Introduction
As the world's population continues to grow, so does the need for effective wastewater treatment. Properly managing wastewater is essential to maintaining the health and safety of our communities and the environment. A critical component of wastewater treatment is the protection of the pumps used in these systems. In this blog post, we'll explore the importance of grinding in wastewater treatment pump protection and why it's crucial to the overall efficiency and success of these systems.
The Role of Pumps in Wastewater Treatment
Wastewater treatment plants rely on a variety of pumps to move water and waste through the treatment process. These pumps are responsible for tasks such as transferring raw sewage, pumping treated effluent, and recirculating sludge. The pumps must be able to handle solid materials, including debris and waste, which can be found in wastewater.
The Challenge: Protecting Pumps from Damage
One of the most significant challenges faced in wastewater treatment is the potential damage to pumps caused by solid materials, such as rags, plastics, and other debris. If these materials are not adequately managed, they can clog or damage the pumps, leading to costly repairs, downtime, and decreased efficiency in the treatment process.
The Solution: Grinding in Wastewater Treatment
Grinding plays a critical role in protecting wastewater treatment pumps from damage. By breaking down solid materials into smaller particles, grinding equipment helps prevent clogs and damage to pumps, ensuring they continue to operate efficiently.
Inline grinders, such as those manufactured by Franklin Miller, are installed directly in the wastewater flow path. These grinders use sharp, hardened steel cutters to shred and reduce the size of debris, making it easier for the pumps to handle and transport the materials.
Benefits of Grinding for Wastewater Pump Protection
Increased Pump Efficiency: With solid materials effectively ground into smaller particles, pumps can operate more efficiently and with less strain. This reduces the likelihood of clogs and damage, ensuring the wastewater treatment process runs smoothly.
Reduced Maintenance Costs: Grinding helps prevent clogs and pump damage, which in turn leads to less frequent maintenance and repair costs. This not only saves time but also reduces the overall expense of wastewater treatment plant operation.
Prolonged Pump Lifespan: By protecting pumps from damage and reducing strain, grinding equipment helps extend the life of wastewater treatment pumps. This results in long-term cost savings and increased operational efficiency.
Environmental Impact: Properly functioning pumps are essential for effective wastewater treatment. Grinding equipment ensures that pumps can effectively manage solid materials, leading to more successful treatment outcomes and a reduced impact on the environment.
Franklin Millers Offerings
Taskmaster:
The Taskmaster is a powerful grinder that is ideal for a variety of applications, including solids reduction, wastewater treatment, and more. It is available in several different models, each with its own unique features and capabilities. Some of the key benefits of the Taskmaster include its ability to handle tough materials, its low maintenance requirements, and its high capacity grinding capabilities.
Dimminutor:
The Dimminutor is a versatile grinder that is designed to handle a wide range of solids, including wipes, rags, and other tough materials. It is ideal for use in wastewater treatment facilities and other high flow environments where solids reduction is a critical component of the process. The Dimminutor is available in several different sizes and configurations to meet the specific needs of each application.
Super Shredder:
The Super Shredder is a high-performance inline grinder that is designed to handle large volumes of solids and sludge. It is ideal for use in wastewater treatment facilities, food processing plants, and other industrial settings where solids reduction is a critical component of the process. Some of the key features of the Super Shredder include its ability to handle tough materials, its low maintenance requirements, and its high capacity shredding capabilities.
Conclusion
Grinding is a crucial component in wastewater treatment pump protection, ensuring that these essential systems continue to operate efficiently and effectively. By incorporating grinding equipment into the wastewater treatment process, operators can reduce maintenance costs, extend pump lifespans, and ultimately contribute to a healthier environment. As the demand for wastewater treatment continues to grow, the importance of grinding in pump protection will only become more critical to the success of these systems.
The Importance of Choosing the Right Grinder
The cannabis industry has experienced rapid growth, and as a result, businesses are seeking efficient and reliable equipment to streamline their processes. One key component in cannabis processing is the grinder, which plays a crucial role in preparing the plant material for further processing. Selecting the right grinder for your business can significantly impact your productivity, product quality, and long-term success. This comprehensive guide will help you make an informed decision when choosing the best industrial cannabis grinder for your needs.
Understanding Your Cannabis Processing Needs
Before choosing a grinder, it's essential to evaluate your business's specific requirements:
Volume and Capacity Requirements: Determine the amount of cannabis material you need to process daily or weekly, and choose a grinder with the appropriate capacity to handle that volume efficiently.
Types of Cannabis Products: Identify the range of products you want to produce, such as flower, concentrates, or edibles, as this will affect the type of grinder you require.
Scalability and Growth Potential: Consider your business's growth plans and whether your chosen grinder will accommodate increased production volumes in the future.
Key Features to Consider in an Industrial Cannabis Grinder
When comparing grinders, keep these critical features in mind:
Size Reduction Technology: Grinders should provide consistent particle size and be able to handle a variety of materials without damaging essential oils or causing excessive heat.
Material Construction and Durability: Look for grinders made of high-quality materials, such as stainless steel, to ensure long-lasting performance and easy cleaning.
Ease of Cleaning and Maintenance: Grinders with minimal moving parts and easy access for cleaning will save time and effort in the long run.
Safety and Compliance Standards: Ensure the grinder meets industry safety standards and complies with local regulations to prevent potential accidents or legal issues.
Energy Efficiency and Environmental Impact
Selecting an energy-efficient grinder helps reduce operating costs and contributes to a greener, more sustainable operation. Consider grinders with features like low power consumption, low noise emissions, and minimal waste generation.
Evaluating Performance and Reliability
When comparing grinders, pay attention to these performance indicators:
Grinder Throughput: The grinder should process material quickly and efficiently to keep up with your production demands.
Consistency and Quality of Output: A good grinder should produce uniform particle size, ensuring a high-quality final product.
Grinder Lifespan and Warranty: Choose a grinder with a proven track record of durability and reliability, backed by a comprehensive warranty to protect your investment.
As the global population continues to grow, so does the demand for efficient food production and waste management systems. Food waste processing is an essential component of a sustainable environment, and it plays a critical role in conserving resources, reducing pollution, and minimizing landfill space. Franklin Miller, a leading manufacturer of industrial shredders and other size reduction equipment, is committed to providing innovative solutions for food waste processing. In this article, we will discuss the importance of industrial shredders in food waste management and explore their benefits and applications.
Understanding Food Waste
Food waste refers to any edible material that is discarded, lost, or uneaten throughout various stages of the supply chain, from production and processing to retail and consumption. According to the Food and Agriculture Organization (FAO) of the United Nations, roughly one-third of all food produced for human consumption is wasted, which amounts to approximately 1.3 billion tons per year. This waste has significant environmental, economic, and social consequences, making it essential to develop effective strategies for its management and reduction.
The Role of Industrial Shredders in Food Waste Processing
Industrial shredders play a crucial role in food waste processing by reducing the size of waste materials, which allows for more efficient handling, transportation, and disposal. Franklin Miller's industrial shredders are designed to handle a wide range of food waste types, from fruits and vegetables to meats, fish, and dairy products. Here are some of the key benefits of using industrial shredders in food waste processing:
Volume Reduction
By shredding food waste into smaller particles, industrial shredders significantly reduce the overall volume of the waste. This reduction in volume not only leads to decreased transportation and disposal costs but also conserves valuable landfill space
Improved Waste Processing Efficiency: Shredded food waste is more easily processed by downstream equipment, such as pumps, conveyors, and separators. This improved efficiency translates into faster and more cost-effective waste processing operations.
Enhanced Biogas Production: Smaller food waste particles have an increased surface area, which allows microorganisms to break down the organic material more quickly during anaerobic digestion. As a result, shredding food waste can enhance biogas production and contribute to renewable energy generation.
Facilitates Composting: Shredded food waste provides a more uniform particle size, which is advantageous for composting processes. The reduced particle size increases the surface area for microbial activity, resulting in a faster and more efficient composting process.
Compliance with Regulations: Proper food waste management is essential to comply with various local, regional, and national regulations. By employing industrial shredders, companies can ensure they are meeting waste management requirements and reducing their environmental impact.
Franklin Miller's Solutions for Food Waste Processing
Franklin Miller offers a range of industrial shredders and grinders designed specifically for food waste processing. Our equipment is ideal for reducing food waste into smaller particles that can be easily transported and disposed of. Our grinders and shredders are built to handle a variety of food waste materials, including fruits and vegetables, meat and poultry, seafood, and more.
Our products are designed to maximize efficiency, reduce labor costs, and minimize downtime. We offer a range of options to meet your specific needs:
Taskmaster® TM8500 twin shaft shredder: This shredder is designed for smaller food waste processing applications and has a compact design for easy installation in tight spaces. It has a high torque, low-speed design that provides efficient shredding of a wide range of food waste materials, including fruits and vegetables, meat and poultry, and seafood.
Taskmaster® TM1600 twin shaft shredder: This shredder is designed for medium to large food waste processing applications and can handle a wide variety of food waste materials, including fruits and vegetables, meat and poultry, seafood, and more. It has a unique cutting chamber design that provides efficient shredding while minimizing noise and vibration, making it ideal for use in commercial kitchens and other food processing facilities.
Taskmaster® TM2300 twin shaft shredder: This shredder is designed for large volume and high capacity food waste processing applications. It has a powerful motor and rugged construction to handle tough materials, such as fruits and vegetables, meat and poultry, seafood, and more. It can reduce food waste into smaller particles, making it easier to transport and dispose of.
All of these shredders are built with high-quality materials and are designed to maximize efficiency and minimize downtime in food waste processing applications. They are also easy to maintain and come with a range of optional features and accessories to meet your specific needs.
Reduce Your Environmental Impact and Improve Your Bottom Line with Franklin Miller's Food Waste Shredding Solutions
Food waste is a growing problem for businesses and communities around the world. By implementing a food waste shredding solution, businesses can reduce their environmental impact, save money on waste disposal costs, and even create new revenue streams through the production of compost and renewable energy.
Franklin Miller offers a range of industrial shredders and grinders designed specifically for food waste processing. Our equipment is built to handle a wide variety of food waste materials, from fruits and vegetables to meat and poultry, and is designed for maximum efficiency and minimal downtime.
Whether you're operating a commercial kitchen, a food processing facility, or a waste management company, Franklin Miller has the expertise and equipment to help you reduce your environmental impact and improve your bottom line. Contact us today to learn more about our food waste shredding solutions.
Meeting Cannabis Waste Regulations
The Regulations
As the cannabis industry continues to grow, waste disposal and management practices have become increasingly important. With changing regulations surrounding cannabis waste, it is essential for businesses to stay up-to-date and ensure compliance. This article explores the latest cannabis waste regulations and offers guidance for businesses operating in the industry.
Federal vs. State Regulations:
Although cannabis remains a Schedule I controlled substance under federal law, many states have legalized its use, either for medical or recreational purposes. Consequently, individual states have implemented their own regulations for cannabis waste disposal. It is crucial for businesses to follow state-specific guidelines in addition to remaining aware of any changes in federal policies.
Waste Definition and Classification:
Cannabis waste generally refers to any leftover plant material, such as stems, leaves, and roots, as well as any other waste generated during the production, processing, or manufacturing of cannabis products. This waste is typically classified as either hazardous or non-hazardous, depending on the state's regulations and the specific materials involved. It is essential for businesses to understand and correctly classify their waste in order to ensure proper disposal.
Waste Management and Disposal Requirements:
Cannabis waste disposal requirements vary from state to state, but there are some general guidelines that most states follow. These include:
a) Waste Rendering: Cannabis waste must often be rendered unusable and unrecognizable before disposal. This process typically involves grinding and mixing the waste with other materials, such as paper, plastic, or soil.
b) Waste Storage: Secure storage of cannabis waste is vital to prevent unauthorized access, theft, or diversion. Waste storage areas should be well-ventilated, clean, and free from pests.
c) Waste Tracking: Businesses must maintain detailed records of their cannabis waste disposal, including the amount and type of waste disposed, the method of rendering, and the final disposal method. These records should be kept for a minimum of three years or as required by state regulations.
d) Waste Disposal Methods: Approved disposal methods vary by state but may include composting, incineration, or disposal at a licensed solid waste facility. It is essential to follow your state's specific guidelines for waste disposal to ensure compliance and avoid fines.
e) Waste Disposal Companies: Some states require businesses to work with licensed waste disposal companies for the management and disposal of cannabis waste. These companies must adhere to strict regulations and demonstrate expertise in handling cannabis waste.
Regulatory Changes and Compliance:
Cannabis waste regulations are constantly evolving, and businesses must stay informed of any changes to remain compliant. Regularly reviewing state and federal guidelines, attending industry conferences, and consulting with legal or compliance experts can help businesses stay up-to-date with the latest regulations.
Taskmaster Shredders
TASKMASTER® cannabis shredders help cannabis growers meet the regulatory requirements of cannabis waste disposal in a cost-effective and efficient way. The units can process root bulbs, stalks, leaves, and stems and reduce and/or compost both solid and liquid waste to meet state and local safety and environmental regulations. These high capacity units can be hand fed, conveyor-fed or fed by a bucket loader, depending on the model. TASKMASTER industrial shredders are designed to meet any cannabis waste regulatory environment you may encounter. Read more about the TASKMASTER TM8500 and TASKMASTER TM1600.
TASKMASTER® shredders provide a complete shredding solution for cannabis plant waste, medical plant waste, and hemp size reduction. These shredders significantly reduce the volume of output material, making compact disposal or further processing significantly easier and more efficient. The TASKMASTER features dual counter-rotating cutter stacks, designed to carefully intermesh at low speed under close clearance and extremely high torque. They cut, shear, tear, slice, and rip apart solids typically in a strip or chip-like output shape. Each plant can be processed in approximately eight to twelve seconds.
TASKMASTER shredders are used by companies all over the United States and Canada to help with the disposal of their cannabis waste. These powerful shredders are a clean and quiet alternative to a gas-powered wood chipper. They typically employ up to a 15 HP motor and gear drive, and are complete with a stand, hopper and automatic reversing controller.
Read more about Cannabis Shredders here https://franklinmiller.com/applications/cannabis-shredders/, and see TASKMASTER cannabis waste shredders featured on Cannacribs show.
*These regulations are a general guideline. Always check current local laws and regulations for your state. The information presented by Franklin Miller is not legal advice, is not to be acted on as such, may not be current and is subject to change
without notice.
Franklin Miller has been contributing to a greener planet with a broad line of grinders and shredders that aid in wastewater treatment, composting, food waste, recycling worldwide.
Now the company is extending its commitment to a greener planet by converting much of the operations to the use of solar energy. Recently, Franklin Miller has completed a major installation of solar panels on the entirety of the roof of their Livingston, New Jersey headquarters and manufacturing facility. This is the latest initiative of the company in their commitment to being a green manufacturer and to reduce their carbon emissions and footprint. This project, recently completed, is a major green initiative for the company. When the power is not being used by the operation, it will go back to the grid. The system was designed to produce 193,600 kwh of electricity. From LED bulbs inside, to major updates like these solar panels, Franklin Miller is working to be be as environmentally conscious as possible.
Franklin Miller Inc. is committed to being a good corporate citizen and to helping their customers do their part, too.
The City of Fitchburg, Massachusetts was having problems with their new wastewater grinders purchased from a well known manufacturer. “The grinders were nothing but constant trouble right from the start,” said Ken Letourneau from the City of Fitchburg WWTP. They failed routinely. Debris getting stuck between the single tooth cutters was one source of constant breakdowns. Another major problem was that the grinders did not have bottom bearings, causing the rotating shafts to blow out the bottom of the machines and wear away quickly. “They were total junk that caused a lot of downtime,” Letourneau said.
Letourneau began to research replacement grinders and turned to Franklin Miller for a better design. “We were excited about the
benefits of CUTTER CARTRIDGE® technology, and had also heard nothing but good things about the robustness of the machines, which is exactly what we were looking for.” With CUTTER CARTRIDGE technology, every 6 cutters and 6 spacers are combined into one-piece elements. This markedly increases unit strength and eliminates many parts from the unit, simplifying maintenance.
After purchasing their first TM8500 inline grinder in 2011, they were thrilled. “These TASKMASTER® grinders have been absolutely awesome,” Letourneau said.
“We were originally using these machines for galley sludge hauling. We have stopped that service now, and are using these grinders solely for wastewater processing, especially rags and wipes,” Letourneau said.
“Many wastewater treatment plants have been battling ragging and wipes with very little success. Thanks to our set up here, it’s really no problem for us. We have had no downtime at all. Day to day, the grinders have been extremely reliable. At this point, we basically expect nothing outside of routine maintenance and an annual inspection.”
Wipes have become a big issue for the city overall. The screens at the headworks help with some of the wipes, but not all. “The grinders handle all the wipes at that point quite well. We never have ragging or clumping problems at the grinder, which we are very grateful for."
Ross Valley Sanitary District in San Rafael, California services approximately 47,000 mostly residential customers over a 27 square mile service area. They have 5 major pump stations, which is where Ross Valley found themselves having the most trouble. The existing channel grinders were simply not reliable.
“It was constant headache,” said Philip Marcantonio, Senior Collection System Worker. “The pumps were ragging up sometimes twice a week and sometimes twice a day.” The plant reported that the machines were not efficient at all. “It was a lot of extra work on us to keep the stations going,” Marcantonio said. On top of that, the constant downtime was causing even more than extra work; it was costing the district a lot of money. They knew this was not a sustainable system to keep their plant and stations running.
According to Noel Sandoval, Operations Supervisor, that’s when the engineers suggested the plant purchase a Franklin Miller DIMMINUTOR®. “It was a great decision. Once we installed the DIMMINUTOR, all our problems went away.”
The DIMMINUTOR grinder has a design that is truly unique in the industry. It has a few multi-toothed rotary and stationary cutters that are independently adjustable and replaceable without time-consuming unit disassembly. “The Dimmy is a great machine,” Marcantonio said.
The Dimminutor also has a heavy stationary screen that retains the oversized solids and is self-cleared by the rotating cutters. Since it is stationary, it never wears against bottom grit. With its cantilevered design, the DIMMINUTOR needs no seals or bearings near the gritty channel floor. Ross Valley performs routine maintenance every six months or so to inspect and clean the machine. “Maintenance is so simple,” Sandoval said. “We just take off the bolts, clean and inspect each machine... and then we’re done.”
They credit the DIMMINUTOR design of rotating bi-directional cutters as a major reason the units work so well. “The rotating cutters make a huge difference, changing direction every two hours. It pretty much breaks up anything.” Marcantonio added. “The rotating and reversing helps with teeth wear as well as cleaning any stuck debris,” he said. “Our previous grinders just ran until they broke, stopped working, overheated or tripped out. Our on-call staff was working constantly to fix them, costing us so much money. With the DIMMINUTOR units in place, we can now spend our time and money on other things that serve our plant and customers.”
The team at Ross Valley also commended Franklin Miller’s support and customer service. “Franklin Miller customer service is hands down the best,” Sandoval said. “Every time we call with questions, they are there for us. They’ve sent people out to us when we needed, to go over each part and make sure we were at peak performance, and they even hosted us in their New Jersey plant to learn best practices on service and building these machines.”
“The Dimmy is a godsend,” Marcantonio said. “They are truly like they say, built like a tank. It is a workhorse for us.”
Sandoval continued, “We stay with Franklin Miller because not only does the product perform, but the people there are behind it for us 24/7.”
In 2007, "flushable" wipes were introduced to the market. Disposable wipes have a variety of different uses – from sanitary cleansing to make-up removal. The appeal of disposable wipes is that they are convenient and increasingly popular. They are also often now being labeled as “flushable.”
As the wipes increased in popularity and sales increased, the problem at the pumps increased as well. Unlike toilet paper, wet wipes fail to disintegrate. These wipes are not breaking up in the sewer systems the way ordinary toilet paper does. After the wipes are flushed, they tend to bind and clump together, creating huge balls which get tangled in the pumping equipment.
Blockages occur in residential and municipal sewer systems from accumulations of disposable wipes. The pipes, pumps and other equipment that must process the wipes in wastewater treatment systems are often not capable of handling such waste.
Sewerage authorities and wastewater treatment facilities continue to be challenged by the increasing volume of sanitary wipes. These wipes cause time-consuming bottlenecks, clogging and breakdown of pumps and even cause the back up odorous wastewater into houses. The severity of this problem has received worldwide media attention.
Municipalities and sewer districts report accruing anywhere between $400,000 up to $18 million in costs directly attributable to wipes. So, what can municipalities do to not only combat, but overcome this rapidly growing problem? Many municipalities are finding a solution in the installation of grinding and screening equipment.
They have found that by adding grinders in strategic location in the wastewater system, the plugging associated with wipes can be greatly reduced or eliminated. Grinders are being installed at the source, at pump stations or in the wastewater treatment facility, including at the headworks or in locations such as in sludge recirculation lines and at the suction side of pumps.
When wipes build up into mats, mops, balls or large masses, they become an increasingly difficult challenge. According to Korkmaz Oz, Sales Manager of Franklin Miller Inc, a leading manufacturer of wastewater grinders, the key is to prevent wipes from building up into large masses in the first place. Franklin Miller Inc., based in Livingston, NJ., has over 100 years of industry experience and specializes in wastewater grinders.
Franklin Miller developed a range of specialized grinders suited for the particular challenges associates with grinding wipes, providing solutions to the problem for many plants around the country and worldwide. Franklin Miller grinders are proven to reduce pump clogging, protect process and dewatering equipment, reduce solids, and keep wastewater systems running properly. Their grinders are designed for strength and ease of maintenance.
The TASKMASTER® TM8500 grinder features proprietary CUTTER CARTRIDGE® technology for superior performance. The CUTTER CARTRIDGE has a geometry that has proven optimal for wipes handling. Plus, it combines 6 cutters and 6 spacers into rugged one-piece elements, greatly reducing individual cutter parts and increasing unit strength and reliability. The one-piece element allows a stronger and easier to maintain machine, and easily destroys the problem of wipes.
Franklin Miller’s wipes grinders are available in both pipeline and channel configurations. They can be installed with guide rails for easy removal from a manhole as well fully submersible motors.
Wastewater systems suffer when blockages occur. It’s been a particularly difficult and expensive problem due to woven fabrics build-up, especially from wipes – even those that are labeled as flushable contribute to the growing problem. But the good news is more and more wastewater plants are adapting. They have found that they can keep things moving and get peace of mind, and even some sleep, with a properly designed grinder or screen.
The SUPER SHREDDER® in-line disintegrator reduces a variety of liquid borne solids with a unique, low headloss design.
This unit features heavy duty construction and effective operation in such tough applications as tar sands and dredging as well as sewage and sludge waste and process lines. This unit reduces clogging and downtime resulting in tremendous plant savings and a fast payback of the initial cost.
The SUPER SHREDDER reduces solids to fine bits with a unique, high-flow, spherical rotor design. The unit aggressively reduces tough solids from wood, rags, plastics, agglomerates, sands, oil waste, petrified wood and more with its powerful, high torque design. Because its design maintains a high percentage of open area, this rugged processor remains practically invisible to flow. It quickly goes to work protecting pumps and enhancing the operation of process equipment. Plus, its innovative design makes this unit ideal for applications where high capacity and low headloss are essential.
The SUPER SHREDDER is simple to install in straight-through pipe systems and connects via 150# ANSI drilled flanges. This 24” SUPER SHREDDER (SS2400) is driven by a direct coupled gear drive that employs up to a 50HP motor. Its cutters are constructed in stainless steel with a precision Tungsten Carbide hardfacing to withstand a high grit environment. The hardfacing has many times the abrasion resistance of any alloy steel for long life and unequalled durability. This unit was provided with mechanical seals rated for up to 300 psi (20bar).
In today's cutthroat industrial world, achieving maximum efficiency is crucial for manufacturers to beat out their competition.
But did you know that most manufacturing businesses are only operating at around 60-80% efficiency? That means up to a whopping 40% loss is affecting bottom lines because of issues like defective products and inefficient machinery.
However, new technology and mechanics are being used to drive production in more effective ways, thus increasing their income.
One important piece of equipment that more industries are taking advantage of is the lump breaker.
Because of their economical and low-maintenance design, lump breakers are being used by some of the largest manufacturers in the world for a plethora of uses.
What Is a Lump Breaker?
Lump breakers are used to break solids, lumps, and agglomerates down to a desired size with a once-through, non-churning, crushing action. They are capable of handling wet, sticky, dry, hard, or soft substances.
After inserting a product into a lump breaker, large particles are crushed by rotating blades as they move through a set of stationary comb-like blades. The particles are reduced in size until they are small enough to pass through and discharge from the lump breaker.
Lump crushing equipment improves downstream processing by creating materials that are easier to deal with. However, they can also be used within any part of a processing system.
What Are Some Benefits of Using a Lump Breaker?
Lump breakers provide many benefits to those who invest in them, such as reducing plant downtime, increasing processing speed, and improving product consistency. We’re now going to break down five major benefits of using a lump breaker for your processing needs.
1. Multifunctional Use and Extraordinary Processing Capabilities
The most important benefit of a quality lump breaker is its variety of capabilities that can be used in several parts of the production process.
They can be used to:
Break down lumps
Expedite mixing
Granulate minerals
Maintain smooth process lines
Create more uniform consistency
Not only are they multi-functional, but they can be used for several kinds of materials. These include:
Chemicals
Sugar
Plastics
Coal
Ammonium nitrate
Gypsum
Detergents
Soda ash
Minerals
Salts
Because of their diverse ability to work in different processes as well as on different materials, the same kinds of lump breakers can be seen in several different industries across the world.
2. Deagglomeration After Prolonged Storage or Transport of Materials
After long periods of storage, dry bulk materials will often become compressed. Particles will naturally become denser as the finer materials sift their way to the bottom while the larger particles stay on top. This process causes air pockets to collapse, creating large compression lumps.
Some common examples of where this might happen include:
Super sacks
Silos
Rail cars
IBC's
Day bins
Even worse, if the containers are exposed to humidity or moisture, they can create even harder lumps that take more energy to break apart.
A common solution to this will be to install lump breakers below their silos to break the material down. This is common in sugar processes.
3. Creation of More Efficient Conveyance
When materials create large lumps, getting them from one place to another is much more difficult and inefficient, especially if you use pneumatic conveying.
By getting rid of agglomerates, raw materials are much easier to handle on a belt conveyor.
With a lump breaker, you can create materials that are the right air to particle ratio (depending on the density of the powder). Not only will this make conveyance more efficient, but it could save you from a tremendous headache because of equipment failure when hard lumps stuff a rotary valve in your machinery.
By having more conditioned, dry powder from a lump breaker, your screw feeders, vibrating feeders, and rotary valves will all work smoother.
4. Adds Higher Value to Other Equipment Processes
Lump breakers affect the efficiency of just about any piece of equipment that your raw materials run through, which can save you time and money in the long run.
For example, screening equipment. When something like salt or sugar is stored for a long time and is exposed to moisture, it can form large, solid lumps. If you feed these tough lumps into a screener, you can do severe damage to the screen mesh and the powder sieve.
Screeners scalp oversize particles off the top of the distribution curve and police foreign objects off of the production line. They are not meant to break apart agglomerates.
Another example is milling equipment. If the powder that is added to a mill isn't uniform in size, the mill will not work efficiently.
One last example is the blending of spice mixtures or instant food packets. If lumps are not broken down, it can cause inconsistent taste throughout the product.
By using a lump breaker to reduce these materials, you can prevent inefficiencies and breakdowns from happening to other equipment.
Read More: Watch our powerful pallet shredding Taskmaster XL tear apart pallets with ease.
5. Lump Breakers Make Transportation More Efficient
If you regularly move raw materials from place to place, lumps can add extra energy and cost to your transportation fees.
Transporting large lumps is tough and can even be impossible in certain situations. Once broken down, transportation becomes much easier after the material has been reduced in size.
Key Takeaways
Lump breakers are becoming highly necessary in several industries because of their flexible functions and benefits.
When choosing the perfect lump breaker for your industry, there are several parameters that you should consider first. These include:
Bulk density of the material being crushed
Moisture content
Consistency and fiber content of materials
Heat sensitivity of materials
Particle size
The good news is that Franklin Miller has been a leader in size reduction technology for over 100 years and features some of the best lump breakers for everything from chemicals, food, and minerals to plastics, pharmaceuticals, and more.
Contact us today to find the perfect solution for your industry!
In 2017, it was found that the U.S. produced 267.8 million tons of waste. This includes both residential and commercial items being thrown away.
Out of this total, approximately 35 percent of the waste was recycled or composted, leaving only 139 million tons to find its way to a landfill.
Waste in general can have a negative impact on the environment, but industrial waste specifically is incredibly hazardous.
That’s why many businesses and industries are looking for ways to reduce their environmental impact by recycling what they can. Shredding machines can help with the process.
Read on for some tips on how to find the machine that will get your shredding jobs done right.
Know What Shredding Machines You Need
The first thing in getting your shredding jobs done right is to know what type of industrial shredder you need.
There are many different ways to shred material. Here are a few:
Grinders – The most thorough way to shred materials is to put it through a shredder. Whatever you put into this shredder comes out the other end as dust.
Strip-cut – These shredders cut the material into even, rectangular sheets.
Cross-cut – This type of shredder will cut the material twice. It generally starts with a strip cut and then finishes with a horizontal cut. Depending on the type of blades the shredder has, the resulting particles will be square- or diamond-shaped.
Particle-cut – This shredder cuts in pretty much the same way as a cross-cut shredder, but the shape of the resulting particles will be even more specific.
Other ways to shred include micro- and crypto-cuts.
An industrial shredder has the ability to cut just about any material you put into it. However, when it comes to finding the right one, you need to consider what your specific needs are.
For example, if you are a financial institution trying to get rid of sensitive account information, then getting an industrial paper shredder that does particle cuts or grinds will keep this information from falling into the wrong hands.
If you don’t need to make sensitive information difficult to read, then choosing the right shredder will depend on different factors.
What Are You Shredding?
When it comes to finding the right shredder machine for your business, you need to consider the type of material you will be shredding.
If your business primarily takes care of metal, then buying a metal shredder will work the best.
Should you have a lot of plastic that you are trying to recycle or reduce before throwing out, then a plastic shredder is going to be your best option.
In addition to thinking of your current shredding needs, you might also consider where your business will be going in the future.
You might mainly shred paper right now, but if there’s the possibility of shredding plastic or metal in the future, buying an industrial shredder that can handle all these materials is in your best interest.
How Does the Material Need to be Cut?
The four types of cuts that shredders can make were listed above. Knowing which one is best for your business will depend on what you are doing with the shredded material.
If you are preparing metal or plastic for recycling, then using a strip shredder may be all that you need.
Should you be planning on composting your materials, then making them as small as possible is beneficial. That’s when a grinder can come in handy.
What Contaminants Will be in the Shredded Material?
No matter how careful you are, the material that you shred will get contaminated in some way.
This isn’t necessarily a bad thing, but it will have an impact on the type of shredder you get for your business.
You might think you are only going to use your shredder for wood materials, especially waste that comes from construction sites. However, it’s possible that nails or screws might still be in the wood.
Unless you plan on removing every single one of these before placing the wood into the shredder, you might consider getting a machine that can handle small bits of metal.
How Much Material Do You Need to Shred?
If you have a lot of material that needs to be shredded on a daily basis, then you need to make sure that your shredder can handle the job.
This might include getting a larger machine that is more durable and has heavy-duty blades.
Should you find that you only need to shred once in a while, then you don’t want to spend more than necessary.
Shredders come in a wide range of sizes and capabilities, so it’s possible to find one that will fit all of your business needs.
Benefits of Using a Shredder
One of the biggest advantages to adding a shredder to your business is that it can help reduce the amount of waste that finds its way into landfills.
If you are looking for a way to recycle or repurpose some of your waste, then you need a shredder.
Shredders allow you to break down large items into smaller items. This makes the pieces easier to recycle and repurpose.
Some of the most commonly shredded items include food waste, tires, plastics, wood, paper, pallets, steel drums, and electronic components.
The shredded material can then be turned into a variety of different items, including compost, mulch, and plastic bags.
In some cases, recycled tires and wood are also added to public playgrounds to make the area softer and more inviting to kids.
No matter what, the material isn’t being tossed into a landfill where it can cause damage to the soil and water sources.
5 Factors to Consider
Industrial manufacturers and consumers dispose of countless items faster than waste management professionals can process them.
An industrial shredder is not a small purchase, so you must be sure you're getting the right machine for your unique needs. Take a look at our five tips on choosing your next industrial shredder.
1. Input Material
The input material is the first thing you need to consider when choosing an industrial shredder for your business. Looking at shredders that don't process your input material is a waste of valuable time and resources.
With that in mind, at Franklin Miller, we provide customers with machines that can shred the following materials:
Bulk waste
Cannabis waste
Electronic waste
Fish
Food waste
Hemp
Medical Waste
Metal
Paper
Plastic
Rubber
Shipboard
Steel drums
Textiles and clothing
Tires
Wipes
Wood pallets
If you're disposing of something wet or stringy, putting it through a shredder not optimized for that type of material could clog or break the machine. Even if you're disposing of something simpler, such as wood, be sure that the shredder you opt for is capable of breaking it down properly.
Just like with shopping for a pair of shoes or a new home, don't just settle on the first one you find. Do your research to find out the best industrial shredder for what you want to process now and might want to in the near future. At Franklin Miller, we even offer testing in our facility to guarantee the unit you choose is a good fit for shredding your specific material.
You shouldn’t have to buy an individual machine for each material you shred. See which units are compatible with several different types of waste. Also, consider the size of the input material when choosing a shredder for your business. Large pieces in small machines often cause clogs.
Even if they do make it to the output bin, the material may not be fully shredded. Additionally, small pieces processed by large blades won't result in uniform pieces, or might not shred at all. That all being said, our TASKMASTER® units can reduce a wide variety of bulk solids up to 80%.
2. Capacity & Size
Other questions you need to ask about the input material are the size of the material and how much you intend to shred at a time. It's important not to overload a shredder for best performance but also for safety, as an overloaded machine could malfunction.
While you technically can put a small amount of material in a large shredder, there is such a thing as too small of a load, so make sure you are considerate of that.
If you plan on shredding multiple load sizes, ensure the shredder is adjustable to handle that capacity. If that's not something you can find, you might consider trying to cut down the size of larger loads and get a medium-sized shredder that handles both.
If you feel you have unusual requirements, you should talk to the manufacturer to make sure the machine you buy suits your needs.
3. Reuse What You Can
Businesses often purchase industrial shredders to dispose of non-hazardous waste and materials that can be repurposed, but the wrong shredder can destroy those plans.
If you plan on reusing shredded waste material, figure out what specifications you need the output to meet to have value. Buying a shredder will help guarantee uniform output size.
If you hope to shred multiple materials with one machine and want to reuse one or more of them, make sure you can do so without contaminating the product.
4. Where to Store Your Industrial Shredder
Most prospective shredder buyers have a plan for storing their shredder. Unless you're getting a small industrial shredder, you need a good amount of space where the machine will sit, as these are not like the paper shredders you keep at home.
Dimensions aren't the only factor you need to consider. Your storage space's climate and other conditions should factor into your choice of a shredder.
If you have a climate-controlled, dry indoor space for storage, you're primed to store most shredders, though you should still check any model's storage specifications.
If you have nothing but outdoor space or have unusual indoor conditions like a freezer or wet production floor, be sure the shredder can safely handle that environment.
5. Maintenance Protocols
All equipment needs regular care, and shredders are no exception.Industrial shredder systems need periodic lubrication and oil changes to maintain optimal performance and output material. In addition, grinding blades can wear down over time if not maintained.
Some shredders are easier for owners to service themselves than others. Find out where the access panel is and if it's feasible for you to service the machine yourself, or if you need to bring in outside professionals.
Another aspect of maintenance to consider is determining what kind of service the vendor provides. Having the vendor's help, or a team of shredding experts at your disposal, keeps your machine in top condition.
Finding the Right Shredder
Once you know exactly what your business is going to be shredding and how you want the material cut, you can then start your search for a supplier of shredding machines.
You won’t have to look far… At Franklin Miller, we have been a leader in size reduction technology for three generations.
We have shredders that can handle any job and material. Our machines are built to exceed all of your expectations.
Whether you are looking to shred your materials so they can be recycled or repurposed or just to reduce the amount of waste you produce, we have the shredders you’re looking for.
Get in touch with us today!
Metal recycling is one of the best ways that a business can contribute to saving the planet from major economic loss caused by climate change.
If recycling scrap metal is something that you are looking to get your business into, then you may wonder how it works.
The process of recycling is done in stages and each stage brings the metal closer to something that can be used once again. Here is a look at all the stages of the scrap metal recycling process.
What Is Metal Recycling?
Metal recycling is the process by which waste metal is processed into new metal. The recycling of old metals can make new products. Once the products have exceeded their life span, the metal can be recycled again and used to make other products.
The two main types of metals that can be recycled are ferrous and non-ferrous metals. Ferrous metals that can be recycled are steel and iron. Nonferrous metals that can be recycled are titanium, aluminum, and brass.
The Advantages of Recycling Metal
Recycled metal comes with several advantages. The biggest one is that it reduces waste. There will be less metal in landfills if everyone recycles.
Metals do not break down easily, and sometimes they do not break down at all. It will just sit in the landfill for several years.
Another benefit of using recycled metal instead of creating metal from scratch is that recycled metal uses less energy than creating new metals. To get virgin metal, the mining process will have to take place.
This can severely affect the natural reserves that are in the environment. Mining can be very detrimental to wildlife as well. When recycled metal is used, there is no need for any further mining to take place, as all the resources are already in place.
The Process of Recycling Metal
Four major steps take place to recycle metal so that it can be used again. Each part of the process is separate and very distinct. Here is a closer look at each stage of the process.
Segregation
The first step in the metal recycling process is segregation. During this time, the collected scrap metal is separated. This type of organization is necessary to ensure that the recycling process goes smoothly.
The metal is separated by size and weight. The different densities of material will be taken into consideration when they are being sorted. Sometimes products get trapped in the metal and they will need to be removed.
For example, plastic may get trapped in between the metal. This is a foreign object that will need to be removed before the recycling process begins. The removal of raw materials such as plastic ensures that the finished product is pure.
In the past, segregation was done by hand, but this is no longer the case. Now there are several machines available that automatically detect the type of metal and the size and separate them automatically.
Preparation
The next step of the metal recycling process is preparation. During this time, the materials are put in a metal shredder to cut down on the recycling process time.
This is why the segregation process is so important. It ensures that the materials being shredded are as similar as possible.
Shredding
To be as efficient as possible with your scrap metal recycling, you’re going to want to purchase the right shredder. There are different shredders that can dispose of materials in different sizes. These materials include bulk waste solids, liquid and solid waste, as well as sludge and biosolids. Franklin Miller will listen to your needs and recommend the perfect metal shredder for you.
What’s even better about the shredding process when you have an industrial shredder is that there is minimal work required. So not only are you going to shred scrap metal on-site, but you’ll have a system that’s easy to use.
The shredding part of this process also ensures that there are smaller amounts of emissions used during the next stage of the scrap metal recycling process, which is burning.
Burning
Once the material has been segregated and shredded, it is time for the burning process to begin. The burning process makes all the scrap metal have the same density.
The metal is put in a furnace and then put under high heat. The heat binds the metal together.
Different metals have varying melting points. The melting point will determine how long it takes for shredded metal to become molten metal. For the process to go faster, the amount of the shredded metal being processed can be reduced.
The bottom line is that the melting point of the metal is critical in creating molten metal. For example, iron has a higher melting point than zinc.
Formation
The next step in the metal recycling process is formation. At this point, all the metals are taken out of the furnace and are created as ingots. When the material is in an ingot format, it is in its purest form.
These ingots are shaped to form bars of metal. The ingot can also be transported as a liquid and sometimes powder to manufacturing plants where they are transformed into products.
Save Money by Recycling Scrap Metal
One of the easiest ways to save money is by using the same materials repeatedly. By recycling your scrap metal, you can do just that.
If your business regularly has scrap metals lying around, the best thing you can do is to plan to recycle the metal so that it can be used productively.
This means that there is no need for metal to be lying around without being recycled for use once again. Recycling scrap metal has been made less complex by using machinery.
If you are interested in purchasing equipment to recycle scrap metal, please contact us.
