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The Penray Companies, Inc. - Wheeling Facility

Parent Companies:
PLZ Aeroscience
EPA Facility ID:
100000186728
Other ID:
Facility DUNS:
94292307
Parent Company DUNS:
0

Location:

Address:
440 Denniston Court
Wheeling, IL 60090
County:
COOK
Lat / Long:
42.079, -87.557 (Get map)
Method:
GPS Code Measurements (Psuedo Range) Standard Positioning Service SA OFF
Description:
Storage Tank
Horizonal accuracy:
10 m
Horizontal reference datum:
World Geodetic System of 1984
Source map scale:

Owner/Operator:

Name:
The Penray Companies, Inc.
Phone:
(847) 459-5000
Address:
440 Denniston Court
Wheeling, IL 60090 -4731
Foreign Address:

Person responsible for RMP implementation:

Name:
Suzanne Kalfus
Title:
EH&S Manager

Emergency contact:

Name:
Suzanne Kalfus
Title:
EH&S Manager
Phone:
(847) 459-5019
24-hour phone:
(224) 254-5363
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(847) 459-5000
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Cook County LEPC
Full-Time Equivalent Employees:
47
Covered by OSHA PSM:
Yes
EPCRA section 302:
No
CAA Title Air Operating Permit:
No
CAA Permit ID#:
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Jan. 28, 2013
Inspecting Agency:
Starr Technical Risks
Using Predictive Filing:
No

Processes:

Aerosol Filling Operation
RMP ID:
1000086063
CBI claimed:
No
Program Level:
3
NAICS:
All Other Miscellaneous Chemical Product and Preparation Manufacturing (325998)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
82,440
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
March 14, 2018
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000068625

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

None

3. Toxics: Alternative release

None

4. Flammables: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Aerosol Filling Operation)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Blast walls

5. Flammables: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Aerosol Filling Operation)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain

6. Five-year accident history

Jan. 9, 2014 at 08:00
ID:
1000053482
NAICS:
All Other Miscellaneous Chemical Product and Preparation Manufacturing (325998)
Duration:
6 hours
Chemicals involved:
  • Propane
Release events:
Gas release
Fire
Weather conditions at time of event
Wind speed:
None
Temperature:
-23.00 ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
0
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$75000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
600
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Unusual weather conditions
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised maintenance
  • Revised training
  • Revised operating procedures
  • New process controls
  • New mitigation systems
  • Revised emergency response plan
  • Changed process

7. Prevention: Program level 3

Aerosol Filling Operation, All Other Miscellaneous Chemical Product and Preparation Manufacturing (325998)
Prevention Program ID:
1000072696
Safety Review Date
March 1, 2018
PHA Update Date
March 8, 2017
PHA Techniques
  • What if
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Blast Walls
  • Deluge System
  • Enclosure
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Controls
  • Process Detection
  • Mitigation Systems
  • None Recommended
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Observation
Procedure Review Date
Jan. 15, 2018
Training Review Date
May 16, 2017
Maintenance Review Date
Jan. 15, 2018
Maintenance Inspection Date
March 13, 2018
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 14, 2017
Management of Change Review Date
March 31, 2017
Pre-startup Review Date
March 31, 2017
Compliance Audit Date
Dec. 12, 2017
Compliance Audit Change Completion Date
Jan. 31, 2018
Incident Investigation Date
Jan. 9, 2014
Incident Invest. Change Completion Date
Dec. 31, 2015
Participation Plan Review Date
March 2, 2018
Hot Work Review Date
March 31, 2017
Contractor Safety Review Date
March 31, 2017
Contractor Safety Eval. Date
July 9, 2014

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
Yes
Facility Own Response Plan:
No
Specific Facility Response Plan:
Yes
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
Yes
Plan Review Date:
Response Training Date:
Feb. 11, 2017
Local Response Agency:
Local Response Agency Phone:
(847) 459-2662
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
No
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
No
Subject To - Other:

Executive Summary

The Penray Companies, Inc. is a manufacturer of liquid and aerosol chemical products and services for the transportation industry. Our customers recognize us for our knowledge of their business, our technical competence, our ability to provide fair value for the dollar, and our overall reputation in the industry. Penray people are dedicated to providing quality products and services using safe and environmentally acceptable manufacturing techniques uniquely applied to fill customer needs.



The management of Penray is dedicated to creating an environment where employee participation is encouraged and creativity is recognized. In order to meet or exceed our customer and community's expectations, we provide our employees with the necessary training and tools to fulfill their individual missions. In this process all employees are expected to work in a team environment and to treat one another, customers, suppliers and our neighbors with respect and without discrimination.



It is Penray's intent to produce and sell only those products that can be manufactured, used and disposed of in a safe and environmentally acceptable manner. We will operate in compliance with all applicable laws and regulations. We, therefore, continuously review all Penray's procedures, practices, and our products, in order to ensure compliance and minimize risks to our employees, neighbors and our customers.



The production process at the Wheeling manufacturing plant consists primarily of the mixing, filling and packaging of aerosol products. The production process begins in the filling room where three production lines, including one double line are housed. At the beginning of the production line, empty aerosol cans move to the filling machines that dispense a measured amount of product formulation into the can. The product formulation is blended in a separate mixing room and then piped to the filling machines. After being filled, the cans are topped and sealed and then sent throug
h an aerosol propellant-filling machine where the aerosol propellant is injected into each can.



Once the propellant has been placed in the cans, cans move out of the filling room into the main production section of the plant. There, the cans first pass through a heated water-testing tank that tests each can for safety. Following this safety check, spray tips and plastic caps are put in place and the product is date coded. The finished aerosol cans are then packed in cartons which are sealed by a gluing machine, stacked on pallets and then moved to finished goods inventory.



The Wheeling facility is located at 440 Denniston Court, Wheeling, Illinois 26 miles northwest of downtown Chicago. It houses the executive and administrative offices for The Penray Companies, manufacturing facilities, laboratory, inventory storage, chemical storage and blending facilities.



The property consists of a modern one-story masonry and metal-sided industrial building containing approximately 88,300 square feet. The facility includes approximately 10,000 square feet of modern air-conditioned office space and asphalt paved parking with room to accommodate employee and customer needs. The facility also contains two loading docks, one to receive materials and the other to ship finished goods. Penray also owns a able empty lot adjacent to the facility.



The facility's laboratory tests all products that are manufactured for content and safety requirements. All research and development operations are conducted at the Wheeling laboratory. The laboratory is considered modern and well equipped by industry standards and is capable of performing all potential services required by the facility.



Penray's manufacturing facility in Wheeling, Illinois works closely with community and has a very good relationship with the Wheeling Fire Department. The Wheeling Fire Department recognizes our needs and concerns in case of a worst-case scenario and any other event that may affect our
employees and our residential and industrial neighbors and has response activities coordinated to take place should an unlikely event happen. Wheeling's Fire Department orientation programs for personnel, Fire Prevention inspection program, and review of Penray's Emergency Response helps the Wheeling Fire Department to coordinate with Penray and limit the risks and concerns that may be generated.



The following are Penray's Emergency Response Coordinators:

Primary Emergency Response Coordinator

Suzanne Kalfus

EHS Manager

Work Telephone Number: (847) 459-5019

24-hour Telephone Number: (224) 254-5363

Secondary Emergency Response Coordinator

Steve Abrams

VP of Operations

Work Telephone Number (847) 459-5007

24-hour Telephone Number (312) 343-434361

Alternate Emergency Response Coordinator

Gordon Hess

Maintenance

Work Telephone Number (847) 459-5024

24-hour Telephone Number