Document LgyJo6O43vLdzjZJwqEak6y1X

Report Prepared by: Report Approved by: NPDES Pretreatment Compliance Sampling Inspection Report Newburg Egg Processing Corporation 17 Novogrodsky Road Woodridge, New York NYP009823 March 15-16, 2023 ROBERT Digitally signed by ROBERT MORRELL _M_O__R_R__E_L_L________D_ate_: 2_02_3_.05_.1_0 1_2_:05_:3_9 -_04_'0_0' _ Robert Morrell, Geologist Monitoring Operations Section Date: ________________ Cocuzza, Phil Digitally signed by Cocuzza, Phil _________________Da_te_: 2_02_3_.05_.1_0_13_:0_3:1_3_-0_4'0_0_' Philip Cocuzza, Supervisor Monitoring Operations Section Date: ________________ Newburg Egg Processing Corporation Inspection Date: March 15-16, 2023 Page 2 of 10 Newburg Egg Processing Corporation Inspection Date: March 15-16, 2023 1.0 OBJECTIVE On March 15-16, 2023, at the request of the Water Compliance Branch, the United States Environmental Protection Agency (USEPA) conducted a National Pollutant Discharge Elimination System (NPDES) Pretreatment Compliance Sampling Inspection (CSI) at Newburg Egg Processing Corporation in Woodridge, New York. The objective of the CSI was to gather information necessary to determine compliance with the general pretreatment requirements of 40 CFR Part 403 and the industrial user permit issued by the Village of Woodridge Wastewater Treatment Plant (WWTP). In addition, two stormwater outfalls were sampled for benchmark pollutants permitted under MultiSector General Permit (MSGP) sector U (Food and Kindred Products). 2.0 KEY PARTICIPANTS Listed below are key inspection participants and contact information, grouped by organization. U.S. Environmental Protection Agency Robert Morrell, Geologist, Lead Inspector Morrell.robert@epa.gov, 732-906-6804 Thuan Tran, Physical Scientist Tran.thuan@epa.gov, 732-321-4455 Newburg Egg Processing Corporation Joel Halpert, Plant Manager yoli@newburgegg.com, 845-434-8115 ext. 118 Chiam Weiss, Chief Operator 3.0 FACILITY DESCRIPTION 3.1 General Information Newburg Egg Processing Corporation is located at 17 Novogrodsky Road in Woodridge, New York. The facility is a manufacturer of egg products, including hard boiled eggs and liquid egg products. The company is categorized as Standard Industrial Classification (SIC) Code 2015 (Poultry Slaughtering and Processing), which includes the drying, freezing, and breaking of eggs. The plant operates 24 hours per day, 5 days per week. The wastewater treatment plant operates 24 hours per day, 6 days per week. The plant started its manufacturing operations in the 1980's and currently has approximately 200 employees. Page 3 of 10 Newburg Egg Processing Corporation Inspection Date: March 15-16, 2023 3.2 Process Information Shell eggs are delivered to the facility on pallets. Approximately two million eggs are processed each day. The eggs are directed to one of two process lines: liquid and hard boiled. For the liquid product line, the shell eggs are received and immediately refrigerated. The eggs are then subjected to washing, breaking, separating, combining (whole eggs), sniffing, and straining. The liquid eggs are then chilled before being conveyed to the mixing tank, where water and dry ingredients are added. The liquid product is then stored in the raw holding tank at 40oF. The liquid product is then conveyed to the pasteurizer, a critical control point, where the temperature is maintained at greater than 140oF. After pasteurization, the product is stored in the pasteurized product holding tank. From here, the final product is shipped in bulk by tank truck or packaged and stored in the finished product storage area. For the hard boiled product line, the raw eggs are received and immediately refrigerated. The eggs are then subjected to washing, pricking, and cooking, which is a critical control point. During cooking, the temperature is maintained at 165oF - 190oF. The cooked eggs are then transferred to primary cooling, where the temperature is lowered to 55oF - 60oF. After cooling, the eggs are peeled and conveyed to secondary cooling, where the temperature is lowered to less than 40oF. The eggs are placed in buckets with brine and are transferred to the finished product storage room. After draining, the eggs are vacuum sealed in pouches and labeled. The final product passes through a metal detector before being stored in the finished product storage room at less than 40oF. The finished product is then shipped to the customer. Process water for the facility is provided by the Village of Woodridge. Potable water is used for the mixing tank on the liquid product line and the brine tank on the hard boiled product line. Process wastewater is generated from the clean-in-place (CIP) caustic solution that is used for cleaning the batch product tanks and lines. Raw process wastewater is collected at a pump station, where it is pumped to one of two 30,000-gallon storage tanks. The wastewater from the storage tanks is conveyed to two 30,000-gallon aerated equalization tanks, where sulfuric acid is added to lower the pH. The wastewater flows into a mixing tank, where caustic and ferric are added to further adjust the pH to around 6.5. The wastewater is conveyed to two dissolved air floatation (DAF) tanks in series, where a polymer is added. Finally, the treated wastewater flows into the effluent monitoring chamber and is discharged through Outfall 001 to the Village of Woodbridge Wastewater Treatment Plant. Sludge from the DAF tanks is collected in a holding tank and dewatered using a filter press. The dewatered sludge is shipped off-site for disposal. Page 4 of 10 Newburg Egg Processing Corporation Inspection Date: March 15-16, 2023 3.3 Facility Self-Monitoring Information Pretreatment wastewater samples are collected weekly by the Village of Woodridge WWTP personnel. 24-hour composite samples are collected for the analysis of 5-day biochemical oxygen demand (BOD5), total suspended solids (TSS), total phosphorus, total kjeldahl nitrogen (TKN), and oil and grease. Grab samples are collected weekly for pH. Flow is monitored continuously. Ultimate oxygen demand (UOD) is calculated using BOD5 and TKN. 4.0 EPA SAMPLING/INSPECTION ACTIVITIES 4.1 Sampling Activities On March 15, 2023, an automatic composite sampler was set up at the effluent monitoring chamber for Outfall 001. The sampler was programmed to collect an aliquot of the effluent wastewater every 15 minutes for 24 hours. After 24 hours, the automatic composite sampler was disassembled, and the composite sample jug was mixed thoroughly before filling the sample containers. The 24-hour composite sample was analyzed for BOD5, TSS, total phosphorus, and TKN. During the 24-hour sampling survey, three grab samples were also collected at Outfall 001 for oil and grease. A grab sample for pH was collected and analyzed in the field. The 24-hour flow was recorded from the totalizer. On March 16, 2023, two stormwater outfalls were observed to be flowing into the adjacent wetland due to snow melting in the facility's paved parking lot. Outfall 003 was sampled by directly filling the sample containers at the end of the discharge pipe. This grab sample was analyzed for TSS, TKN, total phosphorus, and chemical oxygen demand (COD). Outfall 002 was sampled by directly filling the sample containers at the end of the discharge pipe. This grab sample was also analyzed for TSS, TKN, total phosphorus, and COD. The discharge from Outfall 003 was clear and the discharge from Outfall 002 was slightly turbid. All sample containers, preservation techniques, and holding times were in accordance with U.S. EPA requirements specified in 40 CFR Part 136. All samples were placed in a cooler with wet ice and transported to the U.S. EPA Region 2 Laboratory in Edison, New Jersey. Split samples were collected and given to the facility representative. Page 5 of 10 Newburg Egg Processing Corporation Inspection Date: March 15-16, 2023 5.0 ANALYTICAL RESULTS Newburg Egg Processing Corporation Pretreatment CSI - Outfall 001 March 15-16, 2023 Parameter Discharge to POTW Local Discharge Local Discharge Limit - Daily Limit- Monthly Maximum Average (lb/day) pH (su) 7.19 6.0 - 9.0 (range) -- Flow (gpd) 157,572 100,000 -- BOD5 (mg/l) 242 (318 lb/day) 380 317 TSS (mg/l) 17.0 (22 lb/day) 210 175 Phosphorus (mg/l) 0.521 (0.68 lb/day) Monitor only Monitor only TKN (mg/l) 28.8 (38 lb/day) 45 38 UOD (mg/l) 492.6 (647 lb/day) 775 646 Oil and Grease - Grab #1 (mg/l) Not detected 50 42 Oil and Grease - Grab #2 (mg/l) Not detected 50 42 Oil and Grease - Grab #3 (mg/l) Not detected 50 42 Newburg Egg Processing Corporation - Stormwater Outfall 002 March 16, 2023 Pollutant Outfall 002 Benchmark - MSGP Sector U COD (mg/l) Not detected 120 TSS (mg/l) Not detected 100 Phosphorus (mg/l) 0.0696 2 TKN (mg/l) 0.580 6 Newburg Egg Processing Corporation - Stormwater Outfall 003 March 16, 2023 Pollutant Outfall 003 Benchmark - MSGP Sector U COD (mg/l) Not detected 120 TSS (mg/l) Not detected 100 Phosphorus (mg/l) Not detected 2 TKN (mg/l) 0.460 6 6.0 FINDINGS 6.1 Sampling Result Findings Total flow for the 24-hour sampling period was 157,572 gpd, which exceeds the daily maximum flow of 100,000 gpd in the industrial user permit. Analytical results indicate that all parameters (except flow) did not exceed daily maximum discharge limitations in the industrial user permit during the 24-hour sampling survey. Page 6 of 10 Newburg Egg Processing Corporation Inspection Date: March 15-16, 2023 Using the EPA analytical results for Outfall 001 and the flow data provide by the facility, the calculated loadings for BOD5 and UOD slightly exceeded the monthly average limitations of 317 lb/day and 646 lb/day, respectively. Oil and grease samples are currently listed as 24-hour composite samples in the industrial user permit issued by the Village of Woodridge. Oil and grease samples should be collected as grab samples. Analytical results indicate that the pollutant benchmarks for Sector U of the MSGP were not exceeded at stormwater outfalls 002 and 003 on the day of sampling. 7.0 ATTACHMENTS Photographs (#1 - #3) Laboratory Data Report Chain of Custody / Field Data Form Page 7 of 10 Newburg Egg Processing Corporation Inspection Date: March 15-16, 2023 Photo #1: View of the pretreatment discharge location for Outfall 001. Page 8 of 10 Newburg Egg Processing Corporation Photo #2: View of stormwater Outfall 002. Inspection Date: March 15-16, 2023 Page 9 of 10 Newburg Egg Processing Corporation Photo #3: View of stormwater Outfall 003. Inspection Date: March 15-16, 2023 Page 10 of 10 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Region 2 Laboratory 2890 Woodbridge Avenue Edison , New Jersey 08837 732-906-6886 Phone 732-906-6165 Fax April 04, 2023 Bob Morrell Monitoring & Assessment Branch LSASD/MAB Edison, NJ 08837 RE: Newburg Egg Processing Corp. - 2303018 Enclosed are the results of analyses for samples received by the laboratory on 03/16/2023. The signature below reflects the laboratory's approval of the reported results. If you have any questions concerning this report, please refer to Project Number 2303018 and contact the laboratory. Sincerely, John R. Bourbon Chief, LSASD/LB Project Narrative: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Region 2 Laboratory Final Report Project: Newburg Egg Processing Corp. - 2303018 Project Number: 2303018 The National Environmental Laboratory Accreditation Conference Institute (TNI) is a voluntary environmental laboratory accreditation association of State and Federal agencies. TNI established and promoted a National Environmental Laboratory Accreditation Program (NELAP) that provides a uniform set of standards for the generation of environmental data that are of known and defensible quality. The EPA Region 2 Laboratory is NELAP accredited. The Laboratory tests that are accredited have met all the requirements established under the TNI Standards. Condition Comments None Comment(s): The "Sample Analysis Date and Time" is included in the results section for any analyte with a prescribed holding time of 72 hours or less. Data Qualifier(s): U- The analyte was not detected at or above the Reporting Limit. J- The identification of the analyte is acceptable; the reported value is an estimate. K- The identification of the analyte is acceptable; the reported value may be biased high. L- The identification of the analyte is acceptable; the reported value may be biased low. NJ- There is presumptive evidence that the analyte is present; the analyte is reported as a tentative identification. The reported value is an estimate. U.S.E.P.A Region 2 Laboratory NOTE: The results recorded in this report relate only to the samples as received on the date and at the time noted Reported: 4/4/2023 Page 1 of 8 Reporting Limit(s): UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Region 2 Laboratory Final Report Project: Newburg Egg Processing Corp. - 2303018 Project Number: 2303018 The Laboratory was able to achieve the appropriate limit for each analyte requested. Field ID Outfall001-Grab#1 Outfall001-Grab#2 Outfall001-Grab#3 Outfall001-24 Hr. Comp. Outfall003-Grab Outfall002-Grab SUMMARY REPORT FOR SAMPLES Laboratory ID 2303018-01 2303018-02 2303018-03 2303018-04 2303018-05 2303018-06 Matrix Aqueous Aqueous Aqueous Aqueous Aqueous Aqueous Date Sampled 03/15/2023 11:17 03/15/2023 15:21 03/16/2023 10:25 03/16/2023 10:57 03/16/2023 11:21 03/16/2023 11:25 Date Received 03/16/2023 14:45 03/16/2023 14:45 03/16/2023 14:45 03/16/2023 14:45 03/16/2023 14:45 03/16/2023 14:45 U.S.E.P.A Region 2 Laboratory NOTE: The results recorded in this report relate only to the samples as received on the date and at the time noted Reported: 4/4/2023 Page 2 of 8 Analysis Biochemical Oxygen Demand Chemical Oxygen Demand Nitrogen, Total Kjeldahl Oil & Grease Phosphorus Residue, Non-Filterable UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Region 2 Laboratory Final Report Project: Newburg Egg Processing Corp. - 2303018 Project Number: 2303018 SUMMARY REPORT FOR METHODS Method SM 5210B SOP C-21 Rev 2.8 EPA 410.4 SOP C-53 Rev 2.8 EPA 351.2 SOP C-40 Rev2.8 EPA 1664A SOP C-126 Rev 1.7 EPA 365.1 SOP C-68 Rev 2.8 SM 2540D SOP C-33 Rev 3.8 Certification NELAP NELAP NELAP NELAP NELAP NELAP Matrix Aqueous Aqueous Aqueous Aqueous Aqueous Aqueous U.S.E.P.A Region 2 Laboratory NOTE: The results recorded in this report relate only to the samples as received on the date and at the time noted Reported: 4/4/2023 Page 3 of 8 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Region 2 Laboratory Final Report Project: Newburg Egg Processing Corp. - 2303018 Project Number: 2303018 Analyte Field ID: Outfall001-Grab#1 GC - Sanitary Oil & Grease Field ID: Outfall001-Grab#2 GC - Sanitary Oil & Grease Field ID: Outfall001-Grab#3 GC - Sanitary Oil & Grease Field ID: Outfall001-24 Hr. Comp. Sanitary Biochemical Oxygen Demand Nitrogen, Total Kjeldahl Phosphorus Total Suspended Solids Field ID: Outfall003-Grab Sanitary Chemical Oxygen Demand Nitrogen, Total Kjeldahl Phosphorus Total Suspended Solids Field ID: Outfall002-Grab Sanitary Chemical Oxygen Demand Nitrogen, Total Kjeldahl Phosphorus Total Suspended Solids Result Qualifier Reporting Limit Units Batch Sample ID: 2303018-01 Date and Time of Analysis* --- U 6.10 mg/L B303080 Sample ID: 2303018-02 --- U 6.10 mg/L B303080 Sample ID: 2303018-03 --- U 6.30 mg/L B303080 Sample ID: 2303018-04 242 28.8 0.521 17.0 2.00 1.00 0.0500 10.0 mg/L mg/L mg/L mg/L B303053 B303067 B303055 B303054 03/22/2023 07:41 Sample ID: 2303018-05 --0.460 ----- U L 20.0 mg/L B303060 0.100 mg/L B303067 U 0.0500 mg/L B303055 U 10.0 mg/L B303054 Sample ID: 2303018-06 --- U 20.0 mg/L B303060 0.580 0.100 mg/L B303067 0.0696 0.0500 mg/L B303055 --- U 10.0 mg/L B303054 U.S.E.P.A Region 2 Laboratory NOTE: The results recorded in this report relate only to the samples as received on the date and at the time noted Reported: 4/4/2023 Page 4 of 8 Analyte Batch B303080 Blank (B303080-BLK1) Oil & Grease LCS (B303080-BS1) Oil & Grease LCS Dup (B303080-BSD1) Oil & Grease Matrix Spike (B303080-MS1) Oil & Grease Matrix Spike (B303080-MS2) Oil & Grease UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Region 2 Laboratory Final Report Project: Newburg Egg Processing Corp. - 2303018 Project Number: 2303018 GC - Sanitary - Quality Control Result Reporting Limit Units Spike Source %REC Level Result %REC Limits RPD RPD Limit --- U 5.00 mg/L 35.8 5.00 mg/L 40.00 90 78-114 37.5 5.00 mg/L 40.00 94 78-114 5 20 Source: 2303018-01 48.1 5.00 mg/L 40.00 1.80 116 78-114 Source: 2303014-09 49.2 5.00 mg/L 40.00 5.00 110 78-114 U.S.E.P.A Region 2 Laboratory NOTE: The results recorded in this report relate only to the samples as received on the date and at the time noted Reported: 4/4/2023 Page 5 of 8 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Region 2 Laboratory Final Report Project: Newburg Egg Processing Corp. - 2303018 Project Number: 2303018 Sanitary - Quality Control Analyte Batch B303053 Blank (B303053-BLK1) Biochemical Oxygen Demand LCS (B303053-BS1) Biochemical Oxygen Demand LCS (B303053-BS2) Biochemical Oxygen Demand LCS (B303053-BS3) Biochemical Oxygen Demand Duplicate (B303053-DUP1) Biochemical Oxygen Demand Matrix Spike (B303053-MS1) Biochemical Oxygen Demand Matrix Spike Dup (B303053-MSD1) Biochemical Oxygen Demand Batch B303054 Blank (B303054-BLK1) Residue, Non-Filterable LCS (B303054-BS1) Residue, Non-Filterable Result Reporting Limit Units Spike Source %REC Level Result %REC Limits RPD RPD Limit --- U 2.00 mg/L 170 mg/L 198.0 86.0 84.6-115.4 175 mg/L 198.0 88.3 84.6-115.4 179 mg/L 198.0 90.3 84.6-115.4 Source: 2303018-04 309 2.00 mg/L 242 24.2 25 Source: 2303018-04 564 2.00 mg/L 396.0 242 81.2 75-125 Source: 2303018-04 611 2.00 mg/L 396.0 242 93.1 75-125 8.00 200 --- U 10.0 mg/L 54.0 10.0 mg/L 55.10 98.0 85-115 U.S.E.P.A Region 2 Laboratory NOTE: The results recorded in this report relate only to the samples as received on the date and at the time noted Reported: 4/4/2023 Page 6 of 8 Analyte Batch B303054 LCS Dup (B303054-BSD1) Residue, Non-Filterable Duplicate (B303054-DUP1) Residue, Non-Filterable Batch B303055 LCS (B303055-BS1) Phosphorus LCS Dup (B303055-BSD1) Phosphorus Matrix Spike (B303055-MS1) Phosphorus Matrix Spike (B303055-MS2) Phosphorus Batch B303060 Blank (B303060-BLK1) Chemical Oxygen Demand Blank (B303060-BLK2) Chemical Oxygen Demand UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Region 2 Laboratory Final Report Project: Newburg Egg Processing Corp. - 2303018 Project Number: 2303018 Sanitary - Quality Control Result Reporting Limit Units Spike Source %REC Level Result %REC Limits RPD RPD Limit 55.0 10.0 mg/L 55.10 99.8 85-115 1.83 20 Source: 2303018-04 18.0 10.0 mg/L 17.0 5.71 20 8.50 0.250 mg/L 8.450 101 90-110 8.57 0.250 mg/L 8.450 101 90-110 0.8 20 Source: 2303014-01 1.13 0.0500 mg/L 1.000 0.0806 105 90-110 Source: 2303018-04 1.50 0.0500 mg/L 1.000 0.521 98 90-110 --- U 20.0 mg/L --- U 20.0 mg/L U.S.E.P.A Region 2 Laboratory NOTE: The results recorded in this report relate only to the samples as received on the date and at the time noted Reported: 4/4/2023 Page 7 of 8 Analyte Batch B303060 LCS (B303060-BS1) Chemical Oxygen Demand LCS Dup (B303060-BSD1) Chemical Oxygen Demand Matrix Spike (B303060-MS1) Chemical Oxygen Demand Batch B303067 Blank (B303067-BLK1) Nitrogen, Total Kjeldahl Blank (B303067-BLK2) Nitrogen, Total Kjeldahl LCS (B303067-BS1) Nitrogen, Total Kjeldahl LCS Dup (B303067-BSD1) Nitrogen, Total Kjeldahl Matrix Spike (B303067-MS1) Nitrogen, Total Kjeldahl Matrix Spike (B303067-MS2) Nitrogen, Total Kjeldahl UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Region 2 Laboratory Final Report Project: Newburg Egg Processing Corp. - 2303018 Project Number: 2303018 Sanitary - Quality Control Result Reporting Limit Units Spike Source %REC Level Result %REC Limits RPD RPD Limit 207 40.0 mg/L 194.0 107 90-110 198 40.0 mg/L 194.0 102 90-110 4 20 Source: 2303018-05 50.6 20.0 mg/L 50.00 16.4 68 90-110 --- U 0.100 mg/L --- U 0.100 mg/L 13.7 0.200 mg/L 12.40 110 90-110 13.4 0.200 mg/L 12.40 108 90-110 2 20 Source: 2303014-08 14.7 0.500 mg/L 4.000 10.2 112 90-110 Source: 2303018-04 33.6 1.00 mg/L 4.000 28.8 120 90-110 U.S.E.P.A Region 2 Laboratory NOTE: The results recorded in this report relate only to the samples as received on the date and at the time noted Reported: 4/4/2023 Page 8 of 8 US ~PA R~GION 2 LABORATORY CHAIN OF CUSTODYI FIELD DATA FORM Page _. _ of _ pages SURVEY NAME & LOCALITY tV _ v. ,- PROGRAM: SF D Decision RCRA D RCRA ENF D 0307 =~ ::..: . T NPDES D B304 "'. SDWA D C215 ~'. AM D B224 CAA D A305 DESCRIPTION & INSTRUCTIONS ~ CHECK IF ESTIMATED CONCENTRATIONS, -I SPLIT LIMITS ~ SAMPLE ~----'----------------------------------~ INCLUDING LOCATION, SPECIAL REPORTING PROJECT LEADER, PROGRAM RESULTS CODE TSCA D L306 00 D FIFRA B253 I [Preservative I (circle) '"f '0 P -~I , l _ D CRIMINAL ENF D Collection Time (24hr clock) ////111////111 Begin: End Collection Date A=aqueous B=aqueous C=soil D=sediment ,f:=sludge atrix: (chlorinated) F=multiphasic G=solvent H=biota I=oil J=other , ~ Yd N D Relinquished By! Relinquished By: IRelinquished By: 2345678910 Person Assuming Responsibility for Sample(s): Preservative Added & Checked O=ice 7=FAS 1=H2S04 pH<2 8=ZnAc 2=HN03 pH<2 9=NaOH pH>12 3=HCI pH<2 10=NH4CI 4=Na2S203 5=NaOH pH>9 6=Ascorbic Acid irne ate Received By: revised 10/25/2004