WQ0004967_Final Permit_19930708

State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street - Raleigh, North Carolina 27604
James B. Hunt, Jr., Governor
July 8, 1993
Mr. Dwight Gilbert, President, Board of Directors
Carolina Apple Processors Cooperative, Inc.
Route 6, Box 87-B
Hendersonville, North Carolina 28739
Dear Mr. Gilbert:
Jonathan B. Howes, Secretary
Subject: Permit No. WQ0004967
Carolina Apple Processors, Inc.
Wastewater Spray Irrigation and
Treatment Facility
Henderson County
In accordance with your renewal request received March 5, 1993, we are forwarding herewith
Permit No. WQ0004967, dated July 8, 1993, to Carolina Apple Processors, Inc. for the continued
operation of the subject wastewater treatment facilities. This permit authorizes the subject wastewater
treatment facility to accept and treat wastewater from the production of juice from concentrate ONLY.
Please be advised, the Division is issuing this permit for a period of one year with the
understanding that .when the request for permit renewal is submitted, this request shall also include
appropriate plans, specifications and documentation for modifications to the existing lagoon and spray
irrigation facilities. This request must include plans for the installation of a liner, an evaluation of the
clarifier and solids handling equipment for the adequacy of treating wastes from the processing of whole
apples and other modifications as deemed necessary prior to the Division allowing a renewal of the permit
and processing of whole apples.
This permit shall be effective from the date of issuance until September 30, 1994, shall void Permit
No. WQ0004967 issued October 9, 1992 and shall be subject to the conditions and limitations as specifier)
therein. Please pay particular attention to the monitoring requirements in this permit. Failure to establish an
adequate system for collecting and maintaining the required operational information will result in future
compliance problems.
Regional Offices
Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem
7041251-6208 919/486-1541 704/663-1699 919/571-4700 9191946-6481 919/395-3900 919/896-7007
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

If any parts, requirements, or limitations contained in this permit are unacceptable to you, you have
the right to request an adjudicatory hearing upon written request within 30 days following receipt of this
permit. This request must be in the form of a written petition, conforming to Chapter 150B of North
Carolina General Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer 27447,
Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please contact Mr. Michael D. Allen at
[phone].
Sincerel , nn
L.�1. C
jjL
A. Pres Howard, r., P.E.
Director
cc: Henderson County Health Department
Asheville Regional Office, Water Quality
Asheville Regional Office, Groundwater
Groundwater Section, Jack Floyd
Training and Certification Unit
Facilities Assessment Unit

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
SPRAY IRRIGATION SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as
amended, and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Carolina Apple Processors, Inc.
Henderson County
FOR THE
continued operation of a 20,000 GPD non -discharge industrial wastewater treatment facility consisting of a
0.5 million gallon capacity aerated lagoon with two (2) 15 hp floating mechanical aerators, a clarifier, a
sludge holding tank from which the sludge will be applied to approved nearby farmland, and spray
irrigation facilities to apply wastewater generated from the processing of apple juice from concentrate only,
to approximately 7.05 acres of land to serve Carolina Apple Processors, Inc. with no discharge of wastes
to the surface waters, pursuant to the renewal request received March 5, 1993, and in conformity with the
project plan, specifications, and other supporting data subsequently filed and approved by the Department
of Environment, Health and Natural Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until September 30, 1994, shall void Permit
No. WQ0004967 issued October 9, 1992 and shall be subject to the following specified conditions and
limitations:
I. PERFORMANCE STANDARDS
I. The spray irrigation facilities shall be effectively maintained and operated at all times so that
there is no discharge to the surface waters, nor any contamination of ground waters which
will render them unsatisfactory for normal use. In the event that the facilities fail to
perform satisfactorily, including the creation of nuisance conditions or failure of the
irrigation area to adequately absorb the wastewater, the Permittee shall take such immediate
corrective action to correct the problem, including actions as may be required by the
Division of Environmental Management.
2. In the event the irrigation system ceases to function due to mechanical or other problems, or
in the event unsuitable weather conditions prevent the operation of the spray irrigation
system, Carolina Apple Processors, Inc. shall discontinue plant operations until the system
can be restored to proper operation.
3. The issuance of this permit shall not relieve the Permittee of the responsibility for damages
to surface or groundwaters resulting from the operation of this facility.

4. The sludge generated from these treatment facilities must be disposed of in accordance with
General Statute 143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
5. Diversion or bypassing of the untreated wastewater from the treatment facilities is
prohibited.
6. The following buffers shall be maintained:
a) 400 feet between wetted area and any residence or places of public assembly under
separate ownership,
b) 150 feet between wetted area and property lines,
c) 100 feet between wetted area and wells,
d) 100 feet between wetted area and drainageways or surface water bodies,
e) 50 feet between wetted area and public right of ways,
f) 100 feet between wastewater treatment units and wells,
g) 50 feet between wastewater treatment units and property lines.
Some of the buffers specified above may not have been included in previous permits for
this waste treatment and disposal system. These buffers are not intended to prohibit or
prevent modifications, which are required by the Division, to improve performance of the
existing treatment facility. These buffers do, however, apply to modifications of the
treatment and disposal facilities which are for the purpose of increasing the flow that is
tributary to the facility. These buffers do apply to any expansion or modification of the
spray irrigation areas and apply in instances in which the sale of property would cause any
of the buffers now complied with, for the treatment and disposal facilities, to be violated.
The applicant is advised that any modifications to the existing facilities will require a permit
modification.
1. The facilities shall be properly maintained and operated at all times.
2. Upon classification of the facility by the Certification Commission, the PerrrAttee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at Ieast equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class II, III, and IV facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202.
3. A suitable vegetative cover shall be maintained.
4. Irrigation shall not be performed during inclement weather or when the ground is in a
condition that will cause runoff.
5. Adequate measures shall be taken to prevent wastewater runoff from the spray field.
6. Two (2) feet of freeboard shall be maintained at all times in the holding pond.
7. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater resulting from the operation of this facility.
2

8. No type of wastewater other than that from Carolina Apple Processors,. Inc. shall be
sprayed onto the irrigation area.
9. No traffic or equipment shall be allowed on the disposal area except while installation
occurs or while normal maintenance is being performed.
10. Public access to the land application sites shall be controlled during active site use. Such
controls may include the posting of signs showing the activities being conducted at each
site.
11. The only waste that may be discharged into the lagoon shall be comprised of non -contact
cooling water, washdown water and bleach water (2 gallons of bleach water per 1,500 plus
gallons of water) used for the rinsing of the juice tanks.
12. A maximum spray irrigation rate of 0.25 inches per acre per day with a total accumulation
of 1 inch per week shall not be exceeded.
III. MONITORING AND REPORTINQ REQMEMENTS
1. Any monitoring (including groundwater, surface water, soil or plant tissue analyses)
deemed necessary by the Division of Environmental Management to insure surface and
ground water protection will be established and an acceptable sampling reporting schedule
shall be followed.
2. Adequate records shall be maintained by the Permittee tracking the amount of wastewater
disposed. These records shall include, but are not necessarily limited to the following
information:
a) date of irrigation,
b) volume of wastewater irrigated,
C) field irrigated,
d) length of time field is irrigated,
e) continuous weekly, monthly, and year-to-date hydraulic (inches/acre) loadings for
each field,
f) weather conditions, and
g) maintenance of cover crops.
3. The effluent from the subject facilities shall be monitored by the Permittee at the point prior
to irrigation every March, July and November for the following parameters:
BODS TSS
NH3 as N pH
TDS Chlorides
4. Three copies of all operation and disposal records (as specified in condition I112) and all
effluent monitoring data (as specified in condition III 3) and any other data as may be
required shall be submitted on or before the last day of the following month to the
following address:
NC Division of Environmental Management
Water Quality Section
Facility Assessment Unit
PO Box 29535
Raleigh, NC 27626-0535
41

IV.
5. Noncompliance Notification:
The Permittee shall report by telephone to the Asheville Regional Office, telephone no.
[phone] as soon as possible, but in no case more than 24 hours or on the next
working day following the occurrence or first knowledge of the occurrence of any of the
following:
a_ Any occurrence at the wastewater treatment facility which results in the treatment of
significant amounts of wastes which are abnormal in quantity or characteristic, such
as the dumping of the contents of a sludge digester; the known passage of a slug of
hazardous substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures
of pumps, aerators, corepressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-
pass directly to receiving waters without treatment of all or any portion of the
influent to such station or facility.
d. Any time that self-monitoring information indicates that the facility has gone out of
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also.file a written report in letter
form within 15 days following first knowledge of the occurrence. This report must outline
the actions taken or proposed to be taken to ensure that the problem does not recur.
GROUNDWATER E REMENTS
1. A properly sized pump capable of producing sufficient drawdown shall be installed and
properly operated in the existing monitor/recovery well. The water recovered by the well
shall be discharged into the lagoon.
2. A lagoon liner shall be installed before the processing of any whole fruit. The liner shall
conform to 15A NCAC 2H .0219 (f). However, a permit amendment must be requested
and approval obtained prior to this installation or the processing of any whole fruit.
3. The three (3) existing monitor wells shall be sampled every March, July and November for
the following parameters:
NO3 pH
Dissolved Iron TOC
Total Dissolved Solids Chloride
Water Level Total Coliforms
Fecal Coliform SO4
Volatile Organic Compounds - In November only (by Method 1 or Method 2 below)
Method 1: Method 6230D (Capillary - Column), "Standard Methods for the
Examination of Water and Wastewater", 17th edition, 1989
Method 2: Method 502.2 "Methods for the Determination of Organic Compounds in
Drinking Water', United States Environmental Protection Agency - 600/4-
88/039
12

The measurement of water level must be made prior to sampling for the remaining
parameters. The depth of water in each well shall be measured from the surveyed point on
the top of the casing.
The measuring points (top of well casing) of all monitoring wells shall be surveyed to
provide relative elevations of the measuring point for each monitoring well.
If TOC concentrations greater than 10 mg/l are detected in any downgradient monitoring
well, additional sampling and analysis must be conducted to identify the individual
constituents comprising this TOC concentration. If the TOC concentration as measured in
the backaround monitor well exceeds 10 mg/l, this concentration will be taken to represent
the naturally occurring TQC concentration. Any exceedances of this naturally occurring
TOC concentration in the downgradient wells shall be subject to the additional sampling
and analysis as described above.
If any volatile organic compounds are detected by method 6230D, or the equivalent method
502.2, then EPA methods 604 and 611 must also be run to detect other organic compounds
which may be present. The results of all analysis specified in the monitoring requirements,
including 604 and 611 if required, must be submitted simultaneously.
The results of the sampling and analysis shall be sent to the N.C. Division of
Environmental Management on Form GW -59 (Compliance Monitoring Report Form) every
April, August and December.
4. The Compliance Boundaiv_ for the disposal system is specified by regulations in 15 NCAC
2L, Classifications and Water Quality Standards applicable to the groundwater of North
Carolina. An exceedance of Groundwater Quality Standards beyond the Compliance
Boundary is subject to penalty provisions applicable under General Statute 143-215.6(1)a.
For facilities permitted on or after December 30, 1983, the Compliance Boundary is
established at the lesser of 250 feet from the lagoon and spray fields or 50 feet within the
property boundary.
Any sale or transfer of property which affects the location of the compliance boundary shall
be reported immediately to the Director. The Permittee shall not transfer land within an
established compliance boundary unless the Permittee has satisfied all the requirements of
15A NCAC 2L. 107 (e and f).
The REVIEW BOUNDARY for the disposal system is specified by regulations in 15
NCAC 2L, Groundwater Classifications and Standards. A REVIEW BOUNDARY is
established around disposal systems midway between the Compliance Boundary and the
perimeter of the waste disposal area. When the concentration of any substance equals or
exceeds the maximum allowable concentration of that substance at the REVIEW
BOUNDARY, as determined by monitoring, the permittee shallie ther (i) demonstrate,
through predictive calculations or modeling, that natural site conditions, facility design and
operational controls will prevent a violation of standards at the Compliance Boundary; -Q—r,
(ii) submit a plan for the alteration of existing site conditions, facility design or operational
controls that will prevent a violation of standards at the Compliance Boundary, and
implement that plan upon its approval by the Director.
4. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall
be provided.
V. IIN PE TI

1. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
2. The Permittee or his designee shall inspect the wastewater treatment and disposal facilities
to prevent malfunctions and deterioration, operator errors and discharges which may cause
or lead to the release of wastes to the environment, a threat to human health, or a nuisance.
The Permittee shall keep an inspection log or summary including at least the date and time
of inspection, observations made, and any maintenance, repairs, or corrective actions
taken by the Permittee. This log of inspections shall be maintained by the Permittee for a
period of three years from the date of the inspection and shall be made available upon
request to the Division of Environmental Management or other permitting authority.
3. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, enter and inspect any property,
premises or place on or related to the disposal site and facility at any reasonable time for the
purpose of determining compliance with this permit; may inspect or copy any records that
must be kept under the terms and conditions of this permit; or may obtain samples of
groundwater, surface water, or leachate.
VI. GENERAL CONDITIONS
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans, specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
3. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a name change of the Permittee, a formal permit request must be
submitted to the Division of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of this request will be considered on its merits and may or may
not be approved.
4. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6A to 143-215.6C.
5. The issuance of this permit does not preclude the Permittee from complying with any and
all statutes, rules, regulations, or ordinances which may be imposed by other government
agencies (local, state, and federal) which have jurisdiction.
6. This permit shall become voidable unless the agreements between Carolina Apple
Processors, Inc, and the owners of the sludge application sites are in full force and effect.
7. Prior to any transfer of this land, a notice shall be given to the new owner that gives full
details of the materials applied at this site.
8. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of the project.
9. The annual administering and compliance fee must be paid by the Permittee within thirty
days after being billed by the Division. Failure to pay the fee accordingly may cause the
Division to initiate action to revoke this permit as specified by 15 NCAC 2H.0205 (c)(4).
0

10. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its
extension. Upon receipt of the request, the Commission will review the adequacy of the
facilities described therein, and if warranted, will extend the permit for such period of time
and under such conditions and limitations as it may deem appropriate.
Permit issued this the 8th day of July, 1993
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
A. Presto oward, Jr., PIE., Director
Division ofEnvironmental Management
By Authority of the Environmental Management Commission
Permit Number WQ0004967
7

DIVISION OF ENVIRONMENTAL MANAGEMENT
July 7, 1993
MEMORANDUM
To: Betsy Johnson
Instream Assessment Unit
From: Greg Nizich
NPDES Permits Unit
Subject: Allied Signal Inc
NPDES Permit #NCO001899
Chatham County
Hopefully you can answer a few questions about this permit so that I can get it out of
here:
1) COD is not regulated by the Federal Guidelines and should not have been
included with the WLA request. Does BOD have to be recalculated if COD is
omitted?
2) I would like your feedback on the RRO comments from Feb 22, 1993. Some
of their responses differ from your memo of Feb 26, 1992.
3) Under "Quarterly Pollutant Analysis" in Allied's letter, it was requested that
metals monitoring be removed. Please respond.
I have both your and the RO's memos, as well as a copy of Allied's original comment
letter.
Enclosure

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State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Managetnent
512 North Salisbury Street • Raleigh, North Carolina 27611
James B. Hunt, Jr., Governor A. Preston Howard, Jr., P.E.
Jonathan B. Howes, Secretary Director
MEMORANDUM
To: Training and Certification
From: Michael D. Allen, State Engineering Review Group
Subject: Rating Sheet for Permit Number WQ0WIA( -7
Date: A- 77-q-!>
The subject permit is a renewal of Permit No. _ Wt�(�49(p-� , issued 10 - 9 - 92
therefore, a new rating sheet is not required. The existing rating is unchanged.
Regional Offices
Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem
7041251-6208 9191486-1541 7041663-1699 9191571-4700 919/946-6481 919/395-3900 9191896-7007
Poltution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer