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

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.

Automated Rock Removal and Conveying System Enhances SPIRALIFT® SR

The SPIRALIFT® SR septage receiving system now features an optional automated rock removal system. This unique system enhances the ease of use of the system grinder and tramp-trap. Rocks are a consistent problem with septage receiving and various methods of removal are used. With the SR a unique TASKMASTER TT grinder includes a trap system to settle out the rocks with a high level of efficiency. Typically the operator opens a manual gate valve and the rocks fall into a container. Other systems have baskets and a hatch door which needs to be lifted out of a series of pipes. With the new SR Automated rock removal, an automated gate valve opens on a pre-planned cycle and the rocks fall into an enclosed screw conveyor. They are then conveyed directly into a bin for easy disposal without operator assistance. This system is preferred by plants who do not want to do the rock removal manually. Read more about the Spiralift SR here.

Wastewater Case Studies·April 20, 2015

DIMMINUTOR® Protects Pottstown Equipment From Abrasion, Clogging

The Pottstown, Pennsylvania Wastewater Treatment Plant handles the wastewater generated by 15,000 area homes, commercial businesses, and industrial sites located in the borough of Pottstown and three nearby townships. The facility is rated for 15.6 mgd and treats an average flow of 7 million gallons of sewage a day. The plant uses a multi-stepped treatment process to purify the wastewater so it can be safely returned to the environment. Proper treatment of the influent remains an essential first step. By reducing plastics, rags, wood and other incoming solids to fine bits, downstream pumps, and other equipment are protected from abrasion and clogging. With this in mind, the wastewater facility has relied upon the unparalleled grinding ability of the DIMMINUTOR® Wastewater Grinder to keep plant operations running smoothly. The units themselves are constructed for dependable service and simplified maintenance. Long life, too. This year, the plant purchased a Turbo DIMMINUTOR DM36 to be used in tandem with a unit bought in 1991.”That DIMMINUTOR was part of the original plant upgrade,” says Brent Wagner, Plant Superintendent. “ Over the years it has been rebuilt several times but is still operational. We have had no problems. The units do what they are designed to do.” The two units are installed in channels at the headworks with a bar screen in front of each one. Once the solids are finely ground and screened, the wastewater flows into a grit system where centrifugal force removes the grit, pulling it to the bottom. The water passes into a pre-aeration tank and is oxygenated. It then flows to an aeration tank, mixing with microorganisms for treatment. A clarifier settles the organisms out and takes the cleared water off. The water is chlorinated and then returned to the Schuylkill River. Mr. Wagner admits to some reservations about the way sludge is handled. “60% of our solids handling is exterior sludge. We currently send all of those solids to a landfill. With concerns about the long term effect on the environment, this doesn’t make sense. Hopefully, by the beginning of next year, the sludge will be recycled.” In the meantime, the DIMMINUTOR, after 18 years, remains the grinder of choice. “We like the units. We have had no problems with them. They do what they are designed to do,” Wagner concludes. The DIMMINUTOR provides the first line of defense in a wastewater treatment plant headworks or pump stations. Sewage solids are captured on a curved screen where rotary cutters sweep them into adjacent stationary cutters with a continuously rotating high torque action. As the cutters intermesh at close clearance, they shear, tear and crush the solids to a size small enough to pass through the fine screen slots. This unit’s rugged screens are cut with laser precision from heavy stainless steel plates. Unique features of the Dimminutor include No seals or bearings located at the bottom of the unit where high concentrations of grit accumulate. Stainless Steel screens and cutters. Each cutter is independently removable and adjustable without unit removal. The DIMMINUTOR is available in several models from 15″ (382 mm) through 36″ (915 mm) handling flow rates up to 30 mgd (1.3 cubic meters). They are available for submersible applications using our exclusive Submersible C.I.A. motors. See our full line of wastewater grinders

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.

Wastewater Case Studies·February 5, 2015

Case Study: Channel Disintegrator Solves Ragging Problem, Eliminates Downtime For Maryland Pump Station

The Route 108 pumping station located in Howard County, Maryland serves a large, affluent mostly residential area. The station pumps 3.5mgd of wastewater for further processing to the Patapsco Wastewater Treatment Plant in Baltimore. When necessary, the treatment plant is bypassed and the wastewater is sent instead to the Little Patuxent Water Reclamation Plant. This arrangement, though uncommon, had always worked well until one day things took a turn for the worse. “The problems began when the station was taken off-line while we did some upgrades to it,” said Superintendent, Bob Funk. “When we went back on-line a year later, the pumps were unable to run a full day without clogging up with rags.” “Something had changed,” Funk explained. “We think that it was the construction of some nursing homes nearby. We began to see a lot more rags that were probably flushed down the toilets including shredded diapers, cleaning cloths, and other debris. It was a real mess. Every day someone had to spend up to four hours cleaning out the pumps. We desperately needed to find a solution and soon.” “”We contacted several vendors and asked them for their ideas on how to best manage the situation,” he continued. “One suggestion was a climber screen to catch the rags before they entered the pumps. But that meant dealing with the collected screenings. A better option was a grinder placed in front of the pumps to grind the debris finely enough so that it could be passed along to the treatment plants for further processing.” “Our first choice was a Franklin Miller DIMMINUTOR® T25 Channel Disintegrator which we ultimately purchased. Before we made a final decision, we were invited to Ocean City, Maryland where we could see the DIMMINUTOR in operation and talk to the operators using it. They said they were very happy with it.” “Franklin Miller did a great job of engineering the DIMMINUTOR for our conditions. Everything was prefabricated, making it easy for our maintenance crew to install and maintain. We are now able to run our pumps twenty-four hours a day every day with virtually no pump clogging. In the time we’ve owned the unit, we’ve cleaned out just two jams; one caused by a log and the other by a plastic manhole cover. In both cases, the DIMMINUTOR went right back to work.” “The DIMMINUTOR T25 has proven to be an excellent choice,” Funk concluded.

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.”

Industrial Case Studies·February 5, 2015

Case Study: DELUMPER® Crusher LP Protects Downstream Equipment from Tramp

For the past eight years, a paper products manufacturer has used the DELUMPER® 1075LP Lump Breaker in an unusual application on an expensive process line. The material being processed is a mix of carbon and sulfuric acid. During production, tramp materials such as ferrous and nonferrous bolts become trapped in the products and can play havoc on the downstream equipment if they are not removed. According to the plant manager: “We tried all kinds of metal separators and none of them did what we wanted. They couldn’t handle non-ferrous objects or they didn’t work on metal bolts trapped in the product. We use the DELUMPER LP like a sacrificial component to catch both kinds of material and it has been the best solution for our needs.” During the processing operation, over-sized lumps and clumps are de-agglomerated by the DELUMPER’s long fingers to a size that easily fits through the unit’s heavy bar grating. Encapsulated bolts are broken free from the product and are caught on the grating. The unit is installed in a free falling position. “We want to purchase another 1075 LP Crusher with a finer grating to capture even smaller bolts,” concluded the plant manager. “It definitely protects our equipment.” The DELUMPER 1075 LP Crusher is provided with a one-piece seamless uni-body housing. The extended LP cutter teeth 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. Optional features include an extended outboard bearing, convenient side door for easy access and a hopper for feeding. Output sizes are adjustable by changing the speed or the comb. The size of the material handled could be as large as the throat opening. The ultra compact DELUMPER Crusher is designed to be used in open or closed systems such as ducts, chutes or pipes. The unit requires only 13″ headroom space inline. The DELUMPER Lump Breaker can be supplied as a stand-alone unit crusher or as part of a complete engineered system.

Industrial Case Studies·February 5, 2015

Case Study: DELUMPER® Crushes Soda Ash Scale

A leading mineral mining and processing plant recently turned to Franklin Miller for help in solving a long-standing problem. The facility, located in Wyoming , is a major producer of soda ash, the common name for sodium carbonate. Derived from trona ore, the soda ash has significant economic importance because of its application in manufacturing glass, paper, chemicals, detergents and other products. Trona ore is converted to soda ash in a multi-step process. The ore is heated in a kiln and is transformed into sodium carbonate. Water is added, and the solution is filtered to remove impurities. The liquid is then boiled off to form crystals,which are separated in a centrifuge and dried. While the conversion process appears to be straightforward, it very often was complicated by a mineral called eitelite. During production, this scale-like material would form on the walls of the dissolver tanks. Thermal shifts would cause the eitelite to flake off and large chunks would clog small pumps and pipelines, impeding production and reducing process efficiency. Trona ore is converted to soda ash in a multi-step process. The ore is heated in a kiln and is transformed into sodium carbonate. Water is added, and the solution is filtered to remove impurities. The liquid is then boiled off to form crystals,which are separated in a centrifuge and dried. While the conversion process appears to be straightforward, it very often was complicated by a mineral called eitelite. During production, this scale-like material would form on the walls of the dissolver tanks. Thermal shifts would cause the eitelite to flake off and large chunks would clog small pumps and pipelines, impeding production and reducing process efficiency. For years, the company had looked for a solution, testing many devices and units without success. The application is complicated by the severe abrasive nature of the material. Then, Franklin Miller was asked to assess the entire operation and they recommended a powerful in-line processor that would quickly pulverize the difficult agglomerate lumps. A PIPELINE DELUMPER® was installed and the processor was put through a testing program that lasted a year. The company was so pleased with the unit’s performance that they subsequently purchased and installed three more units. The PIPELINE DELUMPER® in-line processor crushes, disperses and suspends tough solids in fully enclosed pipe systems. This unit eliminates blockages, works the stream to free flow and prevents damage to pumps and other equipment. It is suitable for wet, dry, pressure or gravity systems. In applications worldwide, the PIPELINE DELUMPER® has demonstrated its processing and cost-effective benefits. The ultra-compact, straight through PIPELINE DELUMPER is designed for easy installation. This fluid-tight pressure rated unit has the full throughput capacity of the pipe to which it is connected. Its working principle employs rugged impeller teeth passing through a heavy bar grating to reduce the size of the product. These teeth completely clear the slots of the bar grating and at the same time clean the entire pipe cross section area. The unit can be supplied with optional hardfaced cutters. A heavy fused coating of chrome boride is applied in a nickle-based substrate to form a solid fused surface with a Rockwell C in excess of Rc 65. This provides extended life in abrasive service. Franklin Miller offers a full line of crushers to handle a wide variety of applications.

Industrial Case Studies·February 5, 2015

Case Study: DELUMPER® LP Crusher Improves Cocoa Butter Processing

Chef Rubber, based in Las Vegas, Nevada, is a manufacturer and distributor of specialty supplies for chefs and well-known confectioners. The products include silicones, molds, colorants and colored cocoa butter. These unique tools are widely used by artisan chefs to create edible works of art for special events, competitions and other artistic applications. With the recent optimization of their web site, the company experienced worldwide demand for their products and a large increase in sales. It soon became clear that in order to keep up with the expanding business, they would have to upgrade some of their material handling and production practices. “We needed to take a look at how we process cocoa butter, one of our most popular products,” explained Paul Edward, Director of Operation. “It is widely used by chocolatiers and pastry chefs to make their showpiece creations.” “We purchase a very specific type of cocoa butter from Venezuela that comes to us in fifty pound blocks,” he continued. “The first step in the process is to break the blocks down to smaller pieces. Until recently, this meant shaving each block by hand and that wasn’t going to work anymore.” ‍ After examining their options, the company turned to Franklin Miller for a solution. A DELUMPER®1075 LP Crusher was subsequently purchased after a test run with the cocoa butter passed with flying colors. The DELUMPER LP lump breaker processes hard, soft, sticky, dry or wet substances at high volume. The unit features extended cutter teeth that rotate through a rugged bar grating. This powerful processor reduces oversized solids up to the unit’s full input opening size. With each rotation, the teeth clean the slot openings making the unit automatically self-clearing. The result is an efficient, exceptionally low friction cutting action that is excellent for large quantities of food, chemicals, fats, waxes, plastics, filter cake, and more. The units are provided in various sizes with single, dual or triple shaft configurations for capacities up to 27,000 lbs./hr. An optional hardfacing of chrome boride fused coated to all cutting teeth is provided for superior life in abrasive service. Units are available in carbon steel, T304L or T316L stainless steel construction. “The DELUMPER lump breaker has made a big difference,” said Edward. “It chops the blocks down in no time at all. In addition, the stainless steel interior makes it very easy to clean.” “The unit is so big and powerful that I could do a semi truck load of cocoa butter in a day if it was needed,” he concluded.

Wastewater Case Studies·February 5, 2015

Wastewater Treatment Upgrade: Embracing Efficiency with Franklin Miller's DIMMINUTOR®

Fredericton, Canada, a city of 50,000 residents, is the capital of the Canadian Province of New Brunswick. The Wastewater treatment plant, operated by the Fredericton Pollution Control Commission, is a secondary activated sludge system designed to treat an average flow of 5mgd. Septage and incoming wastewater flow through screens which direct oversized objects to the channel grinders where they are reduced to a fine particulate. The solids are allowed to settle in the primary clarifier, are dewatered and sent to a compost site. Treated effluent is discharged into the Saint John River. Until 2009, when the plant began construction for a major upgrade to the existing infrastructure, equipment was purchased as needed. Replacing the existing channel grinders with more cost effective units became a priority. “We had two Muffin Monsters at our wastewater treatment plant, but the cost of overhaul every three years got to be very expensive and our maintenance budget took quite a hit,” explained Doug Sewell, Maintenance Supervisor. “We began to look for a less costly alternative,” he continued. “We installed the first DIMMINUTOR® DM25 xf in 2003 and liked it so well that we purchased another one in 2006.” According to Sewell, the decision was a very good one. “The units are extremely reliable, the cost to operate them is very low and the company’s service and personnel have been topnotch,” he concluded. The DIMMINUTOR DM25 Channel Comminutor provides effective, automatic screening and grinding of wastewater solids in straight through channels and wet wells. This powerful unit reduces plastics, wood, rags and other solids to fine bits, enhancing plant operation and improving the reliability of pumps and other downstream equipment. The unit employs a smooth, continuously rotating design with high torque. As its three bidirectional rotary cutters intermesh at close clearance with stationary cutters, solids are finely reduced to a size small enough to pass through a sizing screen. With no gaps or openings between the screen and cutters, output is controlled and complete reduction assured. The DIMMINUTOR has an intrinsically open design to handle high flow rates with low head-loss. This unit is extremely easy and economical to maintain and features individually replaceable cutters, oil lubrication and a simple rotary design requiring no auxiliary diverter screens. A unique, cantilevered design eliminates seals or bearings near the gritty channel floor. Every component of the unit is constructed for precision and long life.

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