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Product updates, industry insights, case studies, and company news from Franklin Miller.

All News Blog (15) Industrial Case Studies (22) Latest News (53) Solid Waste Case Studies (7) Wastewater Case Studies (44)

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

Wastewater Case Studies·February 23, 2017

The TASKMASTER® TITAN® saves time and worries

The Roseland, NJ pump station is one of the largest high-flow stations feeding into the Caldwell Wastewater Treatment Plant. The pump station originally used a trash rack in the channel coming into the station. This arrangement made it necessary for a worker to climb down into the confined space once a day to access and empty the trash rack manually. This was a very time-consuming process and was expensive for the station to keep up with such frequent manual maintenance. By installing the TASKMASTER® TITAN®, the challenges were instantly resolved. The brand new machine was installed in front of the bar rack. This eliminated the manpower needed and a big portion of their day that was spent manually maintaining the system. The TASKMASTER TITAN is a workhorse that can handle such heavy objects as sanitary wipes, rags, shoes, blocks of wood and many different items that find their way into wastewater systems. The Titan is a powerhouse and is working well at handling the high flows. The station has no more maintenance issues at all. Its unique design features two cutter stacks. One stack intermeshes with a second one that has oversized cutters. The result is unsurpassed grinding performance, durability, superior solids feeding and high flow capacities. “Time was saved, and worries were saved,” said Ray Cornetto who worked with the installation of this machine. “The TITAN is a powerhouse and is working well at handling the high flows. The station has no more maintenance issues at all.”

Wastewater Case Studies·February 23, 2017

Union Township, NJ Automates Pump Station with TASKMASTER®

Union Township, New Jersey was having a lot of trouble with their pump station. Although a small pump station, it was extremely cumbersome to maintain. The station was using a trash basket with a ladder and rail system to screen solids. This was extremely time-consuming, used an excess of manpower and proved to be ineffective at times. They knew they needed a better solution. Because Franklin Miller had successfully retrofitted a competitor’s machine in the past, the Township of Union, Department of Public Works decided to approach FMI for a solution. The county removed the trash basket when Franklin Miller fabricated a machine and components to fit directly in the same space while still using their current rail system. “It was an extremely easy installation for us,” said Ray Cornetto, who worked on the installation. “There were no issues installing this machine and there have been no issues with running it.” He went on to report that the Franklin Miller TASKMASTER TM8500 series not only solved the issue of manpower, but automated their “We no longer have to clear the basket. This automated system has made everything simple. The station is checked once in a while and that’s it. They can move on to the next job.”

DELUMPER® Bulk Bag Unloader (BBU) Unloads and Conditions Product

The DELUMPER® Bulk Bag Unloader (BBU) is a heavily constructed system designed for convenient unloading materials even if they contain lumps and agglomerates. This unit employs a gyrator to effectively fluidize the materials for dependable discharge from the bags. Then, a heavy-duty built-in DELUMPER crusher conditions and freshens the product. The result is an effective pre-engineered unloading and product conditioning system built to DELUMPER quality and dependability standards. The BBU is designed for trouble-free operation and is supplied with a rubber-coated nylon flex sleeve and rubber isolators, allowing the machine to run quietly and with low vibration. An electric hoist with pendant allows for easy mounting of the bulk bag and a valve is supplied for controlling the discharge flow rate. The DELUMPER BBU’s streamlined design is designed for low maintenance with very few moving parts and rugged construction throughout. The unit’s DELUMPER Crusher features heavy-duty construction built to the highest quality standards. The crusher features a one-piece body, low noise or vibration, precision construction and effective shaft seals. It is available in several styles in either carbon steel or stainless steel construction. The system is supplied with a control system that fully integrates all functions. Options for the DELUMPER BBU Bulk Bag Unloader include sanitary finish, full stainless steel construction, discharge flexible screw conveyor, load cells for weight metering, auxiliary manual bag dump built-in to feed small batches and ingredients, and special sizes and engineered solutions to meet specific requirements.

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.

TASKMASTER TITAN® TM20060 "Full Cut" Grinder with High Flow Capability

The TASKMASTER® TITAN® TM20060 is the latest addition to the TASKMASTER TITAN grinder line. This unit builds on the patented, twin-shaft counter-rotating cutter design of the TASKMASTER TITAN. Its design features one cutting stack that intermeshes with a second one having a much larger diameter to rip, tear and shred solids entrained in liquid flow to fine particles so they can be more easily processed by pumps and other equipment. The TM20060 has a higher flow and larger throat opening than previous models. Unlike other units, the TITAN has an intrinsically high flow cutting chamber with a substantial inlet opening size that doesn’t rely on auxiliary diverting screens for flow capacity. The patented TITAN TM20060 design has substantially more capacity than the TM14000 models while employing the same 5HP motor and drive. These units are available with TEFC, XP as well as FMI’s explosion-proof submersible motors. Other options include hydraulic drives and shaft extensions. Guide rails and channel frames allow for easy installation even in deep wet wells. The TITAN TM20060 is available in single, tandem and duplex versions in standard iron and steel as well as stainless steel construction. They are available in standard as well as stainless steel construction. The standard units are 21-1/2” wide by up to 67” tall while the Duplex versions are 34” wide by up to 67” tall.

Wastewater Case Studies·September 22, 2015

DIMMINUTOR® Saves Monterey County Time, Money, and Manpower

The pump stations at Monterey Regional Water Pollution Control Agency (MRWPCA) were having a problem with their channel grinders. The twin-shaft, drum-style channel grinders were used in the ten pump stations in the region that feed into the main Monterey Regional plant. The plant is located in northern Monterey County, California, on 100 acres, and has a capacity to treat 29.6 million gallons per day. It receives 18.5 million gallons of water each day from the 250,000 people it serves, and uses a primary treatment processes of physical separation using a bar screen and settling tanks, and a secondary treatment of using microscopic organisms found naturally in the environment. The pump stations were having major trouble with the channel grinders. They were constantly breaking down and needing to be rebuilt. It was causing a lot of downtime, extra manpower, putting a strain on their maintenance budget, and interrupting their treatment process. They knew they had to replace the machines with something better. That’s when they turned to Franklin Miller, to learn more about the DIMMINUTOR®. “When we heard about the stack cutter assembly in Franklin Miller’s DIMMINUTOR, we wanted to learn more,” Bret Boatman, Maintenance Supervisor, said. “The fact that the DIMMINUTOR has no bottom bearings was very attractive, as the bottom bearings on the other company’s units kept giving out.” Once they installed the DIMMINUTOR, the effect was immediate and dramatic. “We have so much less downtime and maintenance costs on the new machines. Ordering, installing and using the DIMMINUTOR has been very straightforward.” Over the past seven years, the plant has switched out eight of their old twin-shaft units to the Franklin Miller DIMMINUTOR. The DIMMINUTOR provides automatic screening and grinding of liquid-borne solids with a straight through open channel design. This unit reduces plastics, wood, vegetable matter, disposables, and other oversized items to a fine particulate. The DIMMINUTOR’S unique design, heavy precision construction, dependable operation and simplified maintenance have earned it a solid reputation amongst operators and specifying engineers worldwide. The unit has been specifically designed to handle tough wipes which have been a significant issue for plants nationwide. The DIMMINUTOR is designed for reliable operation and easy maintenance. For example, with its cantilevered design, the DIMMINUTOR needs no seals or bearings near the gritty channel floor. The unit’s screen is stationary so it never wears against bottom grit. Each cutter is interchangeable and cutters can be removed or adjusted independently. The unit’s seals and bearings are immersed in an oil bath for long life and low maintenance. “The experience with Franklin Miller has been great, from the machines, of course, down to ordering parts and the exceptional customer service.”

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.”

Powerful Crusher with New Enclosed Stainless Steel Stand and Hinged Hopper

The DELUMPER® 1075 LP Crusher reduces hard or soft, heat sensitive, sticky or wet agglomerates and lumps at high volume without degrading the material or causing a rise in temperature. The unit is available with a variety of auxiliary equipment. This unit was provided with a fully-enclosed stainless steel stand and a special pivoted hopper. This hinged hopper that tilts allows quick access to interior components for cleaning and service. The DELUMPER LP lump breaker features extended cutting teeth that rotate completely through a heavy bar cage, self-clearing the slots with each rotation. Each tooth is built for precise balance, interchangeability and smooth operation. Output sizes are adjustable by changing the speed or the comb. The unit’s low-friction cutting action is excellent for large quantities of sludge cake, agglomerated chemicals, plastics, fats, waxes or solid waste. These features and others are available on other DELUMPER Models as well.

Franklin Miller Unveils Expanded Manufacturing Facility

Franklin Miller Inc. was proud to unveil the grand opening of the major expansion to their Livingston, New Jersey manufacturing facility at a ribbon cutting celebration on July 12, 2016. This addition includes new offices, a test facility and a high bay manufacturing area. Franklin Miller manufactures size reduction and screening equipment for environmental and industrial applications worldwide. William Galanty, president of Franklin Miller, spoke at the ceremony about the company’s expansion and continued growth in manufacturing, as well as detailing the three generations and nearly 100 years Franklin Miller has been in business. In attendance was Alfred Anthony, mayor of Livingston, as well as representatives from the office of Senator Cory Booker, the Livingston Chamber of Commerce, the Livingston Town Council and the Livingston Business Improvement District. Pictured: Dinesh Suryawanshi, Projects Specialist, Office of Senator Cory Booker; Beth Lippman, Exec Director BID/Chamber; Mike McMane, Chamber Board of Directors; Monte Ehrenkranz, President Chamber of Commerce; Al Anthony, Mayor; William Galanty, President, Franklin Miller Inc.; Jacob Galanty, General Manager, Franklin Miller Inc.; Rudy Fernandez, Councilman; Jessica Marone Parkes, Chamber of Commerce; Ira Drucks, Chamber of Commerce.

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.”

SRH Hauler Station

The S270-SRH Hauler Station is a comprehensive control system that provides an automated interface for septage truck haulers to securely access and operate a Franklin Miller septage receiving station without the need for plant personnel. This unit, coupled with the TASKMASTER® TT grinder or SPIRALIFT® SR grinding and screening system, provides a complete turn-key solution for automating the receiving of septage into a sewage plant headworks without burdening either plant personnel or equipment. The S270-SRH Hauler Station Control identifies haulers via a card swipe system, permits access, tracks loads, records transactions and prints transaction receipts. Drivers begin the process with one swipe of their access card. Once the driver’s ID is validated by the system, the hauler simply touches the start button and the system’s automated operation is initiated. The S270-SRH is equipped with a touch screen HMI interface that displays transaction information, the system status and provides access for system administration. The unit is available in HaulerLogic™ software for remote operation, account administration and billing.

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