Document 6ZO1nZ4jmMKbRO17OK6D0eRo

DATE: SUBJECT: FROM: THRU: TO: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 MAR 1 9 2019 CLEAN AIR ACT INSPECTION REPORT Color Communications Inc., Chicago, Illinois Jason Schenandoah, Environmental Engineer AECAB (IL/IN) Nathan Frank, Section Chief AECAB (IL/IN) File BASIC INFORMATION Facility Name: Color Communications Inc. Facility Location: 4000 West Fillmore St, Chicago, Illinois Date of Inspection: February 26, 2019 EPA Inspector(s): 1. Jason Schenandoah, Environmental Engineer 2. David Sutlin, Environmental Engineer Other Attendees 1. Steve Winter, Director, Color Communications Inc. 2. Rich Cochran, Facilities Engineer, Color Communications Inc. 3. Louis Silva, Lead Maintenance, Color Communications Inc. 4. Bob Kester, Operations Manager, Color Communications Inc. Contact Email Address: stewin@ccicolor.com Purpose of Inspection: To investigate compliance with the Clean Air Act. Facility Type: Coating and printing Arrival Time: 2:00 pm Departure Time: 4:00 pm Inspection Type: l:8l Unannounced Inspection Announced Inspection OPENING CONFERENCE l:8l Credentials Presented l:8l CBI waming to facility provided The following information was obtained verbally from Color Communications Inc. (CCI) personnel unless otherwise noted. Company Ownership: CCI was sold to a new owner in October 2017. Process Description: CCI produces color cards for the home improvement and automotive industries. Production is split between three buildings: 4000, 4100, and 4242 West Fillmore. The 4242 building has three coating lines and one spray line. The spray line has not been in operation in recent years. Two of the coating lines (Coating Lines 1 & 4) use almost exclusively water-based coatings and vent directly to atmosphere, while Coating Line 3 has a Permanent Total Enclosure (PTE) around the coating application area that vents to a catalytic oxidizer. Substrate travels continuously from the coating application area through a series of ovens, and emissions from it also vent to the catalytic oxidizer. The 4100 building has one spray line (Spray Line 2) that vents its emissions to a regenerative thermal oxidizer (RTO). Both the 4100 and 4242 buildings have color mixing stations where materials are mixed to obtain the desired color. Customer-provided pigment formulations are used to create the home improvement color cards, while a process called color matching is used to create the pigment formulation for automotive color cards. For all lines, substrate (e.g. paper, film, etc.), on rolls or in sheet form, is fed through the line. Layers of coating and paint are sprayed or poured onto the substrate, and then ovens are used to cure the coatings. Several coating/painting applications can occur on one line. At the end of the line the product is rolled up or stacked and sent to building 4000 for further processing. In building 4000, several processes can occur depending on what is required of the finished product. The rolls can be slit into thinner rolls. Sheets can be printed using one of four printers. Finally, the sheets or rolls will be cut to size and may be mounted depending on the final product. Finally, the product is bound and packaged. Staff Interview: 90% of the paint used at the facility is water-based. Adhesive used for mounting in the 4000 building is also water-based. Mr. Silva stated that he has seen outlet temperatures on the catalytic oxidizer reach the 800F-900F range. Mr. Winters stated that Coating Lines I and 4 use nearly all water-based coatings and paints. Solvent-based coatings and paints are occasionally used, but the operation remains compliant with all limits. All PTEs are monitored for pressure drop compliance and will shut down operation on the lines if the pressure drop is out of compliance. Page 2 of 4 TOUR INFORMATION EPA toured the facility: Yes Data Collected and Observations: Some of the heat ducts on Spray Line 2 were not connected to the blowers on the ovens. Photos and/or Videos: were taken during the inspection. Field Measurements: were not taken during this inspection. CLOSING CONFERENCE Requested documents: Requested the reports for the latest stack test for both the catalytic oxidizer and RTO. SIGNATURES Page 3 of4 APPENDICES AND ATTACHMENTS Appendix A: Digital Image Log Page 4 of 4 Facility Name: Color Communications Inc. Facility Location: 4000 West Fillmore St, Chicago, Illinois Date of Inspection: February 26, 2019 APPENDIX A: DIGITAL IMAGE LOG 1. Inspector Name: David Sutlin 3. Company/Facility Name: Color Communications Inc. 5. Number of Images: 7 2. Date(s) of Inspection: February 26, 2019 4. Street Address, City, State: 4000 West Fillmore St, Chicago, Illinois 6. Archival Record Location: Photos are saved to a CD-R labeled "Color Communications; Chicago, IL; 2/26/2019; Inspection Photos" Image Number File Name Date and Time (incl. time zone and DST) Latitude and Longitude 41.86838, 1 P2260032.JPG 2/26/2019 14:15 -87.729662 41.868333, 2 P2260033.JPG 2/26/2019 14:44 -87.729444 41.868333, Description of Image Regenerative Thermal Oxidizer 4100 building Start of spray line 2 with PTE in back!:!round 3 P2260034.JPG 2/26/2019 14:47 -87.729444 Spray line 2 ovens 41.868333, Detached air vent from blower at oven on 4 P2260035.JPG 2/26/2019 14:49 -87.729444 spray line 2 41.868333, 5 P2260036.JPG 2/26/2019 14:51 -87.729444 41.868333, RTO readout 4100 building 6 P2260037.JPG 2/26/2019 15:11 -87.729444 Catalytic oxidizer display in 4242 building 41.868333, Parameter readout catalytic oxidizer 4242 7 P2260038.JPG 2/26/2019 15:15 -87.732222 building Appendices Page 1 of 1