Document YG8GYGzEynp54v2OkkJ7xpx3N

SUBJECT: FROM: THRU: TO: UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 5 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 CLEAN AIR ACT INSPECTION REPORT Owens Corning Foam Insulation, LLC, Rockford, Illinois Charles Hall, Environmental Engineer Charles G. AECAB (MN-OH) Hall Digitally signed by Charles G. Hall Date: 2021.08.18 12:17:23 -05'00' Brian Dickens, Section Chief AECAB (MN-OH) Brian Dickens Digitally signed by Brian Dickens Date: 2021.08.18 12:30:40 -05'00' File, Owens Corning Foam Insulation, Rockford, Illinois BASIC INFORMATION Facility Name: Owens Corning Foam Insulation, LLC Facility Location: 2710 Laude Drive, Rockford, Illinois 61109-1497 Date of Inspection: 12 July 2021 EPA Inspector(s): 1. Charlie Hall 2. Brittany Cobb Other Attendees: 1. Micki Vanderpool, Plant Leader 2. Todd Baughman, Health & Safety Leader 3. Mike Anderson, Maintenance Planner and Scheduler 4. Robin Edmiston-Bennett, Regional Environmental Leader for Insulation (closing conference by telephone only) Contact Email Address: micki.vanderpool@owenscorning.com Purpose of Inspection: partial compliance evaluation Facility Type: foam insulation manufacturer Regulations Central to Inspection: The facility's Lifetime Operating Permit, which includes limitations on opacity, particulate matter, and organic material. Page 1 of 3 Arrival Time: 09:00 a.m. CDT Departure Time: 11:30 a.m. CDT Inspection Type: Unannounced Inspection Announced Inspection OPENING CONFERENCE Presented Credentials Stated authority and purpose of inspection Provided Small Business Resource Information Sheet Small Business Resource Information Sheet not provided. Reason: Not a Small Business. Provided CBI warning to facility The following information was obtained verbally from Vanderpool, Baughman, and Anderson unless otherwise noted. Process Description: Owens Corning Foam Insulation (OCFI) owns and operates two foam insulation board manufacturing lines. The primary raw materials are polystyrene resin pellets and blowing agent. Additional raw materials include colorants. The pellets are loaded into a surge bin, heated, blowing agent added, and then extruded through a die and to form a continuous board of foam insulation onto a set of rolling conveyors. The rolling conveyors are inside a cylindrical tunnel. The tunnel is inclined and feeds the continuous board into a 105,000-gallon water bath to cool it. A vacuum removes any remaining water. OCFI prints product information including its insulation rating on one side. The board is then cut to its final width. The trimmings and dust are collected to be recycled into the process. The board is cut to its final length. OCFI collects the boards into bundles; and stores them in a warehouse before shipment. The components of the internal and external polystyrene scrap reclaiming process are: one scrap grinder and two ground fluff storage silos each with product recovery cyclone controlled by a fabric filter; two reclaimed polystyrene pellet extruders; and one polymer grinder with a cyclone and a fabric filter. TOUR INFORMATION EPA Tour of the Facility: Yes. Data Collected and Observations: During the plant tour, the inspectors did not notice any unusual odors or evidence of emissions from the fabric filters. The foam insulation board is pink and thus any emitted particles would be pink. OCFI is not required to install, operate, calibrate, and maintain continuous emission, opacity, or parameter monitoring systems. Page 2 of 3 Photos and/or Videos: were not taken during the inspection. Field Measurements: were not taken during the inspection. RECORDS REVIEW The inspectors reviewed OCFI's annual and semiannual emission reports from 2017 to 2020 for records of: emissions of particulate matter, particulate matter-10, and volatile organic materials; and operating schedules. OCFI manages its maintenance records in a SAP database. The inspectors reviewed examples of daily, monthly, and annual records for the facility's two baghouses. CLOSING CONFERENCE Provided U.S. EPA point of contact to the facility Requested documents: Aerial Facility Drawing Air Emission Reports for 2017 through 2020 Material Safety Data Sheet for the ink Process flow diagram Compliance Assistance: The inspectors did not provide compliance assistance. Concerns: The inspectors did not identify any areas of concern. DIGITAL SIGNATURES Digitally signed by Charles G. Charles G. Hall Hall Date: 2021.08.18 12:17:06 -05'00' Charles Hall, Environmental Engineer Digitally signed by Brian Brian Dickens Dickens Date: 2021.08.18 12:31:26 -05'00' Brian Dickens, Section Chief Page 3 of 3