Taskmaster Biomass

At CRBM Marine Biology Research Center in Quebec, Canada, researchers were in search of a grinder for a project involving marine biomass. A big part of this research project was focused on finding and extracting marine molecules that could fight against major diseases such as cancer (breast, lung, prostatic and intestinal). For the research, marine materials such as hard shells, lobster pieces, stretchable fish skin and even large and resistant seaweed needed to be ground to a homogeneous size so the research elements could be effectively extracted from the material. Getting the output size right was imperative to having a workable material for the very delicate extractions and research.

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When establishing a processing and freeze-drying system for an exotic mushroom customer, Van Drunen Farms in Momence, Illinois found themselves in search of a solution for a unique set of challenges.Van Drunen Farms specializes in processing high-quality ingredients through a multitude of processing methods and services, including freeze-dried, drum-dried, frozen and infused, as well as dietary supplements.The company needed help processing specialty exotic mushrooms. The mushroom spores are grown in wet rice holes. Once grown, the mushrooms are frozen in bulk and sent in forty-pound blocks to Van Drunen for processing. This is where the problem came in.Van Drunen needed a high-quality, reliable crusher that could break the blocks while keeping them frozen. Output size was also a driving factor. Because the pieces would be freeze-dried after processing, the output size couldn’t be too fine. The pieces would have to have an output size between 3/8 and 1/2 inch. The company began exploring options, but had trouble finding a solution that would be able to deliver the right size output, keep the product frozen, and be reliable and well-built.

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Size-reduction machinery manufacturer Franklin Miller Inc. has filled a necessary niche with its equipment designed for the rubber industry, most notably the VULCANATOR® brand granulator, which can reduce rubber without typical heat build up.

“The machine employs a unique low friction, low-heat-rise design, eliminating the need of many granulators for expensive auxiliary cooling systems,” said Franklin Miller President William Galanty. “The VULCANATOR also significantly reduces subsequent processing time, dissolving processes and manufacturing costs by reducing the rubber to the desired size,” he said.

“The units can be built in stainless or carbon steel, for wet or dry processing,” he said. The equipment also may include a pneumatic discharge system and cyclone separator.

“Depending on the model, the VULCANATOR can reduce 75-pound to 90-pound bales of rubber at varying rates of speed,” Galanty saidVulcanator_. The four model sizes range from the 40-horsepower KMIO up to the 250-hp KM50, with the KMIO handling somewhat smaller sheets, slabs, chunks and rejects.

“During the reduction process, material is fed into the unit by conveyor or by hand, and rugged rotary knives pull it into the cutting area and disintegrate the slabs to a size fine enough to pass through a special sizing screen. The machine controls the output by the screen size, which acts like a classifier and recirculates the particles until they reach the desired size,” Galanty said.

“Franklin Miller was founded in 1918 in East Orange, N.J. as a producer of ice crushers and ice cream freezers. It services a variety of customers, including rubber manufacturers and companies that make products from natural and synthetic rubber, tire recyclers, pharmaceutical manufacturers, adhesives producers, plastics makers, waste processors and more,” Galanty said.

“The VULCANATOR’s applications include integration into a conveying or dissolving system for rubber manufacturing, as well as a primary or secondary granulator for materials other than rubber,” Galanty said.

It’s also been used as a secondary sizer installed below the company’s TASKMASTER® brand twin-shaft shredders and for recycling purposes.

“The VULCANATOR has a unique market,” the Franklin Miller executive said. ”The domestic rubber industry has been slow. However, for manufacturers looking for the savings gained from improving efficiency, this unit can pay for itself in short order.”

The firm has tested a wide variety of natural and synthetic rubber materials and the unit has “handled them all beautifully,” Galanty said. “The main material issue is that the rubber not be too sticky before reduction,” he said.

“The VULCANATOR is a niche product,” he said, “but it serves an important service to the rubber industry.”

“Franklin Miller’s other rubber industry machinery includes the TASKMASTER and the DELUMPER®, which is used for breaking up crumb rubber and rubber agglomerates,” he said.

“The company, now on its third generation of family ownership and employing up to 50, also houses a VULCANATOR and other equipment at its in-house testing facility for trials on customer materials,” Galanty said.

In addition to standard equipment, Franklin Miller can supply custom designs or complete turn-key systems, with the objective of increasing processing speed and reducing waste and costs. Besides rubber, the firm’s broad line of equipment is used in applications such as plastics, chemicals, waste handling and wastewater treatment.

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A commercial mushroom composting company in Pennsylvania needed help with a problem in their compost production process. The compost, made from hay, straw, horse manure, chicken litter, corn cobs and more, is processed on an eight-acre concrete slab, also called a wharf. The runoff from the rain and water used during the compost process washes off the wharf and into a pit and then travels through a pipe that carries it to the two-million gallon lagoon behind the wharf. From there, the company recycles the water by pumping it back to begin the process again. Unfortunately, the process wasn’t as smooth as they had hoped. Sediment and pieces of the organic material were continuously washing down into the pit and traveling to the lagoons, causing major clogs. This presented a serious issue for the company as it was slowing down their process, causing downtime, and making a mess of their lagoons. That’s when they contacted Franklin Miller for a solution.

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Delumper LP 5 shaft

When a major global leader in agricultural products needed help reducing wet and sticky agglomerates in a very tight plant location, Franklin Miller was ready with a custom solution.

The customer produces phosphate, nitrogen and potash, three critical crop nutrients and provides fertilizer to growers worldwide to make their crops thrive, so they can produce more high-quality food to meet the growing global demand.

When the company began having problems with their phosphate production, causing the material to agglomerate and clog their equipment, they knew they would have to find a solution. Acid and ammonia are added to phosphate to make it granular, causing the material to be sticky and wet and prone to agglomerates.

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Steel Fire Equipment in Ontario, Canada needed help with their polymer production. The plant produces polymer for fire extinguishers. The pneumatic production system processes chemicals that often clump and sometimes even form into stone. They needed a crusher that could break up these chunks or the material would not flow through the system and the entire process would come to a halt. Steel Fire also needed the machine to be able to handle their production rate of 3000 – 4000 pounds of material a day and be powerful enough to break up very hard chunks.

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Guardian Industries Corp.’s float glass plant in South Carolina was in search of a crusher to aid in their glass production process. They needed a unit that could break up the electrostatic precipitator material and prevent pneumatic transport plugs. Without the efficient breaking of these lumps, the process was interrupted, wasting time and money.

Delumper LP With HopperThe process for float glass production consists of mixing sand, soda ash, limestone and other raw materials in a batch house, then melting them in a glass melting furnace. The “continuous ribbon” is formed in the tin bath, where they “float” the molten glass over molten tin and form it to a continuous ribbon of glass of specific widths and thickness to be cut to customer requirements.

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Delumper L

ADM Cocoa Plant in Hazle Township, Pennsylvania needed help with their cocoa bean production. The plant processes two and a half million pounds of cocoa beans each day, turning them into cocoa powder, cocoa butter, and chocolate liquor. The company needed a machine to process sugar with over-sized lumps that could occur in transport or storage. Unless these agglomerated clumps were reduced to a granular form, the process could not work dependably. The machine also had to handle the large quantity of sugar processed daily and be sanitary.

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American Laboratories, Inc. is a leading manufacturer of enzyme products for many food, dietary supplements, nutritional and industrial applications. The company has grown steadily, currently operating three facilities in Omaha, Nebraska. To keep pace with this expansion, the company realized, some years ago, that a more efficient way to process the enzyme material was necessary. After examining their options, they made a decision to purchase a Franklin Miller DELUMPER® Crusher 1077 S4.

“We use the DELUMPER Crusher to break up large cakes of enzyme products,” explains Vern Maly, Vice President of Production. “The solid, crunchy material is easily broken up into smaller pieces by the unit so that it can be further milled.”

“The DELUMPER Crusher suits our needs. Because it runs at a slower speed, it doesn’t generate much dust. When you are dealing with enzymes, that is very important,” says Maly. “Ease of cleaning is another benefit,” he continues. “We take off the cover, slide out the drum, clean it daily and its ready to go.”

“We’re very satisfied with the DELUMPER Crusher,” concludes Maly. “It worked well immediately after we installed it and, after seven years, the crusher continues to operate trouble-free.”

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