Document 06k0OyRZE8qEYbQX5QqoYX4Rm
DATE: SUBJECT: FROM: THRU: TO:
UNITED STATES El'i'VIRONMENTAL PROTECTION AGENCY REGIONS
77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604
JUN 2 8 2019
CLEAN AIR ACT INSPECTION REPORT Winpak Heat Seal Corporation (Winpak), Pekin, Illinois
Victoria Nelson, Environmental Engineer AECAB (MI/WI)
Sarah Marshall, Section Chief AECAB (MI/WI)
File
BASIC [NFORMATION
Facility Name: Winpak Heat Seal Corporation (Winpak)
Facility Location: 1821 Riverway Drive, Pekin, Illinois
Date of Inspection: May 7, 2019
EPA Inspectors: 1. Victoria Nelson, Environmental Engineer 2. Eleanor Kane, Environmental Engineer
Other Attendees: 1. Robert Brott, Winpak, Plant Manager 2. Julia Stover, Winpak, Process Engineer
Contact Email Address: Robert.Brott@winpak.com; Julia.Stover@winpak.com
Purpose of Inspection: To assess compliance with the Clean Air Act and the facility's operating permit
Facility Type: Foil and film printing
Arrival Time: 1:30 PM Central Time Departure Time: 4:00 PM Central Time
Inspection Type: ~ Unannounced Inspection D Announced Inspection
OPE.NIN~~-G- CONFERENCE~
~ Credentials Presented ~ CBI warning to facility provided
The following information was obtained verbally from the attendees unless otherwise noted.
Process Description: Winpak receives inks, solvents, and aluminum foil with a heat seal as raw materials. Winpak operates three flexographic presses that print designs on foil lids for plastic containers. Printing is done by coating etched plates vvith ink and pressing onto foil. Plates are photosensitive sleeves with the desired design imprinted in the plating room. The plating room is equipped with a solvent still to aid plate imaging. Custom color inks are mixed in the ink room. Once printed, lids are cured in curing ovens and then punched out of foil rolls on die cutters and shipped to customers. Each of the three presses are housed in a permanent total enclosure (PTE) that is continuously monitored for differential pressure. The PTE and the plating room are exhausted to a regenerative thermal oxidizer (RTO).
Staff Interview: The facility operates 24 hours a day for six or seven days out of each week and has 193 employees. The three presses are interlocked with the RTO. In 2018, vVinpak resolved an enforcement action v.~th the Illinois Environmental Protection Agency (IEPA), requiring them to obtain and operate pursuant to a new construction permit applying Best Available Control Technology (BACT).
TOUR INFORMATION
EPA toured the facility: Yes
Data Collected and Observations: EPA inspectors toured the press room, ink room, plating room, and cutting operations. In the ink room, EPA observed ink mixing and found an open inactive drum containing ethyl acetate. The ink room is not exhausted to the RTO.
Photos and/or Videos: were taken during the inspection. EPA collected three recordings with the FLIR optical gas imaging camera to observe potential uncontrolled emissions ofVOCs.
Field Measurements: were not taken during this inspection.
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RECORDS REVIEW
Process flow diagram
CLOSING CONFERENCE
Requested documents: Most recent RTO stack test report Emissions inventory for previous 12 months Most recent PTE test report PTE pressure drop readings averaged over three hours for first two weeks of May 2019 Safety Data Sheets for most conunonly used solvents, inks, and chemicals containing hazardous air pollutants
Compliance Assistance: EPA reconunended that Winpak keep solvent drums closed when not actively in use.
SIGNATURES / 7
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Facility Name: Winpak Heat Seal Corporation (Winpak) Facility Location: 1821 Riverway Drive, Pekin, Illinois Date of Inspection: May 7, 2019
APPENDICES AND ATTACHMENTS
Appendix A: Digital Video Log
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Facility Name: Winpak Heat Seal Corporation (Winpak) Facility Location: 1821 Riverway Drive, Pekin, Illinois Date of Inspection: May 7, 2019
Al'PENDIX A: DIGITAL VIDEO LOG
1. Photographer Name: Victoria Nelson
3. Company Name: Winpak Heat Seal Corporation (Winnak)
5. Number of Videos:
3
2. Dates of Inspection: Mav 7, 2019
4. Street Address, City, State:
1821 Riverway Drive, Pekin, Illinois
6. Archival Record Location:
C:\Users\Vnelson\OneDrive - Environmental Protection Agency (EPA)\Iargeting and lnsnections\FLIR Videos
Video Number 1
File Name MOY_2424.mp4
2
MOY_2425 .mp4
0
MOY 2426.mp4
Date 6/28/2019
6/28/2019
6/28/2019
Description of Image
Open drum of ink in the PIE for the nresses Open ethyl acetate drum in ink room RIO stack
Appendices Page 1 of 1