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Industrial Case Studies·April 4, 2019

Taskmaster® Shredder Featured on Latest Episode of Canna Cribs

Proper waste disposal is a regulatory requirement of growers and processors in the booming medical and recreational marijuana industry. Cannabis cultivators and dispensaries like The House of Dankness in Colorado are not allowed to simply throw away the unusable plant scraps. Instead, they must shred and then mix the leaves, stalks and stems with other material, such as cardboard and rock wool, to render the resulting mix unusable and undesirable. But the House of Dankness had a problem. They burned through three different shredders that just didn’t hold up to their cannabis waste. It wasn’t until they found Franklin Miller’s TASKMASTER® TM8500 industrial duty shredder that they found a unit with the functionality and reliability they needed. Jump To Section How to maintain TASKMASTER® Cannabis Shredders? Features How to maintain TASKMASTER® Cannabis Shredders? In a recent episode of Cannacribs, Kelsey Rodgers, the Flower Quandrant Lead for the House of Dankness, spoke highly of the TASKMASTER. Rodgers stated the TASKMASTER® Cannabis Shredders reliably handles their waste and praised the shredder for its low maintenance. “We maintain it about once a week … clean the teeth, maybe put some oil through it. And other than that, maybe once a month, we’ll fully take it apart and give it a nice, good cleaning.” Features The TASKMASTER® TM8500 is a precision manufactured shredder that employs two intermeshing cutter stacks that rotate at low speed but with very high torque to provide the reliable shredding the facility needed. In just eight to twelve seconds, the TASKMASTER® can cut, shear, tear, slice, and rip apart solids – like leaves, stems and full stalks, generating a chip-like output. Additionally, the TASKMASTER shredder is quiet in operation and suitable for indoor use. That’s because it’s electrically driven so it doesn’t generate the fumes of gas powered chippers. Shredding maintenance problems are now a thing of the past at Rare Dankness. The TASKMASTER® TM8500 has helped them successfully process the cannabis waste in a manner that saves time, money and ensures regulatory compliance. Franklin Miller’s TASKMASTER® line of shredders offers a full array of features – including customizable chamber and tooth sizes as well as configurations that can be engineered to meet a variety of requirements.

Industrial Case Studies·November 15, 2017

Taskmaster Aids in Biomass Research

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. During the research process, lipids, proteins and other valuable residues such as carbonite calcium, enzymes and other molecules, all extracted from the marine biomass, are used. These molecules are also used for researching and producing cosmetics, natural health products as well as food and vitamin supplements. When they first began their research, CRBM was using a basic meat grinder. The results were uneven and unreliable and the material frequently got stuck in the grinder and ruined. It was also a slow and tedious process that could not keep up with the demand of the research. “To obtain the proper molecules for this research, the grinding output has to be perfect in order for the extraction step to work,” said Simon Cartier, CRBM Project Manager and Process Development Research Officer. “There are so many factors that can affect output, so we had to find a machine that could provide the exact size and quality that we needed. The grinding and homogenizing is always the first step in many of our processes, such as hydrolysis, so it is crucial to achieve appropriate grinding in order to obtain the best extraction yield after grinding.” “We looked for a long time to find a grinder that would allow us to crush various marine biomasses and learned about many different options before finding the TASKMASTER®.” When they installed the TASKMASTER in 2015, they expected to have to run the material through 2 or 3 times to obtain the desired output size. Instead, they were happy to find the TASKMASTER gave them the fine homogenous output with a perfect surface size and contact with their material only going through once. “We were shocked and incredibly happy,” said Cartier. “This has taken our research to higher levels much faster. It is a fantastic product for any marine biomass application.” The TASKMASTER TM8500 is a twin-shaft industrial grinder (a fine shredder) that features an 8.5” wide cutting chamber up to 60” long and a direct drive. It features a fully-sealed housing, mechanical shaft seals and CUTTER CARTRIDGE® technology with unique cutting profiles. “The addition of the TASKMASTER in our facility was essential. Using the TASKMASTER prior to extraction allows us to easily facilitate the marine proteins and peptides, marine lipids and other types of interesting molecules for our research.” “We looked for so long and wow, did we find it! What a good choice this was for us. It worked very, very well. We are very happy with it.” According to Simon Cartier, the company loves their TASKMASTER so much they are spreading the news. They even let another division borrow the TASKMASTER for their own research grinding algae. “Every pilot plant should have a TASKMASTER grinder!”

Industrial Case Studies·October 30, 2017

Crusher Provides Cool Solution for Freeze-Dried Mushrooms

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. “We needed to find a machine that could keep the material frozen during processing,” said Rick Owenga, Plant Manager at Van Drunen Farms. “We pride ourselves on the high quality of our end product, so this was an imperative part of process we had to maintain.” That’s when they turned to Franklin Miller to see if they had a solution. “We had heard of Franklin Miller quite a bit in the food processing industry,” Owenga said. “We were hopeful they would have a solution for our exotic mushroom processing needs.” Franklin Miller had a machine that exactly matched what the company needed. Van Drunen Farms purchased and installed a stainless steel DELUMPER® Model 1075L on a custom support and feed system in 2015. DELUMPER® “L” Series Lump Breakers reduce product to desired output size with a positive, once-through chopping action. Cutting teeth mounted to a smooth drum rotate through sizing combs to process agglomerates and chunks and reduce oversized particles to their basic grain size without over-grind, heat rise or fines. The DELUMPER Lump Breaker has been running in their plant ever since and has made Van Drunen’s mushroom processing headaches disappear. “The DELUMPER does a great job,” Owenga said. “It does exactly what we need and doesn’t give us any problems. Our customer is very happy and so are we.” Looks like Van Drunen Farms got the cool solution they were looking for. SEE OUR FULL LINE OF DELUMPER CRUSHERS AND LUMP BREAKER

Industrial Case Studies·February 23, 2017

SCREENMASTER® CS Bar Screen to the Rescue at a Commercial Composting Plant

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. At the suggestion of Franklin Miller engineers, the company installed an all stainless steel mechanical bar screen called the SCREENMASTER® Model CS, which would automatically remove the debris. The unit was set up in the pit, screening the debris before it could get to the lagoons. “Before we had the SCREENMASTER, all that junk went into the lagoons,” said Andy Jones, who started this business over 25 years ago. “It was impossible to stop all that sediment from getting in there. It kept clogging the pumps and impellers.” “Now it stays nice and clean,” Jones said. “We’ve had the SCREENMASTER CS for a few years now and we have no problem with the pumps at all. It’s simply a wonderful piece of equipment.” The SCREENMASTER CS features a series of rakes mounted on oversized perforated rake baskets that clears solids from a stainless bar rack and lifts them up out of the channel. It’s easy to install in new or existing channels. The SCREENMASTER installs at a 75° inclination so it has a very small footprint. The design features a simple, continuous rotary motion. As the rake head passes through the bar slots collecting debris, it travels up the unit’s dead plate until it reaches a special scraper supplied with a dash pot for smooth operation. The screenings then drop out the unit’s discharge chute into a bin, conveyor or SPIRALIFT® CS screenings washing system. The unit is available in a variety of widths up to 78” (2 m) wide and for a lift height of up to 38 ft. (11.6 m). LEARN MORE ABOUT THE SCREENMASTER CS BAR SCREEN

Industrial Case Studies·June 10, 2016

VULCANATOR® Reduces Full Rubber Bales to Granules; Minimizes Heat Rise

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 said. 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.

Industrial Case Studies·August 31, 2015

Custom DELUMPER® LP 5-Shaft Crusher Fits in Tight Location

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. “Because of these sticky lumps and agglomerates, we had a lot of downtime in the plant. Our processes were interrupted, and it was just a mess,” said the company’s project manager. Franklin Miller engineers designed a crusher for the customer’s phosphate production. This custom DELUMPER® model LP employed 5 shafts to reduce sticky and wet agglomerates, reducing the size of the lumps while handling the high volume of material effortlessly, something no other machine could do. One of the most important properties to the folks at the plant was about how to maintain the machine in place, and the 5-shaft DELUMPER LP allows them to do that. Franklin Miller engineers employed in the design special split bearings and seals to allow for easy independent removal of each shaft. “The accessibility to replace parts without moving the machine was a key aspect for us. We can easily replace or service one shaft or another without changing the other shafts, or without removing the machine from operating. It has really increased productivity when we need to do maintenance.” After leaving the DELUMPER®, the material goes into the dryer and screens. Any out of spec solids are sent back through the entire process and run through the DELUMPER® again. DELUMPER LP Crushers reduce hard or soft, heat sensitive, sticky or wet agglomerates and lumps at high volume. These straight-through units employ extended cutting teeth that rotate completely through a heavy bar cage. Oversized solids up to the unit’s full input opening size are reduced by this powerful processor. With each rotation, the teeth clean the slot openings, making the unit automatically self-clearing. Optional hardfacing is available. “The DELUMPER® has made such a huge difference in our process. It’s easy to maintain in place which means less downtime for our plant and more product yield. The DELUMPER® is an invaluable part of the company's phosphate production.”

Industrial Case Studies·June 12, 2015

DELUMPER® Aids in Polymer Production

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. After researching possible solutions, they found that the Franklin Miller DELUMPER® crusher could meet their needs. The dry chemicals are fed into the DELUMPER in either 100 kg sacks or in 25 kg or 50 kg bags. Lumps can often be as big as a fist and very hard. “It works great,” said Andy Fill, purchasing manager. “Even with the challenges the material often presents, there is no problem with the DELUMPER doing exactly what we need.” The DELUMPER® L Series Crushers reduce product to a desired output size with a positive, once-through, chopping action. Cutting teeth mounted to a smooth drum rotate through sizing combs to process agglomerates and chunks and reduce oversized particles to their basic grain size without over-grind, heat rise or fines. DELUMPER Crushers reduce lumps, crush minerals, improve product consistency, facilitate mixing, drying and conveying, and keep process lines running smoothly. These units have extraordinary processing capabilities on a wide range of materials including chemicals, sugar, food, minerals, urea, ammonium nitrate, salts, colors, plastics, pharmaceuticals and more. DELUMPER L Series crushers typically utilize specially designed teeth mounted on a smooth, rotating drum to intermesh with sizing combs, reducing solids to their basic grain size without overgrind, heat rise or fines. Lumps up to full inlet opening size can be processed. The unit runs at low speed and creates little vibration or noise. The unit has worked well for Steel Fire for more than a decade. Says Andy Fill, “We have had no problems at all with the DELUMPER.”

Industrial Case Studies·June 5, 2015

DELUMPER® Crusher Plays Important Role in Float Glass Production

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. The 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. The company chose a DELUMPER® Model 1077L , based on its simple, clean design. They installed the DELUMPER lump breaker in their pollution control electrostatic precipitator. The particulate matter is collected by the electrostatic precipitator and pneumatically transported to a storage silo. The pneumatic transport is sensitive to clumps. The DELUMPER was installed before the pneumatic transporter in the process to reduce plugging problems associated with clumps entering the transport system. About 6000 pounds of material passes through the DELUMPER each day. The unit operates continuously, breaking up pieces as large as a grapefruit. “Prior to the installation, the transporter was plugging 1-5 times per week. Since the installation of the DELUMPER, the system has not experienced any plugging,” said Eric Rouse, Hot End Manager. The DELUMPER® L Series Crushers reduce product to a desired output size with a positive, once-through, chopping action. Cutting teeth mounted to a smooth drum rotate through sizing combs to process agglomerates and chunks and reduce oversized particles to their basic grain size without over-grind, heat rise or fines. DELUMPER lump breakers reduce lumps, crush minerals, improve product consistency, facilitate mixing, drying and conveying and keep process lines running smoothly. These units have extraordinary processing capabilities on a wide range of materials including chemicals, sugar, food, minerals, urea, ammonium nitrate, salts, colors, plastics, pharmaceuticals and more. Lumps up to full inlet opening size can be processed. The unit runs at low speed and creates little vibration or noise. “We are very happy with the DELUMPER. It has eliminated 1-5 plugging events per week. Each event was an hour long tear down and clean out of the transport system. The DELUMPER has saved us manpower as well. Aside from some preventative maintenance, the unit has been very reliable.”

Industrial Case Studies·April 24, 2015

The DELUMPER®: A Sweet Success at ADM

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. After researching available options, ADM decided on a Franklin Miller DELUMPER® L. They are thrilled that they did. It has saved them time, money and manpower. “If it wasn’t for the DELUMPER,” said Brian Shpock at ADM Cocoa, “we would probably have to beat on the sugar lumps with a sledgehammer 24 hours a day.” The DELUMPER® L handles 200,000 pounds of sugar each day, with lumps up to 24”, though on average they are 6-8 inches. The DELUMPER® L has a unique streamlined design that is both versatile and easy to maintain and clean. The unit’s ultra-compact housing disassembles for cleaning and maintenance in less than a minute. The DELUMPER also features a variable speed direct drive that can precisely meet exacting application requirements. The unit is constructed with a sanitary, fully stainless steel design. The unit has a straight-through product flow with no bends or offsets to assure no accumulation within the unit and make installation easy. The DELUMPER® Lhas been in use in the ADM plant for four and a half years. “It’s been great. No problems. So far, so good.” Shpock said.

Industrial Case Studies·March 19, 2015

Case Study: Crusher Breaks Up Large Cakes of Enzyme Products

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 DC1077S4. “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.” The DELUMPER® S4 series crushers are specially designed and built to meet the highest quality and sanitary standards. The units employ a precision aligned, smooth rotating drum with integral teeth that rotate through a set of sizing combs. This mechanism produces a once-through, non-destructive crushing action that reduces oversized particles to their basic grain size without over-grind or over-work of material. The result is improved product consistency for enhanced processing, feeding and packaging. The units feature an ultra-sanitary design, easy interior access, cantilevered design, clean-in-place capability, quick change-over of cutting elements and a meticulously polished finish. A convenient access door provides fast and easy access to the interior of the cutting chamber for cleaning.

Industrial Case Studies·February 5, 2015

Case Study: 24" PIPELINE DELUMPER® Heavy-Duty Inline Processor

This 24″ PIPELINE DELUMPER® was design to handle 84,000 lbs/hr of polypropylene for a major petro-chemical company. The unit features 24 inch inlet and outlet flanges, stainless steel construction and a 50 HP motor to handle oversized agglomerates of polypropylene. The unit de-agglomerates troublesome scale and lumps that can cause operational difficulties for a petro-chemical plant. Reliability is critical as the unit is to be installed extremely high up in a relatively inaccessible area. The DELUMPER® was supplied with an intrinsically safe speed detection system to provide instantaneous feedback on unit rotational status. Other features included teflon packings, proprietary high profile cutter design for optimized feeding and effective particle reduction with little heat rise or headloss. The PIPELINE DELUMPER has proven its reliability in countless installations worldwide. This proven processor reduces agglomerates and solids, protects downstream equipments and improves flow properties. The unit connects via standard ASA flanges directly in pressurized, fully enclosed systems like an ordinary valve. Units are available for 3″ through 24″ pipe sizes. The DELUMPER can be supplied for up to 600 psi systems, for liquid, pneumatic or gravity systems. Units are supplied with packing seals, single or double mechanical seal systems and dry nitrogen shaft seals.

Industrial Case Studies·February 5, 2015

Case Study: DELUMPER® Chews Up Meat Products Pumping Problem

PROBLEM: Maxton Meat Processors, Inc. in Maxton, NC, was experiencing a major pumping problem of their difficult to transport meat products. As part of their process, Maxton employed a pumping system to transport the meat solids at 200 psi. The chicken parts mixed with powders and oils had a tendency to lump up, plugging their pipeline system, preventing the material from being pumped through the system pipes before further processing. Their pumps were clogging and bridging was occurring within the pipeline system. The result was a frequent need to dismantle and clean out the piping. The plugged pumps required frequent maintenance. When production schedules were not being met an urgent solution was called for. SOLUTION: Franklin Miller engineers, working closely with Maxton, determined that a PIPELINE DELUMPER® would most likely solve the problem. Initially skeptical that this inline unit could handle the difficult solids encountered in their system, Maxton agreed to put a unit in on a rental basis. The results were immediate and impressive. The solids and agglomerates were intensively processed and disintegrated by the forceful intermeshing of the unit’s cutting elements. Not only did the frequent plugging problems cease, but the need for pump tear down was eliminated as well. Based on the results of the initial rental, the unit was purchased by Maxton. The PIPELINE DELUMPER is an inline, pressure rated, flanged unit that employs a rugged bar grating and impeller both constructed of stainless steel. The cutting elements in this case were provided with a fused coated hardfacing of chrome boride. The unit is driven by an electric motor and drive. These pressure rated units are provided with a choice of packings, double or single mechanical seals or gas seals. The units are available for pipe sized of 3″ through 24.”

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