NC0072575_Special Order by Consent_20171109 (2)

NPDE!i DOCUMENT SCARMINL COVER SHEET
NPDES Permit:
NCO072575
Sanford Processing Plant
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Special Order by Consent (SOC)
Owner Name Change
Staff Comments
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
November 9, 2017
T1210 doctimeat iM printed on reuse paper - ignore any
content on the rezrerse INide

Water Resources
ENVIRONMENTAL OUAIITY
November 9, 2017
Mr. Tim Singleton
Pilgrim's Pride Corporation
484 Zimmerman Road
Sanford, NC 27330
ROY COOPER
Gm•ernor
MICHAEL S. REGAN
Secretary
LINDA CULPEPPER
Interim Director
Subject: Special Order by Consent Completion
Sanford Processing Plant
Permit No. NCO072575
SOC No. WQS15-002
Lee County
Dear Mr. Singleton:
This letter confirms on time completion of all required activities and activities associated with the Special
Order that was initially entered into with the Division in February 2016. If you have questions, please
contact Brianna Young of my staff at 919-807-6333, or via e-mail [Brianna.Young@ncdenngov].
S' erely,
rG
Linda Culp per /
Interim Director, Division of Water Resources
cc: NPDES Files
Central Files
Raleigh Regional Office
Tina Pedley, Complex Environmental_ Manaeer, Sanford Processing Plant [484 Zimmerman
Road, Sanford, NC 27330]
State of North Carolina I Fm6onmental Quality I WaterResotaces
1617 Mall service Center I Raleigh, North Carolina 27699-1617
919 707 9000

Young, Brianna A
From:
Smith, Danny
Sent:
Thursday, November 02, 2017 4:33 PM
To:
Young, Brianna A
Cc:
Cashion, Ted
Subject:
SOCs
Mayo (Person County) and Pilgrim's Pride (Lee County) SOCs are complete.
Thanks!
Danny
Danny Smith, Supervisor
Raleigh Regional Office
Water Quality Regional Operations
Division of Water Resources
[phone]

`0
pilgrim-ps,_,
Via Certified Mail 7015 1730 0000 8145 3575
7015 1730 0000 8145 3582
September 15, 2017
Raleigh Regional Supervisor �u,o tZ57S
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources— Water Quality Permitting Section RECEIVEGI NCDEQ/DWR
1617 Mail Service Center
Raleigh NC 27699-1617 SEP 19 2017
Water Quality
Re: Pilgrim's Pride Corporation, Sanford, NC Permitting Section
Special Order by Consent
EMC SOC WQ S15-002
Quarterly Report
To whom it may concern:
This letter acknowledges September 15, 2007 being the end of the SOC. We are under
compliance minus the fecal issues noted in the last letter for August 2017. The construction
project has been completed.
Please contact me by phone at 919-895-3457 or via e-mail at [e-mail]
should you have any questions.
Sincerely,
Tina Pedley
Complex Environmental Manager
tel [phone]

`0
pjlgrirm's.
Via Certified Mail 7015 1730 0000 8145 3544 n1tp07Z5-?5
7015 1730 0000 8145 3551
September 1, 2017
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S15-002
Quarterly Report
To whom it may concern:
RECEIVEDINCDEQIDWR
SEP 0 7 2017
Water Quality
Permitting Section
Pursuant to Special Order by Consent 2.d., Pilgrim's is providing this item completion
progress report.
Permit Limit Compliance
Pilgrim's has been in compliance with the Permit Limits for ammonia and Total
Nitrogen. On August 11 we had a 1200 MPN/100ml fecal coliform exceedance. We feel this is
not a true indication of our system's performance. The fecal exceedance is believed to be an error
as we had tests performed before and after this event, both samples were well under our limits.
Our chlorination system is working properly and our gas chlorination system has been feeding at
the rate it historically has. Our certified lab agrees that is not accurate based on our history. We
have made changes to our process to ensure we are doing everything to keep our fecal numbers
under the permit limits. The certified lab is also pulling the samples for us now to ensure the
operator does not contaminate the sample. We had a Piedmont Chlorinator technician come in
and inspect the chlorine system as well as increase the amount of chlorine we can feed daily. We
drained the contact chamber to verify there were no solids present in the bottom. The only thing
we found was a dead frog in the effluent area just before the parshall flume. We had the line
between the parshall flume and the steps (where we sample for fecal) jetted out. Our tertiary
treatment will be cleaned with sodium hypochlorite to increase disinfection. We have also had a
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second lab pull samples to compare results. The second lab uses a different type of bottle. The
total chlorine in the contact chamber and the total residual chlorine on August 1 I were both high
showing the chlorination system was operating correctly.
We also have a contract with Terra Renewal to remove 25% of our solids. We are
currently waiting on the permit from DEQ to move forward with that project.
Please contact me by phone at 919-895-3457 or via e-mail at tina.pedlev(c),pilerims.com
should you have any questions.
Sincerely,
�a Pe
Tina Pedley
Complex Environmental Manager

pilgrim-Ps�
RECEIVEDINCDEIDIDWR
AUG 0 9 2017
Water Quality
Permitting Section
Via Certified Mail 7015 1730 0000 8145 3391
7015 1730 0000 8145 3407
July 25, 2017
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S15-002
Quarterly Report
To whom it may concern:
Pursuant to Special Order by Consent 2.d., Pilgrim's is providing this quarterly progress report.
Activities Undertaken and Comnleted
Construction of the treatment plant upgrade was completed by March 31, 2017. This included the
new anaerobic lift station, anoxic denitrification tank, associated nitrate recycle pumps and piping, sludge
holding tank and belt press. The anoxic denitrification system has been placed into operation and is
working well.
Compliance
Pilgrim's has been in compliance with the Permit Limits and Interim Limits since the February 5,
2016 effective date of the SOC.
Please contact me by phone at 919-895-3457 or via e-mail at tina.pedlev6Dpilprims.com should
you have any questions.
Sincerely, J&0_�&4
Tina Pedley
Complex Environmental Manager
tel [phone]

0
pilgrim'Psa
February 3, 2017
Danny Smith, Supervisor
NCDENR, Surface Water Protection
Raleigh Regional Office
3800 Barrett Drive
Raleigh, NC 27609
Re:
Dear Mr. Smith,
Amendment of Scheduled Event
Pilgrim's Pride Corporation
Sanford, North Carolina
EMC SOC WQ S 15-002
As mentioned in our Quarterly Reports, Pilgrims has been progressing well on
construction of the wastewater treatment improvements at our Sanford, NC plant. Several
pictures of the $5 million in improvements are attached. The SOC in paragraph 2.c. has a
scheduled date for completing construction of March 13, 2017. As we have also documented in
the Quarterly reports, there have been some delays in the project. Out of an abundance of
precaution, we are requesting an extension of the Complete Construction date to April 7, 2017.
Our contractor has experienced delays due to permitting with the city of Sanford and
weather. There was a four -week delay in starting construction due to the city of Sanford in
issuing building and electrical permits. Hurricane Matthew and other heavy rain added another
week to two weeks of delays. In December 2016 several winter storms with snow and ice added
to those delays. In addition, several aeration blowers needed for the sludge storage tank are
manufactured in Europe and scheduled for delivery in late February. We have been meeting
frequently with the contractor to convey the urgency of completion and the contractor believes
they will be able to complete the project by the scheduled date of March 13". However, due the
potential for unforeseen contractor delays, additional snow or ice, and delays in equipment
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delivery associated with international shipping and customs, we feel it is better at this time to
communicate that risk and request an extension.
Please note that we have met all other scheduled dates, have been in compliance with the
interim permit limits since February 2016, and will meet the scheduled date for compliance with
the final effluent limits of June 15, 2017. Pursuant to paragraph 7 of the SOC, please approve our
request for an extension of the Complete Construction date to April 7, 2017.
Please contact me by phone at 970-347-5730, or via e-mail at
dave.townsendOoilarims.com should you have any questions or require additional information.
Sincerely,
pl"4
David A. Townsend, P.E.
VP Environmental Engineering
Attachments — photos

pi�grirns 1770 Promontory Circle
Greeley. CO 80634-9039 USA
tot B70 506 8000
tax 800 !27 53fi6
v;ww.pilgrims.com

i 1770 Promontory Circle
pilgrim Greeley, CU UU634-9039 USA
w
tat 970 506 3000
fax [phone]
wwwpilCrims.com

pilgrim-PSN
Via Certified Mail
January 27, 2017
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
7014 0150 0001 8782 4990
7014 0150 00018782 4983
2`'�
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S15-002
Quarterly Report
To whom it may concern:
RECEIVED/NCDEQ/DWR
JAN 31 2017
Water Quality
Permitting section
Pursuant to Special Order by Consent 2.d., Pilgrim's is providing this quarterly progress
report.
Activities Undertaken and Completed
The anoxic and sludge holding tanks have been constructed. The lift station and pump
building structures are nearly complete. Most underground piping has been completed. The
mechanical equipment for the anoxic denitrification system is also nearing completion. The
sludge handling system mechanical equipment is not all on -site yet. The belt press and the
aeration blowers for the sludge tank will be delivered in mid to late February The electrical work
and controls for the equipment is progressing, but can't be completed until all equipment is
delivered and installed.
There was a four -week delay in starting construction due to the city of Sanford in issuing building
and electrical permits. In addition, hurricane Matthew and other heavy rain added another week
to two weeks of delays. At this time the contractor states they will complete the project in mid -
March. Pilgrims will continue to monitor progress and promptly communicate to the state any
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additional delays. We may need to request an extension of the construction completion date of
March 13, 2017, but not the final compliance date which is June 15, 2017.
Permit Limit Compliance
Pilgrim's has been in compliance with the Permit Limits and Interim Limits since the
February 5, 2016 effective date of the SOC.
Please contact me by phone at 919-895-3457 or via e-mail at tina.pedley2pilgrims.com
should you have any questions.
Sincerely,
Tina Pedley
Complex Environmental Manager

"0
Via Certified Mail
October 26, 2016
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
70153430000109473933
70153430000109473926
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S 15-002
Quarterly Report
To whom it may concern:
report.
REGEIVEDI 0DEQIDWR
OCT 31 2016
vJster Quaiity
Permitting Section
Pursuant to Special Order by Consent 2.d., Pilgrim's is providing this quarterly progress
Activities Undertaken and Completed
The contractor is pouring concrete for the lift station, pump and belt press buildings and
tank foundations. Associated underground piping for these structures has been completed. There
was a four week delay in starting construction due to the city of Sanford in issuing building and
electrical permits. In addition, hurricane Matthew and other heavy rain added another week of
delay. At this time the contractor still states they can meet the construction completion deadline.
Pilgrims will continue to monitor progress and promptly communicate to the state any additional
delays.
Permit Limit Compliance
Pilgrim's has been in compliance with the Permit Limits and Interim Limits since the
February 5, 2016 effective date of the SOC.
tel [phone]
fax [phone]

Please contact me by phone at 919-895-3457 or via e-mail at [e-mail]
should you have any questions.
Sincerely, n
P"_C
Tina Pedley
Complex Environmental Manager

pilgrim,pso
Via Certified Mail 70140150000187824587
70140150000187824594
July 26, 2016
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S15-002
Quarterly Report
To whom it may concern:
RECEIVED/NCDEQ/DWR
AUG 02 1-u10
Water Quatity
Perm tiny Section
Pursuant to Special Order by Consent 2.d., Pilgrim's is providing this quarterly progress report.
Activities Undertaken and Completed
Pilgrim's has received the E & S Permit. We are in the process of obtaining the building permits. The contractor
has started to order equipment and has been on site to begin setting up their equipment.
Permit Limit Compliance
Pilgrim's has been in compliance with the Permit Limits and Interim Limits since the February 5, 2016 effective
date of the SOC.
Please contact me by phone at 919-895-3457 or via e-mail at [e-mail] should you have any
questions.
Sincerely,
Tina Pedley
Complex Environmental Manager
tel [phone]

pilgrim -PS
Via Certified Mail
July 26, 2016
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
7 (� ( s
70140150000187824525
70140150000187824518
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S15-002
Solids Management Plan
To whom it may concern:
RECEIVED/NCDEOMWR
AUG 0 2 2016
Water Quality
Permitting Section
Pursuant to Special Order by Consent 2.b.3, Pilgrim's is providing this solids
management plan.
Pilgrim's Pride Solids Management Plan and Implementation Schedule
The Pilgrim's poultry processing facility produces solids from the pretreatment system
and the biological treatment plant. In 2015 Pilgrim's installed a dissolved air floatation (DAF)
unit to remove solids and oil and grease from the pretreatment system. Previously these materials
were being discharged to the anaerobic lagoon. The solids are now diverted for beneficial
recycling at a nearby rendering facility.
As part of the project being completed for the SOC, Pilgrim's will install a belt filter
press for management of waste activated sludge (WAS). Previously, the WAS was pumped to
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the anaerobic lagoon. Beginning in 2017, the belt press dewatered WAS will be sent to either a
composting facility for recycling, or land applied by a third -party contractor offsite.
The implementation of the DAF pretreatment unit and belt filter press for WAS will
prevent significant future accumulation of solids in the anaerobic lagoon.
Pilgrims estimates that the current anaerobic lagoon contains approximately 1200 dry
tons of bottom solids and 300,000 ft.3 of grease material floating at the surface of the lagoon.
Based on probing of the lagoon, it likely has 25% - 50% free capacity remaining. Pilgrim's is
soliciting bids from third -party contractors to remove 25% of each type of material over the next
four years to clean the lagoon out over time. It is necessary to slowly clean out the lagoon in
order to keep it in service and provide anaerobic first stage biological treatment. Significant
agitation and disturbance could cause excess solids discharge from the lagoon and upset
downstream treatment units. Lagoon cleanout will begin in 2017. Sludge depths will be
reevaluated after the 2017 cleanout.
The third party contractor will be required to meet all NCDENR requirements. The
preliminary plan is to dispose of grease cap material in an approved landfill. Bottom solids will
be land applied to agricultural land. The contractor will obtain all necessary land owner
approvals, NCDENR permits and comply will NCDENR rules for application method, timing,
nutrient management, land slope and crop requirement, agronomic rates, pathogen reduction and
vector controls.
Please contact me by phone at 919-895-3457 or via e-mail at tina.peedlevna ailerims.com
should you have any questions.
Sincerely,
Tina Pedley
Complex Environmental Manager

pilgrim-pSo
Via Certified Mail 70132250000199711596
70132250000199711602
May 27, 2016
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S 15-002
Scheduled Events
To whom it may concern:
RECEIVED/NCDEQ/DWR
JUN 0 2 2016
Water Quality
Permitting Section
Pursuant to Special Order by Consent 2.c., Pilgrim's has completed the following events:
Begin Construction
On March 7, 2016 construction of piping and valve connections to the existing concrete
aeration tank began. Pilgrim's management has approved $5.4 million for the wastewater
improvement project; a construction contract has been signed and the contractor will mobilize on -
site for additional construction activities during the month of June. We plan to complete
construction by the scheduled date of March 13, 2017.
Please contact me by phone at 970-347-5730 or via e-mail at
[e-mail] should you have any questions.
Sincerely,
Dave Townsend
VP Environmental
tel [phone]
fax [phone]

pilgrin��s�
April 29, 2016
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S 15-002
Scheduled Events
To whom it may concern:
RECEIVEDINCDEUDWR
MAY 0 9 2016
Water Quality
Permitting Section
On April 27, 2016, I sent a letter regarding scheduled event completion pursuant to
Special Order by Consent 2.c. However, I did not include a copy of the referenced Treatment
Unit Investigation report. Attached is a copy of the report by Reid Engineering titled Final
Design Summary of Wastewater Treatment Upgrade dated April 26, 2016.
Please contact me by phone at 970-347-5730 or via e-mail at
[e-mail] should you have any questions.
Sincerely,
Dave Townsend
VP Environmental
tei 970 506 8000

nth is tlre�
Reid En ineelvlg
.Ps�
Final Design Summary
of
Wastewater Treatment
System Upgrade
Qt
p1tgnnn,,,S-
Pilgrim's Pride
Sanford, North Carolina
April 26, 2016
Prepared by:
RECEIVEMCDEQ IVR
MAY 0 9 2016
Water Quality
Permitting Section
Reid Engineering Company, Inc.
Environmental & Civil Engineering Consultants
540-371-8500 I www.Re!dEngineering.com
1210 Princess Anne Street I Fredericksburg, VA 22401
Contact: Wade Tanner, P.E. Email: [e-mail]

FINAL DESIGN SUMMARY OF WASTEWATER
TREATMENT SYSTEM UPGRADE
for
PILGRIM' S PRIDE
Sanford, North Carolina
TABLE OF CONTENTS
A. DESCRIPTION OF PROJECT............................................................................................... 1
B. WASTEWATER POLLUTANT LOADINGS AND FLOWS ............................................... 2
C. DISSOLVED AIR FLOTATION (DAF) FIRST STAGE PRETREATMENT SYSTEM
(Existing)................................................................................................................................. 3
D. ANAEROBIC LAGOON SECOND STAGE PRETREATMENT SYSTEM (Existing)....... 4
E. ANAEROBIC LAGOON SHORT CIRCUIT / BY-PASS LINE ........................................... 8
F. ANAEROBIC LAGOON EFFLUENT PUMP STATION (New) .......................................... 9
G. ANOXIC REACTOR #1 (New)............................................................................................ 10
H. NITRATE RECYCLE PUMP STATION (New).................................................................. 15
I. CONVERT EX. SCHREIBER TANK INTO NITRIFICATION REACTOR #2
(Modification)........................................................................................................................ 16
J. FINAL CLARIFIER (Existing)............................................................................................. 23
K. SLUDGE RETURN AND WASTE SLUDGE PUMP STATION (Modification) ............... 25
L. WASTE SLUDGE STORAGE TANK (WSST) (New) ........................................................ 25
M. BELT PRESS SLUDGE DEWATERING SYSTEM (New) ................................................ 28
N. PLANT SITE DRAIN PUMP STATION (New).................................................................. 31
O. CHEMICAL STORAGE -FEED EQUIPMENT FOR ACTIVATED SLUDGE PROCESS
(Existing)............................................................................................................................... 31
P. EXPECTED FINAL EFFLUENT QUALITY...................................................................... 34

FINAL DESIGN SUMMARY OF
WASTE WATER TREATMENT SYSTEM UPGRADE
for
PILGRIM'S PRIDE
Sanford, North Carolina
A. DESCRIPTION OF PROJECT
1. Pilgrim's Pride desires to upgrade the existing Wastewater Treatment System (WWTS) at
their facility in Sanford, North Carolina. The treatment system is being upgraded to
provide increased Total Nitrogen (TN) pollutant removal efficiency to install a new
Anaerobic Pretreatment Lagoon Effluent Pump Station; install a new Waste Activated
Sludge Storage Tank; a belt press sludge dewatering system for long term sludge
management capability; and, to install a new Anoxic Reactor to operate upstream of the
existing Schreiber Reactor for capability to comply with existing permit limits for Total
Nitrogen concentration.
The processing plant capacity is approximately 134,000 birds/day over two kill shifts per
day followed by a nightly sanitation clean-up shift, 5 to 6 days per week. The total
average wastewater flow volume discharged from the Pilgrim's facility is approximately
0.85 MGD, 5 to 6 days per week, with a maximum flow volume of 1.0 MGD, 6 days per
week.
The existing wastewater treatment system consists of primary screening, first stage
pretreatment by one existing DAF Cell and second stage pretreatment by one existing 17
MG covered Anaerobic Lagoon (AL) operated to provide 7 day flow equalization. The
existing second stage pretreatment AL effluent is discharged by gravity into a single
stage biological treatment system consisting of a 2.5 MG Schreiber activated sludge
reactor tank and a 78-foot diameter gravity Final Clarifier. Final effluent polishing is
provided by a Schreiber Fuzzy Filter tertiary filtration system and final effluent
disinfection by chlorination and de -chlorination. Disinfected final effluent flows by
gravity to a cascade post aeration prior to discharging to Outfall 001 in Deep River.
To provide the required wastewater treatment capacity for improved TN removal
efficiency, the existing single stage activated sludge WWTS will be upgraded into a two -
stage biological nitrogen removal (BNR) system. The two -stage anoxic -aerobic
(denitrification-nitrification) treatment system is designed to provide BOD removal,
ammonia removal, nitrate -nitrogen removal, and TN removal. The upgrade would
include the installation of one new, above grade, Anoxic Reactor # 1 tank to operate as a
first stage anoxic (low DO) reactor upstream of existing Schreiber tank which would be
operated as a second stage aerobic (high DO) Nitrification Reactor #2. A new Nitrate
Recycle (NR) Pump Station would be installed to recycle mixed liquor from Nitrification
Reactor #2 back into Anoxic Reactor # 1.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.

2. Summary of WWTS Upgrade Components Included in the Project:
a. Upgrade existing recycle whitewater system and existing Pretreatment DAF Cell
System to improve solids removal capacity. Install a mixer in the raw wastewater
pump station wet well.
b. The existing Covered Anaerobic Lagoon (AL) will continue to provide second stage
wastewater pretreatment and 7 day flow equalization. The AL will be provided with
a new biogas waste gas burner.
c. New Anaerobic Lagoon Effluent Pump Station to pump AL effluent to the New
Anoxic Reactor #1.
d. One New Anoxic Reactor #1 to provide nitrate -nitrogen and BOD removal by
biological denitrification. Nitrates will be recycled from the existing downstream
Schreiber Tank — Nitrification Reactor #2 back to Anoxic Reactor # 1.
e. Convert the existing Schreiber Tank into New Nitrification Reactor #2.
f. New Nitrate Recycle Pump Station to pump mixed liquor containing nitrate nitrogen
from the Nitrification Reactor #2 effluent back to the New Anoxic Reactor # 1.
g. New Waste Sludge Storage Tank and Belt Press Sludge Dewatering System.
h. New Wastewater Equipment Buildings for the enclosure of the new Anaerobic
Lagoon Effluent Pumps; New Belt Press Dewatering System and Controls; and, the
new Nitrate Recycle Pumps and Controls.
B. WASTEWATER POLLUTANT LOADINGSAND FLOWS
1. Wastewater Sources
a. Wastewater at the facility is generated from the poultry first processing and rendering
plant operations and discharged to the WWTS.
b. Domestic sanitary wastewater generated at the facility is segregated from the
industrial wastewater for separate treatment and disposal.
2. Processing Plant Production Capacity
a. 134,000 chickens/day processed over two kill shifts, 5 to 6 days/week @ 8.5 lbs live
weight kill per chicken.
b. Rendering facility is operated 24 hours per day, 5 to 6 days/week.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 2

3. Wastewater Flows
a. Average Flow Volume = 0.85 MGD, 5 to 6 days per week
b. Maximum Flow Volume = 1.0 MGD, 6 days per week
C. DISSOLVED AIR FLOTATION (DAF) FIRST STAGE PRETREATMENT SYSTEM
(Existing)
1. Pollutant Concentrations and Loadings
a. Average pollutant concentrations and loadings contained in the first stage
pretreatment DAF Cell effluent discharged to the new second stage pretreatment
Anaerobic Lagoon (AL) @ 0.85 MGD:
Pollutant
Concentration
#/day
COD
3,200 mg/L
22,685#/day
BOD
2,000 mg/L
14,178#/day
TSS
1,000 mg/L
7,089#/day
O&G
200 mg/L
1,418#/day
TKN
150 mg/L
1,063#/day
b. Maximum pollutant concentrations and loadings contained in the first stage
pretreatment DAF Cell effluent discharged to the new second stage pretreatment
Anaerobic Lagoon (AL) @ 1.0 MGD:
Pollutant
Concentration
#/day
COD
4,300 mg/L
35,862#/day
BOD
2,500 mg/L
20,850#/day
TSS
1,500 mg/L
12,510#/day
O&G
300 mg/L
2,502#/day
TKN
185 mg/L
1,543#/day
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 3

D. ANAEROBIC LAGOONSECOND STAGE PRETREATMENT SYSTEM (Existing)
1. General Description of Process
a. The existing DAF Cell will continue to provide first stage wastewater pretreatment
upstream of the existing Anaerobic Lagoon. The DAF Cell will be operated with no
chemicals or a single polymer in order to keep the AL influent wastewater pollutant
loadings within the design valves in order to maximize the efficiency of the AL
operation.
b. Pretreated wastewater will discharge by gravity from the existing DAF Cell into the
Anaerobic Lagoon.
c. One existing 17 MG volume Anaerobic Lagoon will provide 7 day hydraulic flow
equalization and second stage wastewater pretreatment prior to discharge to the
activated sludge biological final treatment system. The Anaerobic Lagoon has a
floating high density polyethylene (HDPE) cover for biogas collection in order to
minimize odors.
2. Design Assumptions
a. Wastewater Flows
1) The average daily influent flow volume of pretreatment DAF Cell Effluent
wastewater = 0.85 MGD
2) The maximum daily influent flow volume of pretreatment DAF Cell Effluent
(partially pretreated processing plant wastewater) = 1.0 MGD
b. Pollutant Concentrations and Loadings
1) Maximum pollutant concentrations and loadings in the DAF effluent wastewater
@ 1.0 MGD, 6 days/week:
Pollutant
Concentration
#/day
COD
4,300 mg/L
35,862#/day
BOD
2,500 mg/L
20,850#/day
TSS
1,500 mg/L
12,510#/day
O&G
300 mg/L
2,502#/day
TKN
185 mg/L
1,543#/day
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 4

3. Lagoon Liner
a. The Anaerobic Lagoon is provided with an existing 80 mil HDPE liner.
4. Equalization Volume Calculation
a. The storage volume required to provide 7 day hydraulic flow equalization with 6
processing days @ 1,000,000 gallons/day plus one weekend non production day @
300,000 gallons/day.
1.0(6 days)+0.3
1) Q7_ 7 days — 0.9 MGD, 7 days/week
2) EQ Volume Required = (1.0 MGD — 0.9 MGD)(6 days) <— 0.6 MG
b. The storage volume required to provide 7 day hydraulic flow equalization with 5
processing days @ 1,000,000 gallons/day plus two weekend non production days @
300,000 gallons/day =
1.0(5 days)+0.3(2 days)
1) Q7_ 7 days = 0.8 MGD, 7 days/week
2) EQ Volume Required = (1.0 MGD — 0.8 MGD)(5 days):5 1.0 MG
5. 7 Day FEB/Anaerobic Lagoon Volume
a. The existing 17 MG lagoon will be operated as 7 Day FEB/Anaerobic Lagoon to
provide combined 7 day hydraulic flow equalization and second stage wastewater
pretreatment.
b. 7 Day FEB Anaerobic Lagoon
Volume Description
Total Volume @ HWL = 23'
17 MG
Average 7 day Equalization Volume
1.5 MG
Minimum Operating Volume a Normal LWL = 20.5'
15.5 MG
Average Operating Volume
16.25 MG
c. The Lagoon will have an overall depth of 25' which provides 2' of free board at the
HWL of 23'.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 5

6. Anaerobic Lagoon BOD Loading Rate Calculation and Predicted BOD Removal
Efficiency
a. Minimum Operating Volume in the Anaerobic Lagoon = 15.5 MG = 2,072 x 103ft3
b. Maximum BOD loading = 20,850#BOD/day, 6 days/week.
c. Design BOD loading rate (BODLR) at total average volume:
20,850#BOD/day 3
BODLR (avg) = 2,072 x 103ft3 _ 10#BOD/1,000 ft
_< 10#BOD/1,000 ft3
d. At a design BOD loading rate _< 10#BOD/1,000 ft3, the new anaerobic lagoon is
expected to provide an overall BOD removal efficiency > 80 %.
7. Anaerobic Lagoon Floating Cover, Bio Gas Ventilation System, Bio Gas Blowers, and
Bio Gas Burner Flare Design
a. Floating Membrane Cover
1) The existing Anaerobic Lagoon is provided with a floating polyethylene cover to
provide odor control; gas containment and collection; improved heat retention; fly
prevention; and, increased BOD removal efficiency.
2) The floating lagoon covers is constructed of 80 mil thickness HDPE.
b. Bio Gas Collection
1) The lagoon cover is provided with a peripheral bio gas collection/vent system
which conveys collected gas by suction to bio gas blowers located near the inlet
end of the lagoon.
c. No Gas Production
1) Methane Gas
Average daily volume
of methane gas produced < 8.5 ft3 gas/#BOD removed x
(20,850# BOD/day)(0.80)
< 141,780 ft3/day methane gas
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 6

Maximum daily volume
of methane gas produced < 9.0 ft3 gas/#BOD removed x
(20,850# BOD/day)(0.90)
< 168,885 ft3/day methane gas
2) Bio Gas
Total bio gas produced assuming biogas is 65% to 70% methane
< 168,885 ft3
0.65
< 260'000 ft3/day; 6 days/wk biogas
180 cfm for 24 hours/day biogas blower
operation
540 cfm for 8 hours/day biogas
blower operation
d. Bio Gas Flare
1) One new 8" gas burner flare will be provided for flaming bio gas exhausted from
under the anaerobic lagoon cover. The burner flare is sized for flaring up to 540
cfm (32,400 cF/hr) for 8 hours/day operation.
2) The gas burner is provided with a drip trap and drain.
3) Propane will be utilized as a fuel source for the pilot system.
4) The flare is provided with an automatic ignition system that will start the pilot
flame when the Biogas Blower has been called to start.
e. Flame Arresters
1) Flame arresters are provided on the gas blower intake line from the lagoon and
discharge line to the Biogas flare.
2) Condensate wastewater is drained from the Flame Arrestors using an electric
operated drip trap mounted on the drain plug of the Flame Arrestor. The drip trap
is provided with an insulating jacket to minimize the freezing potential of the
water in the drip trap.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 7

f. Bio Gas (BG) Blower
1) Two 10 HP blowers are provided to draw the BG through anaerobic lagoon
biogas collection piping and compress the BG to a discharge pressure of
approximately 2 psig. The blowers are rated at 540 scfm @ 2 psi. Normally one
of the blowers will be operated approximately 8 hours/day to draw biogas from
under the cover of the Anaerobic Lagoon and transfer biogas to the waste gas
burner flare. The second blower is provided as an installed stand-by.
2) The blowers are provided with a manually controlled variable speed drive to
allow adjustment of the compressed BG flow rate over a 2/1 ratio of
approximately 270 scfm to 540 scfm.
8. Condensate Trap
a. Biogas from the lagoon passes through a 12-inch stainless steel Condensate and
Sediment Trap unit to separate condensate wastewater from the gas stream and
remove sediment particles entrained in the biogas.
b. The condensate wastewater is drained from the Condensate and Sediment Trap using
an electric operated drip trap mounted on the sediment trap. The drip trap is provided
with an insulating jacket to minimize the freezing potential of the water in the drip
trap.
E. ANAEROBIC LAGOON SHORT CIRCUIT/BY-PASS LINE
1. General
a. The Anaerobic lagoon is provided with an influent by-pass line which provides
capability to discharge a controlled portion of the total influent wastewater flow
volume into the outlet zone of the Anaerobic Lagoon in order to increase and control
the BOD:TKN ratio of the blended Anaerobic Lagoon effluent wastewater that is
pumped into the Activated Sludge (AS) Final Treatment System. The desired
BOD:TKN ratio of the AS influent wastewater is between 3:1 to 4:1 to provide
sufficient carbon source to achieve the sufficient nitrate -nitrogen removal to comply
with the ELG limit for TN.
2. Design Assumptions
a. Total Maximum Influent Flow Volume and Rate = 1.00 MGD = 700 gpm
b. Total Average Influent Flow Volume and Rate = 0.85 MGD _< 590 gpm
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 8

c. Average Influent Short Circuit Flow Volume and Rate = 40% to 60% = 240 gpm to
420 gpm = 0.35 MGD to 0.42 MGD.
3. By -Pass Flow Meter and Anaerobic Lagoon Influent Flow Meter
a. One new 6" magnetic flow meter and downstream flow control valve is provided in
the AL influent by-pass line to measure, indicate, and totalize the AL by-pass influent
flow.
F. ANAEROBIC LAGOON EFFLUENT PUMP STATION (New)
1. General
a. The Anaerobic Lagoon Effluent Pump Station will pump the AL effluent pretreated
wastewater into Anoxic Reactor #1 or alternatively Nitrification Reactor #2.
2. Design Assumptions
a. Maximum Effluent Pumping Volume and Rate = 1.0 MGD = 700 gpm.
b. Average Effluent Pumping Volume and Rate = 0.85 MGD <_ 600 gpm.
3. Pump Selection and Controls
a. Two 15 HP self -priming sewage pumps are provided to pump AL effluent wastewater
through a new force main to Anoxic Reactor #1 or alternatively Nitrification Reactor
#2.
b. Each pump is rated at 800 gpm @ 35 feet. Operation of one pump at reduced speed is
required to pump the design maximum flow rate of 700 gpm. Operation of one pump
at a reduced speed will pump the design average flow rate of 600 gpm. The second
pump is provided as an installed standby pump.
c. Each pump will be provided with a variable frequency drive for automatic pump
speed control. The pump speed and pumping rate will be automatically adjusted to
maintain a manually selected constant discharge flow rate to Anoxic Reactor #1.
d. One new 8" magnetic flow meter and downstream flow control valve is provided in
the pump station discharge header to measure, indicate, and totalize the total flow rate
pumped to Anoxic Reactor #1.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
9

G. ANOXIC REACTOR #1 (New)
1. General
a. One new 74 ft diameter x 21 ft tall x 19 ft side water depth, 0.6 MG Anoxic Reactor
#1 is provided for first stage activated sludge BNR treatment to accomplish
carbonaceous BOD removal and denitrification of nitrate nitrogen recycled from
Nitrification Reactor #2.
b. A new Nitrate Recycle Pump Station will be provided to pump mixed liquor
containing nitrate nitrogen from the outlet of Nitrification Reactor #2 back into the
inlet of Anoxic Reactor #1. Nitrate recycle flow rate capacity will be provided from
the Nitrification Reactor #2 back in to Anoxic Reactor #1 at rate of up to 4Q = 400%
= 4(1.0) = 4.0 MGD, at the maximum daily volume of 1.0 MGD.
2. Design Assumptions
a. Wastewater Flows
1) Average daily pretreated wastewater flow volume from AL = 0.85 MGD, 7 days
week
2) Maximum daily pretreated wastewater flow volume from AL = 1.0 MGD
b. Pollutant Concentrations and Loads
1) Average pollutant concentrations and loadings contained in the Anaerobic Lagoon
effluent without influent Short Circuit flow @ 0.85 MGD, 7 days/week:
Pollutant
Concentration
#/day
cBOD
200 mg/L(1)
1,418#/day
TSS
200 mg/L
1,418#/day
O&G
50 mg/L
355#/day
TKN
150 mg/L
1,063#/day
(')Assuming an average BOD removal in the AL of 90%
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
10

2) Average pollutant concentrations and loadings contained in the Anaerobic Lagoon
effluent pumped to the new Anoxic Reactor # 1 @ 0.85 MGD, 7 days/week,
assuming the operation of the AL Short Circuit flow to provide a BOD:TKN ratio
of3:1:
Pollutant
Concentration
#/day
cBOD
450 mg/L
3,190 4/day
TSS
200 mg/L
1,418 #/day
O&G
50 mg/L
355 #/day
TKN
150 mg/L
1,063 #/day
3) Maximum pollutant concentrations and loadings contained in the Anaerobic
Lagoon effluent pumped to the new Anoxic Reactor # 1 @ 1.0 MGD, 7
days/week, assuming the operation of the Anaerobic Lagoon Short Circuit flow to
provide a BOD:TKN ratio of 2.7:1:
Pollutant
Concentration
#/day
cBOD
500 mg/L
4,170#/day
TSS
300 mg/L
2,502#/day
O&G
100 mg/L
834#/day
TKN
185 mg/L
1,543#/day
3. Anoxic Reactor # 1 Process Design
a. Volume available in 74 ft diameter x 21 ft tall x 19 ft side water depth Anoxic
Reactor #1 Tank = 0.6 MG.
b. Calculate MLVSS and MLSS concentrations @ the minimum summer season
expected design mixed liquor temperature = 25°C at the maximum daily wastewater
flow volume = 1.0 MGD and maximum pollutant loadings:
1) For BOD removal assuming a carbonaceous BOD removal rate =
0.45#BOD/#MLVSS @ 25°C and assuming 85% BOD removal:
4,170#BOD/day)(0.85) < 8,000#MLVSS @ 250C
0.45
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 11

2) For NO3-N removal assuming a denitrification rate = 0.07 NO3-N/#MLVSS @
25°C in first stage activated sludge Anoxic Reactor #1; assuming a nitrogen
uptake by the biomass of approximately 3 mg/L N/100 mg/L BOD (4,170#/day
BOD x 0.03 =125#/day); assuming a nitrate recycle rate = 4Q.
% NO3-N removed
40 = ,40
4Q + 1Q 5Q
= 80% NO3-N removal
TKN nitrified = 1,543#TKN/day — 125#TKN/day
= 1,418#TKN nitrified/day
NO3-N denitrified = 1,418#TKN nitrified/day(0.80 denitrified)
= 1,134#NO3-N denitrified/day
= 1,134#NO3-N denitrified/day <_ 16,200 #MLVSS @ 25°C
0.07
The #MLVSS required for NO3-N removal exceeds that required for BOD
removal and therefore governs the MLSS concentration required in Anoxic
Reactor # 1.
3) The required average MLVSS and MLSS concentrations in the 0.60 MG volume
Anoxic Reactor #1 for BOD removal and NO3-N removal at the 25°C summer
season operating temperature assuming MLVSS/MLSS = 0.85
16,200#
(8.34)(0.6 MG) <— 3,237 mg/L
3,237 mg/L
0.85 < 3,809 mg/L MLSS @ 25°C
Assume MLSS < 4,000 mg/L in Anoxic Reactor #1 during summer season for
conservative design approach
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 12

c. Calculate MLVSS and MLSS concentrations @ the minimum winter season expected
design mixed liquor temperature = 15°C at the maximum daily wastewater flow
volume = 1.0 MGD and maximum pollutant loadings:
1) For BOD removal assuming a carbonaceous BOD removal rate =
0.35#BOD/#MLVSS @ 15°C and assuming 85% BOD removal:
4,170#13OD/day)(0.85) < 10,200#MLVSS @ 15°C
0.35
2) For NO3-N removal assuming a denitrification rate = 0.05 NO3-N/#MLVSS @
15°C in first stage activated sludge Anoxic Reactor #1; assuming a nitrogen
uptake by the biomass of approximately 3 mg/L N/100 mg/L BOD; assuming a
nitrate recycle rate = 4Q = 400%.
1,134#NO3-N denitrified/day < 22,700#MLVSS @ 15°C
0.05
The #MLVSS required for NO3-N removal exceeds that required for BOD
removal and therefore governs the MLSS concentration required in Anoxic
Reactor # 1.
3) The required average MLVSS and MLSS concentrations in the 0.5 MG Anoxic
Reactor #1 for BOD removal and NO3-N removal at the 15°C winter season
operating temperature assuming MLVSS/MLSS = 0.85
22,700#
(8.34)(0.6 MG) = 4,536 mg/L
4,536 mg/L
0.85 < 5,337 mg/L MLSS @ 15°C
Assume MLSS < 5,500 mg/L in Anoxic Reactor #1 during winter season for
conservative design approach
d. Calculations indicate that the Anoxic Reactor #1 is of adequate volume for
accomplishing first stage activated sludge carbonaceous BOD removal and nitrate
nitrogen removal at the minimum summer and winter season activated sludge basin
temperatures. If the winter temperature decreases below 15°C the MLSS
concentration will need to be increased above 5,500 mg/1 and/or the decrease the flow
volume pumped to Reactor #1 from the AL.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 13

4. Anoxic Reactor #1 Mixing and Aeration Equipment Design
a. Calculate Mixing Requirements in Anoxic Reactor #1:
l) bhp required for mixing a 3,000 to 6,000 mg/L biological MLSS concentration =
30 HP/MG
bhp required = 30 HP(0.60 MG) —< 20 HP
2) One (1) new 20 HP downward pumping surface mixer is provided to keep the
contents of the basin completely mixed.
b. Calculate Oxygen Transfer Requirements in Anoxic Reactor #1 at the maximum daily
flow volume of 1.0 MGD:
1) For synthesis assuming a maximum of 85% BOD removal and an oxygen demand
of 0.60#02/BOD in Reactor #1:
AOTR1= 0.60#02/#BOD(4,170#BOD/day)(0.85) = 89#02/hr
24
2) For endogenous respiration assuming a 20% of the total activated sludge biomass
weight is contained in Reactor #1 and assuming an oxygen demand of
0.80#02/BOD:
0.80#02/#BOD(0.20)(4,170#BOD/day) —
AOTR2= 28#02/1ir
24 —
3) For removal of recycled nitrate nitrogen assuming an oxygen reuse of
2.80#02/#NO3-N denitrified, and, assuming 80% nitrate nitrogen removal
efficiency:
2.80#02/#NH3-N(1,134#NO3-N/day) —
AOTR3= 132#02/hr
24 —
4) Total oxygen transfer requirement in Anoxic Reactor #1:
AOTR (total) = 89#02/hr + 28#02/hr - 132#02/hr
= (15)#02/hr < 0#02/hr
Normally oxygen will be supplied to Anoxic Reactor #1 with the Nitrates recycle
from Nitrification Reactor #2.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
14

5. Nitrate Mixed Liquor Recycle
a. The new Nitrate Recycle Pump Station will provide a nitrate recycle flow rate
capacity = 4Q = 400% of the design maximum throughput flow volume = 1.0 MGD =
4(1.0 MGD) = 4.0 MGD.
6. Expected Effluent Quality of Anoxic Reactor #1
a. To ensure a conservative design approach the following Reactor #1 effluent pollutant
concentrations are assumed for the design of downstream Nitrification Reactor #2 at
the @ 1.0 MGD maximum daily flow volume and 0.85 MGD average daily flow
volume:
Pollutant
Concentration
Loading
Average
Maximum
Average
Maximum
BOW)
< 50 mg/L
< 75 mg/L
417#/day
625#/day
TKN(2)
< 135 mg/L
< 170 mg/L
1,126#/day
L,418#/day
(IP Assumes 85% BOD removal in Anoxic Reactor #1 at maximum loadings
(2) 3% nitrogen uptake in biomass
H. NITRATE RECYCLE PUMP STATION (New)
1. General Description
a. One new Nitrate Recycle Pump Station is provided to recycle mixed liquor containing
nitrate nitrogen from Reactor #2 back into Reactor # 1.
b. One new Nitrate Recycle force main is provided from the Nitrate Recycle Pump
Station discharge to the inlet of new Anoxic Reactor #1.
2. Design Assumptions
a. Wastewater Flow
1) Average daily wastewater flow volume = 0.85 MGD, 7 days/week
2) Maximum daily wastewater flow volume = 1.00 MGD
b. Nitrate Recycle Flow
1) Maximum nitrate recycle flow pumping rate required = 400% = 4Q = 4(1.0
MGD) = 4.00 MGD = 2,800 gpm.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 15

3. Pump Selection
a. Two new 20 HP self -priming Nitrate Recycle Flow pumps are provided each rated at
1,400 gpm at 30 ft.
b. Operation of two pumps in parallel is required to provide a total nitrate recycle flow
rate = 4Q = 4.0 MGD = 2,800 gpm.
c. Operation of one pump will provide a nitrate recycle flow rate = 2Q = 2.0 MGD =
1,400 gpm.
4. Variable Speed Drives
a. Each Nitrate Recycle Pump is provided with a variable speed drive for control of
pump speed and pumping rate.
b. The variable speed drives are manually controlled.
5. Nitrate Recycle Flow Meter
a. One 14" dia. Nitrate Recycle Flow meter is provided in the pump station discharge
header to measure, indicate and totalize the nitrate recycle flow to Anoxic Reactor #1.
L CONVERT EX. SCHREIBER TANK INTO NITRIFICATION REACTOR #2
(Modirication)
1. General
a. The existing 160 ft diameter x 18 ft tall x 16.0 ft side water depth, 2.4 MG volume
Schreiber Tank will be modified to operate as Nitrification Reactor #2 for second
stage aerobic activated sludge treatment to accomplish final carbonaceous BOD
removal and ammonia nitrogen removal by biological nitrification.
b. The TKN and ammonia nitrogen in the Reactor #2 influent is converted to nitrate
nitrogen by the biological nitrification process achieved in Reactor #2. Over 80% of
the nitrates produced in Reactor 42 are recycled back into Anoxic Reactor 41.
2. Design Assumptions
a. Wastewater Flow
1) Average wastewater flow volume = 0.85 MGD, 7 days/week
2) Maximum wastewater flow volume = 1.0 MGD
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 16

b. Pollutant Concentrations and Loadings
1) Maximum daily pollutant concentrations and loadings in influent from Reactor # 1
@ 1.0 MGD and average daily pollutant concentrations and loadings in the
influent from Reactor #1 @ 0.85 MGD:
Pollutant
Concentration
Loading
Average
Maximum
Average
Maximum
BODO)
< 50 mg/L
< 75 mg/L
354 #/day
625#/day
TKN(2)
< 135 mg/L
<_ 170 mg/L
957 #/day
1,418#/day
Assumes 85% BOD removal in Anoxic Reactor # 1
cz� 3% nitrogen uptake in biomass
3. Nitrification Reactor #2 Design Calculations
a. Volume available in existing 160 ft diameter x 18 ft tall x 16.0 ft side water depth
Nitrification Reactor #2 = 2.4 MG
b. Calculate MLVSS and MLSS concentrations required in the Reactor #2 for BOD and
TKN removal at the minimum expected summer season mixed liquor operating
temperature of 25°C assuming at the maximum daily wastewater flow volume = 1.0
MGD:
1) MLSS required for BOD removal assuming a carbonaceous BOD removal rate =
0.50#BOD/#MLVSS @ 25°C and 85% BOD removal in upstream Reactor #1
625#BOD/day
0.50 _< 1,300# MLVSS @ 250C
2) MLVSS required for TKN removal assuming a nitrification rate = 0.07#TKN
/#MLVSS @ 250C
1,418#TKN/day
0.07 < 20,300#MLVSS @ 250C
3) Required MLVSS and MLSS concentrations in the existing 2.4 MG Reactor #2
for BOD removal and nitrification at the minimum expected summer season
mixed liquor operating temperature = 250C assuming MLVSS/MLSS = 0.85
1,300# + 20,300#
(0.85) _< 26,000# MLSS
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
17

26,000#
8.34(2.4 MG) = 1,300 mg/L MLSS @ 25°C
<_ 2,000 mg/L MLSS @ 25°C
c. Calculate MLVSS and MLSS concentrations required in the Reactor #2 for BOD and
TKN removal at the minimum expected winter season mixed liquor operating
temperature of 15°C and the maximum TKN and BOD Loadings:
1) MLSS required for BOD removal assuming a carbonaceous BOD removal rate =
0.35#BOD/#MLVSS @ 15°C and 85% BOD removal in upstream Reactor #1
625#BOD/day
0.35 <_ 1,800# MLVSS @ 15°C
2) MLVSS required for TKN removal assuming a nitrification rate = 0.05#TKN
/#MLVSS @ 15°C
1,418#TKN/day
0.05 < 28,400#MLVSS @ 15°C
3) Required MLVSS and MLSS concentrations in the existing 2.4 MG Reactor #2
for BOD removal and nitrification at the minimum expected winter season mixed
liquor operating temperature = 15°C assuming MLVSS/MLSS = 0.85
1,800# + 28,400#
(0.85) < 36,000# MLSS
36,000#
8.34(2.4 MG) < 1,800 mg/L MLSS @ 15°C
d. Assume MLSS concentration _< 3,000 mg/L in both activated sludge reactors during
winter seasons for conservative design approach.
e. Calculations indicate that BOD removal by biological synthesis of carbonaceous
matter and TKN removal by biological nitrification to < I mg/L will be attained in the
2.4 MG Reactor #2 system down to a basin mixed liquor temperature of 15°C @
3,000 mg/L MLSS during the winter season.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 18

4. Nitrification Reactor #2 Mixing and Aeration Equipment Design
a. Calculate Mixing Requirements in Nitrification Reactor #2:
1) scfm required for mixing a 3,000 mg/L to 6,000 biological MLSS concentration =
20 scfm/kcf
scfm required = 20 HP(320 kcf) < 6,400 scfm
2) Three (3) existing 60 HP positive displacement blowers each rated at 1,100 scfm
@ 8.0 psi and one (1) new 60 HP positive displacement blower rated at 1,100
scfm @ 8.0 psi are provided for complete mixing in the Nitrification Reactor #2.
b. Calculate the Maximum Oxygen Transfer Requirements in Nitrification Reactor #2 at
the maximum daily influent flow volume of 1.0 MGD and influent BOD = 75 mg/L.:
1) For synthesis of BOD remaining in the Reactor #2 effluent assuming an oxygen
demand of 0.60#02/#BOD:
0.60#02/#BOD(625#B OD/day)
AOTRI= 24=16#02/hr
2) For endogenous respiration of biomass in Nitrification Reactor #2 assuming an
oxygen demand of 0.80#02/#BOD and approximately 80% of total biomass in
Reactor #2:
0.80#02/#BOD(4,170#BOD/day)(0.80) —
AOTR2= 111 #02/hr
24 —
3) For nitrification of ammonia assuming an oxygen demand of 4.57#02/#TKN
nitrified in Reactor #2:
AOTR3=4.57#02/#TKN(1,418#TKN nitrified/day) — 270#02/hr
24
4) Total Maximum oxygen transfer requirement in Reactor #2:
AOTR (total) = 16#02/hr + 111 #02/hr + 270#02/hr
<— 400 #02/hr
c. Calculate the Average Oxygen Transfer Requirements in Nitrification Reactor #2 at
the average daily influent flow volume of 0.85 MGD and an influent BOD = 50
mg/L:
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 19

1) For synthesis of BOD remaining in the Reactor #2 effluent assuming an oxygen
demand of 0.60#02/#BOD and 85% BOD removal in Reactor #1:
0.60#02/#BOD(3,190#BOD/day)(0.15)
AOTR � = =12#02/hr
24
2) For endogenous respiration of biomass in Nitrification Reactor #2 assuming an
oxygen demand of 0.80#02/#BOD and approximately 80% of total biomass in
Reactor #2:
0.80#02/#BOD(3,190#BOD/day)(0.80)
AOTR2= = 85#02/hr
24
3) For nitrification of ammonia assuming an oxygen demand of 4.57#02/#TKN
nitrified in Reactor #2:
4.57#02/#TKN(957#TKN nitrified/day)
AOTR3= —182#02/hr
24
4) Total Average oxygen transfer requirement in Reactor #2 @ the average flow
volume = 0.85 MGD:
AOTR (total) = 12#02/hr + 85#02/1117 + 182#02/hr
= 279#02/hr <— 300#02/hr
d. Calculate the required corresponding maximum standard oxygen transfer rate
required:
Css
SOTR = AOTR GXMr DO) a1.024) T-21
Where DO = 2.0 mg/L (DO in Nitrification Reactor #2)
b = 0.95
a = 0.6 @ 3,000 to 6,000 mg/L MLSS with fine bubble diffusers
1.024(T-20) = 1.267 @ average T = 300C
Cw = 7.63 @ sea level, 30°C
Cs = 9.2 @ sea level, 200C
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 20

Site Altitude < 1,000 feet
Pressure
Correction Factor = 0.964
Csw = 7.63(0.964) [(14.7)+ (0.5)(0.433)(15L
14.7
7.63(0.964)(1.22) = 8.98 mg/L
CSs = 9.20 r14.7+ (0.5)(0.433)(15)*]
L 14.7
9.20 (1.22) = 11.22
* Diffuser center line depth = 15 ft. in the 16 foot side water depth with the diffusers
at 12 inches above the basin floor.
11.22
SOTR = AOTR [(0.95)(8.98)-2.0]0.6(1.267)
SOTR < 2.3 (AOTR)
SOTR < 2.3(400)
SOTR < 920#02/hr
e. Calculate subsurface aeration equipment air sparging requirements:
1) The oxygen available per cfm per hour =
X = 0.23 (0.075#/ft3)(60 min/hr)
= 1.035#02/cfm/hr @ 687 inlet air
2) Subsurface diffuser oxygen stripping or transfer efficiency at 16 ft. side water
depth in the fine bubble diffusers = 21 %
3) scfm required = SOR
(x)(e)
scfm = 920#02/HR
(1.035)(0.21) = 4,232 scfm
scfm < 4,400 scfm
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 21

4) Max. design compressor pressure with maximum 15 ft. diffuser air sparge
submergence:
_ (15 ft.)(0.433) + 1.5 psi < 8.0 psi (pressure loss plus pressure drop in air supply
lines and in diffusers
f. Oxygen transfer and mixing is provided by existing fine bubble diffuser tubes
mounted on the rotating aeration bridge. The total maximum air sparging capacity of
the diffuser tubes = 4,400 scfm. Air can be supplied by operating the four 60 HP
positive displacement blowers each rated at 1,100 scfm @ 8.0 psi. With three
blowers in operation, the air sparging rate = 3,300 scfm and the oxygen transfer rate >
690 #02/hr (SOTR) = 300 #O2/hr (AOTR). With four blowers in operation, the air
sparging rate = 4,400 scfm and the oxygen transfer rate > 920 #O2/hr (SOTR) = 400
#02/hr (AOTR).
g. A total of three (3) existing 60 HP positive displacement blowers each rated at 1,100
scfm @ 8.0 psi and one (1) new 60 HP positive displacement blower rated at 1,100
scfm @ 8.0 psi are provided for complete mixing in the Nitrification Reactor #2.
5. Instrumentation and Controls
a. An existing DO Sensor is provided in Nitrification Reactor #2. The DO sensor is
used to provide automatic control of the air supply blowers for Reactor #2.
b. An existing pH sensor is provided in Nitrification Reactor #2. The pH sensor is used
to provide pH indication for manual control of the magnesium hydroxide feed pumps
to maintain the pH value in the Reactor #2 at an acceptable range for biological
treatment.
6. Evaluate Sludge Wasting Requirements from the Activated Sludge Process
a. Calculate waste activated sludge production at the maximum daily BOD loading rate
and at average MLSS concentration of 4,000 mg/L:
1) F/M = 4,170#BOD/day
(4,000 mg/L)(2.9 MG)(8.34)
< 0.05#BOD/#MLVSS
2) Y = Expected Activated Sludge Production Rate @ 0.05 F/M ratio
0.50#waste sludge/#BOD
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
22

3) # Waste Sludge = (0.50)(4,170)
< 2,100#/day
4) The calculated volume of waste activated sludge (WAS) to be wasted from the
Final Clarifier at 10,000 mg/L average sludge concentration =
2,100#/day
(0.010)(8.34) < 26,000 gpd, 7 days/week <_ 20 gpm (over 24 hrs / day)
5) WAS will be pumped from the Final Clarifier to the New Waste Sludge Storage
Tank.
J. FINAL CLARIFIER (Existing)
1. Design Assumptions
a. Wastewater Flow
1) Average daily throughput flow volume = 0.85 MGD
2) Maximum daily throughput flow volume = 1.0 MGD
3) Average inflow rate with 100% sludge recycle rate = (0.85 MGD)(2) <_ 1.7 MGD
4) Average inflow rate with 200% sludge recycle rate = (0.85 MGD)(3) < 2.55 MGD
5) Maximum inflow rate with 100% sludge recycle rate = (1.0 MG13)(2) < 2.00
MGD
6) Maximum inflow rate with 200% sludge recycle rate = (1.0 MGD)(3) <_ 3.0 MGD
b. Pollutant Concentrations and Loads
1) Mixed liquor solids loadings rate at the maximum design throughput flow rate =
1.0 MGD and with 100% sludge recycle rate @ 6,000 mg/L MLSS concentration
(1.0 MGD)(6,000 mg/L)(8.34)(2.0)/24 = 4,170#/hr.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 23

2) Mixed liquor solids loadings rate at the maximum design throughput flow rate =
1.0 MGD and with 200% sludge recycle rate @ 6,000 mg/L MLSS concentration
(1.0 MGD)(6,000 mg/L)(8.34)(3.0)/24 = 6,255#/hr.
2. Calculate Clarifier Loading Rates
a. One existing 78 ft. diameter x 13.0 ft. side water depth final clarifier is provided with
bottom scrapper sludge removal mechanism, surface skimmer and scum box.
b. The 78 ft. dia. circular clarifier will have an effective surface overflow diameter = 74
feet, an effective surface overflow area = 4,300 ft2; and an effective clarifier floor
area = 4,778 ft2
c. Clarifier Volume = 464,700 gallons
d. Maximum Hydraulic Surface Loading Rate (HSLR)
HSLR = 1,000,000 gpd
4,300 ft2
< 233 gpd/ft2 @ maximum design throughput flow rate = 1.0 MGD
e. Maximum Solids Loading Rate (SLR) assuming an influent flow rate = 1.00 MGD
and a 100% sludge recycle rate with a MLSS concentration _< 6,000 mg/L
SLR = (1.0 MGD)(2)(8.34)(6,000 mg/L)
4,778 ft2
< 21 #/ft2/day
f. Minimum hydraulic detention time (HDT) assuming an influent flow rate = 1.0 MGD
and a 100% sludge recycle rate
HDT = (464,700 gallons)(24)
(1,000,000) (2)
5.6 hours
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 24

K. SLUDGE RETURNAND WASTE SLUDGE PUMP STATION (Modit<cation)
1. Two existing 3 HP screw sludge return pumps are provided in the Sludge Return Pump
Station located adjacent to the Final Clarifier. The pumps are provided to recycle
activated sludge from the Final Clarifier to Reactor #2. Each pump is rated at 1,050 gpm
which is equivalent to a sludge recycle rate = 150% of the maximum throughput flow rate
= 700 gpm = 1.0 MGD.
2. One sludge return pump will normally be operated to provide a sludge recycle rate = 50%
to 100% of the maximum throughput flow rate = 1.0 MGD. Two sludge return pumps
can be operated in parallel to provide a sludge recycle rate up to 300%. The second
sludge return pump is provided as a standby sludge return pump.
3. The two existing submersible Waste Activated Sludge (WAS) pumps will be replaced
with two new larger capacity pumps in the existing wet well to pump WAS to the Waste
Sludge Storage Tank. Each new pump is rated at 200 gpm @ 60' TDH. Normally, one
pump will operation and the second is provided as an installed standby. Each new pump
will be provided with a variable frequency drive for manual speed control.
4. One existing magnetic flow meter is provided on the waste sludge line to indicate and
totalize the waste activated sludge discharge rate and volume wasted to the Waste Sludge
Storage Tank.
L. WASTE SLUDGE STORAGE TANK (WSST) (New)
1. General
a. One New Waste Sludge Storage Tank (WSST) is provided for storage and thickening
of Waste Activated Sludge (WAS).
b. WAS flow volume will be pumped from the sludge recycle flow of the existing
gravity Final Clarifier into the new WSST for storage and thickening of WAS.
Thickened WAS will be pumped from the WSST to the new Belt Press for
mechanical dewatering.
2. WSST Design
a. One new 34 ft. dia. x 18 ft. tall x 16 ft. maximum liquid depth, 100,000 gallon
volume Waste Sludge Storage Tank (WSST) will be provided for gravity thickening,
decanting and storage of waste activated sludge prior to sludge dewatering by belt
presses followed by ultimate disposal by land application.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
25

b. Evaluate Mixing and Aeration requirements in WSST:
1) Mixing Requirements
a) Maximum Tank Volume = 100,000 gallons = 14 x 103 ft3
b) scfm required for mixing 1 % to 2% TSS concentration = 40 scfm / 1,000 cf
scfm required = 40 scfm (14) < 560 scfm
c) Two new 50 HP positive displacement blowers each rated at 600 scfm @ 9.0
psi will be provided to keep the contents of the tank completely mixed. One
blower will be normally operated and the second blower provided as an
installed stand-by.
2) Aeration Requirements
a) At the average pollutant loading concentration, assume an average oxygen
uptake rate in the WSST of 0.20#02/#BOD. The average BOD loading at
0.85 MGD and 450 mg/L BOD concentration = 3,190#BOD/day. The oxygen
transfer rate required to maintain aerobic conditions in WSST Tank assuming
an oxygen uptake rate of approximately 0.20#02/#BOD, is calculated as
follows:
AOTR = 0.20#02/#BOD(3,190#BOD/day)
24
= 27#02/hr < 30#02/hr
b) Calculate the required corresponding maximum standard oxygen transfer rate
required:
SOTR = AOTRI
( SIP
CSS I
- DO) a (1.024) T-21 J
Where DO = 1.0 mg/L (average DO in WSST)
B = 0.95
a = 0.60 @ < 2% TSS with subsurface
coarse bubble jet aeration diffusers
1.2677(T-20) = 1.209 @ maximum T = 300 C
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 26

Cw = 7.63 mg/L @ sea level, 300 C
Cs = 9.20 mg/L @ sea level, 20'0 C
Site Altitude < 500 feet
Pressure
Correction Factor > 0.992
Csw = 7.63 (0.992)(14.7) + (0.5)(0.433)(10)
14.7
7.63 mg/L(1.191) = 9.09 mg/L
Css = 9.20 14.7 + (0.5)(0.433)(10)
14.7
Css = 9.20 mg/L(1.199) = 11.03 mg/L
10 foot average depth WSST with the coarse bubble diffusers installed 1.0
above the basin floor.
11.03
SOTR = AOTR [(0.95)(9.09)-1.0]0.60(1.209)
SOTR = 2.0 (AOTR)
SOTR < 2.0 (AOTR)
SOTR < 2.0 (30) < 60#02/hr
c) Calculate subsurface aeration equipment air sparging requirements:
(1) The oxygen available per cfm per hour =
x = 0.23 (0.075#/ft3)(60 min/hr)
= 1.035#02/cfm/hr @ 68° inlet air
(2) e = subsurface diffuser oxygen stripping or transfer efficiency at 16 ft.
maximum air sparge depth = 12%
(3) scfm required = SOTR
(x)(e)
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 27

scfm (average) = 60#02/HR
(1.035)(0.12) < 570scfm
< 600 scfm
(4) Max. design blower pressure with 16 ft. maximum liquid depth in WSST
tank — 1.0 ft. diffuser height above tank floor = 15 maximum diffuser
submergence:
= (15 ft.)(.433) + 1.5 psi < 8.0 psi (pressure loss plus pressure drop in air
supply lines and in air grid air diffuser sparges)
c. A new tide flex coarse bubble diffused aeration header system will be installed in the
WSST for oxygen transfer and mixing with 48 coarse bubble diffusers.
d. Compressed air is supplied to the diffuser system in the WSST by operation of two
new 50 HP positive displacement (PD) blowers each rated at 600 scfm @ 9.0 psi.
M. BELT PRESS SLUDGE DEWATERING SYSTEM (New)
1. General Description
a. One new 1.0 meter BDP Model 3DP-1 belt filter press will be installed in the existing
DAF Building and used to mechanically dewater waste activated sludge prior to
ultimate disposal of dewatered sludge by off -site disposal.
b. One new 1.0 meter BDP belt filter press is provided, rated at 150 gpm sludge flow
capacity and 1,500#/hour solids loading capacity (dry basis).
2. Waste Sludge Volume and Water Content
a. Waste Activated Sludge Volume and Dry Weights
1) The estimated maximum daily waste activated sludge volume = 26,000 gpd @
1.0% solids
2) The estimated maximum waste activated sludge dry weight < 2,100#/day
3. Belt Press Design Operation
a. One 1.0 meter belt filter press and gravity belt thickener will be used for sludge
dewatering. The belt press is rated at an influent sludge feed rate of 2000 gpm flow
capacity and 1,000-1,500#dry solids/hr. Operation of the belt press for one shift 5
days per week of up to 4 hours/day is required to dewater the estimated maximum
waste sludge volume of 2,100#dry solids/day.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
28

b. Calculated belt press operation time @ 5 days per week:
2,100#ds/day :54 hrs/day
1,000(,7)
c. Calculated belt press feed rate:
26,000 gpd t7_-Z 160 gpm
(4 hr)(60) 5
4. Belt Press Sludge Feed Pump
a. One new Belt Press Feed Pump pre -piped and mounted on the Belt Press skid will be
used to pump WAS from the WSST to the Belt Filter Press. The pump is provided
with a variable frequency drive to allow the feed rate to the belt presses to be
manually set or automatically controlled to maintain a constant feed rate to the belt
press.
b. One new 5 HP progressive cavity positive displacement sludge pump is provided
rated at 200 gpm @ 69 ft. (30 psi) TDH.
c. One new 4" magnetic flow meter is provided in the belt press sludge feed line to
accurately measure, indicate and totalize the sludge flow pumped to the Belt Press.
5. Dewatered Sludge Cake Storage
a. Dewatered sludge will discharge from the Belt Press by an auger to storage trailer
prior to hauling off -site for ultimate disposal.
6. Belt Press Filtrate Disposal
a. Filtrate wastewater discharged from the Belt Press will flow by gravity to the new
plant site drain pump station.
7. Chemical Storage -Feed Equipment for Belt Press Sludge Dewatering System
a. For polymer flocculation of sludge being pumped into the Belt Press, the following
chemical feed equipment is provided:
1) One polymer solution make-up/ pumping system rated at 0 to 4 gphr neat polymer
with 0-240 gphr dilution water capacity are provided for dosage of polymer
solution into the sludge flow pumped into the Belt Press. The neat polymer pumps
have automatic variable speed drives where the dosage rate can be automatically
controlled.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
29

8. Dewatered Sludge Volume and Water Content
a. The estimated average sludge volume of 26,000 gpd @ 1.0% solids concentration
will be dewatered by the Belt Press to approximately 15% to 18% solids
concentration depending upon sludge temperature, polymer flocculent dosage
efficiency, and biological solids dewatering characteristics.
b. The estimated average dewatered waste activated sludge cake volume for ultimate
disposal =
(2,100#/day)0.95 x (7/5)
(0. 1 5)(10.4#/gal)
< 11800 gpd = 19,000#/day < 9.5 Yd3/day (5 days per week of Belt Press Operation)
assuming a belt press solids capture efficiency of 95%, a dewatered sludge solids
content of approximately 15% and an average dewatered sludge weight of 10.4#/gal =
78#/ft3 = approximately 2,000#/Yd3.
9. Belt Wash System
a. The belt press skid will use non -potable water to automatically wash the filter belts.
Each of the belts is provided with a belt wash spray bar/nozzle assembly to clean the
full width of the belts after the sludge cake has been discharged.
b. The total water demand for the belt wash system is 50 gpm of non -potable reuse plant
water.
c. A 15 HP booster pump is provided pre -piped and mounted on the belt press skid to
boost the washwater pressure to a minimum of 120 psi.
10. Belt Tracking System
a. The belt filter press is provided with an automatic hydraulic belt tracking and
alignment system. Each belt is provided with a tracking sensor that will send a signal
to the control panel.
b. A 3.0 HP hydraulic power unit with a 20 gallon receiver tank is provided pre -piped
and mounted on the belt press skid to provide the required hydraulic capacity for the
tracking system.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
30

N. PLANT SITE DRAIN PUMP STATION (New)
1. Design Assumptions
a. WSST Decant Flow Rate
1) Design maximum tank drain flow rate _< 150 gpm.
b. Belt Filter Press Drainage Waste Water
1) Washwater usage = 50 gpm
2) Maximum Belt Press filtrate waster volume <_ 200 gpm
3) Total Belt Press Drainage flow rate = 250 gpm
c. Maximum Flow Rate to Pump Station = 400 gpm
2. Pump Selection
a. Two constant speed drive 10 HP submersible sewage pumps are provided rated at 400
gpm @ 40 feet total head
b. Operation of one pump is required to pump a flow rate = 400 gpm to Anoxic Reactor
#1.
c. The second pump is provided as an installed standby. Automatic Lead and Standby
pump operation with automatic pump sequence alternator is provided.
d. Both pumps will be provided with automatic on -off liquid level controls from the
pump station wet well and HWL Alarm.
O. CHEMICAL STORAGE -FEED EQUIPMENT FOR ACTIVATED SLUDGE PROCESS
(Existing)
1. The following equipment is provided for mixing, storage and pumping chemical solutions
that are necessary for operation of the Activated Sludge BNR Treatment System and
Final Clarifier:
a. For pH adjustment of mixed liquor contained in the Nitrification Reactor #2 to
maintain the activated sludge nitrification process mixed liquor pH between 7.2 to 8.2
units; and to maintain the final effluent pH above 6.0 units:
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 31

1) One existing 10' dia. x 9'-6" tall, 5,300 gallon bulk storage tank with a 3 HP
vertical shaft impeller mixer is provided for storage of commercially purchased,
pre -mixed 62% strength magnesium hydroxide solution. Magnesium hydroxide
solution will be dosed into the Reactor #2 to maintain mixed liquor pH above 6.8
units in the biological nitrification process.
2) Two existing magnesium hydroxide (MgH) solution pumps with automatic stroke
drives are provided each rated at 1 - 20 gphr @ 60 psi to dose MgH solution into
the 1.0 MGD maximum design flow rate pH adjustment. One pump @ 20 gphr
will inject MgH at a rate of over 3,800#/day > 450 mg/L (dry basis) into Reactor
#2 for pH control. A second MgH pump is provided for parallel operation, as an
installed standby.
3) Calculated MgH dosage rate for nitrification of 1,418# of TKN @ 7.0# alk/#TKN
when partial biological denitrification is achieved in the Reactor #1.
a) (1,418#NH3 -N) nitrified/day x 7.0# alk/#TKN
< 9,930#alk/day
b) estimated alkalinity available in AL effluent wastewater = (1,000
mg/L)(8.34)(1.0 MGD) <_ 8,340#/day
c) required alkalinity in effluent = (200 mg/L)(8.34)(1.0 MGD) =1,670 #/day
d) @ 1.7# CaCO3 alk/# MgH solution
9,930# - 8,340# + 1,670# < 1,920# MgH/day
1.7# MgH/#alk
Conservatively assumes no alkalinity recovery from denitrification process.
Denitrification process will recover approximately 3.0#alk per #NO3-N
denitrified.
e) @ 62% maximum MgH solution strength the MgH solution volume required
per day and solution dosage rate required/hr =
1,920#/day
0.62 (12.8#/gal) = 240 gpd
< 10 gal/hr
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
32

b. For dosage of organic Carbon Source Solution for carbonaceous BOD feed into
Anoxic Reactor #1 and/or Nitrification Reactor #2 for denitrification process control
and removal of nitrate nitrogen.
1) Non -Flammable carbon source (CS) solution make up and pumping equipment is
provided for dosage of CS into the mixed liquor in Anoxic Reactor #1 and/or
Anoxic Reactor #2. CS solution would be dosed into Reactor #1 and/or Reactor
#2 (during Anoxic cycle) only if insufficient BOD carbon source is available in
the blended raw wastewater to accomplish the required nitrate nitrogen and total
nitrogen removal efficiency.
2) One existing 6,000 gallon bulk storage tank is provided for organic carbon source
(CS) storage. Carbon source solution will be pumped into the Anoxic Reactor #1
influent line.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc.
33

,m
P. EXPECTED FINAL EFFLUENT QUALITY
1. Carbonaceous BOD removal by biological treatment; TKN and ammonia nitrogen
removal by biological nitrification will be accomplished by the two -stage BNR AS
treatment system.
2. The following average daily pollutant concentrations and loadings that are expected in
the final effluent discharge to outfall 001 that is treated through the wastewater treatment
system:
Pollutant
Expected Effluent
Quality
Permit Limits
Monthly
Average
Daily
Max.
Monthly Average
Daily Maximum
mg/L
mg/L
mg/ L
#/day
mg/ L
#day
cBOD
< 5
< 1.0
5
N/A
10
N/A
TSS
< 10
< 20
20
N/A
30
N/A
O & G
< 5
< 10
8
N/A
14
N/A
TKN
< 3
< 5
N/A
N/A
N/A
N/A
Ammonia
< 1
< 2
1
N/A
2
N/A
Total Nitrogen
< 85
< 100
103
N/A
147
NIA
pH
6.5 to 7.5 s.u.
6 to 9 s.u.
Final Design Summary
Wastewater Treatment System Upgrade
PILGRIMS PRIDE — Sanford, North Carolina
Prepared by Reid Engineering Company, Inc. 34

10
pilgriny,so
April 27, 2016
Via Certified Mail 7013 2250 0001 9970 7797
7013 2250 0001 9970 7803
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S 15-002
Quarterly Report
To whom it may concern:
report.
RECEIVEDINCDEQIDWR
MAY 0 4 2A
Water Qua""
Permitting Section
Pursuant to Special Order by Consent 2.d., Pilgrim's is providing this quarterly progress
Activities Undertaken and Completed
Pilgrim's has completed the Treatment Unit Investigation, engineering design
and bidding of the project.
On February 12, 2016 Pilgrim's awarded a contract for installation of piping and valve
connections to the existing concrete aeration tank which was completed in March. On April 25,
2016 Pilgrim's issued a letter notifying a contractor of award of contract for the remainder of the
wastewater upgrade project. Pilgrim's anticipates additional construction activities proceeding
during the month of May or June.
We paid the up -front penalty and have met with our consultant to begin work on the
Solids Management Plan. A meeting with the City of Sanford occurred to discuss potential for
them to treat our wastewater. We concluded it was not logistically or economically feasible to
connect to the city system.
tel [phone]

Compliance
Pilgrim's has been in compliance with the Permit Limits and Interim Limits since the
February 5, 2016 effective date of the SOC.
Pilgrim's had a wastewater spill to an on -site pond on March 5, 2016. The spill was
contained and properly cleanup. It was reported to the state and an NOV was received dated
March 30, 2016 (NOV-2016-PC-0097).
In addition, please revise the main SOC contact information. Brent Glasgow is no
longer associated with the Sanford plant. The new Vice President over the Sanford operation is
Kyle Bolin. Kyle is located in our Greeley, Colorado office at the same address as on this letter
head. I can continue to be the main point of contact for Pilgrim's.
Please contact me by phone at 970-347-5730 or via e-mail at
[e-mail] should you have any questions.
Sincerely,
Dave Townsend
VP Environmental

a0
pilgrim-s--
April 27, 2016
Via Certified Mail 7013 2250 0001 9970 7780
7013 2250 0001 9970 7810
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S 15-002
Scheduled Events
To whom it may concern:
RECEIVEDINCDEQIDWR
MAY 0 4 2016
Water Quality
Permitting Section
Pursuant to Special Order by Consent 2.c., Pilgrim's has completed the following events:
Treatment Unit Investigation
The treatment unit investigation and design engineering have been completed. Attached
is a copy of the report by Reid Engineering titled Final Design Summary of Wastewater
Treatment Upgrade dated April 26, 2016.
Connection to the City of Sanford
Pilgrim's met with the City of Sanford Public Works Director regarding the potential for
the city to treat all or a portion of our wastewater. Connection to the city would require lengthy
pipelines and right-of-way acquisition requiring considerable time and expense. In addition, we
would need to also connect to the city water system in order to obtain sewer service. The costs
for water and sewer service, including surcharges for industrial strength waste, would far exceed
our own costs of wastewater treatment. We concluded that connection to the city was neither
logistically or economically feasible.
tel [phone]

Award Contract, Begin Construction
On February 12, 2016 Pilgrim's awarded a contract for installation of piping and valve
connections to the existing concrete aeration tank which was completed in March. On April 25,
2016 Pilgrim's issued a letter notifying a contractor of award of contract for the remainder of the
wastewater upgrade project. Pilgrim's anticipates additional construction activities proceeding
during the month of May or June.
Please contact me by phone at 970-347-5730 or via e-mail at
[e-mail] should you have any questions.
Sincerely,
Dave Townsend
VP Environmental

pilgrim -,so
Via Certified Mail 70140150000187824693
70140150000187824815
March 14, 2016
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S 15-002
To whom it may concern:
RECENEDINCDEO&NR
MAR 31 2016
Water Quality
ion
Permitting Sec
Pursuant to Special Order by Consent 2.c., Pilgrim's received a quote for the wastewater
upgrade project prior to March 1, 2016.
During design of the project, we encountered a high groundwater table in the area of a
planned new anaerobic lagoon. This resulted in a decision to keep the existing anaerobic lagoon
in service and add a belt press and associated sludge tank, building and pumps stations. Reid
Engineering issued the revised project to bidders on February 22 and final bids are due on March
24, 2016.
Please contact Tina Pedley by phone at 919-895-3457, or via e-mail at
[e-mail] should you have any questions.
Sincerely,
LSi: on
Complex Manager
tel [phone]

pilgrim-PSCE)
Via Certified Mail 70140150000187824693
70140150000187824815
March 14, 2016
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
Supervisor, Compliance & Expedited Permits Unit
NC Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh NC 27699-1617
Re: Pilgrim's Pride Corporation, Sanford, NC
Special Order by Consent
EMC SOC WQ S 15-002
To whom it may concern:
RECEIVEDINCDEOIDWR
MAR 31 Z016
Water Quality
Permitting Section
Pursuant to Special Order by Consent 2.c., Pilgrim's paidthe Up -Front Peanity Payment
via Certified Mail: 7014 1200 0002 2222 9903.
Please contact Tina Pedley by phone at 919-895-3457, or via e-mail at
[e-mail] should you have any questions.
Sincerely,
Tim Singleton
Complex Manager
tel [phone]

PAT MCCRORY
Wa ter Resources
ENVIRONMENTAL QUALITY
February 8, 2016
Brent Glasgow, Vice President
Pilgrim's Pride Corporation
494 Zimmerman Road
Sanford, North Carolina 27330
DONALD R. VAN DER VAART
S. JAY ZIMMERMAN
Subject: SPECIIAL ORDER BY CONSENT
EMC SOC WQ S15-002
Pilgrim's Pride Corporation WWTP, Class 3
EMC SOC WQ S15-002
NPDES Permit NCO072575
Lee County
Dear Mr. Glasgow:
The Division of Water Resources (DWR) hereby transmits for your records a copy of the signed Special
Order by Consent (SOC or the Order) approved by the Environmental Management Commission (EMC).
The terms and conditions of the Order are now in full effect, including those requiring submittal of
written notice of compliance or non-compliance with any SOC schedule date. To cover water -quality
maintenance costs, SOC fees have been revised to include a $500.00 annual fee, pursuant to North
Carolina General Statute 143-215.3D. DWR will invoice Pilgrim's Pride at a later date, with future SOC
fees invoiced annually.
If you have questions, please contact the operations staff at DWR's Raleigh Regional Office at (919) 791-
4200, or contact me in the central office, Joe Corporon [[e-mail]] at [phone].
Attachment: Copy EMC SOC WQ S15-002
cc: Central Files
NPDES Unit— SOC File S15-002
RRO Danny Smith, SWQP Supervisor
cc: RRO Danny Smith
State of North Carolina I Environmental Quality I Water Resources
1611 Mail service Center I Raleigh, North Carolina 27699-1611
919 707 9000

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
COUNTY OF LEE
IN THE MATTER OF )
NORTH CAROLINA )
NPDES PERMIT NC0072575 ) SPECIAL ORDER BY CONSENT
EMC SOC NO. S 15-002
HELD BY )
PILGRIM' S PRIDE CORPORATION )
Pursuant to provisions of North Carolina General Statute (G.S.) 143-215.2, this Special Order by
Consent is entered into by Pilgrim's Pride Corporation, hereinafter referred to as Pilgrim's Pride,
and the North Carolina Environmental Management Commission, an agency of the State of North
Carolina created by G.S. 143B-282, and hereinafter referred to as the Commission:
1. Pilgrim's Pride and the Commission hereby stipulate the following:
a. Pilgrim's Pride holds North Carolina NPDES permit NC0072575 ("Permit") for
operation of an existing wastewater treatment plant ("WWTP") at its Sanford, North
Carolina facility, and for making an outlet therefrom for treated wastewater to the Deep
River, a Class C water of this State in the Cape Fear River Basin.
b. Pilgrim's Pride is unable to consistently comply with the final effluent limits for Total
Nitrogen ("TN") and Ammonia Nitrogen ("NH3 as N") as set forth in Permit. Effluent
limits for these (and other) parameters have been exceeded since September 2013 in the
manner and to the extent as shown in Attachment B to this Order.
c. Pilgrim's Pride is within the jurisdiction of the Commission asset forth in G.S. Chapter
143, Article 2.
d. Compliance with the Permit will require preparation and implementation of a plan for
WWTP upgrades. Pilgrim's Pride has funding for planning, and has retained an
environmental and civil engineering consultant to design upgrades to its WWTP which,
once constructed and operated, will be sufficient to adequately convey and treat
wastewater in compliance with final effluent limits.
2. Pilgrim's Pride, desiring to comply with the Permit, hereby agrees to do the following:
a. As settlement of all known NPDES limit violations of the Permit occurring prior to
entering into this Special Order by Consent, pay an up -front penalty in the amount of
$10,000.00 and $382.15 in costs totaling $10,382.15. A certified check in the amount of
$10,3 82.15 must be made payable to the Department of Environmental Quality and
forwarded to the Director of DWR at 1617 Mail Service Center, Raleigh, North Carolina
27699-1617 by no later than ninety (90) days following the date on which this Order is
approved and executed by the Commission and received by Pilgrim's Pride.

Pilgrim's Pride Corporation
EMC SOC WQ S 1 5-002
Page 12
b. Undertake the following activities in accordance with the indicated time schedule listed
below in Table 1. Event Schedule:
(1.) Treatment Unit Investigations. Conduct investigations into available treatment
operations, measures, or technologies that once constructed, will treat wastewater to
such an extent that the discharge from the Pilgrim's Pride facility will comply with
appropriate final effluent limits. Pilgrim's Pride must communicate in writing the
results of the investigations whereby a report of the proposed treatment unit
changes will illustrate how the reduction of the pollutants will be achieved.
(2.) Connection to the City of Sanford. Conduct an investigation to determine the
availability, suitability, and the willingness of the City of Sanford to accept and
treat all or portions of the Pilgrim's Pride facility process wastewater. If these
investigation efforts support this approach, Pilgrim's Pride will need to conduct
further investigation into technologies, sewer extensions, and pretreatment
requirements that may be needed for the Pilgrim's Pride facility to eliminate their
discharge or reduce their waste load such that Pilgrim's Pride facility will be able to
achieve compliance with appropriate final effluent limits. Pilgrim's Pride must
communicate in writing the results of the investigations detailing why this approach
is or is not appropriate to pursue in order to achieve compliance.
(3.) Solids Management Plan
Within 180 days of signature date of this agreement, Pilgrim's Pride will provide a
Solids Management Plan for this facility. The plan must include the following:
i. The current sludge inventory and current storage capacity for the Pilgrim's
Pride facility.
ii. Actions to determine sludge depth and monitor characteristics sufficient to
evaluate removal options (dewatering and/or stabilization if needed) and proper
disposal of solids as needed to provide adequate volume for proper operation of
the treatment units. Sludge depths and characteristics will be determined every
6 months for the first 24 months of plan implementation.
iii. Strategies and action items associated with the management of existing solids,
solids generated in the future, and solids that will be generated from any new
treatment units that may be constructed as a part of this order, including
performance thresholds mandating implementation of the plan. The ultimate
disposal of solids must be clearly addressed in the Solids Management Plan.
iv. The plan will be reviewed annually to evaluate sludge removal options and
revised, if needed, to include a sludge removal implementation schedule.

Pilgrim's Pride Corporation
EMC SOC WQ S 1 5-002
Page 13
c. Table 1: Event Schedule
EVENT
Completion Date
Up -Front Penalty Payment
No later than 90 days after SOC
effective date
Treatment Unit Investigations written report due
No later than 90 days after SOC
effective date
Connection to the City of Sanford written report due
No later than 90 days after SOC
effective date
Solids Management Plan written report due
No later than 90 days after SOC
effective date
Bid Date — Receipt of Bids from Contractors
March 1, 2016
Award Contract to Selected Contractor — Issue Notice
April 25, 2016
to Proceed (NTP)
Mobilize and Begin Construction
May 9, 2016
Complete Construction
March 13, 2017
Comply with final effluent limits
June 15, 2017
d. Quarterly Reports
Pilgrim's Pride will submit quarterly progress reports detailing the work and activities
undertaken and completed with regard to the upgrades of the WWTP. The quarterly
progress reports must also clearly identify any noncompliance, including violations of
anv interim modified effluent limits that occurred during the reuortina auarter. The
report must include a statement of the reason(s) for noncompliance, remedial action(s)
taken, and a statement identifying the extent to which subsequent dates or times for
accomplishment of listed activities may be affected. The reports are to be submitted as
follows:
One copy must be mailed to:
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
One copy must also be mailed to:
Supervisor, Compliance & Expedited Permits Unit
N.C. Division of Water Resources — Water Quality Permitting Section
1617 Mail Service Center
Raleigh, NC 27699-1617

Pilgrim's Pride Corporation
EMC SOC WQ S 1 5-002
Page 14
The quarterly reports are due in each respective office no later than the thirtieth (30tn)
day of January, April, July, and October for the duration of this Order, beginning
January 30, 2016..
e. Compliance Notification & Reporting— Schedule Events
No later than twenty (20) calendar days after any date identified for accomplishment of
any activity listed in 2.(c) above, Pilgrim's Pride shall submit written notice of
compliance of the completion of the SOC event. In the case of noncompliance, the notice
shall include a statement of the reason(s) for noncompliance, remedial action(s) taken,
and a statement identifying the extent to which subsequent dates or times for
accomplishment of listed activities may be affected.
Compliance notifications shall be submitted to the same addressees noted in 2.(d)
above.
f. Interim Limits
During the time in which this Special Order by Consent is effective, Pilgrim's Pride shall
comply with the interim modified effluent limits for Total Nitrogen (TN) and Ammonia
Nitrogen (NH3 as N) as listed in the table below. Pilgrim's Pride may also be required to
monitor other parameters, as deemed necessary by the Director, in future permits or
administrative letters.
Under this Special Order by Consent, ONLY the parameters listed below (Interim
Modified Effluent Limits) have been modified from the most current NPDES Permit
in effect for Outfall 001. All other effluent limits, monitoring requirements,
frequencies, and permit conditions remain in full effect and are unchanged.
Permit Limits and Modified Limits (SOC)
Current Permit Limits
Interim Modified Effluent
Effluent
Limits SOC
Monthly
Daily
Monthly
Daily
Characteristics
Average
Maximum
Average
Maximum
TN
103 mg/L
147 mg/L
200 mg/L
250 mg/L
NH3 as N
1.0 mg/V
2.0 mg/V
2.0 mg/L
4.0 mg/L
Footnote
1. Listed permit limits are for summer months (April 1 — October 31) only. Permit
winter limits are the same as the summer interim effluent limits, in essence, creating
year-round ammonia nitrogen limits for the life of the Order.
g. During the term of this Order, Pilgrim's Pride will continue to operate the WWTP as best
possible to prevent/minimize any adverse impacts to the surface waters.

Pilgrim's Pride Corporation
EMC SOC WQ S 1 5-002
Page 15
3. Pilgrim's Pride agrees that unless excused under paragraph four (4), Pilgrim's Pride will pay
the Director of DWR, by check payable to the North Carolina Department of Environment and
Natural Resources, stipulated penalties according to the following schedule for failure to meet
the deadlines, limits and reporting requirements set out in paragraphs 2.c., d., e. and f.
Failure to meet a schedule date listed in
$500 per day.
paragraph 2.c.
Failure to comply with interim modified effluent
$2,000 for each monthly average limit
exceedance; $500 for each daily
limit listed in paragraph 21
maximum limit exceedance.
Failure to submit reports, progress reports and
$500 for the first violation; penalty
notice as required by paragraph 2.d. and 2.e.
doubles with each subsequent
assessment for late reports.
Failure to achieve compliance with final effluent
$5,000 (single penalty).
limits on or before May 1, 2017.
4. Pilgrim's Pride and the Commission agree that the stipulated penalties are not due if
Pilgrim's Pride satisfies DWR that noncompliance was caused solely by:
a) An act of God;
b) An act of war;
c) An intentional act or omission of a third party, but this defense shall not be available if
the act or omission is that of an employee or agent of the defendant or if the act or
omission occurs in connection with a contractual relationship with the permittee;
d) An extraordinary event beyond the permittee's control. Contractor delays or failure to
obtain funding will not be considered as events beyond the permittee's control; or
e) Any combination of the above causes.
Failure within thirty (30) days of receipt of written demand to pay the penalties, or challenge
them by a contested case petition pursuant to G.S. 150B-23, will be grounds for a collection
action, which the Attorney General is hereby authorized to initiate. The only issue in such an
action will be whether the thirty (3 0) days has elapsed.
5. Noncompliance with the terms of this Special Order by Consent is subject to enforcement
action in addition to the above stipulations, including injunctive relief pursuant to G.S. 143-
215.6.C.

Pilgrim's Pride Corporation
EMC SOC WQ S l 5-002
Page 16
6. This Special Order by Consent and any terms or conditions contained herein, hereby
supersede any and all previous Special Orders, enforcement compliance schedule letters,
terms, conditions, and limits contained therein issued in connection with the Permit. In the
event of an NPDES permit modification or renewal, any effluent limit or monitoring
requirements contained therein shall supersede those contained in this Special Order by
Consent, except as modified and contained in paragraph 21 above.
7. This Special Order by Consent may be amended provided Pilgrim's Pride has made good
faith efforts to secure funding, complete all construction and achieve compliance within the
dates specified.
8. Failure to meet scheduled dates identified in paragraph 2.c. may terminate this Special Order
by Consent and require the Pilgrim's Pride to comply with the terms and conditions
contained in the permit identified in paragraph La.
9. Pilgrim's Pride, upon signature of this Special Order by Consent, will be expected to comply
with all schedule dates, terms, and conditions of this document.
10. This Special Order by Consent shall expire on September 15, 2017.
For Pilgrim's Pride Corporation:
Brent Glasgow Date
Vice President, Pilgrim"s Pri a Corporation
For the North Carolina Environmental Management Commission:
S. J Z 0�nan, P.G. Date
Director,sion of Water Resources

Corporon, Joe
From: Corporon, Joe
Sent: Wednesday, January 27, 2016 9:41 AM
To: 'Townsend, Dave'
Cc: Hennessy, John [e-mail])
Subject: RE: Pilgrim's Pride SOC EMC No. S15-002 - Draft Final for Permittee's Signature
Mr. Townsend: The SOC is currently proceeding through DWR administrative review in preparation for the Director's
signature. We will forward final copies in due time. We're glad to hear you are proceeding toward SOC deadlines, as
agreed.
Respectfully,
Joe R. Corporon, L. G.
NCDEQ
g Nothing Compares ti .
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: Townsend, Dave [mailto:[e-mail]]
Sent: Friday, January 22, 2016 10:36 AM
To: Corporon, Joe <[e-mail]>
Cc: Smith, Danny <[e-mail]>; Hennessy, John <[e-mail]>
Subject: RE: Pilgrim's Pride SOC EMC No. S15-002 - Draft Final for Permittee's Signature
Mr. Corporon,
I believe the public comment period has closed. Could you please contact me to discuss the next steps in this matter?
We are proceeding with the wastewater upgrade engineering and preparing to meet the scheduled deadlines.
Thanks
Dave Townsend, P.E.
Head of Environmental
[e-mail] I www.oiladms.com
0:970.347.5730 1 C:816.392.2056
1770 Promontory Circle I Greeley, CO 80634
From: Corporon, Joe fmailto:joe.corporonColncdenr.aovl
Sent: Friday, October 30, 2015 10:41 AM
To: Townsend, Dave

Cc: Smith, Danny; Hennessy, John
Subject: Pilgrim's Pride SOC EMC No. S15-002 - Draft Final for Permittee's Signature
Mr. Townsend:
On October 26, the Division's Central Office mailed Brent Glasgow (Pilgrim's Pride) the subject SOC as a
draft final for Pilgrim's signature. We understand you have asked to be copied on this document.
By this follow-up I also provide Attachments "A" and `B" as these supplements were excluded at the time of
mailing (see attached). Upon Pilgrim's signing this document, please return it to my attention. When received, I
will submit it for Public Notice, as required by the NPDES Program.
If I can help further, or if you have questions, please email me or call my direct line [919-807-6394].
Respectfully,
Joe R. Corporon, L.G.
NCDEQ
hm"..
--Nothing Compares
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.
The information transmitted is intended only for the person or entity to which
it
is addressed and may contain confidential and/or privileged material. Any
review,
retransmission, dissemination or other use of, or taking of any action in
reliance upon this information by persons or entities other than the intended
recipient is prohibited. If you received this in error, please contact the
sender

�lir
Affidavit Of Publication: Lee County, North Carolina
'Ihe Sanford Herald is a newspaper with a general circulation to actual paid subscribers admitted to the
United States mail in the Periodicals class in Lee County. The Sanford Herald has been published at least one
day in each calendar week for at least 25 of the 26 consecutive weeks immediately preceding the date of this
affidavit.
Holly Hight, Classified Advertising Representative of The Sanford Herald, a newspaper published in Lee
County in the state of North Carolina, being duly sworn, deposes and says: that the attached advertisement of
notice, in the action entitled:
was duly published in the aforesaid newspaper once a week for consecutive weeks, beginning with
the issue dated th4j_ day o P r-_�_ nd ending with the issue dated the day of
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My Commission Expires

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e' PUBLIC NOTICE
STATE OF NORTH CARO.
LINA
ENVIRONMENTAL MAN-
AGEMENT COMMISSION
1617 MAIL SERVICE CEN-
TER
RALEIGH, NORTH CARO-
LINA 27699-1617
NOTIFICATION OF INTENT
TO ISSUE A CONSENT OR-
DER
Public notice of intent to is.
sue a State Consent Order
to the following:
Pride orporatiOn
(484 Zimmerman Road, San-
ford, NC 27330) has reques-
ted Special Order by Con-
sent WO S15-002 (the Order)
for Its Sanford Processing
Plant Wastewater Treat-
ment Plant (W WTP), a 1.0
MGD W WTP that dis-
charges treated wastewater
to the Deep River in the
Cape Fear River Basin un-
der the authority of NPDES
Permit NC0072575, but is
unable to consistently com-
ply with effluent limits for
Total Nitrogen and Ammo-
nia Nitrogen.
The Environmental Manage-
ment Commission pro-
poses to issue the Order per
Article 21 of Chapter 143,
N.C. General Statutes, and
other regulations effective
January 11, 2016.
Compliance with this Order
requires installation of ne-
cessary treatment compon-
ents to the existing facility.
The Pilgrim's Pride Corpora-
tion shall comply with NP-
DES permit limits with the
exception of the Interim ef-
fluent limitations identified
in the Order. This Order will
expire on June 30, 2017.
A copy of the Order is avail-
able upon request by con-
tacting Joe R. Corporon,
L.G. of the Division of Wa-
ter Resources at 919-807-
6394, or by email at:
[e-mail].
Comments on the proposed
Order received no later than
January 15, 2016 will be
considered in the final de-
termination. A public meet-
ing may be held if there is a
significant degree of public
Interest.
Date: December 2, 2015
Ch
Gerard P. Carroll, airman
Environmental Management
Commission

PUBLIC NOTICE
STATE OF NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
1617 MAIL SERVICE CENTER
RALEIGH, NORTH CAROLINA 27699-1617
NOTIFICATION OF INTENT TO ISSUE A CONSENT ORDER
Public notice of intent to issue a State Consent Order to the following:
Pilgrim's Pride Corporation (484 Zimmerman Road, Sanford, NC 27330) has requested Special
Order by Consent WQ S15-002 (the Order) for its Sanford Processing Plant Wastewater Treatment
Plant (WWTP), a 1.0 MGD WWTP that discharges treated wastewater to the Deep River in the Cape
Fear River Basin under the authority of NPDES Permit NC0072575, but is unable to consistently
comply with effluent limits for Total Nitrogen and Ammonia Nitrogen.
The Environmental Management Commission proposes to issue the Order per Article 21 of Chapter
143, N.C. General Statutes, and other regulations effective January 11, 2016.
Compliance with this Order requires installation of necessary treatment components to the existing
facility. The Pilgrim's Pride Corporation shall comply with NPDES permit limits with the exception
of the interim effluent limitations identified in the Order. This Order will expire on June 30, 2017.
A copy of the Order is available upon request by contacting Joe R. Corporon, L.G. of the Division of
Water Resources at 919-807-6394, or by email at: joe.coMoron e,ncdenr.gov. Comments on the
proposed Order received no later than January 15, 2016 will be considered in the final
determination. A public meeting may be held if there is a significant degree of public interest.
Date: December 2, 2015
.Perard P. Carroll, Chairm�
Environmental Management Commission

Environmental
Quality
October 26, 2015
Brent Glasgow, Vice President
Pilgrim's Pride Corporation
484 Zimmerman Road
Sanford, North Carolina 27330
PAT MCCRORY
Governor
DONALD R. VAN DER VAART
Secretary
Subject: Draft Final - Special Order by Consent
Pilgrim's Pride Corporation W WTP, Class 3
EMC SOC WQ S15-002
NPDES Permit NCO072575
Lee County
Dear Mr. Glasgow:
Attached for your approval and signature are two (2) copies of the subject Special Order by Consent (SOC). Its
terms and conditions should be familiar after multiple discussions and negotiations recently between the Division
of Water Resources (DWR) and Pilgrim's Pride. staff.
Having resolved all questions and issues of both parties to date, we assume the terms and conditions of the SOC
now meet with your approval. Please therefore affix your signature to page 6 of the Order and return the signed
SOC (2 copies) to my attention at the footer address within ten (10) days of the date on this letter.
In signing the SOC, please be aware:
• Your signature holds Pilgrim's Pride to comply with all scheduled activity dates, terms, and conditions.
Please review these carefully as they will be strictly enforced.
Following any scheduled activity, date or deadline, Pilgrim's Pride must submit written notice to the
Division documenting compliance or noncompliance to a scheduled activity or deadline. Failure to
comply subjects you to strict SOC stipulated penalties (see page 5, Sec. 3.).
Upon receiving your signed document, the Central Office will submit the SOC for a thirty (30)-day Public Notice
period, as required by State and Federal regulations. Following this Public Notice period, in the absence of
significant public objection, the Division will issue final active documents. If you have questions, please contact
Mr. Danny Smith in the Raleigh Regional Office at [phone] or in the Central Office, Joe R. Corporon,
L.G. [e-mail]]; direct line [919-807-6394].
tncere
John E. Hennessy, Supervisor
Compliance and Expedited I nit
Attachments: SOC Draft Final [two (2) copies] RECEIVED/DENR/DWR
cc: Raleigh Regional Office w/attachment NOV 1 6
SOC File S 15-002 w/ attachment 1
Central Files w/attachment Water (duality
rljPrmftting Section
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Ralegh, North Carolina 27604
Phone: [phone] FAX: [phone]
Internet www.ncwaterquality.org
An Equal Opportunity 1 Affirmative Action Employer

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
COUNTY OF LEE
IN THE MATTER OF )
NORTH CAROLINA )
NPDES PERMIT NC0072575 ) SPECIAL ORDER BY CONSENT
EMC SOC NO. 515-002
HELD BY )
PILGRIM'S PRIDE CORPORATION )
Pursuant to provisions of North Carolina General Statute (G.S.) 143-215.2, this Special Order by
Consent is entered into by Pilgrim's Pride Corporation, hereinafter referred to as Pilgrim's Pride,
and the North Carolina Environmental Management Commission, an agency of the State of North
Carolina created by G.S. 143B-282, and hereinafter referred to as the Commission:
1. Pilgrim's Pride and the Commission hereby stipulate the following:
a. Pilgrim's Pride holds North Carolina NPDES permit NC0072575 ("Permit") for
operation of an existing wastewater treatment plant ("WWTP") at its Sanford, North
Carolina facility, and for making an outlet therefrom for treated wastewater to the Deep
River, a Class C water of this State in the Cape Fear River Basin.
b. Pilgrim's Pride is unable to consistently comply with the final effluent limits for Total
Nitrogen ("TN") and Ammonia Nitrogen ("NH3 as N") as set forth in Permit. Effluent
limits for these (and other) parameters have been exceeded since September 2013 in the
manner and to the extent as shown in Attachment B.to this Order.
c. Pilgrim's Pride is within the jurisdiction of the Commission as set forth in G.S. Chapter
143, Article 2.
d. Compliance with the Permit will require preparation and implementation of a plan for
WWTP upgrades. Pilgrim's Pride has funding for planning, and has retained an
environmental and civil engineering consultant to design upgrades to its WWTP which,
once constructed and operated, will be sufficient to adequately convey and treat
wastewater in compliance with final effluent limits.
2. Pilgrim's Pride, desiring to comply with the Permit, hereby agrees to do the following:
a. As settlement of all known NPDES limit violations of the Permit occurring prior to
entering into this Special Order by Consent, pay an up -front penalty in the amount of
$10,000.00 and $382.15 in costs totaling $10,382.15. A certified check in the amount of
$10,382.15 must be made payable to the Department of Environmental Quality and
forwarded to the Director ofDWR at 1617 Mail Service Center, Raleigh, North Carolina
27699-1617 by no later than ninety (90) days following the date on which this Order is
approved and executed by the Commission and received by Pilgrim's Pride.

Pilgrim's Pride Corporation
EMC SOC WQ S15-002
Pase 12
b. Undertake the following activities in accordance with the indicated time schedule listed
below in Table 1. Event Schedule:
(1.) Treatment Unit Investigations. Conduct investigations into available treatment
operations, measures, or technologies that once constructed, will treat wastewater to
such an extent that the discharge from the Pilgrim's Pride facility will comply with
appropriate final effluent limits. Pilgrim's Pride must communicate in writing the
results of the investigations whereby a report of the proposed treatment unit
changes will illustrate how the reduction of the pollutants will be achieved.
(2.) Connection to the City of Sanford. Conduct an investigation to determine the
availability, suitability, and the willingness of the City of Sanford to accept and
treat all or portions of the Pilgrim's Pride facility process wastewater. If these
investigation efforts support this approach, Pilgrim's Pride will need to conduct
further investigation into technologies, sewer extensions, and pretreatment
requirements that may be needed for the Pilgrim's Pride facility to eliminate their
discharge or reduce their waste load such that. Pilgrim's Pride facility will be able to
achieve compliance with appropriate final effluent limits. Pilgrim's Pride must
communicate in writing the results of the investigations detailing why this approach
is or is not appropriate to pursue in order to achieve compliance.
(3.) Solids Management Plan
Within 180 days of signature date of this agreement, Pilgrim's Pride will provide a
Solids Management Plan for this facility. The plan must include the following:
i. The current sludge inventory and current storage capacity for the Pilgrim's
Pride facility.
ii. Actions to determine sludge depth and monitor characteristics sufficient to
evaluate removal options (dewatering and/or stabilization if needed) and proper
disposal of solids as needed to provide adequate volume for proper operation of
the treatment units. Sludge depths and characteristics will be determined every
6 months for the first 24 months of plan implementation.
iii. Strategies and action items associated with the management of existing solids,
solids generated in the future, and solids that will be generated from any new
treatment units that may be constructed as a part of this order, including
performance thresholds mandating implementation of the plan. The ultimate
disposal of solids must be clearly addressed in the Solids Management Plan.
iv. The plan will be reviewed annually to evaluate sludge removal options and
revised, if needed, to include a sludge removal implementation schedule.

Pilgrim's Pride Corporation
EMC SOC WQ S 1 5-002
P a g e 13
c. Table 1: Event Schedule
EVENT
Completion Date
Up -Front Penalty Payment
No later than 90 days after SOC
effective date
Treatment Unit Investigations ations written report due
No later than 90 days after SOC
effective date
Connection to the City of Sanford written report due
No later than 90 days after SOC
effective date
Solids Management Plan written report due
No later than 90 days after SOC
effective date
Bid Date — Receipt of Bids from Contractors
March 1, 2016
Award Contract to Selected Contractor — Issue Notice
to Proceed (NTP)
April 25, 2016
Mobilize and Begin Construction
May 9, 2016
Complete Construction
March 13, 2017
Comply with final effluent limits
June 15, 2017
d. Quarterly Reports
Pilgrim's Pride will submit quarterly progress reports detailing the work and activities
undertaken and completed with regard to the upgrades of the WWTP. The quarterly
progress reports must also clearly identify any noncompliance, including violations of
any interim modified effluent limits that occurred during the reporting quarter. The
report must include a statement of the reason(s) for noncompliance, remedial action(s)
taken, and a statement identifying the extent to which subsequent dates or times for
accomplishment of listed activities may be affected. The reports are to be submitted as
follows:
One copy must be mailed to:
Raleigh Regional Supervisor
Water Quality Regional Operations Section
1628 Mail Service Center
Raleigh, NC 27699-1628
One copy must also be mailed to:
Supervisor, Compliance & Expedited Permits Unit
N.C. Division of Water Resources — 'Water Quality Permitting Section
1617 Mail Service Center
Raleigh, NC 27699-1617

r,
Pilgrim's Pride Corporation
EMC SOC WQ S15-002
Page 14
The quarterly reports are due in each respective office no later than the thirtieth (30tn)
day of January, April, July, and October for the duration of this Order, beginning
January 30, 2016.
e. Compliance Notification & Reporting — Schedule Events
No later than twenty (20) calendar days after any date identified for accomplishment of
any activity listed in 2.(c) above, Pilgrim's Pride shall submit written notice of
compliance of the completion of the SOC event. In the case of noncompliance, the notice
shall include a statement of the reason(s) for noncompliance, remedial action(s) taken,
and a statement identifying the extent to which subsequent dates or times for
accomplishment of listed activities may be affected.
Compliance notifications shall be submitted to the same addressees noted in 2.(d)
above.
f. Interim Limits
During the time in which this Special Order by Consent is effective, Pilgrim's Pride shall
comply with the interim modified effluent limits for Total Nitrogen (TN) and Ammonia
Nitrogen (NH3 as N) as listed in the table below. Pilgrim's Pride may also be required to
monitor other parameters, as deemed necessary by the Director, in future permits or
administrative letters.
Under this Special Order by Consent, ONLY the parameters listed below (Interim
Modified Effluent Limits) have been modified from the most current NPDES Permit
in effect for Outfall 001. All other effluent limits, monitoring requirements,
frequencies, and permit conditions remain in full effect and are unchanged.
Permit Limits and Modified Limits (SOC)
Current Permit Limits
Interim Modified Effluent
Effluent
Limits SOC
Characteristics
Monthly
Daily
Monthly
Daily
Average
Maximum
Average
Maximum
TN
103 mg/L
147 mg/L
200 mg/L
250 mg/L
NH3 as N
1.0 mg/V
2.0 mg/Li
2.0 mg/L
4.0 mg/L
Footnote
1. Listed permit limits are for summer months (April 1— October 31) only. Permit
winter limits are the same as the summer interim effluent limits, in essence, creating
year-round ammonia nitrogen limits for the life of the Order.
g. During the term of this Order, Pilgrim's Pride will continue to operate the WWTP as best
possible to prevent/minimize any adverse impacts to the surface waters.

Pilgrim's Pride Corporation
EMC SOC WQ S 1 5-002
Page 15
3. Pilgrim's Pride agrees that unless excused under paragraph four (4), Pilgrim's Pride will pay
the Director of DVVR, by check payable to the North Carolina Department of Environment and
Natural Resources, stipulated penalties according to the following schedule for failure to meet
the deadlines, limits and reporting requirements set out in paragraphs 2.c., d., e. and f.
Failure to meet a schedule date listed in
$500 per day.
paragraph 2.c.
Failure to comply with interim modified effluent
$2,000 for each monthly average limit
limit listed in paragraph 21
exceedance; $500 for each daily
maximum limit exceedance.
Failure to submit reports, progress reports and
$500 for the first violation; penalty
notice as required by paragraph 2.d. and 2.e.
doubles with each subsequent
assessment for late reports.
Failure to achieve compliance with final effluent
limits on or before May 1, 2017.
$5 000 sin .
(single penalty).
y}
4. Pilgrim's Pride and the Commission agree that the stipulated penalties are not due if
Pilgrim's Pride satisfies DWR that noncompliance was caused solely by:
a) An act of God;
b) An act of war;
c) An intentional act or omission of a third party, but this defense shall not be available if
the act or omission is that of an employee or agent of the defendant or if the act or
omission occurs in connection with a contractual relationship with the permittee;
d) An extraordinary event beyond the permittee's control. Contractor delays or failure to
obtain funding will not be considered ' as events beyond the permittee's control; or
e) Any combination of the above causes.
Failure within thirty (30) days of receipt of written demand to pay the penalties, or challenge
them by a contested case petition pursuant to G.S. 150B--23, will be grounds for a collection
action, which the Attorney General is hereby authorized to initiate. The only issue in such an
action will be whether the thirty (30) days has elapsed.
5. Noncompliance with the terms of this Special Order by Consent is subject to enforcement
action in addition to the above stipulations, including injunctive relief pursuant to G.S. 143-
215.6.C.

i
Pilgrim's Pride Corporation
EMC SOC WQ S 1 5-002
Page 16
6. This Special Order by Consent and any terms or conditions contained herein; hereby
supersede any and all previous Special Orders, enforcement compliance schedule letters,
terms, conditions, and limits contained therein issued in connection with the Permit. In the
event of an NPDES permit modification or renewal, any effluent limit or monitoring
requirements contained therein shall supersede those contained in this Special Order by
Consent, except as modified and contained in paragraph 21 above.
7. This Special Order by Consent may be amended provided Pilgrim's Pride has made good
faith efforts to secure funding, complete all construction and achieve compliance within the
dates specified.
S. Failure to meet scheduled dates identified in paragraph 2.c. may terminate this Special Order
by Consent and require the Pilgrim's Pride to comply with the terms and conditions
contained in the permit identified in paragraph La.
9. Pilgrim's Pride, upon signature of this Special Order by Consent, will be expected to comply
with all schedule dates, terms, and conditions of this document.
10. This Special Order by Consent shall expire on September 15, 2017.
For Pilgrim's Pride Corporation:
Brent Glasgow
Vice President, Pilgrim's Pride Corporation
Date
For the North Carolina Environmental Management Commission:
S. Jay Zimmerman, P.G.
Director, Division of Water Resources
Date

Pilgrim's Pride Corporation
EMC SOC WQ S15-002
Page 17
ATTACHMENT A (page 1 of 2)
EMC SOC WQ S15-002
Pilgrim's Pride Corporation - Sanford WWTP
A (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of Special Order by Consent and lasting until
April 30, 2017, the Permittee is authorized to discharge from outfall(s) serial number 001. Such
discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT
EFFLUENT LIMITS
MONITORING REQUIREMENTS
Monthly
Daily
Measurement
Sample
Sample
CHARACTERISTICS
Average
Maximum
Frequency
Type
Location
Flow
1.0 MGD
Continuous
RecordingInfluent
or
Effluent
BOD, 5 day, 20°C
5.0 mg/L
10.0 mg/L
3/Week
Composite
Effluent
(A riI 1 - October 31
BOD, 5 day, 20°C
10.0 mg/L
20.0 mg/L
3/Week
Composite
Effluent
(November 1 - March 31)
NH3 as N
2.0 mg/L
4.0 mg/L
3/Week
Composite
Effluent
Total Suspended Solids (TSS)
20 mg/L
30 mg/L
3/Week
Composite
Effluent
Oil and Grease
8.0 mg/L
14.0 mg/L
3/Week
Grab
Effluent
Dissolved Oxygen
Not less than 6.0 mg/l, daily
3/Week
Grab
Effluent
average
Fecal Coliform
200 / 100 ml
400 / 100 ml
3/Week
Grab
Effluent
(geometric mean)
Total Residual Chlorine (TRC) z
28 µg/L
3/Week
Grab
Effluent
Temperature, °C
3/Week
Grab
Effluent
pH
Not greater than 9.0 S.U.
3/Week
Grab
Effluent
nor less than 6.0 S.U.
Total Nitrogen (TN) 3
200 mg/L
250 mg/L
Monthly
Composite
Effluent
Nitrate/Nitrite Nitrogen, mg/L
Monthly
Composite
Effluent
Total Kjeldahl Nitrogen, mg/L
Monthly
Composite
Effluent
Total Phosphorus, mg/L
Monthly
Composite
Effluent
Chronic Toxicity'
Quarterly
Composite
Effluent
Fecal Coliform, #/100ml
Variable 6
Grab
Upstream &
(geometric mean) 5
Downstream
Temperature, °C 5
Variable 6
Grab
Upstream &
Downstream
Conductivity, µmhos/cm 5
Variable 6
Grab
Upstream &
Downstream
Dissolved Oxygen, mg/L 5
Variable 6
Grab
Upstream &
Downstream
Only the parameters shown in BOLD above have been modified from the terms found in
NPDES permit NC0072575.

Pilgri-m's Pride Corporation
EMC SOC WQ S15-002
Page 18
ATTACHMENT A (page 2 of 2)
EMC SOC WQ S15-002
Pilgrim's Pride Corporation - Sanford WWTP
Footnotes:
1. Sample Locations: E — Effluent; I — Influent; U — Upstream at NCSR 1400; D — Downstream
50 feet above the City of Sanford outfall.
2. The Division shall consider. all effluent TRC values reported below 50 µg/L to be in
compliance with the permit. However, the Permittee shall continue to record and submit
all values reported by a North Carolina certified laboratory (including field certified), even
if these values fall below 50 µg/L.
3. TN = TKN + (NO3-N + NO2-N), where TN is Total Nitrogen, TKN is Total Kjeldahl
Nitrogen, and (NO3-N and NO2-N) are Nitrate and Nitrite Nitrogen, respectively.
4. Chronic Toxicity (Ceriodaphnia) at 9 %; quarterly during January, April, July, October;
See Special Condition A. (2.)
5. Monitoring upstream (U) and downstream (D) are provisionally waived, based on the
Permittee's membership in the Upper Cape Fear River Association. If at any time during
the term of this permit, membership in the association is terminated, the permittee shall
notify the Division immediately, and immediately continue instream monitoring as
stipulated in this permit.
6. Variable: sample upstream and downstream 3/week during summer months of June, July
August, and September, weekly during the rest of the year.
Effluent shall contain no floating solids or foam visible in other than trace amounts.

Pilgrim's Pride Corporation
EMC SOC WQ S15-002
Page 19
ATTACHMENT B (page 1 of 2)
EMC SOC WQ S15-002
Pilgrim's Pride Corporation - Sanford WWTP
Violation
Parameter
Violation Type
Reported
Limit
Units
% Over
Date
Value
Limit
09/13/2013
Ammonia Nitrogen
Daily Maximum
2.24
2.00
mg/I
12
09/27/2013
Ammonia Nitrogen
Daily Maximum
3.04
2.00
mg/l
52
09/30/2013
Ammonia Nitrogen
Daily Maximum
28.80
2.00
mg/l
1340
09/30/2013
Ammonia Nitrogen
Monthly Average
3.27
1.00
mg/l
227
09/30/2013
Total Nitrogen
Monthly Average
115.25
103.00
mg/l
12
September 2013 violations addressed by DWR Notice of Violation NO V-2015-L
V-0229
10/16/2013
Ammonia Nitrogen
Daily Maximum
6.49
2.00
mg/l
225
10/18/2013
Ammonia Nitrogen
Daily Maximum
37.60
2.00
mg/I
1780
10/31/2013
Ammonia Nitrogen
Monthly Average
3.88
1.00
mg/l
288
10/31/2013
Total Nitrogen
Monthly Average
112.00
103.00
mg/I
9
October 2013 violations addressed by DWR Notice of Violation NO V-2015-L
V-0230
11/30/2013
Ammonia Nitrogen
Monthly Average
2.29
2.00
mg/I
15
November 2013 violations addressed by
DWR Notice of Violation NO V-2015-L V-0231
06/13/2014
BOD, 5-Day (20 Deg. C)
Daily Maximum
18.80
10.00
mg/l
88
06/30/2014
Total Nitrogen
Monthly Average
117.00
103.00
mg/l
14
June 2014 violations addressed by DWR Notice of Violation NO V-2015-L V-0232
07/23/2014
Fecal Coliform
Daily Maximum
700.00
400.00
#/100ml
75
07/31/2014
Total Nitrogen
Monthly Average
126.00
103.00
mg/l
22
July 2014 violations addressed by DWR Notice of Violation NOV-2015-LV-0233
08/27/2014
Total Nitrogen
Daily Maximum
162.00
147.00
mg/l
10
08/31/2014
Total Nitrogen
Monthly Average
162.00
103.00
mg/l
57
August 2014
violations addressed by DWR Notice of Violation NO V-2015-L V-0234
10/13/2014
Fecal Coliform
Daily Maximum
3200.00
400.00
#/100ml
700
10/17/2014
Fecal Coliform
Daily Maximum
6600.00
400.00
#/100ml
1550
10/22/2014
Total Nitrogen
Daily Maximum
156.00
147.00
mg/l
6
10/31/2014
Total Nitrogen
Monthly Average
144.00
103.00
mg/l
40
October 2014 violations addressed by DWR Notice of Violation NO V-2015-L V-0235
11/30/2014
Total Nitrogen
Monthly Average
112.00
103.00
mg/I
9
12/10/2014
Ammonia Nitrogen
Daily Maximum
32.40
4.00
mg/l
710
12/31/2014
Ammonia Nitrogen
Monthly Average
5.51
2.00
mg/l
176
12/31/2014
Total Nitrogen
Monthly Average
118.00
103.00
mg/l
15
December 2014 violations addressed by
DWR Notice of Violation NO V-2015-L V-0236

Pilgrim's Pride Corporation
EMC SOC WQ S 1 5-002
Page %,10
ATTACHMENT B (page 2 of 2)
EMC SOC WQ S15-002
Pilgrim's Pride Corporation - Sanford WWTP
01/02/2015
Fecal Coliform
Daily Maximum
2200.00
400.00
#/100ml
450
01/02/2015
Ammonia Nitrogen
Daily Maximum
8.23
4.00
mg/l
106
01/12/2015
Dissolved Oxygen
Daily Minimum
4.30
6.00
mg/l
28
01/13/2015
Dissolved Oxygen
Daily Minimum
5.11
6.00
mg/l
15
01/13/2015
Fecal Coliform
Daily Maximum
1000.00
400.00
#/100ml
150
01/13/2015
Ammonia Nitrogen
Daily Maximum
5.15
4.00
mg/l
29
01/14/2015
Ammonia Nitrogen
Daily Maximum
42.00
4.00
mg/l
950
01/16/2015
Dissolved Oxygen
Daily Minimum
5.40
6.00
mg/l
10
01/16/2015
Ammonia Nitrogen
Daily Maximum
17.90
4.00
mg/l
348
01/19/2015
Ammonia Nitrogen
Daily Maximum
49.90
4.00
mg/l
1148
01/21/2015
Dissolved Oxygen
Daily Minimum
4.14
6.00
mg/l
31
01/21/2015
Chlorine, Total Residual
Daily Maximum
70.00
28.00
ug/l
150
01/23/2015
Dissolved Oxygen
Daily Minimum
4.12
6.00
mg/I
31
01/23/2015
pH
Daily Minimum
5.76
6.00
su
4
01/26/2015
Dissolved Oxygen
Daily Minimum
4.94
6.00
mg/l
18
01/28/2015
Dissolved Oxygen
Daily Minimum
4.69
6.00
mg/l
22
01/28/2015
Total Suspended Solids
Daily Maximum
30.70
30.00
mg/I
2
01/30/2015
Dissolved Oxygen
Daily Minimum
4.70
6.00
mg/I
22
01/31/2015
Total Nitrogen
Monthly Average
138.00
103.00
mg/l
34
01/31/2015
Ammonia Nitrogen
Monthly Average
13.58
2.00
mg/l
579
January 2015 violations addressed by DWR Notice of Violation NOV-2015-LV-0413
02/02/2015
Dissolved Oxygen
Daily Minimum
1.88
6.00
mg/l
69
02/04/2015
BOD, 5-Day (20 Deg. C)
Daily Maximum
24.00
20.00
mg/I
20
02/28/2015
Total Nitrogen
Monthly Average
146.00
103.00
mgll
42
February 2015
violations addressed by DWR Notice of Violation NOV-2015-LV-0414
03/09/2015
Ammonia Nitrogen
Daily Maximum
10.50
4.00
mg/I
163
03/11/2015
Fecal Coliform
Daily Maximum
12000.00
400.00
#/100ml
2900
03/25/2015
Total Nitrogen
Daily Maximum
155.00
147.00
mg/l
5
03/31/2015
Total Nitrogen
Monthly Average
155.00
103.00
mg/I
50
March 2015 violations addressed by DWR Notice of Violation NOV-2015-LV-0415
04/22/2015
Total Nitrogen
Daily Maximum
179.00
147.00
mg/l
22
04/30/2015
Total Nitrogen
Monthly Average
179.00
103.00
mg/I
74
05/04/2015
Total Nitrogen
Daily Maximum
181.00
147.00
mg/I
23
05/18/2015
Total Suspended Solids
Daily Maximum
38.00
30.00
mg/l
27
05/20/2015
Total Suspended Solids
Daily Maximum
44.70
30.00
mg/I
49
05/31/2015
Total Nitrogen
Monthly Average
181.00
103.00
mg/I
76
06/24/2015
Total Nitrogen
Daily Maximum
162.00
147.00
mg/l
10
06/30/2015
Total Nitrogen
Monthly Average
162.00
103.00
mg/I
57
07/29/2015
Fecal Coliform
Daily Maximum
6000.00
400.00
#/100ml
1400
07/31/2015
Total Nitrogen
Monthly Average
138.00
103.00
mg/l
34
April - July 2015 violations have not been addressed by a DWR Notice of Violation

b. SS3
DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES PERMIT NC0072575
Facility Information
Applicant/Facility
Name:
Pilgrim's Pride Corp Sanford Plant
Applicant Address:
484 Zimmerman Road; Sanford, NC 27330
Facility Address:
484 Zimmerman Road; Sanford, NC 27330
Permitted Flow
1.0 MGD
Type of Waste:
Process wastewater, boiler blowdown, condensate, stormwater
Facility/Permit Status:
Class III Minor/Active; Renewal
County:
Lee County
Miscellaneous
Receiving Stream:
Deep River
Stream Classification:
C
Subbasin:
03-06-11
Index No.
17-(38.7)
Drainage Area (mi ):
1122
HUC:
03030003
Summer 7Q10 (cfs)
17
303(d) Listed?
No
Winter 7Q10 (cfs):
32
Regional Office:
Raleigh
30Q2 (cfs):
nd
State Grid / USGS
Quad:
E22SW
Average Flow (cfs):
1240
Permit Writer:
Ron Berry
IWC (%):
8.4%
Date:
2/21/12
BACKGROUND
Pilgrim's Pride Corporation (formerly Gold Kist, Inc.) operates a poultry processing plant in
Sanford, NC. The plant processes live chickens and chicken parts into various packaged chicken
meat products producing 360 million pounds of packed chicken annually. The Permittee is a
member of the Upper Cape Fear Basin Association.
Wastewater from various plant operations, boiler and condenser blowdown, maintenance, and
area stormwater are collected and treated in an advance biological treatment system where the
majority of the treated wastewater is discharged to Deep River, Cape Fear River Basin. This
facility NPDES discharge is subject to federal effluent guidelines CFR 40 Section 432 Subpart L
Poultry Further Processing.
HISTORY
2007 - A new permit was issued with significant changes. Permit requirements were based on
the new federal effluent guideline 432 Subpart L and waste load factors utilizing plant
current operation and production data.
- BOD, NH3-N, and DO limits were defined to meet waste load requirements; BOD and
NH3-N limits were more stringent than the effluent guidelines.
- The federal guidelines required reductions in TSS limits, Oil and Grease limits, and
the addition of total nitrogen limits.
- Fecal coliform secondary standards limits, TRC limit, pH limits, and other special
conditions did not change.
- The Deep River Strategy mandated additional total nitrogen and total phosphorus
monitoring, and a special reopener condition.
- The permit owner name was corrected to show the new owner Pilgrim's Pride.
- A SOC was issued with interim limits to allow Pilgrims Pride time to make the
necessary changes to meet the new permit total nitrogen limits by August 31, 2008.
Fact Sheet
NPDES NC0072575
Page 1 of 1

ti
TREATMENT PROCESS
A tank collects and then pumps the plant's screened wastewater to a covered/lined 17 million --
gallon anaerobic basin. Solids from the screen are sent off -site. A flare is available to incinerate
off gas (methane) from the anaerobic basin.
The anaerobic basin wastewater is pumped to the advance biological treatment system which
consists of an extended aeration basin, a clarifier, a tertiary filter, and
chlorination/dechlorination. Metered treated wastewater flows to a post cascade aeration basin
and then to the outfall, a small portion is recycled for reuse in the plant. Treated wastewater can
be diverted to either a storage lagoon or the irrigation treatment system.
Filter backwash and filter diverted effluent wastewater is collects in the backwash basin, and
pumped to the emergency pond. The emergency pond wastewater including plant stormwater is
disposed of through irrigation.
The advance treatment system biosolids are transferred to an anaerobic basin which provides a
very methodical, slow digestion. The lagoon has been in service for several decades with little
solids removal and has an expected storage capacity beyond the next 40 years. When solid
removal is required additional lagoons are available for dewatering of solids before final
disposal.
Sanitary wastewater is treated and stored in the irrigation ponds. The facility maintains a non -
discharge permit for irrigation. Excess treated wastewater from the advanced treatment system
can be diverted to the sanitary treatment system.
COMPLIANCE
Since issuance of the 2007 permit, this facility committed 36 limit violations and paid $9,958 in
fines. TN violations were the most prevalent and continued into 2011 with 5 violations occurring
between July and October in 2011. Fecal coliform was the next prevalent violation but no
violations have occurred since May 2010.
PERMITTING STRATEGY
Federal guideline 432 general condition and Subpart L applies and will continue unchanged for
O&G, TSS, TN, and pH. BOD, ammonia as nitrogen, and fecal coliform water quality standard
limits are more stringent and will continue (see Table 1).
Table 1: Subpart L Limits
Parameter
Maximum daily
Maximum monthly average
O&G (as HEM)
14 mg/L
8.0 mg/L
TSS
30 mg/L
20 mg/L
TN
147 mg/L
103 mg/L
432 Subpart L Limits Not Applied — WQS/WLA more stringent
BOD
26 mg/L
16 mg/L
NH3-N
8.0 mg/L
4.0 mg/L
Fecal Coliform
Not to exceed 400/100 ml at anytime
DO is a wasteload based limit and will continue.
The Deep River Nutrient Strategy continues to be applicable so TP monitoring and the reopener
condition will continue.
Temperature and TRC requirements will remain the same and continue. A new footnote will be
added to address the 50 µg/L detection limit and reporting protocol.
Fact Sheet
NPDES NCO072575
Page 2 of 2

A Total Nitrogen Compliance Plan special condition will be added to direct the Permittee to
determine a corrective course of action to address the facility continued TN non-compliance.
Data review
DMRs were reviewed for the period of May 2009 to June 2011. DMR data is summarized in
Table 2 below:
Table 2: DMR Data Statistics
Flow
(MGD)*
BOD
(mg/L)*
TSS
(mg/L)*
NH3-N
(mg/L)*
Fecal
Coliform
(#//100 ml)*
Average
0.740
2.75
3.62
0.51
96.6
Maximum
0.91
4.2
8.0
0.9
1534
Minimum
0.53
2.0
1.1
0.2
1.1
O&G
(mg/L)*
DO
(mg/L)
pH
(S.U.)
TRC
(µg/L)
TN
(mg/L)*
Average
5.00
7.80
7.07
25.2
85.91
Maximum
5.3
10.2
7.9
44
119.0
Minimum 1
>5.0 1
6.0
_633—i
> 25
1.3
*Monthly average
Whole Effluent Toxicity
No failures were reported for this permit cycle Chronic Toxicity tests. The Aquatic Toxicology
Unit performed a 24 hour pass/fail chronic test in May 2011 which was passed. The permit
chronic toxicity requirement will continue with the special condition narrative being updated.
Instream Sampling
As a member of the Upper Cape Fear River Basin Association a waiver for instream sampling is
granted. The last reported data was retrieved from the association monitoring stations located
upstream and downstream from Permittee discharge, no impacts were noted.
SUMMARY OF PROPOSED CHANGES
In keeping with Division permit development strategy the following will be incorporated into
this permit:
• Add TRC footnote for reporting and measurement protocol.
• Add special condition for TN Compliance Plan.
• Update chronic toxicity special condition narrative.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice: February 29, 2012
Permit Scheduled to Issue: April 2012
NPDES DIVISION CONTACT
If you have questions regarding any of the above information or on the attached permit, please
contact Ron Berry at [phone] or email [e-mail].
NAME: DATE:
REGIONAL OFFICE COMMENTS
NAME: DATE:
SUPERVISOR: DATE:
Fact Sheet
NPDES NCO072575
Page 3 of 3

IWC Calculations
Pilgram's Pride Corp, Sanford Plant WWTP
NC0072575
Prepared By: Joe Corporon, NPDES Program
Special: Ave Flow 2014-2015 0.553
Enter s7Q10(cfs): 17
Enter w7Q10 (cfs): 32
Residual Chlorine
Ammonia (NH3 as N)
(summer)
7Q10 (cfs)
17
7Q10 (CFS)
17
DESIGN FLOW (MGD)
0.553
DESIGN FLOW (MGD)
0.553
DESIGN FLOW (cfs)
0.85715
DESIGN FLOW (cfs)
0.85715
STREAM STD (ug/L)
17.0
STREAM STD (mg/L)
1.0
UPS BACKGROUND LEVEL (1
0
UPS BACKGROUND LEVEL (mg/L)
0.22
IWC (%)
4.80
IWC (%)
4.80
Allowable Conc. (ugll)
354
Allowable Conc. (mg/1)
16.5
Ammonia (NH3 as N)
(winter)
7Q10 (CFS)
32
Fecal Limit
2001100ml
DESIGN FLOW (MGD)
0.553
(if DF >331; Monitor)
DESIGN FLOW (cfs)
0.85715
(If DF <331; Limit)
STREAM STD (mg/L)
1.8
Dilution Factor (DF)
20.83
UPS BACKGROUND LEVEL (mg/L)
0.22
IWC (%)
2.61
Allowable Conc. (mg/1)
60.8
Servor/Current Versions/IWC
7/20/2015

pilgrim-ws®
June 8,2015
Danny Smith, Supervisor
NCDENR, Surface Water
Protection
Raleigh Regional Office
3800 Barrett Drive
Raleigh, NC 27609
Re: Amendment of Application for SOC
Pilgrim's• Pride Corporation
Sanford, North Carolina
Permit Number NC 0072575
Dear Mr. Smith,
Pilgrim's submitted an application for a Special Order by Consent (SOC) on September
10, 2012. By this letter, we are submitting an amendment to the application and confirming our
commitment to entering into an SOC for the Sanford, North Carolina processing plant. The
amended information provided below is formatted as set forth in original application:
1. Permit Related Information:
Signing officials name and title:
David A. Townsend, PE
VP Environmental
Owners contact:
Tim Singleton,
tel [phone]

Complex Manager
[e-mail]
U. Pre -Application Meeting:
As a follow-up to the 2012 meeting, Tim Singleton, Rodney Hopper, Bruce Morgan and I
met with you and your staff on May 28, 2015.
III. Additional Flow or Flow Reallocation:
No amendment
IV. Necessity Narrative:
Since the Necessity Narrative was submitted in 2012, the following items have been
completed:
1. A dissolved air flotation unit (DAF) was installed in the offal building to remove oil and
grease before effluent enters the anaerobic lagoon.
2. Testing was completed on the anaerobic lagoon and it was determined solids
accumulation has reduced the hydraulic retention time to a few days. Bacteria and
enzyme products from several vendors have been added to the lagoon over the past
several years to degrade the grease cap and accumulated solids. Biogas production has
increased indicating increased digestion of solids, however, the retention time remains
limited. (Plans for replacing the anaerobic lagoon are discussed further below).
3. The operators have made adjustments to the cyclic aeration/anoxic basin to increase time
for denitrification. However, being a single basin the operators have not been able to
provide enough off time to reduce nitrogen consistently below the permit limits. At
times ammonia has exceeded the permit limits when denitrification time was increased.

4. Pilgrim's has worked with several vendors on ways to increase denitrification, including
Novozymes, a supplier of bacterial and enzyme products that are used to augment
wastewater systems. Novozymes provided an experimental fermentation reactor in 2012
at the Sanford facility to grow denitrification bacteria. The Total Nitrogen results did
improve for several months; however, the improvement was temporary.
V. Certification
The engineering report prepared by Rowe Environmental in 2012 concluded that the
existing plant is not capable of reliably meeting the permit limit for Total Nitrogen. Pilgrim's has
tried a number of operational and alternate methods to reduce Total Nitrogen. As discussed
during our May 28°i meeting, we have retained Reid Engineering to evaluate the recent
performance data and design the selected facility upgrades.
Reid Engineering has recommended that we construct a new anaerobic lagoon and
upgrade the single stage activated sludge system to a two -stage biological nitrogen removal
(BNR) system to provide improved nitrogen removal capability. The existing anaerobic lagoon
will be converted to a waste activated sludge digester.
During the time that the BNR system is being constructed, Pilgrim's requests interim
limits for Total Nitrogen and Ammonia. After review the discharge monitoring data for the past
several years, we request that interim limits for Total Nitrogen of 200 mg/L monthly average and
250 mg/L. daily maximum. We also request that the cold -weather Ammonia limits of 2 mg/L
average and 4 mg/L maximum be applied year round until the upgrade is completed and
operational.

VI. Predicted Compliance Schedule
Reid Engineering will provide a construction and compliance schedule that will be
submitted in the near future.
VII. Funding Sources
Pilgrims remains committed to provide the necessary funding to upgrade the Sanford
wastewater treatment plant.
Please contact me by phone at 970-347-5730, or via e-mail at
dave.townsendPpilgrims.com should you have any questions.
Sincerely,
U.-i A,-(f Li
David A. Townsend, P.E.
VP Environmental Engineering

December 13, 2012
Danny Smith, Supervisor
Surface Water Protection
Raleigh Regional Office
1617 Mail Service Center
Raleigh, North Carolina 27699
RE: Application for SOC
Pilgrim's Pride Corporation
Sanford, NC
Permit NO: NC0072575
Dear Mr. Smith,
I am writing to request a change with the Special Order By Consent Application we submitted in
September. In the Necessity Narrative, item number 3 of the things listed we have done to improve our
operation, you will see there was a test being done to identify bacteria that would aid in the de -
nitrification process of our system. Novozymes, out of Salem, Virginia, was working on selecting a
bacterial blend that would aid in our process. They had been working with a small tank using our water
to determine what blend would work the best. As of the submitting of the SOC application, there had
not been a lot of progress on this effort. But at the end of October, a blend was selected and introduced
to our system on November V. It has shown very good results. The addition to the system started at
30 pounds per day and now is down to 10 pounds per day. It has brought the system into compliance
and looks to be working really well. In the next couple of months, we will be working to determine the
level of dosage required. Although this is working well at this time, we feel the real test will be in the
summer months. But we also think adjusting the dosage as the weather warms will take care of the
issues we had with nitrogen in the discharge.
Based on the information above, we would like to withdraw the SOC application at this time but keep it
in the files. If at some time we feel the addition of the de -nitrifying bacteria will not accomplish the goal
of meeting our permit limits, we will move forward with the upgrade to the system. Our goal and
responsibility is to meet our permit limits and we intent to make the changes necessary to make that
happen.
If you have any questions, feel free to call John Gangwer at 540-896-0767.
Rely,
ex Manager, Sanford, NC
Pilgrim's Pride Corporation

r.1
a0
p;lgrirn,Fs»
September 10, 2012
Danny Smith, Supervisor
Surface Water Protection
Raleigh Regional Office
1617 Mail Service Center
Raleigh, North Carolina 27699
RE: Application for SOC
Pilgrim's Pride Corporation
Sanford, NC
Permit No: NC0072575
Dear Mr. Smith,
cz�
This contains the application for the Special Order By Consent for Pilgrim's Pride Corporation in
Sanford, North Carolina. There are three copies of the application and attachments.
If you have any questions, feel free to call me at 540-896-0767 or 540-810-3628.
Sincerely,
Jo, n Gangwer
Director of Environmental Affairs, Eastern Region
Pilgrim's Pride Corporation
330 Co-op Drive
Tirnbervilie, Virginia 22853

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOUR ► t - `_ r, ` ''
DIVISION OF WATER QUALITY
APPLICATION FOR A SPECIAL ORDER BY CONSENT S E P 1 2012 i i
(SO ) L_
I. PERMIT RELATED INFORMATION:
1. Applicant (corporation, individual, or other): i mS Pr ► dt Co reopal
2. Print or Type Owner's or Signing Official's Name and Title:
Wa 11- S h aJ'e r Sew le r VP - c. A iy o`GA 1 le ry,'C-es
3. Facility Name (as shown on Permit): 1 Pr, d 1_, e-� rIi � / /,k'''�
4. Owner Phone: G% - 7 �] 7332 (or)
5. Owner Email: nn vg l as . m ao re— @ p 1 i 2 r i M .f . Lo m
4. Application Date: se92%4 n be r �6 , go 1 �
5. NPDES Permit No. (if applicable): NC o © -7 a ��
6. Name of the specific wastewater treatment facility (if different froin 1.3. above):
&A
II. PRE -APPLICATION MEETING:
Prior to submitting this completed application form, applicants must meet with the appropriate
regional office staff to discuss whether or not an SOC is appropriate for this situation. Please
note the date this meeting occurred and who represented the permittee:
Representative: Toh,v Ga/y 9 k�r , 13r rrcc M droa1v Date: Ty 1 y 3 ayl x
J0o v �1 as / O,',.
III. ADDITIONAL FLOW OR FLOW REALLOCATION:
In accordance with NCGS 143-215.67(b), only facilities owned by a unit of government may
request additional flow.
Additional flow may be allowed under an SOC only in specific circumstances. These
circumstances may include eliminating discharges that are not compliant with an NPDES or
Non -discharge permit. These circumstances do not include failure to perform proper
maintenance of treatment systems, collection systems or disposal systems. When requesting
additional flow, the facility must include its justification and supporting documentation.

fORIN
If the requested additional flow is non -domestic, the facility must be able to demonstrate the
ability to effectively treat the waste and dispose of residuals. The applicant must provide a
detailed analysis of the constituents in the proposed non -domestic wastewater.
The total domestic additional flow requested:
The total non -domestic additional flow requested:
The total additional flow (sum of the above):
gallons per day.
gallons per day.
gallons per day.
Please attach a detailed description or project listing of the proposed allocation for additional
flow, with an explanation of how flow quantities were estimated. Further, any additional flow
requested must be justified by a complete analysis, by the permittee, that additional flow will not
adversely impact wastewater collection/treatment facilities or surface waters.
IV. NECESSITY NARRATIVE: S,, fi Ifa L A m {^'t L
Please attach a narrative providing a detailed explanation of the circumstances regarding the
necessity of the proposed SOC. Include the following issues:
• Existing and/or unavoidable future violations(s) of permit conditions or limits(s),
• The existing treatment process and any process modifications that have been made to
date to ensure optimum performance of existing facilities,
• Collection system rehabilitation work completed or scheduled (including dates),
• Coordination with industrial users regarding their discharges or pretreatment facilities.
Identify any non -compliant significant industrial users and measure(s) proposed or
already taken to bring the pretreatment facilities back into compliance. If any industrial
facilities are currently under consent agreements, please attach these agreements,
• Date and outcome of last Industrial Waste Survey,
• Whether or not the facility is acting as a regional facility receiving wastewater from other
municipalities having independent pretreatment programs.
V. CERTIFICATION: Jcm I¢i"a c A ptezt IL
The applicant must submit a report prepared by an independent professional with expertise in
wastewater treatment. This report must address the following:
• An evaluation of existing treatment units, operational procedures and recommendations
as to how the efficiencies of these facilities can be maximized. The person in charge of
such evaluation must sign this document.
• A certification that these facilities could not be operated in a manner that would achieve
compliance with final permit limits. The person making such determination must sign
this certification.
• The effluent limits that the facility could be expected to meet if operated at their
maximum efficiency during the term of the requested SOC (be sure to consider interim
construction phases).
• Any other actions taken to correct problems prior to requesting the SOC.
2

iO1
VI. PREDICTED COMPLIANCE SCHEDULE: fex. 14-t ,aCh lne�'1"
The applicant must submit a detailed listing of activities along with time frames that are
necessary to bring the facility into compliance. This schedule should include milestone dates for
beginning construction, ending construction, and achieving final compliance at a minimum. In
determining the milestone dates, the following should be considered:
• Time for submitting plans, specifications and appropriate engineering reports to DWQ for
review and approval.
• Occurrence of major construction activities that are likely to affect facility performance
(units out of service, diversion of flows, etc.) to include a plan of action to minimize
impacts to surface waters.
• Infiltration/Inflow work, if necessary.
• Industrial users achieving compliance with their pretreatment permits if applicable.
• Toxicity Reduction Evaluations (TRE), if necessary.
VII. FUNDING SOURCES IDENTIFICATION: j41+a4 ' n'l- 331:
The applicant must list the sources of funds utilized to complete the work needed to bring the
facility into compliance. Possible funding sources include but are not limited to loan
rlo� commitments, bonds, letters of credit, block grants and cash reserves. The applicant must show
that the funds are available, or can be secured in time to meet the schedule outlined as part of this
application.
If funding is not available at the beginning of the SOC process, the permittee must submit a copy
of all funding applications to ensure that all efforts are being made to secure such funds.
Note: A copy of the application should be sufficient to demonstrate timeliness unless regional
office has reason to request all information associated with securing funding.
THE DIVISION OF WATER QUALITY WILL NOT ACCEPT THIS APPLICATION
PACKAGE UNLESS ALL OF THE APPLICABLE ITEMS ARE INCLUDED WITH THE
SUBMITTAL.
Required Items:
a. One original and two copies of the completed and appropriately executed application
form, along with all required attachments.
• If the SOC is for a City / Town, the person signing the SOC must be a ranking
elected official or other duly authorized employee.
• If the SOC is for a Corporation / Company / Industry / Other, the person signing
the SOC must be a principal executive officer of at least the level of vice-
president, or his duly authorized representative.
• If the SOC is for a School District, the person signing the SOC must be the
/ALIN Superintendent of Schools or other duly authorized employee.
3

A
Note: Reference to signatory requirements in SOCs may be found in the North
Carolina Administrative Code [TI5A NCAC 2H .1206(a)(3)].
b. The non-refundable Special Order by Consent (SOC) processing fee of $400.00. A
check must be made payable to The Department of Environment and Natural
Resources. +
c. An evaluation report prepared by an independent consultant with expertise in
wastewater. (in triplicate)
APPLICANT'S CERTIFICATION:
(NO MODIFICATION TO THIS CERTIFICATION IS ACCEPTABLE)
1, &X/ S�i� , attest this application for a Special Order by
Consent (SOC) has been reviewed by me and is accurate and complete to the best of my
knowledge. I understand if all required parts of this application are not completed and if all
required supporting information and attachments are not included, this application package may
be returned as incomplete. (Please be advised that the return of this application does not prevent
DIVO from collecting all outstanding penalties upon request). Furthermore, I attest by my
signature that I fully understand that an upfront penalty, which may satisfy as a full
settlement of outstanding violations, may be imposed. (Note: Reference to upfront penalties
in Special Orders by Consent may be found in the North Carolina Administrative Code [T15A
NCAC 2H .1206(c)(3)].)
Date
Signature of Signinj Official
#
Printed Name of Signing Official
THE COMPLETED APPLICATION PACKAGE, INCLUDING THE ORIGINAL AND TWO
COPIES OF ALL SUPPORTING INFORMATION AND MATERIALS, SHOULD BE SENT
TO THE FOLLOWING ADDRESS:
NORTH CAROLINA DIVISION OF WATER QUALITY
POINT SOURCE BRANCH
1617 MAIL SERVICE CENTER
RALEIGH, NORTH CAROLINA 27699-1617
IF THIS APPLICATION IS FOR A NON -DISCHARGE SYSTEM, THEN SEND TO:
NORTH CAROLINA DIVISION OF WATER QUALITY
AQUIFER PROTECTION SECTION
1636 MAIL SERVICE CENTER
RALEIGH, NORTH CAROLINA 27699-1636
taw) 4

/^
/\
VENDOR NUMBER 123354 - VENDOR NAME NC DEPT OF ENVIRONMENT 8, NATRL RES 2808996 08/24/2012
INVOICE NUMBER DESCRIPTION DATE P.O. NUMBER GROSSAMOUNT DISCOUNT NET AMOUNT
AUG1612 SPECL ORDER BY CONSENT PR 08/16/2012 400.00 0.00 400.00
1099 Reportable
For payment inquiries please call 903-434-7670
o.00 TOTALS
400.00 0.00 400.00
PP= 403
• r s • r
p PILGRIM'S PRIDE CORPORATION HARRIS BANK ROSELLE 7o-155an1s
"GA f Roselle, Illinois
1' Area Code 903 • Phone [phone] • P.O. Box 93 • Pittsburg, Texas 75686
No. 2808996
® Date 08/24/2012
1 $400.00
Pay Four Hundred And 001100 Dollars C� .
TO THE NORTH CAROLINA DIV OF WATER QUALIT
ORDER OF POINT SOURCE BRANCH
1617 MAIL SERVICE CENTER
RALEIGH NC 27699-1617
AUTHORIZED SIGNATURES)
VOID AFTER 90 DAYS
II' 280899611' 1:0719 IS S80i: 04em378oi184 Jim &II■

I
Necessity Narrative
For the last couple of years the waste water plant has been struggling to treat the amount of
nitrogen entering the aerobic part of the system. There have been numerous operational changes and
upgrades to try and get the desired results. Listed below are some of the things that have been done to
improve the level of treatment.
1. All of the diffusers in the aeration basin were replaced in the spring of 2012.
2. The filter media in the fuzzy filter was replaced in the spring of 2012.
3. There is a test being done at this time to grow de-nitrifiers and add to the aeration basin to
help the de -nitrification step.
4. We have regular assistance from Maryland BioChemical for culture to add to the anaerobic
lagoon as well as the aeration basin. They have also assisted us in trying to determine the
changes we need to make to improve the system.
5. We did some extensive testing on the effluent from the anaerobic lagoon to determine
information about the quality of water from the anaerobic lagoon. This has changed over
the years, especially in the summer time. It appears the TKN is higher now than it use to be.
6. There have been numerous operational changes to try and improve the performance. The
latest one was to change the blowers from an ammonia mode to a DO mode of operation.
It seemed the probe monitoring the ammonia was getting some interference from some
other parameter. This was just changed 6 weeks or so ago and has made a difference in the
ammonia results. It has not helped the Nitrates.
7. A secondary screen has been installed in the offal building to take loading off of the
anaerobic lagoon.
The following things are currently being engineered and /or planned to be installed in the near
future.
1. A DAF will be installed in the offal building to remove oil and grease before the anaerobic
lagoon.
2. We are going to try and do some testing on the anaerobic lagoon to determine what the
levels of solids on the top and bottom are at this point. It is very hard to do because it is a
covered lagoon and we can not accomplish this until the gas under the cap is burnt off. It is
currently producing a lot of gas with the warm weather. This will probably be a winter
project.
3. The operators are continually adjusting the operating parameters to improve the results.
It is apparent that we will not be able to de -nitrify in the current system. We are going to have to
/Ot� upgrade the system by installing a de -nitrification step in the system. This will require a new basin,
piping changes, and training in the operation. I am estimating this will take about 18 months to get all of

the engineering completed, approved, and installation done. During this time we will not be able to
comply with the Total Nitrogen in a consistent manner. In the mean time, the operators will be working
hard to achieve the best possible performance.

TF
PERFORMANCE CERTIFICATION REPORT
WASTEWATER TREATMENT SYSTEM
PILGRIM'S PRIDE CORPORATION
484 ZIMMERMAN ROAD
SANFORD, NC 27330
September 6, 2012
prepared b
Vernon D. Rowe, P.E.
rowenviron mental
145 Jefferson Street
Pittsburg, Tx 75686
[phone]
Fax [phone]
Cell [phone]
Email [e-mail]

TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1 INTRODUCTION 1
2 DESCRIPTION OF EXISTING WASTEWATER SYSTEM 3
3 EFFLUENT LIMITS S
4 EXISTING EFFLUENT PERFORMANCE 6
5 ACHIEVABLE PERMIT LIMITS 9
6 PRIOR ACTIONS TAKEN 10
7 PROPOSED SYSTEM UPGRADES 11
IQ

La -
SECTION 1
INTRODUCTION
Pilgrim's Pride Corporation operates a poultry processing facility located at 484 Zimmerman
Road, Sanford, Lee County, NC. Figure No.1 provides an aerial layout of the processing facility
and associated wastewater treatment system.
Wastewater from the facility is treated and discharged into the Cape Fear River Basin under
authorization of NPDES Permit No. NC0072575 issued by the North Carolina Department of
Environment and Natural Resources.
This report provides an assessment of the treatment capabilities of the existing wastewater
treatment system and the ability of the treatment system to comply with the effluent
limitations established in the NPDES permit.
page 1

I f�om�o
Nw rn�l
Ir

Pilgrim's Pride
Lee County NPDES Permit No. NCO072575
January 1, 2009 - March 30, 2012
Descriptive Statistics
Mean Std. Dev. Std. Error Count Minimum Maximum # Mssina Variance Median
TN
NH3
TP
88.233
22.271
1.267
309
1.290
167.000
172
495.980
87.300
.562
.676
.031
481
.100
7.860
0
.457
.430
17.380
9.931
2.754
13
1.330
40.200
468
98.631
16.200
Box Plot
180
160
140
120
100
80
60
40
20
0
-20
TN
Percentiles
TN
10
62.220
25
75.150
50
87.300
75
100.000
90
118.000
Univariate Scattergram
180
160
140
120
100
80
60
40
20
0
_......................... ------
----------
��......
•ice. �_
.................................................................................................................................
-20
Observations
Frequency Distribution for TN
Frnm f>=) To (<) Count
1.290
17.861
1
17.861
34.432
0
34.432
51.003
10
51.003
67.574
39
67.574
84.145
86
84.145
100.716
98
100.716
117.287
43
117.287
133.858
22
133.858
150.429
7
150.429
167.000
3
Total
309
+1 SD
Mean
-1 SD

9
8
7
6
5
Z `;
3
2
1
0
_1
Pilgrim's Pride
Lee County NPDES Permit No. NC0072575
January 1, 2009 — March 30, 2012
Box Plot
9
8
7
6
5
4
3
2
1
0
_1
Univariate Scattergram
TIN
Observations
+1 SD
Mean
-1 SD

Pilgrim's Pride
Lee County NPDES Permit No. NCO072575
January 1, 2009 — March 30, 2012
Percentiles
10 .167
25 .236
50 .430
75 .632
90 .961
Frequency Distribution for NH3
From (>=) To (<) Count
.100
.876
421
.876
1.652
43
1.652
2.428
8
2.428
3.204
2
3.204
3.980
2
3.980
4.756
2
4.756
5.532
1
5.532
6.308
1
6.308
7.084
0
7.084
7.860
1
Total
481

45
40
35
30
25
20
15
10
5
0
45
40
35
30
a. 25
20
15
10
5
0
Pilgrim's Pride
Lee County NPDES Permit No. NCO072575
January 1, 2009 — March 30, 2012
Box Plot
•
•
T
TP
Univariate Scattergram
•
•
....................................................._............................................................................................
•
...........
..................4..............I............
...... .............................
...
f
•
....................................................................................................................................................
•
Observations
+1 SD
Mean
-1 SD

Pilgrim's Pride
Lee County NPDES Permit No. NCO072575
January 1, 2009 — March 30, 2012
Box Plot
1.2
1
.8
.6
.4
.2
0
-.2
Univariate Scattergram
1.2
1
.8
4 .6
.4
.2
0
-.2
Descriptive Statistics
Flow
Mean
.718
Std. Dev.
.178
Std. Error
.005
Count
1211
Mnn-um
.001
Maximum
1.127
# Missing
1
Variance
.032
Median
.738
• • Y •0 0%
goo 0• • • •• •
..
N • •
Observations
+1 SD
Mean
-1 SD

6C 79 q-7.3 33e /oa

n
a0
pllgnm,,s,.
August 14, 2012
Danny Smith
Supervisor, Water Protection
1628 Mail Service Center
3800 Barrett Drive
Raleigh, NC 27669
RE: Pilgrim's Pride Corporation
Application for Special Order by Consent
Letter of Funding Guarantee
Dear Mr. Smith,
Pilgrim's Pride Corporation supports the need for the proposed upgrade to our waste water system in
Sanford, North Carolina. This proposed upgrade will add a de -nitrification step in the process to
improve the treatment of nitrogen and comply with the permit limits. The estimated cost for this
upgrade is about $700,000. We will be adding this to our budget for 2013 so the money will be available
to complete the project. Once the project is fully engineered, if there is any change in the funds needed
for this project it will be adjusted accordingly.
If you have any questions about this project, please contact Doug Moore at the Sanford Complex at the
following number, 919-774-7333.
Sir ,
Walt Shafer
Senior VP
Technical Services
Pilgrim's Pride Corporation
r

ITEM
BEGIN
COMPLETE
_
Preparation of Detailed Plans
and Specifications
September 10, 2012
December 10, 2012
Submittal of Detailed Plans
and Specifications to DENR for
Review and Approval
December 17, 2012
March 18, 2013
Bid Advertising
April 1, 2013
May 1, 2013
Bid Review and Construction
Contract Award
May 11 2013
May 15, 2013
Construction
May 22, 2013
January 14, 2014
Startup/Compliance
January 14, 2014
March 3, 2014
W

CONSTRUCTION/COMPLIANCE SCHEDULE
WASTEWATER TREATMENT SYSTEM
PILGRIM'S PRIDE CORPORATION
484 ZIMMERMAN ROAD
SANFORD, NC 27330
September 6, 2012
prepared b
Vernon D. Rowe, P.E.
rowenvironmental
145 Jefferson Street
Pittsburg, Tx 75686
[phone]
Fax [phone]
Cell [phone]
Email [e-mail]

FIGURE NO. 4— LAYOUT DRAWING —WASTEWATER SYSTEM UPGRADE
page 13

FIGURE NO. 3 — PROCESS FLOW DIAGRAM — WASTEWATER TREATMENT SYSTEM
page 12

14�
SECTION 7
PROPOSED SYSTEM UPGRADES
As has been indicated, it is believed that the existing system is being operated and maintained
as well as possible and the system is achieving effluent levels that are at or better than the
original design levels for the system. The system will have to be upgraded to address loadings
and enhance denitrification capabilities.
Specific upgrades will include:
• Installation of a dissolved air flotation (DAF) system in the offal building to
remove oil and grease and suspended solids upstream of the anaerobic lagoon.
• Construction of a new denitrification basin between the anaerobic lagoon and
the aeration basin.
Figure No. 3 provides a process flow diagram for the system with the new DAF and
denitrification basin. Figure No. 4 provides a layout drawing for the biological treatment
system with the new denitrification basin.
page 11

fgo1 SECTION 6
PRIOR ACTIONS TAKEN
The facility has implemented numerous operational changes and upgrades to attempt to
comply with all permit limits, in particular the total nitrogen limits. A list of the changes and
upgrades completed to date is as follows:
• A secondary screen has been added in the offal room to improve solids removal
upstream of the anaerobic lagoon.
• All diffusers in the aeration basin were replaced in Spring, 2012.
• The filter media in the Fuzzy Filter was replaced in Spring, 2012.
• An ongoing trial is being run at the facility to grow de-nitrifiers in a dedicated reactor
to be added to the aeration basin to increase denitrification.
• Bioaugmentation products have been added to the anaerobic lagoon and the
aeration basin to enhance biological activity.
• An extensive evaluation of the anaerobic lagoon has been completed to assess the
flow through the lagoon as well as the causes for higher effluent total nitrogen levels
from the lagoon. It has been determined that the lagoon potentially has significant
solids build up that might be contributing to the total nitrogen levels due to
nitrogen release. The gas cap on the lagoon is being pumped down. As soon as the
gas cap is down sufficiently the lagoon will be sounded to inventory the solids in the
lagoon to make a decision regarding the potential necessity for solids removal.
• The original design of the aeration basin used an ammonia probe to control the
cycling of blowers. A change has been made to allow operation of the blowers
based on dissolved oxygen levels rather than ammonia levels. This has improved
ammonia nitrogen effluent levels but has not significantly reduced the effluent
nitrate nitrogen levels.
page 10

(001 SECTION 5
ACHIEVABLE PERMIT LIMITS
n
Table No. 4 summarizes the effluent limits the existing can be expected to meet if operated at
maximum efficiency as currently configured.
TABLE NO.4
ACHIEVABLE EFFLUENT LIMITS
PILGRIM'S PRIDE CORPORATION, SANFORD, NC
EFFLUENT CHARACTERISTICS
MONTHLY AVERAGE
DAILY MAXIMUM
Flow
1.0 mgd
BOD, 5 day, 20 deg C (April 1—
October 31)
_
5.0 mg/I
10.0 mg/I
BOD, 5 day, 20 deg C
(November 1— March 31)
10.0 mg/I
20.0 mg/I
NH3N (April 1— October 31)
1.0 mg/I
2.0 mg/I
NH3N (November 1— March
31)
2.0 mg/I
4.0 mg/i
Total Suspended Solids (TSS)
20 mg/I
30 mg/I
Oil and Grease
8.0 mg/I
14.0 mg/I
Dissolved Oxygen
Not less than 6.0 mg/I daily
average
Fecal Coliform
200/100 ml
400/100 ml
Total Residual Chlorine (TRC)
28 ug/I
pH
Not greater than 9.0 S.U. nor
less than 6.0 S.U.
Total Nitrogen
125 mg/I
160 mg/I
page 9

TABLE NO.3
EXISTING EFFLUENT QUALITY
PILGRIM'S PRIDE CORPORATION, SANFORD, NC
Legend: Excee antes of Average E uent Limits
ANAEROBIC
LAGOON
FINAL EFFLUENT
BOD
BOD
TKN
DOD
SS
FECAL
08G
NH3-N
TKN
NO3
TOTAL N
MONTH
mg/L
to TKN
Ratio
mg/L
mWL
mglL
IM100
mgiL
mgiL
mg/L
mg/L
mg/L
FLUENT
6 (APR-OCT)
1. A
1
L T10
{ O -
Jan49
93
0974
955
662
1031
5
6.5
101
148
61.18
Feb-08
65
0 766
111
10.23
2091
4
74
075
1.55
5453
5608
Mar-09
103
1.016
101.4
453
831
7
6
0.32
18
69 02
70.62
A rr09
74
0.590
123.8
4.3
8.1
5
8.4
0.24
13
7404
7534
Ma
78
0.609
128
3.31
685
3
62
02
1.96 1
9162
9156
Jun49
78
0.544
1433
3.8
4.69
3
6.3
0.33
143
949
9633
Jul-09
48
OA15
1158
409
668
4
90
0.53
175
8139
8315
Aug-09
104
0 949
1096
3.9
7.08
4
58
022
201
10455
106.56
Sep49
48
0,368
1303
10.24
523
30
<5
049
192
865
8842
Oct-09
42
0 286
147
302
4.85
5
02
1.42
8458
86
Nov48
217
1 186
1829
363
8.24
38
53
0.65
25
6478
8726
Dec49
81
0 693
1168
243
5.93
6
036
2.48
8201
84 1
Jan-1 O
82
0 857
957
38
3.75
7
<5
0.66
2.04
7905
8109
Feb-10
70
0.522
134
268
3.1
28
6.5
082
17
71.95
7365
Mar-10
66
0 547
1206
39
372
141
5.3
0.75
1.31
71.36
7268
A r-10
80
0.620
129
28
3.18
59
<5
072
1.81
9406
9587
Ma -10
85
0 539
157 8
2 37
395
6
5
0.46
147
9558
9705
Jun10
74
0 568
1303
2.4
282
2
0
054
1.22
99.21
100.42
Jul-10
63
0 535
117.7
215
195
5
0
0.6
2.17
974
9957
Aug-10
97
0.744
130 3
424
5.84
6
1 7.4
048
170
83.21
8492
Se 10
66
0 544
1213
376
3.28
2
61
0.39
1.84
98.23
100.08
Oct-i0
57
0.374
152.3
3.04
3.53
2
<5
0.56
192
8961
91.52
Nov 10
53
0.427
124
37
2.43
3
0
072
1.43
8965
91.06
Dec-10
1 63
0.496
127
5.27
3.3
1
069
2.03
931
9513
Jan41
75
0.626
119.8
ill
04
1
0.39
086
1.04
731
74.14
Feb-11
75
0.604
124.1
3.32
2.45
2
0.56
0.65
608
6145
Mar-11
68
0.516
131.7
3.5
2.82
5
051
0.49
50.4
5089
Apr-1 1
67
0703
123.8
2.87
2.23
5
0
0.42
1.85
77.2
7905
May-11
63
0 510
123.5
435
2.53
5
0
048
076
118.5
119.28
Jun41
58
0 344
168.8
40.02
3.47
2
0
0.27
075
128
129
Ju1-11
51
0 277
184
378
2.67
3
0
049
0.96
135
136
Sep-11
57
0.229
249
0
413
10
25
028
192
159
160.92
Oct-11
50
0 327
1511
0
4.88
2
0
025
0.54
117
117.54
Nov-11
53
0 314
1688
0
3.77
1
0
041
299
944
97.39
Dec-11
59
0 472
125
208
2.89
1
0
035
1.46
917
9316
Jan42
68
0.531
128
0
272
1
0
2.29
1,77
92
9377
Mar-12
55
0.306
179.7
248
5.06
4
9.3
05
2.64
887
913
Apr-12
46
0.188
2448
222
571
13
77
023
2.22
129.33
131.56
May-12
46
0.168
273.1
2-64
775
17
5.7
0.31
51
172
117.13
Jun-12
39
0142
2737
299
471
2
53
6.23
3.24
105
108.24
page 8

/do� In summary, the existing system is capable of complying with all existing permit limits with the
exception of the total nitrogen limits. The facility is being operated as efficiently as is possible
given the original design capabilities of the system. There are not believed to be any immediate
changes that the facility can make to operations that will assure compliance due to the
treatment design limitations of the system. The system will have to be upgraded to provide
additional tankage that facilitates designed nitrification/denitrification capabilities to comply
with all permit effluent limits.
�1
ia*1
page 7

SECTION 4
EXISTING EFFLUENT PERFORMANCE
Table No. 3 summarizes the average effluent quality from the existing wastewater system for
the period of January, 2009 thru June, 2012. The following comments are provided regarding
the permit effluent exceedances that occurred during the period:
• BOD — The BOD limit was exceeded 3 times. There are no specific explanations for
the exceedances. Overall compliance with BOD limits is not considered to be a
major issue
• TSS — The TSS limit was slightly exceeded 1 time. Overall compliance with TSS limits
is not considered to be a major issue.
• Oil and Grease — The 0&G limit was slightly exceeded 4 times. Overall compliance
with TSS limits is not considered to be a major issue.
• NH3N —The NH3N limit was exceeded two times. Overall compliance with NH3N
limits is not considered to be a major issue. However, the November to March limit
of 2 mg/I is relatively low, particularly during the colder months of December thru
February.
• Total Nitrogen —The wastewater treatment system as currently configured was not
designed to denitrify. As a result, the total nitrogen limit has been exceeded 9 times
during the period. The total nitrogen exceedances are being caused by the following
issues:
o Anaerobic Lagoon Total Nitrogen Loadings — Table No. 3 provides the average
BOD and TKN effluent levels from the existing anaerobic lagoon. The TKN levels
from the anaerobic lagoon are well above the permit effluent total nitrogen of
103 mg/I. Due to the fact that the existing system is not designed to fully
denitrify the system is not capable of meeting the total nitrogen limits at all
times due to the generation of nitrate nitrogen during the aerobic biological
treatment process.
o BOD to Nitrogen Ratios —The anaerobic lagoon provides a very high degree of
BOD removal. As a result, the BOD to TKN ratios out of the anaerobic lagoon
into the aeration basin are well below the typical 2.5 to 3.0 ratio needed for
effective denitrification.
o Aeration Detention Time — As indicated, the existing aeration basin was not
originally designed to provide full denitrification. The aeration basin is operated
in a cyclic manner wherein blowers are cycled on and off to provide oxic and
anoxic steps. However, the basin is not large enough to provide adequate
detention time to assure complete nitrification if the blowers are cycled off long
enough to increase the degree of denitrification. The system is operated to
assure minimum ammonia nitrogen levels, with resultant total nitrogen levels
being as low as possible but not always below the permit limits.
I" 1 page 6

SECTION 3
EFFLUENT LIMITS
Table No. 2 provides the effluent limits for the facility.
TABLE NO.2
EFFLUENT LIMITS
PILGRIM'S PRIDE CORPORATION, SANFORD, NC
EFFLUENT CHARACTERISTICS
MONTHLY AVERAGE
DAILY MAXIMUM
Flow
1.0 mgd
BOD, 5 day, 20 deg C (April 1—
October 31)
5.0 mg/I
10.0 mg/I
BOD, 5 day, 20 deg C
(November 1— March 31)
10.0 mg/I
20.0 mg/I
NH3N (April 1— October 31)
1.0 mg/I
2.0 mg/I
NH3N (November 1— March
31)
2.0 mg/I
4.0 mg/I
Total Suspended Solids (TSS)
20 mg/I
30 mg/l
Oil and Grease
8.0 mg/I �^
14.0 mg/1
Dissolved Oxygen
Not less than 6.0 mg/I daily
average
Fecal Coliform
200/100 ml
400/100 ml
Total Residual Chlorine (TRC)
28 ug/1
pH
Not greater than 9.0 S.U. nor
less than 6.0 S.U.
Total Nitrogen
103 mg/I
147 mg/i
page 5

r^\
r�
�JVVIV
l �"A
s
is
FUZZY
SFILTER
CHLORINATI
DECHLORINAtl(*
BASIN
Figure No. 2 — Biological Wastewater Treatment System Aerial Layout
page 4

�4'
SECTION 2
DESCRIPTION OF EXISTING WASTEWATER TREATMENT SYSTEM
Figure No. 2 provides an aerial layout�of the key components of the wastewater treatment
system. A general description of the :key components of the treatment system is provided in
Table No. 1.
Table No.1
Wastewater Treatment System Components
Pilgrim's Pride Corporation, Sanford, NC
COMPONENT
DESCRIPTION
Screening
Primary and secondary screens for feather and
offal recovery and offsite rendering
Equalization Tank
35,000 gallons
Covered/Lined Anaerobic Lagoon with
17,000,000 gallons
Methane Gas Flare
Aeration Basin
2,500,000 gallons Schreiber Process with
magnesium hydroxide addition for alkalinity
control
Final Clarifier
500,000 gallons with return activated sludge
screw pumps
Tertiary Filter
Schreiber Fuzzy Filter with backwash basin and
pumps
Lined Emergency Holding Lagoon
14,000,000 gallons
Disinfection System
Chlorination Basin with Dechlorination Basin
and water reuse pumps
Monitoring Equipment
Effluent Parshall Flume, flow meter, and
composite sampler
Post Aeration
Cascade Aeration Basin
page 3