NC0001406_NPDES Permit Renwal_20011129

DIVISION OF WATER QUALITY
November 29, 2001
MEMORANDUM
TO: Dave Goodrich, Supervisor
NPDES Permitting and Engineering: Unit
THROUGH: Paul E. Rawls
Water Quality Regional Supervisor
Fayetteville Regional Office
FROM: Grady Dobson, Environmental Engineer
Fayetteville Regional Office
SUBJECT: Renewal of NPDES Permit-
NPDES Permit No. HOC 491 406 #
SWA4ftTextil'es;zInc
Erwin, North Carolina
Harnett County
Please find enclosed the staff report and recommendations .of
Office concerning the renewal of subject NPDES permit.
If you have any questions or require further information, please
GD/bs
Enclosure
he Fayetteville Regional
dvise.

:'a
SOC PRIORITY PROJECT: YES_ NO X
If Yes, SOC No.
To: Permits and Engineering Unit
Water Quality Section
Attention: Susan Wilson
Date: November 28, 2001
NPDES STAFF REPORT AND RECOMMENDATIONS
COUNTY: Harnett
Permit No. NC 0001406
PART I - GENERAL INFORMATION
1. Facility and Address: Swift Textiles, Inc.
200 North 13th Street
Erwin, NC 28339
2. Date of Investigation: September 25, 2001
3. Report Prepared by: Grady Dobson, Environmental Engineer, FRO
4. Persons Contacted and Telephone Number: Bailey Barefoot
Director of Safety, Health and Environment
706-571-8485
5. Directions to Site: Plant is located at the end of SR 1857 (West "E" Street) in Erwin, Harnett
County, North Carolina.
6. Discharge Point(s), List for all discharge points:
Latitude: 35° 19' 02" Longitude: 78° 42' 00"
Attach a U.S.G.S. map extract and indicate facility siteand discharge point on map.
U.S.G.S. Quad No.: F 24 NE U.S.G.S. Quad Name: Erwin. NC
7. Site, land available for expansion and upgrading: There is an additional 5 acres available for
expansion.
8. Topography: (relationship to flood plain included):
Plant site is flat and appears to be above the 100 year flood plain.
9. Location of nearest dwelling: None observed with ± 1,000 feet.
10. Receiving stream or affected surface waters: Cape Fear River
a. Classification: Class WS-V
b. River Basin and Subbasin No.: 03-06-18
c. Describe receiving stream features and pertinent downstream uses:
Water supply source, fishing, boating, fish and wildlife propagation.

PART II - DESCRIPTION OF WASTES AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted: 2.5 MGD (Ultimate Design Capacity)
b. What is the current permitted capacity of the Wastewater Treatment facility? 2.5 MGD
c. Actual treatment capacity of the current facility (current design capacity): 2.5 MGD
d. Date(s) and construction activities allowed by previous Authorizations to Construct issued in the
previous two (2) years: N/A
e. Please provide a description of existing or substantially constructed wastewater treatment
facilities:
The existing facility consists of influent ammonia nitrate feed, automatic
mechanical bar screen, mechanical grit removal, -influent recording flow
measurement, CO, influent, pH adjustment, parallel aeration basins utilizing
floating surface aerators, polymer feed system to assist clarification, dual
clarifiers, effluent recording flow measurement, anaerobic sludge digester, two (2)
sludge thickening tanks equipped with mixers and sludge drying beds.
f. Please provide a description of proposed wastewater treatment facilities: None at this time.
g. Possible toxic impacts to surface waters: None known
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 DWQ Permit No.WQ0006298
Residual Contractor: SYNAGRO
Telephone No.: 336-766-0328
b. Residuals stabilization: PSRP X PFRP_ Other,
c. Landfill: . N/A
d. Other disposal/utilization scheme (specify): , N/A
3. Treatment plant classification (attach complete rating sheet): Grade IV
4. SIC Code(s): 2211
Primary: 55 Secondary: 02
Main Treatment Unit Code: 0 5 0 0 3

PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or are any public monies involved
(municipals only)? N/A
2. Special monitoring requests or limitations (including toxicity) requests: N/A
3. Important SOC, JOC, or Compliance Schedule dates (please attach): SOC pending
Date
Submission of Plans and Specifications N/A
Begin Construction N/A
Complete Construction N/A
4. Alternative Analysis Evaluation: Has the facility evaluated all of the nondischarge options
available? Please provide regional perspective for each option evaluated. This is a permit renewal.
Spray Irrigation:
N/A
Connection to Regional Sewer System:
There is no regional facility capable of taking flow at this time.
Subsurface:: N/A
Other Disposal Options: None noted
5. Other Special Items:
The following is a description of the manufacturing process when the facility was operational:
Swift Textiles, Inc., was a fully integrated denim textile operation which received
cotton from various locations across the United States for the manufacture of
denim. The operation manufactured yarn - prepped and weaved to produce a
finished woven cloth.
The preparation process included longchain rope dyeing of warp yarn. Within this
process, cotton yarns was scoured to remove/reduce natural oils, waxes, or other
foreign substances; cauterized to further clean and prepare fibers for dyeing; rinsed
and dried.
Other processes utilized corn starch, binders, and fixatives to improve the runability
of the yarn in the weaving process. After weaving, cloth was finished by singeing,
washing, overdyeing, and applying starch finishes. Chemicals could include corn
starch, wetting agents, defoaming, sulfur dyes an lubricants.

PART IV = EVALUATION AND RECOMMENDATIONS
As you are aware, all manufacturing operations at both the yarn manufacturing/finishing plant and the
weave plant have been closed since early 2001. We question the appropriateness of reissuance of this _
permit with the identical limits should that be the normal method of reissuance in similar cases. We
recommend that the permit be issued only to facilitate the treatment of domestic waste as that is the stated
need of the permittee. The effluent leaving this WWT Plant is minimal.
We have been advised by Mr. Baily Barefoot, Director of Safety, Health and En ironmental, Swift Denim
Complex, has been sold and will be leased to new occupants. To date, no new occupants have been
recruited. Mr. Barefoot has indicated, by letter (see attached),,that Swift Denim has agreed to provide
sanitary sewer for any new occupants.
It is our understanding that the only flow coming to this facility is from a few homes in the old mill village
part of the Town of Erwin.
It is doubtful that the existing WWT facility with such a minimal flow could 'consistently meet these final
effluent limitations for a treatment system designed to treat textile waste.
•
Should you have any questions,, please advise.
Signature of Report Parer
Water Quality Regional Supervisor
0.1
Date % "

t r�' CS
Treatment Works &
Discharge Point
Swift Textiles, Inc.
NPDES Permit No. NC0001406

PO Box 1400 Columbus GA 31902-1400 tel: [phone]
G a Galey & Lord Company
September 21, 2001
MA ;T•
s. Susa:> \; � ilson
Environmental Engineer II
NCDENR-DW Q
NPDES Permitting Unit
1617 Mail Service Center
Raleigh, N.C.. 27699-1617
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
7000 0600 0022 3964 1002
•
PE: NPDES Permit Renewal Application
Swift Textiles, Inc. (Swift Denim) — Erwin Mills Division
NPDES Permit Number NC0001406
Dear lbs. Wilson:
Enclosed. is the renewal application for Swift Textiles, Inc. (Swift Denim), NPDES Permit No.
NC0001406, utilizing Short Form D as you recommended to Mr. Tins Monroe of Bensinger &
Garrison Environmental (B&G). A copy has been sent to Mr. Paul Rauls, Water Quality Section
Supervisor, of the Fayetteville Regional Office. This application is meant to satisfy the
extension deadline of 10/2/01 given to Swift Denim — Erwin Plant by Mlle NCDENR-D1v Q.
Per your 9/04/01 phone conversation with Mr. Monroe, it was agreed that this permit renewal
was unique and that it would be in the best interest of all concerned to pave a meeting to discuss
all options for the Swift wastewater treatment plant (WWTP). It is car understanding that the
current workload for the NPDES Permitting Unit precludes having a' meeting and reaching a
resolution by the 10/02/01 deadline and: as a -result, you recommend submitting this simple,
economical Short Form D so that an application will be on file, with the Division. This enclosed
application, therefore, is intended to satisfy the renewal application requirement and maintain
NPDES Permit status,
As you are aware, all manufacturing operations at both the yarn manufacturing/finishing plant
and the. weave plant have been discontinued. The main mill, for merj yarn manufacturing and.
finishing plant, has been sold and will be leased to new occupants. T1ie new occupants will be
recruited and are not yet known. Swift has agreed to provide sanitary sewer for anv new
occupants. Per our discussions'with the Town of Erwin, they will not be prepared to entertain
options involving their WWTP• for a time period of at least six to nine months. With all these
parameters and unknowns, disposition of the Swift WWTP becomes complicated. Below is a list
of issues that need to be discussed in a meeting with all interested parties:
denim in any Language

Ms. Susan' Wilson
NCDENR-DWO
September 21, 2001
Page 2.
1. ` Permit renewal
2. Future permit modifications
3. Increased.percentage. of domestic wastewater
4.' Diversion of wastewater flow to the Town of Erwin WWTP
5. Rescinding of the existing permit and closure of the Swift WWTP
6. Potential economic benefit of an operable Swift WWTP including flexibility foi-
occupants of the Swift Plants
Please review the enclosed permit'application at your earliest convenience. Written verification;;
that the application has been accepted, is requested.: Mr. Tim Monroe of Bensinger'& ,Garrison,::;''
Environmental, Inc. (B&G) will be calling you .in a couple of weeks to schedule :a' meeting:,
Should you have any questions, please call me at [phone]. or Tiny Monroe of B&G.;a`
[phone].
Sincerely,
SWIFT DENIM
7/1
Bailey Barefo€t
Director of Safety, Rea lth,,and Environment
Enclosure
cc. Tin'. Monroe — B&G
Paul Rawls NCDENR-DWQ

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Gregory J. Thorpe, Ph D., Acting Dir
Mr. Bailey Barefoot
Swift Denim
233 12th Street
Suite 200
Columbus, Georgia 31902-1400
Dear Mr. Barefoot:
OCT 12 2001
October 12, 2001
T!'w
NCDENR
NORTH CAROLINA DEPARTMENT OF ,
ENVIRONMENT AND NATURAL RESOURCES
Subject: NPDES Permit Renewal Application
Permit NC0001406,
Erwin Mills Division
Harnett County,
The NPDES Unit received your permit renewal application on October 1, 2001. Thank you for submitting
this package.
The permit renewal for this facility has been assigned to Natalie Sierra. This staff member will contact you
if further information is needed to complete the permit renewal. Please note that the NPDES Unit has
several vacant positions. This staff shortage has lasted for over a year and is delaying all permit renewals.
Our remaining permit writers are currently reviewing Authorizations to Construct, speculative limit requests,
major permit modifications and 201. plan updates ahead of permit renewals., This is necessary due to a
variety of factors, including mandatory deadlines in the statutes which govern our program.
If this staff shortage delays reissuance of NC0001406 the existing requirements in .your permit will remain
in effect until the permit is renewed (or the Division takes other action). We appreciate your patience and
understanding while we operate with a severely depleted staff. If you have any additional questions
concerning renewal of the subject permit, please contact Natalie Sierra at [phone], extension 551.
cc:CEayettevilletRegional Office, Water Quality Section
NPDES File
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Sincerely,
Valery Stephens
Point Source Unit,'
919 733-5083, extension 520 (fax) 919 733-0719
VISIT US ON THE INTERNET @ http://h2o.enr.state.nc.us/NPDES [e-mail]

NPDEe P1 RNNIIT APPLICATION - SHORT FORM D
To be filed only by dischargers of 100% domestic wastewater (<1 MGD flow)
,
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
North Carolina NPDES Permit Number
(if known)
1. Mailing address
Facility Name
Owner Name
Street Address
City
State
ZIP Code
Telephone Number
Fax Number
e-mail Address
NC00 01406
Please print or type
of applicant/permittee:
Swift Denim - Erwin Mills Division
Swift Denim
933 l2th Street, Snitp 900
Columbus
Georgia
31902-1400
( 706 ) 571-8485
( 706 ) 571-8478
bailey [e-mail]
2. Location of facility producing discharge:
Name (If different from above)
Facility Contact Person
Street Address or State Road
City / Zip Code
County
Telephone Number
3. Reason for application:
Expansion/Modification *
Renewal
Bailey Barefoot
200 N. 13th Street
Erwin 28339
Harnett
( 910 ) 897-8111
Existing Unpermitted Discharge
New Facility
* Please provide a description of the expansion/modification:
4. Description of the existing treatment facilities (list all installed components with
capacities):
Barscreen Clarifiers (2 at 0.2 mg each) (6) Sludge Drying Beds
Grit Chamber Sludge Storage Tank (1 mg) Sludge Storage Tank (0.7 mg)
Aeration Basins (2 at 2.2 mg each) Digester (1 at 0.3 mg) Sludge Belt Press
Discharge Metering Station
Page 1 of 2 Version 6/99

NPDES PER.IVIIT APPLICATION - SHORT FORM D
To be filed only by dischargers of 100% domestic wastewater (<1 MGD flow)
5. Description of wastewater (check all that apply):
Type of Facility Generating Wastewater
Industrial X Number of Employees
Commercial X Number of Employees
Residential X Number of Homes
School Number of Students/Staff
Other
0-:
0
6 max.
Describe the source(s) of wastewater (example: subdivision, mobile home park,' etc.):
Restrooms from former denim plants, potential lease occupants of plants.
6. Number of separate wastewater discharge pipes (wastewater outfalls):
001 (Wastewater Treatment Plant Discharge) 002 (Water Plant Filter Backwash)
7. If the facility has multiple discharge outfalls, record the source(s) of wastewater for each
outfall:
001 (Wastewater from fo,.mer Swift Denim plants) 002 (Multi -media water filter backwash and
alum sludge decant)
8. Name of receiving stream(s) (Provide a map showing. the exact location of each outfall):
001 - Cape Fear River 002 - Unknown tributary of Cape Fear River
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, .and accurate.
Bailey Barefoot
Printed Name of Person Signing
Director - Safety, Health and Environment
Title
Signature o Applic
� O
Dat Signed
North Carolina General Statute 143-215.6(b)(2) provides that: Any person who knowingly makes any false statement representation, or
certification in any application, record, report, plan, or other document files or required to be maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any
recording or monitoring device or method required to be operated or maintained under Article 21 or regulations of the Environmental
Management Commission implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed $10,000, or by
imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by a fine of not more than $10,000 or
imprisonment not more than 5 years; or both for a similar offense.)
Page 2 of 2 Version 6/99

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PROJECT Na
127900
DATE'
September, 2000
DRAWN BY'
RES
APPROVED BY'
TWM
FILE'
Swift Erw. NPDES
SCALE'
1'=2,000 ft
SOURCE''
DeLorme 3D
TopoQuads
USGS Tops''
Erwin, NC -
NOTES:
Longitude'
781 42' 00'
Latitude!
359 19' 02'
NPDES Permit No.
NC0001406
FIGURE 11 . OUTFALL LOCATION, MAP
SWIFT DENIM, INC.
200• North 13th- Street,,
Erwin, Harnett Co,, North Carolina

\I‘,1.AT4,:9 Michael F. Easley, Govemor
William G. Ross Jr., Secretary
Q(� North Carolina Department of Environment and Natural Resources
Gregory J. Thorpe, Ph.D.
—► Acting Director
'C Division of Water Quality
October 15, 2001
BAILEY BAREFOOT
SWIFT TEXTILES -A SLUDGE/ERWIN
PO BOX 1400
COLUMBUS, GA 31902
Subject: PERMIT NO. WQ0006298
SWIFT TEXTILES -A SLUDGE/ERWIN
HARNETT COUNTY
Dear Permittee:
Our files indicate that the subject permit issued -on 3/27/98 expires on 11/,30/01. We have not received a
request for renewal from you as of this date.
A renewal request shall consist of aletter asking for permit renewal and four (4) copies of a completed
application. For permitted facilities with treatment works, a narrative description of the residuals management
plan, which is in effect at the permitted facility, -must also be submitted with) the renewal application.
Applications may be returned to the applicant if incomplete. j
The General Assembly passed legislation incorporating renewal fees into the annual fee.
Please be advised that this permit must not be allowed to expire. You must submit the renewal request at_
least 180 days prior to the permit's expiration date, as required by the 15 NCAC 2H .0211. Failure to request a
renewal at least 180 days prior to the permit expiration date and/oroperation of a facility without a valid permit
may result in the assessment of civil penalties. NCGS 143-215.6A allows for the assessment of Civil penalties
up to $10,000 per violation per day.
The letter requesting renewal, along with the completed Non -Discharge Peiiiut Application must be sent to:
Division of Water Quality
Non -Discharge Permitting Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
If you have any questions concerning this matter, please contact Thelma Williams at 919 733-5083
extension 556.
Sincerely,
Kim H. Colson, P.E., Supervisor
Non -Discharge Permitting Unit
cc: Fayetteville Regional Office
Central Files
N. C. Division of Water Quality 1617 Mail Service Center
Raleigh, NC 27699-1617 [phone]
NCDENR
Customer Service
1 800 623-7748

if
PO Box 1400 Columbus GA 31902-1400 tel: [phone]: '
f1
G a Galey & Lord Company
September 21, 2001
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
7000 0600 0022 3964 1002
Isis. Susan Wilson
Environmental Engineer II
NCDENR-DWQ
NPDES Permitting Unit
1617 Mail Service Center
Raleigh, N.C.. 27699-1617
RE: NPDES Permit Renewal Application
Swift Textiles, Inc. (Swift Denim) — Erwin Mills Division.
NPDES Permit Number NC0001406
Dear Ms. Wilson:
•
Enclosed. is the renewal application for Swift Textiles, Inc.. (Swift Denim), NPDES Permit No.
NC0001406, utilizing Short,Fonn D as you recommended' to Mr: Time Monroe of Bensinger &
Garrison Environmental (B&G). A copy has been sent to Mr. Paul Rauls, Water Quality Section
Supervisor, of the Fayetteville ' Regional Office. This application ' is meant to satisfy the
extension deadline of 10/2/01 given to Swift Denim — Erwin Plant liy the NCDENR-DWQ.
Per your 9/04/01.phone conversation with Mr. Monroe, it was agreed:that this permit renewal
was unique and that it would be in the best interest of all concerned to bare a meeting to discuss
all options for the Swift wastewater treatment plant (WWTP).. It is otir understanding that the
current workload for the NPDES Permitting Unit precludes having a!' meeting and reaching a
resolution by the 10/02/01 deadline and, as a result, you recolnmend •-submitting this simple,
economical Short Form D so that an application will be on file with thei Division. This enclosed
application, therefore, is intended to satisfy the renewal application r e quirement and maintain
NPDES Permit status. ;k
As you are, aware, all manufacturing operations at both the yarn manufacturing/finishing plant
and the weave plant have been discontinued. The main mill, former yain manufacturing and
finishing plant, has been sold and will be leased to new occupants) The new occupants will be
recruited and are not yet known. Swift has agreed to provide sanitary sewer for any new
occupants. Per our discussions with the Town of Erwin, they will' not. be prepared to entertain
options involving their WWTP for a time period of at least six to nine; months. With all these
parameters and unknowns, disposition of the Swift WWTP becomes complicated. Below is a list
of issues that need to be discussed in a meeting with all interested parties:: ;
,
26
own
denim in any language

Ms. Susan Wilson
NCDENR-DWQ
September 21, 2001
Page 2
1. Permit renewal
2. Future permit modifications
3. Increased percentage of domestic wastewater
4. Diversion of wastewater flow to the Town of Erwin WWTP
5. Rescinding of the existing permit and closure of the Swift WWTP
6. Potential , economic benefit of an operable Swift WWTP including flexibility for new
occupants of the Swift Plants
Please review the enclosed. permit application at your earliest convenience. Written verification
that the application has been accepted is requested. Mr. -Tim Monroe of Bensinger & Garrison
Environmental, Inc. (B&G) will be calling you in a couple of 4e4:to schedule a meeting.
Should you have :any questions; please call me at [phone] or Tim Monroe. of B&G at
[phone].
Sincerely,
SWIFT DENIM
Bailey Barefodt -
Director of Safety, Heth, and Environment
Enclosure
cc: Tim Monroe — Bc&G
' Paul Rawls — NCDENR-DWQ