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Home My WebLink AboutNC0077615_Compliance Evaluation Inspection_20221121ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Halil Ulukaya, CEO Origin Food Group, LLC. 306 Stamey Farm Rd. Statesville, NC 28687 SUBJECT: Notice of Deficiency Compliance Evaluation Inspection Origin Food Group, LLC. WWTP NPDES Permit No. NC0077615 Iredell County Tracking #: NOD-2022-PC-0191 Dear Mr. Ulukaya: NORTH CAROLINA Environmental Quality November 21, 2022 Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on November 8, 2022, by Mr. Wes Bell of this Office. Please advise the facility's Operator -in -Responsible Charge (ORC) of our findings by forwarding the enclosed report. This report is being issued as a Notice of Deficiency (NOD) due to the failure to have a designated operator perform the required visitations (for approximately one month) which is a violation of the subject NPDES Permit and North Carolina General Statute (G.S.) 143-215.1. Please note that G.S. 143-215.6A provides for a civil penalty of not more than twenty-five thousand dollars ($25,000.00), or twenty-five thousand dollars ($25,000.00) per day when the violation is of a continuing nature, against any person who violates or fails to act in accordance with the terms, conditions, or requirements of any permit issued pursuant to G.S. 143-215.1. Penalties may also be assessed for any damage to surface waters of the State that may result from the violation. D_E 11,arliworkt el G. ritmloalal Oat' North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1610 East Center Avenue. Suite 301 1 Mooresville. North Carolina 28115 704.663.1699 It is requested that a written response be submitted to this Office by December 12, 2022, detailing the actions taken to address the violation as discussed in more detail in the attached report. In responding, please address your comments to the attention of Mr. Wes Bell. Should you have any questions concerning this Notice, please do not hesitate to contact Mr. Bell at (704) 235-2192 or at wes.bell@ncdenr.gov. Enclosure: Inspection Report Cc: NPDES Program Files - Laserfiche DNORTH CAPOLI. _E 111.•rhworkt G. rOrmloalal Oat,' Sincerely, �DocuSigned by: fi4 44 4/ H p;zW' F161FB69A2D84A3... Andrew H. Pitner, P.G. Assistant Regional Supervisor Water Quality Regional Operations Section Mooresville Regional Office Division of Water Resources, NCDEQ North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1610 East Center Avenue. Suite 301 1 Mooresville. North Carolina 28115 704.663.1699 United States Environmental Protection Agency E PA Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code 1 IN I 2 I5 21 1 1 1 1 NPDES yr/mo/day Inspection I 3 I NC0077615 111 121 22/11/08 117 Type 18 i i I I 1 1 1 Inspector Fac Type 191 S I 201 1 1 1 1 1 11 1 1 1 I I I 1 1 1 1 1 1 I I I I I 1 11 1 1 1 I 1 P6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 67I2.0 I 70I4 I 71IN I 72 I N I 731 I 74 751 I I 1 I I I I I I 180 l Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Origin Food Group, LLC 306 Stamey Farm Rd Statesville NC 28677 Entry Time/Date 11:35AM 22/11/08 Permit Effective Date 19/04/01 Exit Time/Date 01:OOPM 22/11/08 Permit Expiration Date 24/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Dennis W Murdock//828-238-4659 / Todd Robinson/Area Manager/252-235-8809 / Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Halil Ulukaya,306 Stamey Farm Rd Statesville NC 28687//518-221-0830/ No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran Sludge Handling DispoFacility Site Review Effluent/Receiving Wate Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) Wes Bell of Inspector(s) Agency/Office/Phone and Fax Numbers Date �Docusiyned by: DWR/MRO WQ/704-663-1699 Ext.2192/ 111/21/2022 Oe "-A61696D9OCC3437... Signature of Man ildigigukeRaviewer Agency/Office/Phone and Fax Numbers Date Andrew Pitn r �4' ' H P4451NR/MRO WQ/704-663-1699 Ext.2180/ 11/21/2022 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 sI NPDES yr/mo/day NC0077615 111 121 22/11/08 I17 Inspection Type 18 [j (Cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) RECORD KEEPING SECTION cont'd: The facility was not being operated/visited by one of the designated backup ORCs following the resignation of the previous ORC in September 2022. The non -designated operator has been visiting the wastewater facility for approximately one month. Please be advised that the subject permit requires that either the designated ORC or backup ORC(s) must visit the facility five days per week excluding holidays [Permit Condition Reference: Part II, Section C(1) Certified Operator]. The Permittee must ensure one of the designated backup ORCs operate/visit the facility until a new ORC is designated (within 120 days). Page# 2 Permit: NC0077615 Inspection Date: 11/08/2022 Owner - Facility: Origin Food Group, LLC Inspection Type: Compliance Evaluation Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new El El • ❑ application? Is the facility as described in the permit? • El El El # Are there any special conditions for the permit? El El • El Is access to the plant site restricted to the general public? • ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? • El El El Comment: The last compliance evaluation inspection at this facility was performed by DWR staff on 7/16/2020. Record Keeping Are records kept and maintained as required by the permit? Is all required information readily available, complete and current? Are all records maintained for 3 years (lab. reg. required 5 years)? Are analytical results consistent with data reported on DMRs? Is the chain -of -custody complete? Dates, times and location of sampling Name of individual performing the sampling Results of analysis and calibration Dates of analysis Name of person performing analyses Transported COCs Are DMRs complete: do they include all permit parameters? Has the facility submitted its annual compliance report to users and DWQ? (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? Is the ORC visitation log available and current? Is the ORC certified at grade equal to or higher than the facility classification? Is the backup operator certified at one grade less or greater than the facility classification? Is a copy of the current NPDES permit available on site? Facility has copy of previous year's Annual Report on file for review? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ ❑ ❑ • ❑ Page# 3 Permit: NC0077615 Inspection Date: 11/08/2022 Owner - Facility: Origin Food Group, LLC Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Comment: The records reviewed during the inspection were organized and well maintained. Discharge Monitoring Reports (eDMRs) were reviewed from October 2021 through September 2022. Effluent BOD limit violations were reported in May 2022 (daily maximum) and August 2022 (daily maximum and monthly average). Effluent TSS limit violations were reported in May 2022 (daily maximum and monthly average), July 2022 (daily maximum) and August 2022 (daily maximum and monthly average). The Division has previously addressed these limit violations through the issuances of civil penalty assessments. See "Summary" Section for additional comments. Laboratory Are field parameters performed by certified personnel or laboratory? Are all other parameters(excluding field parameters) performed by a certified lab? # Is the facility using a contract lab? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ Comment: On -site field analyses (pH, temperature and total residual chlorine) are performed under Environlink's field laboratory certification #5212. Statesville Analytical has also been contracted to perform analyses of all permit -required parameters except field. The facility staff must ensure that post calibration checks are performed (on all applicable meters) at the end of the day if these meters are used to perform effluent analyses at multiple facilities (Reference: NC Wastewater/Groundwater Laboratory Certification - Approved Procedure for the analyses of dissolved oxygen, pH and total residual chlorine). Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ❑ ❑ • ❑ Is sample collected below all treatment units? • ❑ ❑ ❑ Is proper volume collected? ❑ ❑ • ❑ Is the tubing clean? ❑ ❑ ■ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 ❑ ❑ • ❑ degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type • ❑ ❑ ❑ representative)? Comment: The subject permit requires effluent grab samples. Operations & Maintenance Is the plant generally clean with acceptable housekeeping? Yes No NA NE Page# 4 Permit: NC0077615 Inspection Date: 11/08/2022 Owner - Facility: Origin Food Group, LLC Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable MODE Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: The facility continues to receive low influent flows and the wastewater is treated on a batch basis. The wastewater treatment facility appeared to be adequately treating the wastewater at the time of the inspection. Process control measurements are being performed and documented. The permittee must ensure to replace all grating and railing that exhibits signs of deterioration and rust. In addition, the permittee must ensure all areas on the clarifier and chlorination areas are equipped with proper grating and railing. Pump Station - Influent Is the pump wet well free of bypass lines or structures? Is the wet well free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Is SCADA telemetry available and operational? Is audible and visual alarm available and operational? Comment: Equalization Basins Is the basin aerated? Is the basin free of bypass lines or structures to the natural environment? Is the basin free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Are audible and visual alarms operable? # Is basin size/volume adequate? Comment: Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ ▪ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? • ❑ ❑ ❑ Are surface aerators and mixers operational? El El • El Page# 5 Permit: NC0077615 Inspection Date: 11/08/2022 Owner - Facility: Origin Food Group, LLC Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Are the diffusers operational? • ❑ ❑ ❑ Is the foam the proper color for the treatment process? ■ ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? • ❑ ❑ ❑ Is the DO level acceptable? • ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/I) • ❑ ❑ ❑ Comment: Both blower/motor units were operational and both check valves operated properly during the on -site test. Secondary Clarifier Is the clarifier free of black and odorous wastewater? Is the site free of excessive buildup of solids in center well of circular clarifier? Are weirs level? Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Comment: Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ▪ ❑ ❑ ❑ Disinfection -Tablet Yes No NA NE Are tablet chlorinators operational? • ❑ ❑ ❑ Are the tablets the proper size and type? • ❑ ❑ ❑ Number of tubes in use? 2 Is the level of chlorine residual acceptable? • El El El Is the contact chamber free of growth, or sludge buildup? • El El El Is there chlorine residual prior to de -chlorination? • ❑ ❑ ❑ Comment: Calcium hypochlorite tablets are used for disinfection. De -chlorination Type of system ? Yes No NA NE Tablet Page# 6 Permit: NC0077615 Inspection Date: 11/08/2022 Owner - Facility: Origin Food Group, LLC Inspection Type: Compliance Evaluation De -chlorination Is the feed ratio proportional to chlorine amount (1 to 1)? Is storage appropriate for cylinders? # Is de -chlorination substance stored away from chlorine containers? Comment: Are the tablets the proper size and type? Are tablet de -chlorinators operational? Number of tubes in use? Comment: Sodium Sulfite tablets are used for dechlorination. Yes No NA NE • ❑ ❑ ❑ 2 Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? El El • El Is flow meter calibrated annually? El El • El Is the flow meter operational? ❑ El • ❑ (If units are separated) Does the chart recorder match the flow meter? El ❑ • ❑ Comment: Instantaneous flow measurements are based on pump run time and pump flow rate (2.3 gpm). Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? El El El • Are the receiving water free of foam other than trace amounts and other debris? ❑ ❑ ❑ • If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ • ❑ Comment: The effluent appeared clear with no floatable solids or foam. Aerobic Digester Yes No NA NE Is the capacity adequate? • ❑ ❑ ❑ Is the mixing adequate? • ❑ ❑ ❑ Is the site free of excessive foaming in the tank? • El ❑ ❑ # Is the odor acceptable? • ❑ ❑ ❑ # Is tankage available for properly waste sludge? • ❑ ❑ ❑ Page# 7 Permit: NC0077615 Inspection Date: 11/08/2022 Owner - Facility: Origin Food Group, LLC Inspection Type: Compliance Evaluation Aerobic Digester Yes No NA NE Comment: The facility is equipped with an aerated sludge holding tank. Wastewater solids are removed on an as -needed basis by Lentz Septic Tank Service. The permittee should initiate a structural evaluation on the wall between the aerated sludge holding tank and aeration basin. All identified areas should be repaired as soon as possible to prevent worsening conditions that could lead to structural failure. Please be advised that the subject permit requires the permittee to properly operate and maintain the facility at all times. Page# 8