Document O3Bm98LY1DMqB007wQVng3R1Q
DATE: SUBJECT: FROM: THRU: TO:
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGIONS
77 WEST JACKSON BOULEVARD CIDCAGO, ILLINOIS 60604
FEB 1-5 2019
CLEAN AIR ACT INSPECTION REPORT Greif Packaging, LLC, Alsip, Illinois
Manojkumar P. Patel, Environmental Engineer AECAB (MI/WI)
Sarah Marshall, Section Chief AECAB (MI/WI)
File
BASIC INFORMATION
Facility Name: Greif Packaging, LLC, Alsip, Illinois
Facility Location: 4300 West 130th Street, Alsip, Illinois 60803
Date of Inspection: 12/18/2018
EPA Inspector(s): 1. Manojkumar P. Patel, Environmental Engineer
Other Attendees 1. Dave Tomaszewski, Plant Manager, Greif Packaging, LLC 2. Lauren Laabs, Mostardi Platt, Consultant for Greif Packaging, LLC
Contact Email Address: dave.tomaszewski@greif.com
Purpose of Inspection: To evaluate compliance with applicable requirements of Illinois State Implementation Plan (SIP) and the Clean Air Act.
Facility Type: NAICS Code 332439 Manufacturing of Metal Containers
Arrival Time: 10:10 AM CST Departure Time: 2:30 PM CST
Inspection Type:
ISi Unannounced Inspection D Announced Inspection
OPENING CONFERENCE
ISi Credentials Presented ISi CBI warning to facility provided
The following information was obtained verbally from attendees unless otherwise noted.
Process Description:
Greif Packaging, LLC (the facility) manufactures metal and plastic drums and industrial bulk containers (IBC) with a capacity from 275 gallons to 330 gallons. Metal coils are received by truck. The facility uses 0.006 mm to 1.40 mm steel sheets for drum manufacturing. The sheet metal used in making each steel drum enters an edge grinder, a machine that rids sheets ofjagged edges, smoothing them instead. The steel sheets then enter a bender, which contains a cylindrical mold to curve and bend the metal according to the mold.
Once the metal is bent, it is fed by a worker into a spot welding machine, which begins to connect the two ends of the metal sheet into a tube by welding several points along the edge. The flanging operation includes feeding the drum into a flange insertion machine to create rim indentations and edges on the top and bottom of the container. The bead expander takes the drum horizontally and expands beads or rolling hoops around the circumference of the container.
Once the steel cylinder body is created, the bottom piece of the container must be created and then connected. The bottoms are stamped down and cut in a pressing machine using special molds. The pre-curler machine smoothes the edges of each bottom piece to prepare it for seaming it to the drum body. Bottom pieces enter a seaming machine along with a drum body which rotates and presses the two pieces together. The now-seamed item prevents leakage of materials that the container will eventually hold.
The interior coating is a one-layer coating, the thickness varies depending on the customer's specifications. Currently, heat set solvent based coatings are applied to all drum interiors by automatic spray guns. The drums are loaded into a conveyorized oven for curing. This process takes several minutes. The curing oven is natural gas fired, and is set at 500F. Emissions from the paint spray booth and dryers are vented to a regenerative therrrutl oxidizer (RTO).
The exterior coating system consists of a spray booth (drum and lid), a conveying line, and a drying oven (350F - 400F). An assortment of colored water-based coatings is used on this line. The booth is equipped with several guns where paint is applied to the drum exterior.
Once the exterior coating is applied and the drum is cured, each drum is assembled with the fittings, labels, and caps before being serit to the drum storage area.
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TOUR INFORMATION
EPA toured the facility: Yes
Data Collected and Observations:
(1) The facility receives outer rings for open top steel drums from a third party vendor. (2) The facility sells 98% of its final product to a third party and the reaming 2% of its final
product is purchased internally. (3) The specialty manufacturing process line manufactures light gauge thiclmess for the
specialty drums. (4) The RTO was installed in or around 2013-2014 and temperature is recorded weekly on
a strip chart. (5) The facility has two blow molding machines to manufacture IBC totes in the steel
cages. (6) The exhaust from the plant processes are routed to the RTO.
Photos and/or Videos: were taken during the inspection.
Field Measurements: were not taken during this inspection.
CLOSING CONFERENCE
Requested documents: 3 years of strip charts from RTO; 3 years ofRTO temperature deviation reports; Current Major Modification to Clean Air Act Permit Program (CAAPP) Permit records; and Technical Data Sheets for all Interior and Exterior Coatings used at the facility.
c1 SIGNATURES
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Facility Name: Greif Packaging, LLC, Alsip, Illinois Facility Location: 4300 West 130th Street, Alsip, Illinois 60803 Date of Inspection: 12/18/20 I8
APPENDICES AND ATTACHMENTS
1.
Digital Image Log
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APPENDIX A: DIGITAL IMAGE LOG
1. Inspector Name: Manojkumar P Patel
3. Company/Facility Name: Greif Packacing, LLC, Alsip, Illinois
5. Number of Images: 47
2. Date(s) of Inspection:
12/18/2018 4. Street Address, City, State:
4300 West 130th Street, Alsip, Illinois 60803 6. Archival Record Location:
"USB Labeled as GREIF PACKAGING LLC, CAA INSPECTION DECEMBER 18, 2018
Image Number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
File Name
Date and Time (incl. time zone and DST}
IMG 7095.JPG IMG 7096.JPG IMG 7097.JPG IMG 7098.JPG IMG 7099.JPG IMG 7100.JPG IMG 7101.JPG IMG 7102.JPG IMG 7103.JPG IMG 7104.JPG IMG 7105.JPG IMG 7106.JPG IMG 7107.JPG IMG 7108.JPG IMG 7109.JPG IMG 7110.JPG !MG 7111.JPG IMG 7112.JPG IMG 7113.JPG IMG 7114.JPG IMG 7115.JPG IMG 7116.JPG IMG 7117.JPG IMG 7118.JPG IMG 7119.JPG IMG 7120.JPG IMG 7121.JPG IMG 7122.JPG IMG 7123.JPG
12/18/2018 12:31 12/18/2018 12:32 12/18/2018 12:33 12/18/2018 12:33 12/18/2018 12:34 12/18/2018 12:34 12/18/2018 12:35 12/18/2018 12:35 12/18/2018 12:36 12/18/2018 12:39 12/18/2018 12:39 12/18/2018 12:39 12/18/2018 12:42 12/18/2018 12:42 12/18/2018 12:42 12/18/2018 12:42 12/18/2018 12:44 12/18/2018 12:45 12/18/2018 12:47 12/18/2018 12:48 12/18/2018 12:52 12/18/2018 12:54 12/18/2018 12:55 12/18/2018 12:55 12/18/2018 12:56 12/18/2018 12:59 12/18/2018 13:01 12/18/2018 13:02 12/18/2018 13:02
Latitude and
Longitude
Description of Image
Uncoil Steel Steel Sheets Storage Area Steel Sheet Welding Machine Welded Steel Cylinder Flange and Beads {both ends} Flange and Bead Conveyor W Beader and Neck End Reduced Top Edge Conveyor with Steel Drums Interior Coating Paint Booth Paint Booth Interior Interior Coating Paint Booth - Lances Paint Drums for Coating Process Paint Drums Paint Drums Paint Drums RTO pickup from Paint Booth+ Curing Oven RTO Pickup from Curing Oven (Mid-Section) Curing Oven Outlet (Exhaust to Atmosphere) Not Ducted to R Outlet of the RTO (Drums are coated internally} Bottom is inserted to the Steel Cylinder Exterior Paint Oven (Black Color Coating) Exterior Curing Oven (Entrance End) Exterior Curing Oven (Middle Section Entrance} Exterior Coating Cooling Chamber Exhaust (to Atmosphere) N Silk Screening RTO Temperature Control Panel RTO Ducting Layout Screen Strip Chart Recorder
Appendices Page 1 of 2
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IMG 7125.JPG 12/18/201813:04
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IMG 7126.JPG 12/18/2018 13:04
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IMG 7127.JPG 12/18/2018 13:05
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IMG 7128.JPG 12/18/2018 13:11
34 IMG 7129.JPG 12/18/2018 13:16
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iMG 7130.JPG 12/18/2018 13:18
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IMG 7131.JPG 12/18/2018 13:20
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IMG 7132.JPG 12/18/2018 13:27
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IMG 7133.JPG 12/18/2018 13:27
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IMG 7134.JPG 12/18/2018 13:28
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IMG 7135.JPG 12/18/2018 13:28
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IMG 7136.JPG 12/18/2018 13:35
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!MG 7137.JPG 12/18/2018 13:35
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IMG 7138.JPG 12/18/2018 13:35
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IMG 7139.JPG 12/18/2018 13:35
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IMG 7140.JPG 12/18/2018 13:35
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!MG 7141.JPG 12/18/2018 13:37
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IMG 7142.JPG 12/18/2018 13:40
Closer View of Inlet Duct Main Header to RTO RTO IBC Manufacturing Process Parts Paint Booth {Ducted to RTO) Parts Wicket Oven (Notbperating at the time of Visit) Wicket Oven End (Parts Exit Point) Specialty Drum Interior Spray Booth Specialty Paint Booth Exit End Specialty Curing Oven Specialty Interior Curing Oven Composite Blow Molding Machine Blow Molding Machine (Closer View) Blow Molding Machine (View) Composite Blow Molder Composite Drum Plastic Bottles Composite Drum (Plastic Bottles are inserted into Metal Drun Facility's Product Mix Display
Appendices Page 2 of 2