INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM A - GENERAL INFORMATION

Parent Company Information

Parent Company Panaria Group

Street Address - Line 1 Panaria Bassa, 22/a

Street Address - Line 2 41034 Finale Emilia

City Modena

State Italy 

Zip code

Mailing Address (if different) - Line 1 320 W. Main St.

Mailing Address (if different) - Line 2

City Lakeland

State FL

Zip code 33815

Number of Employees in Parent Company >500

Dun and Bradstreet number 00 409 1583

Facility Information

Facility 1 Facility 2 Facility 3 Facility 4 Facility 5 Facility 6 Facility 7

Facility ID 2100500008

Facility Name Florida Tile Inc

Address 1 1247 Alton Rd

Address 2

City Lawrenceburg 

County Anderson

State Kentucky

Zip code 40008

Mailing Address (if different) - Line 1

Mailing Address (if different) - Line 2

City

State

Zip code

Number of employees at facility 100-249

What is your size classification for HAP emissions? Area Source (synthetic)

Hours of operation for this facility (hr/yr) 6000

Facility's primary NAICS or SIC code 327122

Total Number of Periodic Kilns at this Facility 0

Total Number of Tunnel Kilns at this Facility 0

Contact Person for this ICR David M. Johnston

Contact Phone Number 502-839-6911 ext 238

Contact Email Address mike.johnston@floridatile.com

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM A - General Information 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM B - KILN INFORMATION

Facility ID

Kiln ID(s) [Use the 

ID from your permit 

or assign using TK-1, 

2, etc for tunnel, RK1, 2, etc for roller, 

and PK-1, 2, etc for 

periodic]

Reporting Year (if 

not 2007) Type of Kiln

If periodic, 

number of 

identical kilns on 

this line Year Built

Stack 

Diameter (ft)

Does this kiln 

have an Air 

Pollution Control 

Device (APCD)?

Major Product Types Fired 

in Kiln

Annual 

Operating 

Hours for Kiln

 Full Design 

Capacity (tph)

Permitted 

Capacity (tph) 

if applicable

Average/Actual 

Capacity 

Utilization (%) 

(a) Primary Fuel

2100500008 RK-1 Roller Kiln No Wall Tile Natural gas

2100500008 RK-2 Roller Kiln No Wall Tile 0 Natural gas

2100500008 RK-5 Roller Kiln No Wall Tile Natural gas

2100500008 RK-6 Roller Kiln 2007 No Deleted as CBI Deleted as CBI Natural gas

2100500008 RK-1 Roller kiln 1996 No Deleted as CBI Deleted as CBI

2100500008 RK-2 Roller kiln 1996 No Deleted as CBI Deleted as CBI

2100500008 RK-5 Roller kiln 1995 No Deleted as CBI Deleted as CBI

**Permit restriction to only run either Kiln 1 OR 5 until modeling complete. Modeling has been completed. Market conditions are such that we still only run one Kiln or the 

* Only operational July - Dec. Current scheduled to run 24/5/48 or 5760.

(a) For sources that have a maximum permitted production capacity higher than the design capacity, enter the actual capacity utilization, which is defined as the actual production divided by the maximum permitted production 

rate. For sources with an enforceable permit production limit less than the design capacity, enter the average production capacity, which is defined as the actual production divided by the design capacity.

FACILITY and KILN IDs GENERAL INFORMATION KILN SIZE

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM B - Kiln Information 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM B - KILN INFORMATION

Facility ID

Kiln ID(s) [Use the 

ID from your permit 

or assign using TK-1, 

2, etc for tunnel, RK1, 2, etc for roller, 

and PK-1, 2, etc for 

periodic]

2100500008 RK-1

2100500008 RK-2

2100500008 RK-5

2100500008 RK-6

2100500008 RK-1

2100500008 RK-2

2100500008 RK-5

(a) For sources that have a maximum permitted production capacity higher than the design capacity, enter the actual capacity utilization, which is defined as the actual production divided by the maximum permitted production 

rate. For sources with an enforceable permit production limit less than the design capacity, enter the average production capacity, which is defined as the actual production divided by the design capacity.

FACILITY and KILN IDs ADDITIONAL INFORMATION ON PERIODIC KILNS

Secondary Fuel

Percent Use of 

Secondary Fuel (% 

of operating time) Back-up Fuel

Reason(s) backup would be 

used (e.g., NG 

curtailment)

Total time backup fuel was 

used during 

year (hr)

Kiln batch 

capacity (tons)

Average 

batch 

cycle time 

(hr)

Average 

number of 

batch cycles 

per year

Average time 

required to load 

unfired shapes into 

kiln (hr)

Average time 

required to 

unload fired 

shapes from 

kiln (hr)

0% Propane NG curtailment 0

0% Propane NG curtailment 0

0% Propane NG curtailment 0

0% Propane NG curtailment 0

FUEL USAGE

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM B - Kiln Information 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM C - GLAZE APPLICATION INFORMATION

GENERAL INFORMATION

Facility ID

Glaze Line ID(s) 

[Use the ID from 

your permit or 

assign using GZ-1, 2, 

etc]

Number of Spray 

Booths Per Line

Reporting Year (if 

not 2007) Year Built

Annual 

Operating 

Hours for Glaze 

Line

Is this Glaze Line Controlled by 

an Air Pollution Control Device 

(APCD)?

Average 

Percentage of 

HAP's 

Contained in 

Glazes (a)

Glaze Annual 

Consumption 

Annual Consumption 

Units

(H)*(I) 

.... 

Annual Total of 

HAPs In Glazes

HAPs In Glazes 

Units

% of HAP 

Containing Glazes 

that are spray 

applied (if known)

Decorating line #1 1 1996 Yes

Decorating Line #2 2 1996 Deleted Yes

Decorating Line #5 2 1995/1996 as Yes

Decorating Line #6 7 2006 CBI Yes

decorating line #7 8 2006 Yes

90% hydrofilters

98.7% dust collectors

Total 2007 Total 2007 Total 2007 Total 2007 Total 2007 Total 2007

Zinc Chrome Cobalt Iron Nickel Manganese

0 0 1 0 2 0

31 47 78 0 0 0

67 67 0 0 0 0

31 514 62 0 0 0

376 276 0 0 0 0

834 196 0 0 0 0

58 74 0 0 26 0

130 95 0 0 0 0

Deleted 1 4 7 0 0 0

0 0 391 0 0 0

as 16 0 5 0 0 0

0 2 0 0 0 0

CBI 0 61 65 0 0 0

714 0 0 0 0 0

1027 0 0 0 0 0

536 0 0 0 0 0

5900 0 0 0 0 0

932 0 0 0 0 0

68 205 137 342 137 68

0 0 0 617 0 0

4 0 0 0 0 0

0 1 0 0 0 0

40 7 0 13 0 0

174 522 348 870 348 174

0 99 7 0 0 0

83720 0 0 0 0 0 Total pounds of HAPs

94559 2055 1022 1842 511 242 3830

Note: all glaze spray 

booths have dust 

collector systems that 

have a minimum capture 

ratio of 90%. This would 

put our HAP emissions at 

383 lbs maximum.

We have not tracked Glaze usage in the past on a consistant basis as there is no requirement to do so in our 

permit. (We do not have HAPs in our glaze in appreciable amounts).

The following is the total amounts of all metals in our glazes in pounds.

Please note that the vast majority of these are used in our Roto color machines which are not a spray 

application.

**Note: decorating lines #6 and #7 feed Kiln # 6. No separate times are available for each line.

Note: Kiln #2, while still on the permit, has not been run since 2005. It is currently being used for spare 

parts. The decorating line is occassionally used with he feed going to Kiln #1.

FACILITY and GLAZE LINE IDs

(a) A "HAP containing glaze" is any glaze that contains a material or ingredient listed as a metal HAP on the MSDS for that glaze/material.

 PLANTWIDE GLAZE USE

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM C - Glaze Line Info 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM D - KILN APCD INFORMATION

APCD Information BAGHOUSE/FABRIC FILTER (Stand-alone or as part of DIFF or DLS)

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel, RK-1, 

2, etc for roller, and 

PK-1, 2, etc for 

periodic] Stack Diameter (ft)

Control ID # (assign 

based on ID used in 

Title V or using CD-1, 2, 

etc) Type

Reason Control was 

Installed

Number of kilns 

vented to this 

control device

Year control device 

was installed

Total bag surface 

area (ft2)

Bag- material of 

construction

Avg Life of bags 

(yrs)

Air-to-Cloth Ratio 

(see instructions) Cleaning method

Line #1 Kiln n/a

Line #2 Kiln n/a

Line #5 Kiln n/a

Line #6 Kiln n/a

FACILITY and KILN IDs

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM D - Kiln APCD Info 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM D - KILN APCD INFORMATION

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel, RK-1, 

2, etc for roller, and 

PK-1, 2, etc for 

periodic]

Line #1 Kiln

Line #2 Kiln

Line #5 Kiln

Line #6 Kiln

FACILITY and KILN IDs DLS or DIFF DLA

Reagent Type

Reagent feedrate 

(value) Units/ time

Total annual 

reagent usage 

(indicate units)

Is reagent 

recirculated or 

one-pass?

If recirculated, 

average ratio of 

recirculated to 

fresh reagent

Number of 

cascades

Do you use 

reconditioning 

drum/peeler?

What is the rate 

at which 

limestone is 

removed from 

the system as 

waste?

Parameter 

monitored

Monitoring 

frequency

Type of scrubber 

(e.g., venturi)

Liquid flow rate 

(gal/min)

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM D - Kiln APCD Info 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM D - KILN APCD INFORMATION

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel, RK-1, 

2, etc for roller, and 

PK-1, 2, etc for 

periodic]

Line #1 Kiln

Line #2 Kiln

Line #5 Kiln

Line #6 Kiln

FACILITY and KILN IDs OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

Pressure drop 

across scrubber 

(inches of water)

pH range of 

scrubbing liquid

Reagents used to 

maintain pH in 

desired range

Total annual 

reagent usage 

(indicate units) Units / Time

Design or 

Monitoring 

Parameter Units / Time

Design or 

Monitoring 

Parameter Units / Time

Design or 

Monitoring 

Parameter Units / Time

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM D - Kiln APCD Info 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM E - GLAZE LINE APCD INFORMATION

FACILITY and GLAZE LINE IDs CONTROL DEVICE INFORMATION BAGHOUSE/FABRIC FILTER WET SCRUBBER

Facility ID

Glaze Line ID(s) [Use 

the ID from your 

permit or assign 

using GZ-1, 2, etc]

Control ID # (assign 

based on ID used in 

Title V or using CD-1, 2, 

etc) Type

Reason Control 

was Installed

Number of spray 

booths vented to 

this control device

Year control 

device was 

installed

Total bag surface 

area (ft2)

Bag- material of 

construction

Avg Life of bags 

(yrs) Cleaning method

Type of scrubber 

(e.g., venturi)

Liquid flow rate 

(gal/min)

Decorating Line #1 Water curtain

Particulate/ opac. 

control 1 1997

Decorating Line #2 Water curtain

Particulate/ opac. 

control 1 1997

Decorating Line #5 Water curtain

Particulate/ opac. 

control 1 1997

Decorating Line #6 Fabric filter

Particulate/ opac. 

control 17 2006

Decorating Line #7 Fabric filter

Particulate/ opac. 

control 17 2006

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM E - Glaze Line APCD Info 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM E - GLAZE LINE APCD INFORMATION

FACILITY and GLAZE LINE IDs

Facility ID

Glaze Line ID(s) [Use 

the ID from your 

permit or assign 

using GZ-1, 2, etc]

Decorating Line #1

Decorating Line #2

Decorating Line #5

Decorating Line #6

Decorating Line #7

WATER CURTAIN OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

Pressure drop 

across scrubber 

(inches of water)

Water flow rate 

(gal/min)

Width of water 

curtain (ft)

Equipped with 

baffle or mist 

eliminator?

Design or 

Monitoring 

Parameter Units / Time

Design or 

Monitoring 

Parameter Units / Time

Design or 

Monitoring 

Parameter Units / Time

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM E - Glaze Line APCD Info 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM F - TEST DATA

GENERAL INFORMATION TEST INFORMATION ADDITIONAL INFORMATION

FAC ID Control ID

Kiln/Glaze 

Line/ 

Stack ID Test Date Report Date

Type of TestUncontrolled (or inlet to 

control), Controlled, 

Both HF HCl PM HAP Metals

Other (list 

below)

Other (list 

below)

Other (list 

below) Reasons for Test

APCD Parameters 

Monitored During Test Notes

Line 6 Kiln 15,16 Jan 2008 20-Feb-08 X X Compliance verifcation N/A Full test Included

Other Tests CO

POLLUTANTS TESTED (Please put X in box to indicate pollutant was tested)

Please provide copies of full test reports to minimize the need for future information requests. Field notes and raw reading sections can be omitted. However, please include all other sections of the reports, including sample calculations, 

laboratory data, run-by-run emission data, and a description of any deviations from test methods or other anomalies that occurred with the process or control device operations during the test. Please also provide information on the following for 

each test: production rate in units of fired product (tph); APCD parameters monitored and monitored values; and any anecdotal information you believe would potentially be helpful to us. 

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM F - Test Data 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM G - MONITORING AND OTHER COSTS

Facility ID Florida Tile

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh Deleted as CBI

Reagent:

Reagent Cost, $/ton

Waste Reagent disposal cost, $/ton or $/year

Water treatment costs, $/gal Deleted as CBI

Activity Required by Activity Estimated Hours Frequency Staff Level

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as 

CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI

Maintain free-flowing lime (Describe action in 

next box and then add estimated hours, 

frequency, and staff level)

N/A N/A N/A N/A

Meet requirement to "maintain adequate 

amount of limestone in hopper." (Describe 

action taken in next box, then add estimated 

hours, frequency, and staff level). If different 

approaches are taken at different plants, please 

add rows and provide information on each 

approach

N/A N/A N/A N/A

Control Device: baghouse

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as 

CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as 

CBI

Stack Test Costs for the Previous 3 Years

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled stack 

or APCD inlet)? 

Controlled? Both? Cost ($)

Notes (Include Any 

site/preparation 

costs not included in 

estimate)

2008 methods 1-4,10, and 26 Uncontrolled Deleted as CBI Deleted as CBI

Below is a chart with all data we have on our duct collectors

Dia Length

No Bag Bags Bags Air CapacityComments

Desig. Mfg Bags $ in. ft MC/H

Mill Room

??? Pneumafil 160 5.80 4.625 10.00 ???

Old BP

4A Mikropul 288 8.82 4.625 8.33 27,184 - 34,582

4B Pneumafil 316 5.80 4.625 10.00 55,217 - 67,960

4C Mikropul 288 60.00 4.875 6.77 32,281 - 33,980paper, pleated bag @26.3 ft2

New BP

DC-74 Sacmi 264 22.40 5.000 8.33 18,000

DC-75 Sacmi 936 22.40 5.000 8.33 ???

Raw Material Building

DC-73 Carter Day 124 8.82 4.500 8 36,393 bag price is an estimate

Porcelain Glazing Line

Line 6 Pneumafil 256 9.25 4.500 10 48,237

Wall Glazing Lines

Lines 1,2,and 5 hydro-filter ??? - - - - ???

PLANT DUST COLLECTORS

Please also provide separately an itemized list of site/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for 

installing permanent access to sampling ports, etc.)

Standard Activities- DLA (limestone)

Deleted as CBI

Deleted as CBI

Standard Activities- Wet Scrubber or Other Control

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM G - Monit-Other Costs 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM H - ECONOMICS IMPACTS INFORMATION

Product Selling Price Labor Rates as of January 2008

Facility ID Product type

Average Selling Price 

per Ton ($)

Reporting Year for 

Selling Price (if not 

2007)

Operator wage 

rate, $/hr

Maintenance wage 

rate, $/hr

Engineer wage 

rate, $/hr

Managerial/Supervisory 

wage rate, $/hr

2100500008 Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

Deleted as CBI Deleted as CBI Deleted as CBI Deleted as CBI

We do not track the selling price by product that is made in our facility. We sell a 

large variety of products with a substantial number of them imprted and resold on 

the domestic market. The selling price is exceptionally varied. We also sell some of 

the same items at retail and wholesale.

EPA-HQ-OAR-2013-0290-DRAFT-0016

Form H - Economics Info 12/1/2014
INFORMATION COLLECTION REQUEST FOR THE CLAY CERAMICS MANUFACTURING INDUSTRY

FORM I - ADDITIONAL QUESTIONS

Question Response

1. Please provide a copy of the cost estimate for 

your selected control device and explain any 

differences between the estimated and final 

installed costs. Costs should include costs for 

ancillary equipment, such as reconditioning drums, 

water treatment systems, etc N/A

2. Do you currently do any work or operating 

practices (i.e., other than the use of an air pollution 

control device) that would have an impact on HF, 

HCl, or PM emissions from your kilns? If yes, 

please explain. No

3. If you operate periodic kilns, please provide a 

time-temperature profile for each typical batch 

cycle. The profiles should show the duration of 

each temperature phase of the cycle from the time 

the kiln is fired to the time when the fired shapes 

can be removed from the kiln. (See instructions 

for example profile.) N/A

4. If you operate periodic kilns, do you have any 

information regarding technological and/or 

economic limitations to testing those kilns? N/A

5. Please provide a copy of a process flow diagram 

for your facility, if available. See Attached

EPA-HQ-OAR-2013-0290-DRAFT-0016

FORM I - Additional Questions 12/1/2014