion. Ellis may want to consider extending the cycle
time prior to alkali addition to increase dye exhaustion.
Extending the dye cycle by 15 minutes prior to alkali addition
at a cooler temperature (120°F) has been shown to increase
exhaustion and reaction efficiency for some cold type reactive dye
Figure 2 Navy Shade
360 lbs in 600 lbs Braun
Procedure
Temp 100°F
Add salt
Add leveler
Add lubricant
Add acid
Run 1 minute
Heat 110oF
Add dye assistant 3.0%
Add acid dyes 1.2%
Add basic dyes 1.1%
Rise to 210°F at 3° per minute
Run 45 minutes
Cool down 120°F
Drop bath
15.0%
3.0%
2.0%
1.0%
s2.
> Minimize dependence on leveling agents that can reduce dye exhaustion. While leveling agents may
be necessary the facility may be able to reduce the percent owg utilized while maintaining uniform
shade.
➢ Implement a program to track over -dyes, strips, and re -dyes and establish goals of reducing the
percentage of goods requiring these practices.
1 Best Management Practices for Pollution Prevention in the Textile Industry, EPA/625/R-96/004
2 Discussions with Dr. Brent Smith NCSU College of Textiles.
Ellis Hosiery Mills - 4 - April 28, 2004

Division of Pollution Prevention and
Environmental Assistance
North Carolina Department of Environment and Natural Resources
Color Reduction Assessment
Neuville Industries
Hickory, North Carolina
DPPEA
John Burke
February 20, 2004
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]; FAX: [phone]
Neuville Industries - 1 - April 28, 2004

Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. All references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.
Neuville Industries 2 April 28, 2004

Neuville Industries: Color Reduction Assessment
1.0 Introduction
The City of Hickory and Neuville Industries requested assistance from the Division of Pollution
Prevention and Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent
color. The City of Hickory was required by the North Carolina Division of Water Quality to perform a
color reduction assessment to identify best management practices for the major sources of color in its
wastewater. Neuville Industries was identified by the City of Hickory as a source of color. Color testing
of Neuville Industries' effluent was 240 ADMI 2nd half of 2002, 230 ADMI 1' half 2003, and 160 2nd
half of 2003.
On February 20th, John Burke, of DPPEA, met with David Keaton, Dyehouse Manager, to discuss current
operations and sample selected dyebath discharges. The following report provides information on the
generation of color from the Neuville Industries' operations and options for potentially reducing the level
of color.
2.0 Facility Background and Color Analysis
Neuville Industries bleaches, dyes and finishes hosiery blends of
cotton, nylon, and acrylic. Direct, acid and basic dyes are used
for dyeing the hosiery. The facility operates 3 shifts 5 days per
week. Currently, 60% of production is white goods and 40%
dyeing. Some goods are dyed with more than one dye type. A
majority of dyed goods are dark shades.
The dyehouse is equipped with 1 — 300 pound, 5 —160 pound, 5
— 100 pound, 4 — 50 pound paddle dye machines that operate at a
25:1 liquor ratio. Machines are typically operated at 100% full
load or more. The facility currently produces an average of
13,000 pounds per day of finished hosiery and discharges
approximately 110,000 gallons per day of wastewater..
DPPEA targeted dark shade dyeing of the hosiery for color
analysis due to relative large impact these shades have on effluent
color. DPPEA sampled two dyebaths to estimate the percent
exhaustion of dye on the hosiery for a black shade (75% cotton
with direct and 25% nylon with acid) and navy shade (75%
cotton with direct and 25% nylon with acid). Figure 1 provides
the procedure used for the black shade and Figure 2 provides the
procedure used for the navy shade.
Figure 1 Black Shade
260 lbs in 160 lbs Paddle
Procedure
Fill tub
Add wetter 2.0%
Add acid dyes 0.8%
Heat to 190°F
Add direct dyes 3.6%
Heat to 200°F
Heat to 206°F at 1 ° per minute
Hold 10 minutes
Add Salt 4.8%
Run 5 minutes
Add Salt
Run 5 minutes
Add Salt
Add Sulfate
Run 20 minutes
Drop bath
14.4%
31.2%
2.0%
DPPEA performed a visual determination of the exhaustion for
these shades by comparing the spent bath color to a series of diluted samples of the initial dyebath. The
dilutions for the black shade were 70%, 80%, and 90% and for the navy shade 70%, 80%, and 90%.
Based on this analysis, the black shade was estimated at 90% dye exhaustion and the navy shade was
85% exhaustion. Final fixation of dyestuff will be impacted by additional processing steps and was not
evaluated through this analysis. Fixation of direct dyes on cotton goods is typically in the range of 70 to
Neuville Industries 3 April 28, 2004

95% and acid dyes on nylon is 80 to 93%'. The final fixation of
dye for both the black and navy dyeing would probably be within
these ranges for the respective dye types utilized.
3.0 Color Reduction Options
Based on the dyebath exhaustion samples study, Neuville appears
to be getting good exhaustion rates for the dyebaths analyzed
types used. The facility should continue efforts to maintain high
exhaustion of dyestuffs to reduce color in the effluent. The
facility may want to consider dry clean-up only in the dye room
to eliminate the disposal of raw dyes into the wastewater.
Figure 2 Navy Shade
206 lbs in 160 lbs Paddle
Procedure
Fill tub
Add wetter 2.0%
Add acid dyes 2.0%
Heat to 190°F
Add direct dyes 2.9%
Heat to 200°F
Heat to 206°F at 1 ° per minute
Hold 10 minutes
Add Salt 4.8%
Run 5 minutes
Add Salt 14.4%
Run 5 minutes
Add Salt 31.2%
Add Sulfate 2.0%
Run 20 minutes
Drop bath
l Best Management Practices for Pollution Prevention in the Textile Industry, EPA/625/R-96/004
Neuville Industries - 4 - April 28, 2004

Division of Pollution Prevention and
Environmental Assistance
North Carolina Department of Environment and Natural Resources
Color Reduction Assessment
Nu -Sox Finishing
Hickory, North Carolina
DPPEA
John Burke
March 10, 2004
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]; FAX: [phone]
Nu -Sox Finishing - 1 - April 28, 2004

Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. All references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.
Nu -Sox Finishing 2 April 28, 2004

Nu -Sox Finishing: Color Reduction Assessment
1.0 Introduction
The City of Hickory and Nu -Sox Finishing requested assistance from the Division of Pollution
Prevention and Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent
color. The City of Hickory was required by the North Carolina Division of Water Quality to perform a
color reduction assessment to identify best management practices for the major sources of color in its
wastewater. Nu -Sox Finishing was identified by the City of Hickory as a source of color. Color testing
of Nu -Sox Finishing's effluent was 5600 ADMI 2" half of 2002, 343 ADMI 1st half 2003, and <184 2"
half of 2003.
On March 10th, John Burke, of DPPEA, met with Micheal Banks, Owner, to discuss current operations
and sample selected dyebath discharges. The following report provides information on the generation of
color from the Nu -Sox Finishing' operations and options for potentially reducing the level of color.
2.0 Facility Background and Color Analysis
Nu -Sox Finishing bleaches, dyes and finishes hosiery blends of cotton and nylon. Direct and acid dyes
are used for dyeing the hosiery. The facility operates 1 shifts 4 days per week. Currently, 90% of
production is white goods and 10% dyeing.
The dyehouse is equipped with 1 — 400 pound, 1 — 250 pound, 1 —150 pound, 1 — 100 pound, 1 — 50
pound, and 2 — 25 pound paddle dye machines that operate at a
25:1 liquor ratio. Machines are typically operated at 100% full
Toad or more. The facility currently produces an average of 3,000
pounds per day of finished hosiery and discharges approximately
1,000 gallons per day of wastewater.
DPPEA targeted dark shade dyeing of the hosiery for color
analysis due to relative large impact these shades have on effluent
color. DPPEA sampled two dyebaths to estimate the percent
exhaustion of dye on the hosiery for a black shade and a navy
shade, both used direct and acid dyes. Figure 1 provides the
procedure used for the black shade and Figure 2 provides the
procedure used for the navy shade.
DPPEA performed a visual determination of the exhaustion for
these shades by comparing the spent bath color to a series of
diluted samples of the initial dyebath. The dilutions for the black
shade were 80%, 90% and 95% for the navy shade 60%, 70%,
and 80%.
Based on this analysis, the black shade was estimated at +90%
dye exhaustion and the navy shade was just above 70%
exhaustion. Final fixation of dyestuff will be impacted by additional processing steps and was not
evaluated through this analysis. Fixation of direct dyes on cotton goods is typically in the range of 70 to
Figure 1 Black Shade
30 lbs in 50 lbs Paddle
Procedure
Fill tub
Add leveler
Add soda ash
Add acid dyes
Add direct dyes
Heat to 210°F
Hold 10 minutes
Add salt in three parts
Hold 10 minutes
Add acetic acid
Hold 15 minutes
Reduce Heat
Hold for 15 minutes
Drop bath
1.0%
0.5%
0.7%
5.6%
60.0%
0.5%
Nu -Sox Finishing 3 - April 28, 2004

95% and acid dyes on nylon is 80 to 93%'. The final fixation of
dye for both the black would probably be within this range for the
respective dye types utilized but the navy would be below these
ranges.
3.0 Color Reduction Options
Based on the dyebath exhaustion samples study, there may be
some opportunities to increase dye exhaustion. The facility may
want to consider the following options.
➢ Installing temperature gauges on all the dye machines to
improve control of rate of temperature increase and set
operating temperatures.
> Ensure operators are adding salt in required amounts and
emphasize the importance of staggering salt additions. The
black shade salt addition was added in three parts but that did
not appear to be the case for the navy shade.
> Optimize time -temperature profile scheme to achieve
maximum exhaustion of dye. Work with dye supplier to
identify most appropriate profile for darker shades. Rate of
temperature rise, final hold temperature and length of exhaustion phase will impact final exhaustion.
> Reduce dependence on auxiliaries like dye levelers that impede exhaustion. Assess the value in
adding sulfate and leveler at the end of the dye cycle, which may reduce dye exhaustion. The
increase percent of leveler used in the navy bath may have impacted exhaustion levels.
Figure 2 Navy Shade
196 lbs in 150 lbs Paddle
Procedure
Fill tub
Add leveler 2.0%
Add acid dyes 0.4%
Add direct dyes 2.5%
Heat to 210°F
Hold 10 minutes
Add Salt in three parts 40.0%
Hold 10 minutes
Add Ammonium Sulfate 1.0%
Hold 15 minutes
Reduce heat
Hold 15 minutes
Add Leveler 0.5%
Hold 10 minutes
Drop bath
1 Best Management Practices for Pollution Prevention in the Textile Industry, EPA/625/R-96/004
Nu -Sox Finishing - 4 - April 28, 2004

Division of Pollution Prevention and
Environmental Assistance
North Carolina Department of Environment and Natural Resources
Color Reduction Assessment
Spectrum Textured Yarns
Hickory, North Carolina
DPPEA
John Burke
March 23, 2004
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]; FAX: [phone]
Spectrum Textured Yarns - 1 -
April 28, 2004

Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. All references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.
Spectrum Textured Yarns - 2 April 28, 2004

Spectrum Textured Yarns: Color Reduction Assessment
1.0 Introduction
The City of Hickory and Spectrum Textured Yarns requested assistance from the. Division of Pollution
Prevention and Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent
color. The City of Hickory was required by the North Carolina Division of Water Quality to perform a
color reduction assessment to identify best management practices for the major sources of color in its
wastewater. Spectrum Textured Yarns was identified by the Cif of Hickory as a source of color. Color
testing of Spectrum Textured Yarns' effluent was 410 ADMI 2 half of 2002, 220 ADMI 1' half 2003,
and 382 2nd half of 2003.
On March 23'd, John Burke, of DPPEA, met with Tim Harris, Dyehouse Manager, to discuss current
operations and sample selected dyebath discharges. The following report provides information on the
generation of color from the Spectrum Textured Yarns' operations and options for potentially reducing
the level of color.
2.0 Facility Background and Color Analysis
Spectrum Textured Yarns dyes and finishes polyester and nylon yarn. Disperse and acid dyes are used
for dyeing the yarn. The facility operates 3 shifts 6 days per week. 100% of production is dyed goods.
The dyehouse is equipped with 3 — 2200 pound, 2 —1100 pound, 1 — 800 pound, 2 — 525 pound, 2 — 250
pound, and 1 —180 pound package dye machines that operate at a 8:1 liquor ratio. Machines are typically
operated at 90% of full load. The facility currently produces an average of 33,000 pounds per day of
finished yarn and discharges approximately 400,000 gallons per day of wastewater.
DPPEA targeted dark shade dyeing of polyester yarn for color
analysis due to relative large impact these shades have on effluent
color. DPPEA sampled one dyebath to estimate the percent
exhaustion of dye on the yarn for a black shade using disperse dyes.
Figure 1 provides the procedure used for the black shade.
DPPEA performed a visual determination of the exhaustion for
these shades by comparing the spent bath color to a series of
diluted samples of the initial dyebath. The dilutions for the black
shade were 80%, 90% and 95%.
Based on this analysis, the black shade was estimated at +90% dye
exhaustion. Final fixation of dyestuff will be impacted by
additional processing steps and was not evaluated through this
analysis. Fixation of disperse dyes on polyester goods is typically
in the range of 80 to 92%'. The final fixation of dye for the black
would probably be within this range for the respective dye types
utilized but the navy would be below these ranges.
3.0 Color Reduction Options
Figure 1 Black Shade
2223 lbs in 2400 lbs Package
Procedure
Fill tub 140°F
Add acetic acid 56%
Add lubricant
Hold 9 min
Add dispersant
Add disperse dyes
Hold 3 min
Circulate 5 min at 205°F
Circulate 5 min at 230°F
Circulate 25 min at 272°F
Circulate 1 min at 170°F
Drain
0.5%
0.7%
0.7%
3.8%
1 Best Management Practices for Pollution Prevention in the Textile Industry, EPA/625/R-96/004
Spectrum Textured Yarns - 3 - April 28, 2004

Based on the dyebath exhaustion samples study, Spectrum Yarns appears to be getting high exhaustion.
DPPEA does not have any suggestions related to these dyeing operations. This dye sample did not
include the using of leveling agents, which can significantly reduce exhaustion if added in excess.
Spectrum Textured Yarns 4 April 28, 2004

Division of Pollution Prevention and
Environmental Assistance
North Carolina Department of Environment and Natural Resources
Color Reduction Assessment
Moretz Mills
Hickory, North Carolina
DPPEA
John Burke
April 28, 2004
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]: FAX: [phone]
Moretz Mills - 1 - April 28. 2004

•
Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. All references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.
Moretz Mills 2 April 28, 2004

ctp
Moretz Mills: Color Reduction Assessment
1.0 Introduction
The City of Hickory and Moretz Mills requested assistance from the Division of Pollution Prevention and
Environmental Assistance (DPPEA) in assessing opportunities for reducing effluent color. The City of
Hickory was required by the North Carolina Division of Water Quality to perform a color reduction
assessment to identify best management practices for the major sources of color in its wastewater.
Moretz Mills was identified by the City of Hickory as a source of color. Color testing of Moretz Mills'
effluent was 703 ADMI 2nd half of 2002, 240 ADMI 1' half 2003, and 93 2"d half of 2003.
On April 28th, John Burke, of DPPEA, talked with Bennett Hanchey regarding the operations at the
Hickory facility. The company is not currently dyeing at the Hickory facility.
2.0 Facility Background
Moretz Mills bleaches, washes and finishes hosiery. The facility operates 1 shift 5 days per week
produces 4,000 pounds of hosiery and discharges 27,000 gallons per day. The dyehouse is equipped with
2 — 600 pound Braun dyeing machines.
3.0 Color Reduction Options
DPPEA does not have any suggestions related to these operations since dyeing is not currently
performed.
Moretz Mills 3 - April 28, 2004