NC0004618_Permit Issuance_20090831

NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins
Governor Director
August 31, 2009
Mr. Henry Griffin
Vice President Manufacturing
Alamac American Knits, LLC
P. O. Box 1347
Lumberton, NC 28359-1347
Dee Freeman
Secretary
Subject: Issuance of Renewal NPDES Permit
NPDES PermitNC0004618
Alamac American Knits, LLC WWTP/WTP
Class III
Robeson County
Dear Mr. Griffin:
Division personnel have reviewed and approved your application for renewal of the subject permit.
Accordingly, we are forwarding the attached NPDES discharge permit. This permit is issued pursuant to
the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement
between North Carolina and the U.S. Environmental Protection Agency dated October 15, 2007 (or as
subsequently amended).
After further evaluation a technical correction was made to Outfall 002 parameters. The backwash
discharge is a non -chlorinated waste stream from a process water treatment filter plant and as such is
subject to non -potable water plant monitoring requirements. As a result some metal parameters
monitoring and toxicity monitoring listed in the draft permit are no longer applicable. However, be aware
that Best Management Practices to mitigate potential erosion and sedimentary discharges to Jacob's
Swamp must be maintained and are required for your facility to meet North Carolina standards.
Quarterly mercury monitoring for Outfall 001 will not be removed but remain because of the
impairment to the Lumber River.
Summary of Changes in Issued Permit from Active Permit
1) Outfall 001, footnote on effluent conductivity was added. Effluent conductivity must be measured
and reported as an actual value, not as greater than a value.
2) Outfall 002, settleable solids and turbidity monitoring was removed. Requirements for process
water treatment plant are equal to minimum Greensand filter WTP requirements and as such
settleable solids and turbidity monitoring are no longer required.
3) Outfall 002, total iron, total nitrogen, and total phosphorus monitoring was added. At a minimum
these parameters must be monitored to be consistent with metal and nutrient policies.
4) Outfall 002, permitted compliance flow limit of 0.24 MGD based on the monthly average was added.
Current standards require this discharge to have a compliance flow limit.
Page 1 of 2
16.17 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: 91"07-64951 Customer Service: 1-877-623-6748
Internet. http:i I h2o.state.nc.us I
An Equal Opponunin 1 ARnialive Action Employer
NorthCarolina
Naturally

If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty (30)
days following receipt of this letter. This request must be in the form of a written petition, conforming to
Chapter 150B of the North Carolina General Statutes, and filed with the Office of Administrative Hearings
(6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless such demand is made, this
decision shal I be final and binding.
Please note that this permit is not transferable except after notice to the Division. The Division
may require modification or revocation and reissuance of the permit. This permit does not affect the legal
requirements to obtain other permits which may be required by the Division of Water Quality or permits
required by the Division of Land Resources, the Coastal Area Management Act or any other Federal or
Local governmental permit that may be required.
If you have any questions concerning this permit, please contact Ron Berry at telephone number
[phone].
Sincerely,
Coleen H. Sullins
Attachments
Cc: Fayetteville Regional Office/Surface Water Protection Section (email)
EPA Region iv/Marshall Hyatt (email)
Environmental Sciences Section/Aquatic Toxicity Unit/Susan Meadows (email)
Central Files
NPDES Unit
Page 2 of 2

Permit No. NC0004618
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful
standards and regulations promulgated and adopted by the North Carolina Environmental
Management Commission, and the Federal Water Pollution Control Act, as amended, the
Alamac American Knits, LLC
Lumberton Plant
is hereby authorized to discharge wastewater from a facility located at
Alamac American Knits, LLC
Industrial WWTP and WTP
1885 Alamac Road
Lumberton, NC
Robeson County
to receiving waters designated as Lumber River and Jacob's Swamp in the Lumber River Basin in
accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, II, III and IV hereof.
This permit shall become effective October 1, 2009.
This permit and authorization to discharge shall expire at midnight on July 31, 2014.
Signed this day August 31, 2009.
c : Coleen H. Sullins, irect `
Division of Water Quality
By Authority of the Environmental Management Commission

Permit No. NC0004618,
SUPPLEMENT TO PERMIT COVER SHEET
All pre vious NPOES Permits issued to this facility, whether for operation or discharge are hereby
revoked. As of this permit issuance, any previously issued permit bearing this number is no longer
effective. Therefore, the exclusive authority to operate and discharge from this facility arises under
the permit conditions, requirements, terms, and provisions included herein.
Alamac American Knits, LLC
Industrial WWTP and WTP
Is hereby authorized to:
1. Continue to operate an existing 2.5 MGD industrial wastewater treatment plant
consisting of:
Manual bar screen
Influent meter
Aeration basin
Mechanical blowers
Splitter box
Two (2) clarifiers
Two (2) 5 acre polishing ponds
Effluent meter
Effluent composite sampler
Collection sump
Outfall 001 discharge pump(s) with automatic control
Filter press
Solids feed system to filter press, and
Discharge of treated wastewater from the treatment of non -contact cooling water,
boiler blowdown, ground water remediation, water softener wastewater, other
process wastewater in said treatment works through Outfall 001 to the Lumber River
classified as C, Swamp water in the Lumber River Basin as specified on the attached
map.
Continue to operate an existing process water filter treatment plant discharging
0.24 MGD backwash wastewater and consisting of:
D Mechanical aeration tower
D Two(2) anthracite sand filters
D Effluent meter
D Clearwell
D Post chlorination
D Post chemical addition, and
4. Discharge of process water filter treatment plant backwash wastewater through
Outfall 002 to Jacob's Swamp classified as C, Swamp in the Lumber River Basin as
specified on the attached map.

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Facility 1
Name:
r C r1vilf, (L 1 FCu: 'I Fte�h. 1 sty,
USGS Quad: 122SE Southwest Lumberton, NC
outran 001 outfall 002 L[Facility
Latitude: 340 36' 32.6" N 34° 35' 13.7" N cation
Longitude: 79° 0' 32.2" W 79° 0' 12.4" W
Stream Class: C, Sw
Subbasins 03-07-51 Alamac American Knit, LLC
Receiving Stream: 001 -Lumber River, 002 — Jacob's Swamp Robeson County

PermitNC0004618
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of this permit and lasting until expiration, the
Permittee is authorized to discharge treated industrial waste from Outfa//OOI. Such discharges shall be
limited and monitored by the Permittee as specified below:
EFFLUENT
CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS
Monthly
Average
Weekly
Avera a
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample
Location
Flow
2.5 MGD
Continuous
Recording
Influent or Effluent
BOD, 5 day, 200C
94.5 Ibs/day
189 Ibs/day
3/Week
Composite
Effluent
COD
1890 lbs/day
3780 Ibs/day
3/Week
Composite
Effluent
Total Suspended Solids (TSS)
412 Ibs/day
824 Ibs/day
3/Week
Composite
Effluent
pH
Not more than 9.0 s.u. nor less than 6.0
S.U.
3/Week
Grab
Effluent
Dissolved Oxygen (DO)
Not less than 5.0 mg/L daily average
3/Week
Grab
Effluent
Dissolved Oxygen (DO), mg/L
(June 1 - September 30)
3/Week
Grab
Upstream &
Downstream 1
Dissolved Oxygen (DO), mg/L
(October 1 - May 31)
Weekly
Grab
Upstream &
Downstream 3
Temperature, °C
Not more than 32 °C
3/Week
Grab
Effluent
Temperature, °C
(June 1 - September 30)
3/Week
Grab
Upstream &
Downstream
Temperature, °C
(October 1 - May 31)
Weekly
y
Grab
Upstream &
Downstream 1
Conductivity, µmhos/cm 2
3/Week
Grab
Effluent
Conductivity, pmhos/cm
(June 1 - September 30)
3/Week
Grab
Upstream &
Downstream 1
Conductivity, pmhos/cm
(October 1 - May 31)
Weekly
Grab
Upstream &
Downstream 3
Kjeldahl Nitrogen (TKN)
Monitor & Report, mg/L
Monthly
Composite
Effluent
Nitrite/Nitrate Nitrogen
(NO -N + NO -N)
Monitor & Report, mg/L
Monthly
Composite
Effluent
Total Nitrogen (TN)
TN = (NO -N + NO -N) + TKN
Monitor & Report, mg/L
Monthly
Calculated
Effluent
Sulfides
3.8lbs/day
7.5lbs/day
Quarterly
Grab
Effluent
Total Chromium
1.9 Ibs/day
3.8 Ibs/day
Quarterly
Composite
Effluent
Total Phenols
1.9 Ibs/day
3.8 Ibs/day
Quarterly
Grab
Effluent
Total Copper, µg/L
Quarterly
Grab
Effluent
Total Zinc, µg/L
Quarterly
Grab
Effluent
Mercury, ng/L (Method 1631E)
Quarterly
Grab
Effluent
Perchloroethylene, µg/L
Quarterly
Grab
Effluent
Trichloroethylene, µg/L
Quarterly
Grab
Effluent
1,2-cis-dichloroethylene, pg/L
Quarterly
Grab
Effluent
Vinyl Chloride, µg/L
Quarterly
Grab
Effluent
Chronic Toxicity 3
Quarterly
Composite
Effluent
(Footnotes on next page)

Permit NC0004618
(Continued A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS)
Footnotes:
1. Sample locations: Upstream = Chestnut Street Extension Bridge, Downstream = Chippewa Street Bridge.
Samples taken in conjunction with effluent samples.
2. Conductivity measurement must be conducted to determine and report actual value.
3. Chronic Toxicity Limit (Ceriodaphnia dubia) P/F at 3.2% during March, June, September, and December.
See Special Condition A.(3). Toxicity monitoring shall coincide with effluent sampling.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
There shall be no discharge of oily sheen or films.
A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of this permit and lasting until expiration, the
Permittee is authorized to discharge process water filter plant backwash wastewater from Outfa// 002.
Such discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT
LIMITS
MONITORING REQUIREMENTS
Monthly
Weekly
Daily
Measurement
Sample
Sample
CHARACTERISTICS
Average
Average
Maximum
Frequency
Type
Location
Flow
0.24 MGD
Event
Estimate
Effluent
Total Suspended Solids (TSS)
30 mg/L
45 mg/L
2/Month
Grab
Effluent
pH
Not greater than 9.0 s.0 nor less than
2/Month
Grab
Effluent
6.0 s.u.
Total Iron, mg/L
Monthly
Grab
Effluent
Kjeldahl Nitrogen (TKN)
Monitor & Report, mg/L
Monthly
Grab
Effluent
Nitrite/Nitrate Nitrogen
(NO -N + NO -N)
Monitor & Report, mg/L
Monthly
Grab
Effluent
Total Nitrogen (TN)
TN = (NO -N + NO -N) +TKN
Monitor & Report, mg/L
Monthly
Calculated
Effluent
Total Phosphorus (TP)
Monitor & Report, mg/L
Monthly
Grab
Effluent
There shall be no discharge of floating solids or visible foam in other than trace amounts.
All samples taken during a backwash discharge event.

Permit NC000461•8
A. (3.) CH RONIC TOXICITY PERMIT LIMIT OUTFALL 001 (QRTRLY)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 3.2%.
The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in
the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or
subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions. The tests will be performed during the months of
March, June September, and December. Effluent sampling for this testing shall be performed at the
NPDES permitted final effluent discharge below all treatment processes.
lf the test procedure performed as the first test of any single quarter results in a failure or ChV below
the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the
two following months as described in "North Carolina Phase // Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the
highest concentration having no detectable impairment of reproduction or survival and the lowest
concentration that does have a detectable impairment of reproduction or survival. The definition of
"detectable impairment," collection methods, exposure regimes, and further statistical methods are
specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed. If reporting pass/fail
results using the parameter code TGP38, DWQ Form AT-1 (original) is sent to the below address. If
reporting Chronic Value results using the parameter code THP38, DWQ Form AT-3 (original) is to be sent
to the following address:
Attention: NC DENR / DWQ / Environmental Sciences Section
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Section no later
than 30 days after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate
signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if
chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is
required, the permittee will complete the information located at the top of the aquatic toxicity (AT) test
form indicating the facility name, permit number, pipe number, county, and the month/year of the
report with the notation of "No Flow" in the comment area of the form. The report shall be submitted to
the Environmental Sciences Section at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring
will be required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division
of Water Quality indicate potential impacts to the receiving stream, this permit may be re -opened and
modified to include alternate monitoring requirements or limits.
If the Permittee monitors any pollutant more frequently then required by this permit, the results of such
monitoring shall be included in the calculation and reporting of the data submitted on the DMR and all
AT Forms submitted.
NOTE: Failure to achieve test conditions as specified i6 the cited document, such as minimum control
organism survival, minimum control organism reproduction, and appropriate environmental controls,
shall constitute an invalid test and will require immediate follow-up testing to be completed no later
than the last day of the month following the month of the initial monitoring.

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No.N00004618
Revised. • 8120109
Facility Information
Applicant/Facility
Name:
Alamac American Knits, LLC
Applicant Address:
P.O. Box 1347; Lumberton, NC 28359-1347
Facility Address:
1885 Alamac Road; Lumberton, NC 28359
Outfall 001
Permitted Flow
2.5 MGD
Type of Waste:
Treated industrial
Facility/Permit Status:
Class III /Active; Renewal
County:
Robeson Count
Receiving Stream:
Lumber River
Stream Classification:
C, Sw
Subbasin:
03-07-51
Index No.
14-(13)
Drainage Area (mil):
712
303(d) Listed?
No (Mercury -Fish
consumption)
Summer 7Q10 (cfs)
128
Regional Office:
Fayetteville
Winter 7Q10 (cfs):
128
State Grid / USGS
Quad:
122SE SW
Lumberton, NC
30Q2 (cfs)
199
Average Flow (cfs):
853
IWC (P/o):
3.2%
Outfall 002
Permitted Flow
0.2 MGD
Type of Waste:
Conventional WTP discharge
Facility/Permit Status:
Class II /Active; Renewal
County:
Robeson Count
Receiving Stream:
Jacobs Swamp
Stream Classification:
C, Sw
Subbasin:
03-07-51
Index No.
14-17
Drainage Area (mil):
-
303(d) Listed?
No (Mercury -Fish
consumption)
Summer 7Q10 (cfs)
Regional Office:
Fayetteville
Winter 7Q10 (cfs):
-
State Grid / USGS
Quad:
1225E SW
Lumberton, NC
30Q2 (cfs)
Permit Writer:
Ron Berry
Average Flow (cfs):
Date:
6/18/09
IWC (%):
Revised:
1 8/20/09
BACKGROUND
Alamac American Knits, LLC is a major manufacturer of knit apparel. Several intermediate
sources are used and intermediate products are also manufactured at the facility. The
primary production route starts with the knitting process, goes to the dyeing process, and
ends with the finishing process.
The facility operates a permitted 2.5 MGD industrial waste treatment plant and a
conventional WTP with a monthly average maximum reported wastewater discharge of 0.18
MGD. The treated waste water from the waste treatment plant discharges into a 1.5 mile
pressure waste water line that discharges into the Lumber River, designated as Outfall 001.
This waste line also collects other wastewater from an adjacent power plant facility. The
backwash waste stream from the water treatment plant discharges into a ditch on site which
then flows approximately 200 feet to Jacob's Swamp, designated as Outfall 002. Both
receiving streams classifications are C, Sw and are part of the Lumber River Basin.
Condensation, non -contact cooling water blowdown, boiler blowdown, ground water
remediation, water softener backwash/rinse, and process wash water are sent to the
industrial waste treatment plant. The influent passes through a bar screen, a metering flume
before entering an aeration basin. The softener waste streams are discharged directly to the
Fact Sheet
NPUES NCO004618
Pan. t of d

aeration basin. A molasses type material is added to the aeration basin to enhance the
biological activity. From the aeration basin the flow proceeds to a splitter box that diverts set
flows to two clarifiers. The treated waste water from the clarifers are diverted to one of two 5
acre polishing ponds. The polishing ponds discharge through an effluent metering flume and
into a collection sump where the flow is pumped to the pressured treated wastewater line.
An effluent composite sampler collects samples at the effluent metering flume.
The collected solids are routinely pumped from the clarifier(s) to a filter press. The extracted
liquid from the filter press operation flows back to the clarifier(s). The solids are collected in
a spreader truck owned and operated by the permittee. As required the solids are land
applied.
Multiple wells supply raw water to a mechanical aeration tower. The water exits the tower
and flows to two parallel anthracite/sand media gravity filters. The filtered water collects in a
clear well where chlorination and corrosion inhibitor are added. The process filtered water
demand is 1.0 MGD. As required the gravity sand filters are backwashed using non -
chlorinated internal water sources, discharging the waste water to an area ditch with heavy
vegetation. At the end of the ditch prior to Jacob's Swamp the backwash water flows through
a metering weir.
All domestic wastewater is routed to the City of Lumberton WWTP.
HISTORY/COMPLIANCE
This facility has no significant compliance issues. There has been no significant changes in
the manufacturing process other than a trend towards less production. The industrial waste
treatment and water treatment processes remain unchanged.
PERMITTING STRATEGY OUTFALL 001
Effluent Guidelines
Based on the description of the knit operation, dyeing, finishing, blending of natural and
synthetic fibers, are all part of this operation. 40 CFR 410.50 (Subpart E - Knit Fabric
Finishing Subcategory) Sections 419.51 and 419.53 were applied to determine effluent mass
based limits for the industrial waste treatment plant. Daily production data for 5 years, 2004
to 2008. was used to determine a statistical profile. The PlFeyie......eFFA,t had- .15..d d-a4,
PF9dWGti8R value ef 37,796 lbsiday whiEh is equal te a 66.894 weighted value. of the G---FF
data. For consistency, to promote no increase in mass loading, and by BPJ 37,796 Ibs/day will
be used to determine the applicable mass limits in this renewal.
Table 1: Calculation Limits, Subpart E
410.52 a &c (BPT) & 410.53
a & c (BAT)
Ibs/3000 Ibs
Production Values
(Ibs/day)
New limits
(Ibs/day)
Daily
Maximum
Monthly
Maximum
Daily
Maximum
Monthly
Maximum
Daily
Maximum
Monthly
Maximum
BOD, 5 day
5.0
2.5
37796
37796
189
94.5
COD
60+40
30+20
37796
37796
3780
1890
TSS
21.8
10.9
37796
37796
824
412
Sulfite
0.20
0.10
37796
37796
7.6
3.8
Total Phenols
0.10
0.05
37796
37796
3.8
1.9
Total Chromium
0.10
0.05
37796
37796
3.8
1.9
H, s.u. 1
6.0 - 9.0
6.0 - 9.0
Table 2: Comparison of Limits
Renewal Permit Limits
(Ibs/da)
Maximum reported values,
DMRs 2006-2008 Ibs/da)
Compliance Violations - DMR
Data to Limits
Daily
Maximum
Monthly
Maximum
Daily
Maximum
Monthly
Maximum
Daily
Maximum
Monthly
Maximum
BOD, 5 day
189
94.5
95
58.5
No violations noted
COD
3780
1890
1771
1245.8
T55
824
412
385
213.2
Sulfite
7.6
3.8
0.64
0.64
Total Phenols
3.8
1.9
0.10
0.1
Total mium Chro
3.8
1.9
0.10
0.1
H, s.u. 1
6.0
- 9.0
9.0
Fact Sheet
NPDES NC0004618
Pa I of d

Reasonable Potential Analysis (RPA)
The Division conducted EPA -recommended analyses to determine the reasonable potential
for toxicants to be discharged by this facility, based on DMR data from January 2006 to
December 2008 and from the 1 PPA submitted with the renewal application. In several cases
only one value was available. Evaluations were conducted for arsenic, beryllium, cadmium,
chromium, copper, lead, mercury, molybdenum, nickel, phenol, selenium, silver, zinc,
trichloroethylene, and vinyl chloride.
Results suggest reasonable potential for the facility to discharge copper, silver, and zinc in
excess of WQS, all three metals are action level parameters. Facility has passed last 16
toxicity test. No changes will be made in the copper and zinc quarterly monitoring
frequency. Silver monitoring will not be. added. Mercury did not have a reasonable potential
to exceed WQS but it is part of the impairment under a TMDL so it will continued to
monitored quarterly using Method 1631 be Feme y a ` 8M the peFFni'
Data review
DMRs were reviewed for the period of January 2006 to December 2008. DMR data for Outfall
001 is summarized in Table 3 below:
Tahle 3- Outfall 001 Effluent DMR Data
Flow
Dissolved
pH
Total
Total
Conductivity
Temperature
Monthly
Oxygen
(s'u')
Nitrogen
Phosphorus
(µmhos/cm)
(C)
(MGD)
(m /L)
(m /L)
(m /L)
Average
0.496
7.19
8.35
8.22
1.69
>1415
19.4
Maximum
0.64
10.6
9.0
16.6
4.9
-
30
Minimum
0.26
5.0
7.7
2.7
.5
5
Will continue required parameters and monitoring frequency as defined in existing permit.
Will add footnote to instruct permittee to provide effluent conductivity data in terms of
actual values.
Whole Effluent Toxicity
The permit requires quarterly chronic toxicity testing using ceriodaphnia dubia, at 3.2%
effluent concentration. The facility passed the 16 toxicity tests submitted since March 2005.
Will continue chronic toxicity compliance as defined in existing permit.
Instream Data Impact
Temperature, conductivity, and dissolved oxygen are measured routinely at designated
points upstream and downstream from the discharge. The conductivity had some impact.
Will continue instream monitoring program as defined in existing permit.
PERMITTING STRATEGY OUTFALL 002
Will apply Eewveatieaal Water Treatment Plant Strategy for Greensand filter as appropriate
guide lines for this process water filter treatment plant wastewater discharge as e� wtl 0 A ed 0R
EUFFeRt pelicy. The requirements for effluent settleable solids and turbidity sampling will be
removed. New requirements for effluent monitoring for aluminum ealci m
total eeppeF, total iron, total nitrogen, total phosphorus will be added.
Compliance requirements for permitted flow will be added. Based on
data supplied by permittee the permitted flow monthly average limit will be 0.24 MGD.
. The existing pH and TSS compliance will remain unchanged. For clarity
the pH compliance range will be listed on the limit page.
During the current permit cycle no violation occurred.
An open ditch conveys the intermittent backwash wastewater approximately 200 feet to
Jacob's Swamp. Sufficient BMPs are in place to mitigate erosion and sedimentary discharges
into Jacob's Swamp. Will emphasize BMPs in the cover letter.
Fact Sheet
NPUES NC0004618
Pan, R of A

SUMMARY OF PROPOSED CHANGES
In keeping with Division policies the following will be incorporated into the permit:
• Outfall 001: Effluent monitoring for mercury will be removed.
• Outfa11001: A footnote stating the effluent conductivity to be measured and
reported in actual values will be added.
• Outfall 002: Effluent limitations and monitoring for settleable solids and turbidity
will be removed.
• Outfall 002: Effluent monthly monitoring for
total EeppeF, total iron, total nitrogen, and total phosphorus will be
added
Outfall / 02i 9ffl nt q -Reel. GhF8RiE t..AEit.. ... _ -
ROWF nLlSiRg 'i AgPhRiidubi_
at 90% effluent e A ntFatio will be added._, ..
• Outfall 002: Permitted flow limit based on monthly average will be added.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice: July 1, 2009
Permit Scheduled to Issue: August 2009
NPDES DIVISION CONTACT
If you have questions regarding any of the above information or on the attached permit,
please contact Ronj�erry at [phone] or email [e-mail].
NAM
REGIONAL OFFICE COMMENTS
NAME:
/d l
SUPERVISOR: DATE:
Fact:heet
NPDES NC0004618
Dann d of d

Berry, Ron
From: Hyatt. [e-mail]
Sent: Tuesday; July 07, 2009 9:06 AM
To: [e-mail]
Subject: re NC0004618, Alamac Knit Fabrics
EPA has no comments on this draft permit.

FW Alamac American Knits LLc draft permit cover letter and fact sheet
7/28/09:
Talked to Mark Brantley about why the wTP requirments changed. Permittee asked Mark
about reason for more
monitoring and WET test. Agreed I would review.
Determined this is not potable water so will apply Greensand guidelines as best fit.
Will
change requirements in final permit, remove metals except iron and WET test, will
revise fact sheet.
From: Lopez, Dale
sent: Thursday, June 25, 2009 8:31 AM
To: Berry, Ron; Henson, Belinda; Brantley, Mark
cc: Lopez, Dale
subject: Fw: Alamac American Knits, LLC draft permit, cover letter and fact
sheet
Attachments: Microsoft word - Permit draft cover.pdf; Microsoft word - Fact sheet
Formal.pdf
Ron,
It looks very good to me! you put in lot of work on it.
Thank you for sending the draft,
Dale
From: Berry, Ron
sent: Thursday, June 25, 2009 8:21 AM
To: Lopez, Dale
subject: RE: Alamac American Knits, LLC draft permit, cover letter and fact sheet
Dale,
Here are the attachments.
Thanks
Ron Berry [e-mail]
Engineer I
DWQ/Point source/NPDEs
NCDENR
Phone: [phone]
Fax: [phone]
office: Archdale Building Room 925N
E-mail correspondence to and from this address may be subject to the North Carolina
Public Records
Law and may be disclosed to third parties.
From: Lopez, Dale
sent: Tuesday, June 23, 2009 4:59 PM
To: Berry, Ron
subject: RE: Alamac American Knits, LLC draft permit, cover letter and fact sheet
Hi Ron,
The email didn't have the attachments.
Thanks,
Dale
From: Berry, Ron
Sent: Tuesday, June 23, 2009 2:57 PM
To: Lopez, Dale
subject: Alamac American Knits, LLC draft permit, cover letter and fact sheet
Page 1

FW Alamac American Knits LLc draft permit cover letter and fact sheet
Dale,
Attached are the NPDEs draft, cover letter, and fact sheet for you, or whomever
you believe in the
Regional office, to review and comment upon. The permit will no go out to public
notice July 1, 2009.
Please provide a response, you may respond via email or you can print out the fact
sheet and provide
comments by mail. Thanks
Ron Berry [e-mail]
Engineer I
DWQ/Point Source/NPDES
NCDENR
Phone: [phone]
Fax: [phone]
office: Archdale Building Room 925N
E-mail correspondence to and from this address may be subject to the North Carolina
Public Records
Law and may be disclosed to third parties.
Page 2

NORTH CAROLINA
Cumberland County
AFFIDAVIT OF PUBLICATION
Public NuIia
NumbC lma linvimnmrn -
Ial s
COImI6sIOnMPDlS Unit
I617 MulS ior fkniv
Rakigh. NC 2"INN-I6I)
Nmiu of Insrn, to hsu a
NPDPS Wwucu,ma Pamlil
The Nunn Cmolin. finvinm-
memal Mmugemem C--
Pn,,cans Io iss
NPI)M v kwudis-
charge pemm m the
fPLefeY��mG 1liu en low_
Wnnrn Is RgµminB
the pm ymmit ill he
f n1 h -111 - 1 maw. afc,
ticc. M INXbor of Iha NC
Division of W.mr Qnaldy
(DWfy may hid . Puhh,
Irving =wind then, ba s
inac am MLgra oAndf m,hlic
curn
moms Mfor mat..,. R
quest/ m DWQ al the abtc
addma. lmmmlm Pnxms
may visit Ibe DWO 41 512 N.
al ImPm.Imn all
pelmite am Ihia ou-
y he (R,m on arc
www.pcwatlgoali -
a by Wling (9197
Tha Town of Saalhan Pinu
IRWqrra1N wal f In
N(lgM9Tr8 for ilsnKTP i
Manic County. Tbw Pem,il -
tm dcIchh-uT¢� is bumm
filler-backw 1, aM claM
wanawaun to AMdCII
C k. Wmbv%'er Bain.
Rabasorl County Water De-
panmem has agiim for R-
nnanl f a NCOOR6991
fur the , a Drive W nI in
Rdse,m Counly.. This Pat -
Imam digdua,, filla
twckwnh w.vnwver In an
mlamm Irilml.y 10 uuk
lamb swamp in Ibe Luau v
Rlva Basin.
Ranaaan calmly wnaa fx-
pamt la applim far m-
mwal of puma, N(Mlll ig5
far tha Lumbar Arid WTP
in Robewn County. Tt,i 'P
minor cmunwgcfltt/c-
backwaah wa awana Io an
Mnnmlm tubmvy In Big
anh swamp in Ibe Lumber
Rivee Bain,
Ralewm Count, Wvv Dc-
panment has .PPlim for or-
al of pmnit NCT1p862(N
for Iha Kevnc Rom WfP in
Robamt CouNy. TlaI p1�a
bnm distlurge ca Ella,
ackwash avewmv to
Islemm Inbm vrYy In the
nmba, Rive in dw Lumber
Riw Baia
Rolesut C-.; wmv De-
finillanl ha aWlim for R-
el f Pamit NN01g5 ^
for Ibe .ban WI'P i
Rdwaon County. This ppRR
Mnm dimum,. Rltn-
IMckwah watmwacur In IM
lumbv
River .1 Iha Wmbv lt. c
Bann.
Town of Pemhnke Px m -
M nn 9 a KKmm��I
NC=103 fa Its Peal=
W WTP in Rolmmn Cc int,
Tbia ha imul diacrgc it
nuled waal .Un to Urn-
bR Rive, do WmM Rnv
Baas.
Al.. Anionic.. Kalb, LLC
rtrtqquu mm "nawal of pamil
NlD001618 rut, m
IuninnNt facility in
Robasal, Loamy. Tbaa par.
minotl diuharga me Ilut-
m indmpial watnwner In
th Lumbv River analflly
hs kwah wva iNo Jacob
Swamp, Lambs lkivv Rain.
Norio of InIIa In la. a
Nfd)PS Walewnc I'mmI
1555163
Before the undersigned, a Notary Public of said County and state, duly
commissioned and authorized to administer oaths, affirmations, etc.,
personally appeared. CINDY L. OROZCO
Who, being duly sworn or affirmed, according to law, doth depose and say
that he/she is LEGAL SECRETARY
of THE FAYETTEVILLE PUBLISHING COMPANY, a corporation organized
and doing business under the Laws of the State of North Carolina, and
publishing a newspaper known as the FAYETTEVILLE OBSERVER, in the
City of Fayetteville, County and State aforesaid, and that as such he/she
makes this affidavit; that he/she is familiar with the books, files and
business of said Corporation and by reference to the files of said publication
the attached advertisement of CL Legal Line
ENVIRONMENTAL MANAGEMENT COMMISSION
of NC DIVISION OF WATER QUALITY
was inserted in the aforesaid newspaper in space, and on dates as follows:
7/3/2009
and at the time of such publication The Fayetteville Observer was a
newspaper meeting all the requirements and qualifications prescribed by
Sec. No. 1-597 G.S. of N.C.
The above is correctly copied from the books and files of the aforesaid
bli corporation and pucation.
Title
Cumberland County, North Carolina
Sworn or affirmed to, and subscribed before me, this 6 day
July, A.D., 2009.
In Testimony Whereof, I have hereunto set my hand and affixed my
ial seal, the day and year aforesaid.
My commission expires 05th day of December, 2010.
L TO: NC DIVISION OF WATER QUALITY
1617 MAIL SERVICE CENTER
RALEIGH, NC 27699
0001555163

REASONABLE POTENTIAL ANALYSIS
Alamac American Knits, LLC
NCO004618
THM Period
0
Ow(MGO)
2.5
WW]P Class IV
7O10S (c/s)
123
1WC (%) @ 7010S 2.9384
7O1OW(ds)
128
(a77010W 2.9394
3002 (c/s)
199
Q 3002 1.91
Avg. Stream Flow, OA (ds)
853
@ GA 0.4522
Reclining; Stream Lumber
River
Shea. Gass C, Sw
Outfal 1001
Qw = 2.5 MGD
STANDMIDS &
PARAMETER
TYPE
Cliti 12)
POL
Unite
REASONABLE POTENTIAL RESULTS
RECOMMENDED ACTION
eC laps, Y,FAV/
ace wundadcr Alpyweapy
11)
CNuu, A.
Adana NIA
Cnly we rgd <10 pile
Arsenic
C
10
uyL
1 0 NIA
Note. n<12 Chronic 2211
NO tladeruc
Limited data set
No lurtha actlar
Acute'. NIA
Only we rgd< l Poll
uerynlmn
C
0.:
ug&
1 0 N/A
Note: n<12 Clrmnic: 26
No chrome exceadanca— --- --- --- — —
Limiteddabeat
INO further action
Acute '. 15
Cnly Ore, ritl <2 pg1
Cadmium
NC
2 15
uML
1 0 WA
�-60
No acute ex�_ a—
Nole:n<121
NO chronic ucordanw—.—.—.—.—_—.—.—.—
Limited deb refNo
haebr action
Ali 1,022
Cnly we rid <5 pg4
Chromium
NO
50 1022
ug&
1 0
WA
NO acute eeceedance
Note: n<12
Cbank: 1,702
No MTnic ;.;;dance
Limited deb
aet
Mariana affluent mass Ilmit per EPA Subpart E
ALL19'. ]
Action Inch pa2m&er
Capper
NC
-
ug&
13 1
90.11
Passirg teeklly teal .—___—.—_—_—__
Gaaac 236
Maintain puarterty rtanllMng
Aade WA
NNalandaM
Trlchloreethylerb
NC
30 N
ug4
14 0
9.2
Add pearhlpoa0ime& DCE Increase WA by 3=27.6 yyl
_
l2tmrdc 1.021
No chronk evdied nce—.—.—.—.—_—.—.—.—
MalnOan quarterly monitoring
Ache WA
Muni chloride
NC
_
ug&
15 0 170
Chronic P1
No chronic eaceWili
Maintain quarterly unmoving
Acute: 3a
Call me Ng < 10 Port
Land
NC
10 N 33e
ul
1 0 WA
No acute everadince
Not.: rl<12
Clemk: 310
NO Chronic mea dance — — —------- ---
Llmibd dab set
No lurtha action
Acute. WA
Ok n01 Pee Xrst Rvo edge 2006 adrldl used old rtrcMod
Mercury
NC
12
200W
dill
10 10 fl.4400
_ -------------------------- _
Note: n<12
Clinics : 4W
No.manic eviceMa.
Limped deb ill
Maintain quarterly mmXumg
Aar. WA
Onlyonerd9<WO PBrI
Molyh6murn
A
3500
YWL
1 0 WA
_
Not.: n<12
Climatic, IM242
No dvmk mceMance—
Limited dab Mt
NO IUNKr ectlm
Agile: 261
Only One Ng a 10 inal
nickel
NC
66 281
UWL
1 0 WA
No acme countenance_
Nab: n<12
__
CMmk 2.995
_ _ _ _ _ _
No c rani. enceedance _
Limited dab bet
NO fuller action
Acute: N/A
Only We ad, < 10 pgA
Phenols
A
1 N
uyL
1 0 WA
Nob:.02
Limllatl dab Mai
Maintain entuent muss Fait pa VA Subpart E
Aeolic 56
Only we rail < 10 Win
Selenium
NC
5.0 56
ug/L
1 0 WA
No acute 0_reawrce
Note: n<12
Chmnk: 1]0
_a
NO ghrmkevga nca—---
Limited dab set
No further action
lade'. 1
CnN we rdg <5 pgA, action teed parameter
Silver
NC
C 06 AL 1 23
111&
1 0
WA
panew mi test
Note: n02
Chmec: �--2
NO further xtlon
Limped dab
eet
Acute. 67
Actlan bvel paramelr
Zinc
NC
50 AL 67
di
13 4
91.6
Pawng tockity test
_._.__—_
Gemk:_.1,702
MalnUln puartedymmXOrlrp _
Legend: " Fmshwala puharge,
C = Cdecun;genic
NC = Non-camirrepeamc
A = Aeslhee.
RPA, rya
6/152wit

Date:3/13/09 DMR Data NC0004618 Outfall 001
pb: rdb Alamac American Knits, LLC
O flow Rdg ■ Flow Monthly Avg Permitted Flow
3.000-------- --------- — ---------------------- ----
2.500
2.000 - -------- --- -------
O
01.500 ___..
2 1
1.000
0.500
0.000
o 0 o m m o o m
am h+ '5 o m '� o
m z i i to Z � M Mm "' to z
O BOD Monthly Avg ■ BOD Daily Avg —Monthly Avg Max Limit Daily Avg Max Limit
200 ---------------------------------------------------
180____________________________________________-____-__________________________�
160 ----------------------------------------------------------------------------
140-------- _--- .-------- ------ _----------------- ______-________________________�
120------------- __________________________________-.________..________________
W
d80 _________ ____ _ _.._______-_____■.__� _______________________-it__________-
60 ______ _ ------ - ___ _____
--------- ,
■
20 ------ ■----
0
q `8 0 oto
X0_ 0 0 0 0 o g o 0 0 0 0 0
IL G ¢ ¢ ❑ Z O IWL Z -Wi li ¢ 0) Z ❑
O TSS Monthly Avg ■ TSS Daily Avg —Monthy Max Limit —Daily Max Limit
900 ----- -___.. ____ _---------- .-.------
800 ----- - --- ----
700
600 --------------- ----------
aa
500------------------------------------------------- — -
a 400
300------------- ----------------■----------- - - -----
200 ------ - - - - ----- -- - -�--- ------ -- -
100
0
m m m m m m m m m m n n n n n n n m m m m m m m m m m m
Q o o g q o 0 o q o n n n o q q o q o q o 0 0 0 0 0 0 o q q q o 0 0
m o m m a m m �° y" `� m '" a s o m
� LL f Q g� Q m z❑� LL¢ g¢ g ¢ mz❑

Date:3/13/09 DMR Data NC0004618 Oufall 001
pb: rdb Alamac American Knitts, LLC
O
COD Monthly Avg
■
COD Daily Avg —Monthly Avg
Max Limit —Daily Avg Max Limk
4000
----------------
3500
i
3000
---
-------------
---�
i
2500
-----
-------------------------
It
32000
ie
1500
--------,--
--
--
----
--+
1000
-
-
am
-------��
500
-
-
-------
----
----
0
mo c mo
m m
m
q
m
o
n n
0 0
r n r n n n n
0 0 0 0 0 o q
m m
o 0
m
o
m m
q q
m
o
m m
o q
m
o
m
q
c-8
a
c of G
+ i
t h
i. c h +>
c
c
Sa
>
o
z❑
40 ii
Q to V Z
-�+ �i
i
y
z
O
O pH Rdg —Range Limits
10.0
-----------
---------------------------------
------------
9.5�-
-----------------------------------
--------
9.0 O
O
8.0
O
O
O
O
7.5
---------
-
a
7.0
-------
---
- - -
- -
6.5
--------
--------
6.0
5.5
-----------
—------------------
—
- —----------------
-
------------------
5.0
m m
0 0
m
0
m m
0 0
m
0
n
0
n
0
n n n n
0 0 0 0
m
0
m
0
m
0
m
0
m m
0 0
m
nai
>o
m
'�
m m 0
m
w
m
m o
g
dl
z
m z
fn z
OTN
18.0
-------------------------
----------
—.. _------------------
O
14.0
----------0-----
------------
--------------------------
---
----------
12.0
-----------------
-----------------------
----
— ------------------
E
10.0
---------
C
----0-----------------------------------------
8.0
-0-0-9
---
------------
0-0 ------
-
�-----0--O--O-0---O-�
�- C�--0
6.0
----------------0-------
---------------------
4.0
0
O
2.0
0.0
m m
0 0
m
0
m m
0 0
m
0
n
o
n
q
n n n n
o 0 0 0
m
o
m
q
m
o
m
0
m
o
m
q
m
-' m
o
m
m
A m >o
M
0
'
m
o
2
rn
z
M rn z
n
M
U)
z

Date:3/13/09 DMR Data NC0004618 Outfall 001
pb: rdb Alamac American Knits, LLC
O Conductivity
*All values reported as greater than
1422
---------
-- - - - - -
-------- - - - - -- - -- - - - --
1418
_
__________________
_--- - - - - -—
E1414
u
------
---
----
-------
- -
- - --
--
------------
---..
.-------- - - - - -- ------
c
1408
----------
---------.
-------- - - - - -- --
1406 --------
--____________-__----------------------------------.
_.
-
----
----------- ----
-- —---
-- - - - - ----------------
1402
m co
0 o
co
q
0
o
m
0
0
0
n
0
n
0
n n n
0 0 4
n m
0 0
m m w m w
0 0 0 0 0
i
in
z
�
M
M ' 0
z
' to00
z
CONDUCTIVITY (Monthly Average)
*Upstream■ Downstream
140
-------------------
-----------------------
120
------
------
°
--------------------
e
E
e v il
1111
O a
G ■---
■
■
O■ 0
c80
----------
--
a-*
-----------,-,
°-C
--� 6-e-e-------.
�7-------0
1 60
---------------
---------fa-----4-°----------------S-rV
°---6--,--e-■-
ee
40
-
----------------
----------------------
20
----------
--
-------------------------
0
ro co
0 0
co
0
�o 0
0 0
0
9
n
0
n r
0 0 0 0 0 9
n
0
m w m N m
0 0 0 0 0 0
9
(/Jn
Z
7
rG N
Z
rC 4) Z
OTP Rdg
6.0
-------------------------
---------.
----------------------
5.0
----- -
4.0
----------
°-------------
-
---
3.0
=--------
--
------------------------�--�
—O
---
E------
--
1.0
-*-----------
4---°
O
O
0.0
o
0
4
0
o
q
q 4 q
o
o q o o q q
m
i
m
N
o
Z
m
m m
0
o
Z
m m r)
N Z

Date:3/13/09 DMR Data NC0004618 Outfall 001
pb: rdb Alamac American Knits, LLC
}
Monthly
Ava
3.81bs/davDaily
*Total
Sulfides
♦<
values]Limit:
Avo
Limit: i$ Ibs/dav
1.0---
------------------------------------
-----------------------------------------
0.9
-------
-----------------
-----------
__---------------
0.8
----
------
C.
'/-------------------------------------
—
--
—
vd
U)LO
0.7
--------------v---------s3----------------
♦
---------------------
♦
oo
v
O
0.8
----------
---------.V-V
-----
♦-------------------
-0------
• •
a 0.5
-----
---
-------
- - - -
-----
---
-- ----
---
— ----
-----
— --
------
---
---------------
- 0.4
-------------------------
—-------------------------------------------Od----0
0.3
--------------------------------------
_------------0--------------
0.2
-------------------------------------------------------------
—
---------------
0.1
-------------------------------------------------------------
--------
—
0.0
m m
0 0
m co
0 0
m
0
r
o
n
q
n
o
n
0
r
0
r.
0
0
0
co
0
m
0
m
o
w
q
m
o
m
0
'o
m
m
o
m
2
Co
Co
Z
in
z°
Monthly
Avo
Limit: 1.9 Ibs/dav
*Total Chromium ♦<values
Daily
Avo
Limft: 3.8 lbs/day
1.2
--------------------------------
- —
— ---
— —
-- — —
---------------
------
1.0
---------------------
-------------
------------------------------------
0.8
------
tp------
Co to
-------------------------------------------------------
Q----"00
et
A
O
V
WV
♦
♦ ♦
--
-------------------
----------------------------
a
♦
O
0.4
-------------------------
----
-----------------------------------------------
O
O
0.2
O
0.0
0 0
0 0
0
o
0
0
0
0
0
0
0
0
0
0
0
g 2
in
z°
m
z°
2
Co
z
Monthly
Avo
Limit: 1.9lbs/dav
*Total Phenols ♦<values
Daily
Avg
Limit: 3.8lbs/dav
0.6
-------------------------------
----------------------
-------------------------
0.5
0.4
------------------------------------------------------------------------------
T
W
a0.3
S
------------------------------------------------------------------------------
0.2
0.1
-----
o
O
Co Co
------
4
-----
-------------------------------------
0
od
*
O
O
O
0.0
O
O
O
0 0
0 0
0
0
0
0
0
0
0
0
0
0
0
0
9
Dm
O
m
N
0
O
R
W
N
0
O
�
z
�
�
�
ur
z
�
�
�
(n
z

Date:3/16/09 DMR Data NC0004618 Outfall 001
pb: rdb Alamac Americam Knits, LLC
♦Total Copper
*ALL
VALUES LESS
THAN
0.12
-----
-
--------------------------------------------------
0.10
------
-----
-----*I
-----
♦ ------
------ #---
---------------------------------
— -----------------------------------------
0.08----
.._..---------
-------------------------------------
E
0.04
------------
----------------------------------
—
— --
-- —
------------------
0.02---------------------
---
-------------------------------------------------
0.00
o
?
m
4
n
4
n
4
n n n
9
n
4
m
m
4
m
a 4
m
�'
�
(az
i
z
i
Zo
*Total Zinc ♦<valws
0.12
-------------------------------
---..
0.10
♦ ----
♦
------
-♦--
♦ ♦-
-
----------
-------
0.08
-----
----..
------------
0.06
-----
- -
------------
E
0.04
----
-
-----------
----------------
- -
-------
O
O
O
0.00
m
0
m
0
m
0
m
o
$
n
q
n
o
n n n
0 0 0
n
0
m
o
m
q
m m
o o
m
q
m
o
m
m
o
m
1°
m m
o
m
m
m n
m
'o
fo
Z
(a
Z
tq
z
♦Vinyl Chlonde
*ALL
VALUES
LESS THAN
12.0
-_._
-
----
------------------
-
---------------
-
10.0�
----
----------♦
----�-
8.0-.
--------
6.0
---------
----
--
-
a
4.0
-------
----------.
2.0
0 -♦
------
------
♦_--.
____�__-
__�_____-
-_______..
♦____
0.0
m m
o Q
m
o
m
0
m
o
m
q
n
o
n n n n
0 0 0 0
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Date:3/16/09 DMR Data NC0004618 Outfall 001
pb: rdb Alamac American Knits, LLC
♦Trichlomethylene I
*ALL VALUES LESS THAN
6.0
--------------------
----
------- — ------
--------
..------- ------
5.0
-------------------
---
--♦---- — ------
-----
♦------
♦------------♦
4.0
-
----
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3.0
-
---------------------------
-------
2.0
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1.0
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♦1,2-cis-dichloro-ethylene
'ALL VALUES LESS THAN
EXCEPT FEB 2006
6.0
--------------------------------
----------
-------
-.._
5.0
-- — ------
--------
...----------
- ♦ ----
♦
-----♦---
♦ --- •
4.0
---------
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3.0
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2.0
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1.0 4 0
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Total Mercury
25.0
-----
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R
R
20.0
0
15.0
--.
-.____.
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Mal
LIMIT
10.0
-___.
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Date:3/16/09
pb: rdb
DMR Data NC0004618 Outfall 002
Alamac American Knits, LLC
O DO Rd® —Min Lima
12.0- -- -- ------------------
10.0
8.0
19 6.0
E
4.0
2.0
0.0
m m n n n r n n m m m m m
z g N 2° i ' CO z
DO (Monthly Average) *Upstream ■Downstream
9 ------------------
i
A--------- a ,------------------ ----
s------------------------ ------a--------------�
8 ik- ----0-------- ----- -- --- ---1 s---------------
Ea O----------- -0-8---------- ---- A-0-0-Q
3 -- -- ---------- ---- -------------- ---
2 -- -- - --- ------ ---- --- -------------------------
1 ------ .-------- ----
0
m m m m m m n r n n r n m m m m m m
q 0 0 0 0 0 o q o q q 0 0 q o q 0 0
E y z° ' y z° ' CO z

Date:3/16/09
pb: rdb
35.0
30.0
25.0
20.0 O
U
15.0 - O
10.0
5.0 --- ----
0.0
f u1
30 T
DMR Data NC0004618 Outfall 001
Alamac American Knits, LLC
*Temperature
4 0 4 4 4 R 4 4 4
z° z in z
TEMPERATURE (Monthly Average) *Upstream ■Downstream
■
25 -- --- --- ■ ■ ■ ■ ■ ■ ■ -----
20
■ ■ ■ ■ t -
u
15 ----�-------------�--- ■ ■ ---------------
10--- _------ _0-------- ■ ■ -------------------- —
5----- _------ ----- ---- . ________-------_-_______-_--------- -_- ______
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CHRONIC TOXICITY TEST (LIMIT) @ 3.2%
TGP31B - P/F STATRE 7Day Chr Ceriodaphnia
3/6/06 PASS
3/22105
6/20/06 PASS
6/21/05
9/26/06 PASS
9/27/05
12/19/06 PASS
12/21/05
3/14/07 PASS
7/30/07 PASS
9/26/07 PASS
12/5/07 PASS
3/19/08 PASS
6/17/08 PASS
10/1/08 PASS
1211/08 PASS
PASS
PASS
PASS
PASS

Date:3/16/09 DMR Data NC0004618 Outfall 002
pb: rdb Alamac American Knits, LLC
O Flow Rdg ■ Flow Morllhly Avg
0.600
---- --- ---- ---- -- ---------------------------- -- -- --
0.500
----- ---0 --- --- --- --- ----- ----------- — ----------------
0.400
-- ------------------- ---- —
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p O O
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pp��pp�� pi—--------0
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4 QmQ 4 4 4 �Q$ q q q q 4 q
f g N Z 2 th Z f w Z
O TSS Monthly Avg ■ TSS Daily Avg —Monthy Max Limit --Daily Max Limit
50------------ -------._------- — --------------- — ------- -------------------- —
45
40
------- ._- ----------------------- ---------------------------------------
35
-----------------------------------------------------------------------------
30
t25------
------------ --------------------------------------
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■
15
---- %0---- -------- a ~� --- --- -
10
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- -■-- --wil 6VAb-
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---- --- • --- -------------------------------------------- -
0
m m m m m m m m m m m n n n n n n n n n n m m m m m m m m m m m
0 0 o g o q o 0 0 o q o o q o q o 0 0 o q o o q o 0 0 0 0 0 0 0
m is > � � � Q �
� � Q to Z O A 2 Q G � LL E 2 Q t�1 Z O
O Settleable Solids Monthly Avg ■ Settleable Solids Daily Avg —Monthy Max Umif —Daily Max Limit
0.25 -- - --
0.20
0.15
----. ---- ------ -----------------------
�-----
E
0.10
"ALL READINGS LESS THAN 0.1
0.05
0.00
`g m m m m m m m m m n n r n n n n n r r m m m m m m m m m m m
o `8, o 0 0 0 0 0 o g o 0 0 0 0 o q o 0 0 o q o 0 0 0 o q o_ q o
�' m m
LL Q Q 0 O Z 0 Q Q 0 � � � LL � Q 2 Q Co Z 0

Date:3/16/09
pb: rdb
9
DMR Data NC0004618 Outfall 002
Alamac American Knits, LLC
O pH Rd9 —Renge Limits
-------
4 }-- ---------- -- -- --- - -- --- -- - --- -- - __ _---------..
m m m m m r n n r r n n n n n n n m m m m m m m m m m
g 0$ q o 0 0 0$$ o g o q q q q q q o g q o$$ o 0 0 0
ga =�i r�
TURBIDITY
70------------------------------------------------------------- — — -
-
O Upstream ■ Downstream TWO Limit O
80------------------------------------------ ---------------- — -----
50
40 ------------------ ----------�--------- -------------
■
30 ---------------------------------------
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■ o 0
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■
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DIVISION OF WATER QUALITY
March 5, 2009
MEMORANDUM
TO: Dina Sprinkle
Point Source Branch, NPDES Unit
FROM: Dale Lopez, Environmental Specialis
11 i
DENR - WATER QUALITY
;OU \`CE BIZNNCH
THROUGH: Belinda S. Henson, Regional Supervisor Surface Water ote ion S®c
SUBJECT: Application for NPDES Permit NC0004618
Alamac American Knits/Lumberton
P.O. Box 1347
1885 Alamac Road
Lumberton, NC 28359
Robeson County
Please fmd enclosed a staff report and recommendations from the Fayetteville Regional
Office concerning the application for a new NPDES Permit.
If you have any questions or require any further information, please advise.
/DL
Enclosures

To: Permit and Engineering Unit
Water Quality Section
Attention: Dina Sprinkle
Date: March 5, 2009
NPDES STAFF REPORT AND RECOMMENDATION
COUNTY: Robeson
Permit No.: NC0004618
PART 1— GENERAL INFORMATION
1. Facility and Address: Alamac Wastewater Treatment Plant
P.O. Box 1347
1885 Alamac Road
Lumberton, North Carolina 28359
2. Date of Investigation: October 27, 2008
3. Report Prepared by: Dale Lopez, Environmental Specialist FRO
4. Person Contacted and Telephone Number:
Mark Cabral [phone]
5. Directions to Site:
From Fayetteville, travel south on Hwy 95, take Exit 22 and turn left onto Fayetteville
Road traveling south from its intersection with I-95 in Lumberton. Travel straight a few
miles, and Fayetteville Road becomes Pine Street. Take a right onto 2°d Street and travel
approximately % mile. Turn left onto S. Chestnut Street for a few miles; it will become
Alamac Road. Go straight a few miles until you reach the AlamacKnit plant site on the
left.
6. Discharge Point(s), List for all discharge points:
Plant Outfall 001 : Latitude: 34° 35' 20" Longitude : 79' 00' 50"
Plant Outfa11002 : Latitude: 34' 35' 05" Longitude: 79' 00' 40"
Attach a U.S.G.S. map extract and indicate the treatment facility site and the discharge point on
the map.
U.S.G.S. Quad No. 22 S
U.S.G.S. Quad Name: OW Lumberton, N
0 1� (a
()Ok 0 o
0pZ

Site size and expansion area consistent with the application?
8. Topography (relationship to the flood plain): Oe site is gentlyrollin and fla
9. Location of the nearest dwelling: None within 1,000 fee
10. Receiving stream or affected surface waters:
a. Classification--- Plant Outfall 001: Lumber River Class C-Swam
Plant Outfall 002: Jacobs Swam Class C-Swam
b. River Basin No. umber 03-07-51 and Sub basin No.: UM51
C. Describe receiving stream features and the pertinent downstream uses:
The discharge from the wastewater treatment facility Plant Outfall 001 flows to
the Lumber River, at a point with a 7Q 10 of 128 cfs flow (as according to the
Whole Effluent Toxicity Testing Self -Monitoring Summary --- see attachment).
It is classified as Class C — Sw waters.
The discharge from the wastewater treatment facility Plant Outfall 002 is the
backwash water that contains the residue that is filtered from well water by the
anthracite sand. The only chemical that is added is sodium carbonate (soda ash),
and the discharge should comply with typical "water plant" discharge limitations.
This discharge usually does not enter surface waters, but is absorbed in the
drainage ditch that leads to the surface waters of Jacob's Swamp, Class C — Sw
waters.
PART II - DISCRIPTION OF WASTES AND TREATMENT WORKS
a. Volume of wastewater to be permitted:
5 MG (Ultimate Design Capacity)
b. What is the current permitted capacity of the Wastewater Treatment facility?
.5 MG
C. Actual treatment capacity of the current facility (current design capacity)?
.5 MG
d. Please provide a description of the existing or substantially constructed
wastewater treatment
This is an existing facility that consists of a manual bar screen, a Parshall Flume
with flow measurement, a 2.25 MGD aeration basin, dual clarifiers operating in
parallel, two polishing ponds (each is 5-acres), and polymer feed prior to the
sludge going to the belt press. One (1) of the two polishing ponds is operational
but out of service.
e. Possible toxic impacts to the surface waters:
on

2. Residuals handling and utilizing/disposal scheme:
a. If residuals are being land applied, please specify the DWQ Permit No.
0010563.
Residual Contractor: N/A
Telephone: N/A
b. Residual stabilization: N/A
C. Landfill: N/A
e.
Other disposal/utilization scheme (specify):
The wastewater treatment plant generates approximately 1,600 pounds of bio-
solids each day. An average of 15% Total Solids is removed from the system by
means of a belt press. After the belt press, the solids are loaded by conveyor onto
a spreader truck owned and operated by Alamac American Knits. These
residuals are applied on approved land application sites located in Robeson
County under permit #WQ0010563.
3. Treatment plant classification (attach completed rating sheet): ee Attachmen
4. Alternative Analysis Evaluation: Has the facility evaluated all of the non -discharge
options available: Please provide the regional perspective for each of the options that
were evaluated.
Connection to Regional Sewer System:
Land Application: 6one evaluate
Water Reuse: one evaluat

PART III - OTHER PERTINENT INFORMATION
Is this facility being constructed with Construction Grant Funds or are any public monies
involved? PN
2. Special monitoring or limitations (including toxicity) requests:
Whole Effluent Toxicityand Pretreatmen
3. Important SOC, JOC, or Compliance Schedule Dates (please attach): ®/
Date
Submission of Plans and Specifications....................................................
BeginConstruction.................................................................................... /
Complete Construction.............................................................................. /
4. Alternative Analysis Evaluation: Has the facility evaluated all of the nondischarge
options available? Please provide regional perspective for each option evaluated.
Spray Irrigation: NA
Connection to Regional Sewer System:
Subsurface:
Other disposal options:
5. Other Special Items: on

PART IV —EVALUATION AND RECOMMENDATIONS
1. The applicant is not requesting modification of the facility or increasing flow at this time.
2. A review of the compliance data did not reveal any significant violations.
3. Based upon the previous Compliance Biomonitoring Inspection (see attachment) that was
conducted on October 27, 2008, all units were in service, except for one of the two
polishing ponds (which had been off-line for years). This facility continues to maintain a
high standard for wastewater treatment.
4. This Office recommends continuation of the Special Conditions for Whole Effluent
Toxicity monitoring and Pretreatment Programs.
5. Based upon the above information, this Office recommends reissuance of the said permit
for the continued operation of an existing 2.5 MGD wastewater treatment facility
consisting of a mechanical bar screen, an influent Parshall Flume with ultrasonic flow
meters, a 2.25 MG aeration basin, dual secondary clarifiers, two polishing ponds,
polymer feed (for residuals), belt press for residuals dewatering, effluent weir and flow
meter with ultrasonic flow meter located at the Alamac Knitting facility near Lumberton,
at 1885 Alamac Road, in Robeson County.
6. The section of the Lumber River to which Effluent 001 discharges does not appear to be
HQW, but only Class C-Sw.

Map of 1885 Alamac Rd Lumberton, NC by MapQuest
Page 1 of 2
MAPQVEST
A: 1885 Alamac Rd, Lumberton, NC 28358-8859
your 2008 Credit Score?
0 Fxcellent �o) 750 - 8.10 0
O Good ) 660 - 749 0
O Fair = 620 - 659 0
O Poor- 340 - 619 0
0 I Don't Know ??? O
Find out INSTANTLY!
44 Speak your request and go! Free MapQuest directions by phone: 1-800-FREE411 (1-800-373-3411).
http://www.mapquest.comlmaps?city=Lumberton&state=NC&address=1885+Alamac+Road 2/24/2009

ALAMAC AMERICAN KNITS, LLC
1885 Alamac Road — P.O. Box 1347
Lumberton, N.C.28359-1347
henrv.eritrn at7alamacusa.com
910-618-2255
Henry Griffin
Vice President - Manufacturing
January 26, 2009
Dina Sprinkle
NCDENR / DWQ
Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
SUBJECT: Renewal Package
NPDES Permit NC0004618
Alamac American Knits / Lumberton
Robeson County
Mrs. Sprinkler
RECEIVED
DENR - WATER QUALITY
POINT SOURCE BRANCH
Attached herewith, you will find a completed application package for the renewal of NPDES
Permit NC0004618. In accordance with directions, we have included an original and two copies.
Supporting documentation from December 2007 to November 2008 includes the sludge
management process, production data, a Priority Pollutant Analysis, and Material Safety Data
Sheets for cooling water chemical treatment. Operations at the Alamac American Knits facility
remains the same as when our existing NPDES Permit was issued.
Per Federal (40 CFR 122.41) and North Carolina (I5ANCAC 2H.0105 (e)) regulations for
permit application filing, we request renewal for NPDES Permit NC0004618.
If you have questions, please contact me at the telephone number or e-mail address listed above.
Sincerely,
HY' Henry Gnffin

ALANAC AMERICAN KNITS ISUPPLY
SCHEMATIC OF WATER FLOW I WELLS
LUMBERTON
ROBESON
NORTH CAROLINA
YARN
AIR
CONDITION
KNITTING
COOLING
mvv -
EARWELL IROBESON
FILTERS COUNTY
WATER
SYSTEM
DYEING FIN SHINGI IFINISHED
PRODUCT
ROT WATER
SUPPLY
FILTER BOILERS POTABLE 6
BACKWASH 01 A 02 - SANITARY
LOSS
I (3lsi�J�ruwl
DIATIO WASTEWATER TREATMENT POTW
YACILITY
DISCHARGE OUTFALL 002 'DISCHARGE OUTFALL 001
JACOB'S SWAMP LUMBER RIVER

ALAMAC AMERICAN KNITS, LLC
Residual Management Process
The wastewater treatment plant generates approximately 1,600 pounds of bio-solids
each day. This on average 15.0% material is removed from the system via a belt
press. After belt pressing the residuals are loaded by conveyor onto a spreader truck
owned and operated by Alamac American Knits. These residuals are applied on
approved land application sites located in Robeson County under permit
#WQ0010563.

ALAMAC AMERICAN KNITS, LLC
PRODUCTION ACTIVITY IN POUNDS
01
December
2007
732,532
02
January
2008
516,908
03
February
2008
536,383
04
March
2008
606,447
05
April
2008
416,478
06
May
2008
472,081
07
June
2008
574,882
08
July
2008
306,786
09
August
2008
544,722
10
September
2008
643,657
11
October
2008
462,138
12
November
2008
355,646

I -----------------------
Air Washer #2
ALAMAC AMERICAN KNITS
T.WOOD 0806
Chill Water
Sump
---------------------------
lallers LengthAdthVolume
Depth Cm3 gallons
Ions
#1 24ft
8ft 1.3ft 256 1,894
�2 22ft
12ft 1.Oft 264 1,954
ip 10ft
10ft 8.Oft 800 5,920
d gallons:
9,768
ooling Tower 1,400
95 Marley Quadra Flow SIN# 73844-23202
Cooling
Tower
Chiller 340 Tons
T
1100
Bleed to
Z: --
Brominator W W
BioTec 901T
Continuous F1
Chemical: SWE 3308 Biotec 077 Biotec 100
Feed Point: Cooling Tower Air Washers Cooling Tower
Air Washers
Frequency: continuous (1) gallon MWF (1) quart MWF

Well System
No. 1,2,5,E 275-325 GPM
No. 3 150 GPM
No. 4 450 GPM
Aeration
Tower
ALAMAC AMERICAN KNITTING
PROCESSS WATER SYSTEM
0806 T.WOOD
Chemical
Building
Anthracite
Sand 6µ
Filters
6(+&IGwr�>16 ��6�11
6&Y-W#50
OkTFALi Z
21 OW 10 Ibs daily in 100
s of water.
HTH slug fed 2X/week for algae
Clear Well
Dye and Finishing Operation
1,000,000 GPD

SLUE. 5043
ALAMAC CHEMICAL FEED
BOILERS T.WOOD SWE 9-08
S%N E 5220 Caustic l
S
WATER SOFTENERS
SOFTWA
SWE 6030 added 2 1/2 GPD
to Mix Tank and filled to 50 gals
1-K�4a�2ay (yl,ii,�
ATE RETURN
k-nemicai recu
Pump
To
B
0
I
l
e
r
S
--►
Steam Header

FACT SHEET —LUMBER RIVER BASIN
REVIEW FOR EXPEDITED PERMIT RENEWALS
(Instructions for Permit Writer)
Tn netemfine Pntential Fnr Expedited Permit Renewal
'--) P ,
IN
Reviewe s) /Date:
3a
� 09
c«
Permit Number:
NC0004618
Facilit Name:
Alamac American Knit / Lumberton 0
Sub -basin number:
03-07-51
Receiving Stream:
LUMBER RIVER (2 outfalls aco h oa
Permit Stream Classification:
I C, Sw
t C StJ lJ
Public WWTP
❑
Private WWTP
❑
WTP
❑*
Industrial
❑
Other
* If WTP, add permitted flow limit MGD :
2, s-
ro"°
� o
"O
'E
Pretreatment? YES No
(If YES then contact PERCS for data RPA
TRC limit/footnote? YES/ADD** NO
(If in permit EDIT FOOTNOTE see TRC
FOOTNOTE text
WET testing/footnote? YES/ADD** NO
(If in permit EDIT SPECIAL CONDITION see
WET language text check oomote
NH3 limit? YES/ADD** NO
(if in permit check edit LIMIT for applicable LIM17S
categories, monthly/weeklyorwekly/daily)
**IWC evaluation needed? YES NO
IWC calculation in file? YES NO
Permit Special Conditions? YES/ADD NO
(Iffactlity has BACKUP CHLORINATION see
SPECIAL CONDITION and FOOTNOTE text
Instream monitoring? YES NO
(Check edit where warranted)
303 d listed? YES NO
Watch Listed? YES NO
Permit MODS since last renewal? YES NO
Compliance issues? YES NO
Existing expiration date:
1 7/31/2009
1 Next cycle expiration date:
1 7/31/2014
Miscellaneous Comments
* Apply WTP Permitting
Strategy, WET may be required
* * IWC requires 7 10
ow data check with Basin Coordinator or best source
Select Expedited Catergory That Applies To This Permit Renewal
SIMPLE EXPEDITED - administrative renewal with no changes, or only minor
❑ changes such as TRC or ownership change. Includes conventional WTPs (does not
include permits with Special Conditions, Reverse Osmosis, or Ion -exchange WTPs).
❑ ICOMPLEX EXPEDITED - includes Special Conditions such as EAA, Wastewater
Management Plan, 303(d) listed, toxicity testing, instream monitoring, compliance
concerns, edit NH3 limit, phased limits, stream re -class).
15
NOT EXPEDITED - Mark all of the following that apply:
9[ Major Facility (municipaUindustrial)
[W Permitted flow > 0.500 MGD (requires full Fact Sheet)
❑ Minor Municipal with Pretreatment Program (SIUs)
❑ Minor Industrial subject to Federal Effluent guidelines
❑ Limits based on RPA (toxicants/metals, GW remediation for organics)
❑ Other
2009 Lumber Basin Permit Review/Shared Drive/Lumber Basin