/ReNews_2_2011

renews Reclaim. reuse. recycle.

Issue IV Volume II

- St. Louis Composting goes XXL - Got waste? Make fuel - Savings surprise

“The heart and soul of our operation”

Hybrid high-power

Terminating trash 1

renews Reclaim. reuse. recycle.

Contents Komptech sales territories

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Komptech goes hybrid

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New Crambo Heavy-Duty

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Corn stover to fuel

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Cement kiln fed with RDF

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Turning waste into fuel

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Big fuel savings for CA recycler

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Komptech product overview

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Johannes Pohl, President

New Komptech USA CEO

Marcel Vallen, CEO

Many of you have already met our new CEO, Marcel Vallen. Marcel has over 25 years of experience in our industry, starting out as a machine operator at a landfill, and rising to manage several waste wood and C&D sorting plants.

In 2002 he leveraged his hands-on background as CEO of a recycling consulting company, and for four years he was CEO of a company that sold American grinders to European markets.

Now the shoe is on the other foot, and he’s selling European machines in America. At Komptech, his full-spectrum experience is a great asset. Asked about his hobbies, Marcel named “Traveling” and “Anything with an engine,” two interests he will be able to put to excellent use at Komptech USA! Sincerely, Marcel Vallen, CEO, Komptech USA m.vallen@komptech.com

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In the press of daily business, these ReNews introductions are a great way for me to pause and review the big picture. And this time, the big picture is that the market seems to be strong right now, even more so than before the recession.

I am glad to say that Komptech USA is now experiencing its fourth year in a row of strong growth. Demand for almost all of our product lines has gone up. Financing for our customers has gotten much easier, and we have also been able to establish additional lines.

“The heart and soul of our operation” 8 Komptech old and new in St. Louis

Pohl Position

Back in 2007 when we started in the US, we were the new kid on the block. Now, I’m happy to say that when people invest in equipment we are often one of the top choices they look at. The trade media has us on the radar as well, and we get press mentions five times more often than we did two years ago.

Of course this didn’t happen by itself. We burn a lot of midnight oil and cover a lot of pavement. We go to the trade shows, call prospects, visit customers, and do all the other things that companies do to build business. A big part of our growth can be attributed to our expanding dealer network, which now comprises eight dealers in the US and Canada.

We’re very excited about the coming years. We see a lot of opportunities coming up, and I think that we are in what will become one of the fastest growing industries in the US.

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Komptech sales territories

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Bejac Corporation Kevin Barlet 5695 Van Buren St. Placentia, CA 92870 USA [t] +1 (800) 77-BEJAC [e] kbarlet@bejac.com [w] www.bejac.com

Equipment Depot Kyle Horn 1400 South Loop 12 Irving, TX 75060 USA [t] +1 (972) 438-8000 [e] kyle.horn@eqdepot.com [w] www.eqdepot.com

Mid Atlantic Waste Systems Lance Hood 10641 Cordova Road Easton, MD 21601 USA [t] +1 (800) 338-7274 [e] maws@mawaste.com [w] www.mawaste.com

Simplicity Engineering (N.E.) Inc. James Butler 28 Hawks Circle Westfield, MA 01085 USA [t] +1 (413) 562-8653 [e] simplicityengineering@gmail.com

Powerscreen of Washington, Inc. Pat Lowe 32613 SR 2 Sultan, WA 98294 USA [t] +1 (360) 793-7686 [e] pat@powerscreen-wa.com [w] www.powerscreen-wa.com

Columbus Equipment Company Tim Smith 65 E. Kingston Ave Columbus, OH 43207 USA [t] +1 (614) 443-6541 [e] info@columbusequipment.com [w] www.columbusequipment.com

Powerscreening LLC William Hancock 9725 Brighton Road Henderson, CO 80640 USA [t] +1 (800) 231-5005 [e] sales@powerscreening.com [w] www.powerscreening.com

Komptech Ontario Luke Ellens 400 Jones Road Stoney Creek ON, L8E 5P4 CAN [t] +1 (905) 560-0090 [e] lellens@komptech.ca [w] www.komptech.ca 3

Komptech goes hybrid More and more Komptech machines are dual-power Komptech is constantly looking for ways to help operators cut costs. Fuel savings are a big part of that, and more and more of our machines are hybrid – they have dual power capability.

Our hybrid machines are actually all-electric. The “hybrid” component consists of the ability to run from ground power or with the onboard diesel generator.

All-electric drive has numerous benefits. It is more efficient, less polluting, and quieter. For machine operators in some states, running all-electric from ground power means avoiding costly air permitting.

The addition of a diesel generator means more flexibility, for example where machines need to go to different sites, where ground power is not available. The efficiency of the electric drive components means the diesel generator can be considerably smaller than a conventional diesel engine.

Cribus 3800 E - drum screen

Fuel consumption is minimized to approx. 1.5 gallons per hour.

Hybrid drive is featured in Komptech star and drum screening machines.

Multistar L3 - star screen

Crambo HD Think the Crambo’s tough? So do we. But we’ve made it even tougher The new Heavy Duty (HD) model of the Crambo is designed for especially challenging jobs, like massive hardwood stumps with or without embedded rocks. The Crambo HD is the ultimate in low speed, high torque shredding durability: - Armored drum - Armored teeth - 10% more HP - Upgraded Heavy Duty gear box - Upgraded Heavy Duty drum bearing We’re satisfied that the Crambo HD will come out shining even after the hardest deployments, so we have no hesitation about guaranteeing it for 2 years if a maintenance contract is purchased with the unit. Please call Komptech to find out the details.

Did you know?

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Methane, the primary warming gas emitted by landfills, is about 20 times more damaging than carbon dioxide, the gas released by burning.

Sioux Falls goes Heavy-Duty Landfill operator using new Crambo HD on corn stover

Turning corn waste into fuel The Sioux Falls Regional Sanitary Landfill is first on two counts – the first operator in the country to shred corn stover that will be used to produce energy for an ethanol plant, and the first to use the new Komptech Crambo Heavy Duty version.

Sioux Falls, South Dakota is in the middle of farm country. There are lots of farms growing lots of corn, and that means there is plenty of left-over “stover” – corn cobs, stalks and leaves.

Previously farmers would plough it under, but now it has become a salable commodity. Area ethanol producer Poet uses the stover as a fuel for its process heat – shredded by the Sioux Falls landfill Crambo HD. Stover is not a particularly hard material, so it might seem odd that Sioux Falls would choose the Heavy Duty model of the Crambo to shred it. But stover is very dry and surprisingly tough, and it resists shearing. It can easily nest and clump up, leading to bridging and clogs in feeding. But the Crambo HD, combined with the low-speed, high-torque action, reliably reduces stover to the 3” size needed by Poet for consistent feeding.

Did you know?

Dave McElroy and the staff of the Sioux Falls landfill already had experience with a rental Crambo, and discovered that the low fuel consumption of the shredder was a great plus. It is rated at 12-14 gallons per hour, versus approximately 30-40 gallons per hour for high speed shredders, and in actual use the landfill found that they were only using 11 gallons per hour – “Just like they promised.” So when the stover opportunity came along, Dave McElroy already knew where to turn.

The Sioux Falls landfill will also use the Crambo HD to shred normal C&D debris and wood waste. In any landfill, the smaller the particle size, the faster waste can break down, which makes landfills environmentally safer, as well as boosting upfront production of landfill gas if used on Municipal Solid Waste (MSW).

The Sioux Falls landfill plans to do more recycling down the road, another area where Komptech shredders shine. In the future the landfill is also considering shredding its MSW, for which a Komptech Terminator is a perfect fit.

In the meantime, the current situation is already a win-win for everybody. Sioux Falls landfill has a steady source of revenue for its new machine, ethanol producer Poet has a local source of fuel for its operation, and local farmers find that what was once waste is now another source of income.

The Sioux Falls Regional Sanitary Landfill team takes delivery of their new Crambo Heavy Duty

The town of Horsholm in Denmark gets all of its heat and 20 percent of its electricity from burning trash. 61% of the town’s waste is recycled and 34% is incinerated in waste-to-energy plants.

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Trailer to burner feed system

Komptech star screen is part of innovative Schenck RDF feed system for cement industry

RDF fuel feed integrated into a cement plant Schenck Process is a leading manufacturer of belt scales, mass flow meters, weighfeeders, volumetric and gravimetric feeders, bulk bag discharging systems, fiberglass feeders, controls, and weighing systems for the steel, cement, aggregate, and gypsum industries.

Fuel is a major cost in cement-making, and the industry was one of the first to recognize the cost-saving potential of refuse-derived fuel, or RDF. Of course, like with any industrial process, cement kilns require a standardized fuel.

Now Schenck is offering a "trailer to burner" alternative fuel feed system to cement-makers. This innovative system lets them meter waste materials such as PET bottles, sawdust, tires, paper,

Did you know?

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wood chips, rice, bone meal, and other materials to the main burner and calciner of a cement kiln, reducing the need for fossil fuels such as coal.

The Komptech Multistar 2 SE stationary star screen is part of the system, separating out the 2” minus and sending larger pieces on for shredding. The “Cleanstar” selfcleaning system keeps the stars free of wrap-arounds and debris, for consistent screening efficiency.

With the Schenck system, combined with the Komptech Multistar, cement plants can focus on what they do best – making cement – while using RDF. They don’t need to get into designing a system from the ground up, and since this feed system can handle a

According to the National Renewable Energy Laboratory, by 2020 more than 30,000 megawatts of biomass power could be generated nationwide. About 60 percent would come from energy crops and 40 percent would be supplied from woody biomass. This increase in biomass facilities could support more than 150,000 US jobs and help revitalize rural economies.

wide range of input materials, cement plants can accept waste from a variety of sources and are not as tied to upstream processors.

This cuts costs and makes RDF use more flexible, which in turn should be a big help in encouraging more plants to use RDF.

Got waste? Make fuel Refuse-derived fuel gaining in importance There is energy in everything that exists, whether it grows naturally or is manufactured. This includes waste materials, and a large part of the answer to future energy needs lies in reclaiming the energy that went into making the items that we throw away.

Turning waste into fuel also alleviates landfill space problems. What’s more, using waste as fuel does not add to the amount of surface carbon as fossil fuels do.

enough to break them down. In fact, for some materials like tires this is the only practical disposal method that does not release toxins into the environment.

Post-shredding for final sizing, to injectable (1” minus) or fluidized bed (3-4” minus) fuel. The Komptech Rasor is a purpose-designed postshredder.

Turning waste into fuel is largely a matter of sizing and sorting, two things that Komptech machines do very well. Configurations differ, but systems typically break into three stages:

Putrescible waste such as food scraps and sludge can be turned into biogas. Non-putrescible natural waste such as cuttings and waste wood can be composted to create fertilizer, or burned as fuel. Many kinds of artificial materials, especially those derived from petroleum – plastics and tires – can also be useful fuels if the combustion temperature is high

Pre-shredding to open up waste and reduce it to a consistent particle size for subsequent processing stages.

The Komptech Terminator is highly suitable for this. Separation of the material into different fractions – rolling, fine, coarse, flat, ferrous.

The Komptech Brini is specifically designed for this task.

Of course many configurations are possible. For example, if the feedstock is exclusively wood, it may only be necessary to shred the wood to a certain size. Refuse-derived fuel has become a science in its own right, and as energy costs rise it will continue to be ever more highly developed for specific applications.

Injectable refuse-derived fuel

Typical RDF process flow

Did you know?

RDF for fluidized bed incinerators

Recycling and RDF are natural “teammates” - countries with expanding waste-to-energy capacity, like Denmark and Germany, also tend to have the highest recycling rates.

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CWR's Crambo turning C&D waste into recyclables

“The heart and soul of our operation” CA recycler finds Crambo a perfect fit.

Commercial Waste & Recycling, LLC operates right in the city of Oakland, processing C&D and wood waste.

They set store by efficiency, and in 2010 recycled 93 percent of all incoming materials. Their urban location makes it important to minimize dust production, so when the company began looking for a new grinder last year, they knew they wanted a slow-speed machine.

After much research and many demonstrations, the company settled on a Crambo 5000 and took delivery in March 2011. To say that the company is happy with the machine would be an understatement!

According to owner Joshua Fookes, what really makes the Crambo stand out is its flexibility. There are two processing sides to their operation and the Crambo makes it easy to process multiple feedstocks.

Did you know?

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One side is processing wood and green waste to biofuel. CW&R has contracts with several power plants, which want 3” fuel as an end product.

The company needed to shred waste down to a 3” minus fuel with just one machine; as Joshua put it, “We don’t have the footprint for a secondary machine. We need to go to size in one pass.” The Crambo easily meets that requirement, putting down material that the power plants are happy with.

The other side of the business is processing C&D waste. Here, the output needs to be a 6” end product.

With its ability to change screens, the Crambo is helping the company cover both bases. Not only does it allow them to recover more recyclables, it also lets them switch between sizes relatively quickly by changing out the screens.

Going from wood waste to C&D, the switch takes approximately 25-30 minutes.

A 2009 study by the EPA and NC State University came down strongly in favor of waste-to-energy plants as the most environmentally friendly destination for urban waste that cannot be recycled. The study said that this would not only reduce greenhouse gas emissions and local pollution, but also yield copious electricity.

This means that with just the one machine, CW&R can address both markets. What’s more, the Crambo opens up more revenue streams, one big one being metal waste. The head pulley extracts twice as much metal as they had been getting before, enough extra to pay for the fuel to run the Crambo.

Another new source of revenue is large wood pieces. Unlike the company’s previous tub grinder, the Crambo can even handle logs, so that as Joshua put it, “The stuff we used to throw away, now we can process it.”

The company is so happy with the Crambo that they feature it on their home page. Joshua says, “The day we put it into operation we started making money with it. I don’t want to sound cheesy, but this machine has become the heart and soul of our operation.”

10 years later, still going strong Komptech old and new at a leading Midwest composter

Feeding the new Multistar XXL at St. Louis Composting St. Louis Composting is one of the older companies in the composting business, having started in 1992. They are now the largest composter in their region. For 10 years, a Komptech Hurrikan windsifter has been part of St. Louis Composting’s growth - one of the very earliest Komptech machines sold in the US. The Hurrikan was an investment in quality control, to remove more of the paper and plastic debris from the feedstock. It was also part of the company’s forward-thinking approach.

As Marketing Manager Ashley Bement put it, “Early on, not many composters were doing this, but we were already thinking about how to compost better.”

In its 10 years of operation, the Hurrikan

has amply proven its value. According to Rick Buettner, Equipment Manager, “It extracts all of the paper and plastics from our finished product very well and helps to maintain our quality control. It also separates stones and metals very well too. It is a very well thought out machine.”

As production and sales have grown, so have St. Louis Composting’s machines, and over the years the company has had the opportunity to work with many different machine brands and models. When it came time to invest in a new screener, the company chose a Komptech Multistar XXL. In addition to the positive experience with Komptech in terms of overall design and build quality, the decision for the Multistar

The Multistar XXL isn't called "XXL" for nothing

Did you know?

was driven by throughput – which according to Buettner is three times higher than any other screener.

St. Louis Composting uses the 10-yearold Hurrikan and the brand-new Multistar together, teaming Komptech with Komptech. Together, the machines can produce about 2800 cubic yards in a 6-hour shift, a job that used to take days. The XXL is equipped with one windsifter on the medium fraction, but because of the height of the machine, it does not come with one on the overs fraction. Buettner says that the only thing better would be an XXL with integrated Hurrikan on both decks “But, putting the machines together is certainly getting the job done for us!”

Still sifting after 10 years - St. Louis Composting’s trusty Hurrikan

Average landfill tipping fees in the US in 2010 were $44 per ton, up 6 % over 2009.

(By comparison, in Germany they run $200-300 per ton.)

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Unexpected fuel savings

CA recycler gets a very pleasant surprise

Five years ago, when Steve Malfo was looking for a shredder, Komptech told him he should go electric. Now he’s glad he did.

Todd Dunderdale explains the Crambo's easy operation

Hugh Bedford, Steve Malfo, and Komptech’s Todd Dunderdale check out the easy access of Bedford’s Crambo.

Did you know?

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Bedford Enterprises of Santa Maria CA is a C&D waste recycler, taking wood, steel, stucco, drywall, masonry, and other waste. About 20% of the output is wood processed to 3” minus for fuel generation. Non-recyclables go to blended mulch for landfill daily cover, and recyclables like metals are resold. In total, the company extracts about 87% of waste for recycling, so that only about 13% goes to landfill.

The company is located in an area that takes environmental protection very seriously, and when Steve set out to get a new shredder, the county and the Southern California air pollution authority let it be known that they would be much happier if he went with electric drive, instead of a mobile diesel. So Steve looked around, did his research, and found that the Crambo 5000 would meet his needs. He already knew that the engineering was solid and the machine’s

Methane, the primary warming gas emitted by landfills, is about 20 times more damaging than carbon dioxide, the gas released by burning.

capabilities were a good fit for his operation, so it was not a difficult choice to make.

Now in retrospect, it’s a choice he’s very glad he made. Because with the electric Crambo, he saves at least $5,000 on fuel costs each and every month.

It seemed hard to believe, so we doublechecked. According to Steve, based on his average bills for fuel and electricity for shredding, the electric Crambo saves $2.50 a ton versus what he had been paying for diesel fuel.

At 2,000 tons per month, which is about average for him, that works out to $5,000. He adds that this is based on the diesel prices of five years ago – the savings are actually greater now. Add to that the lower maintenance requirements of an electric machine, and as Steve puts it, he has “seen the light on costs.”

We at Komptech note that results may vary – it all depends on local energy costs and desired product size. But for Bedford Enterprises at least, electric has proven to be the way to go.

Product overview Shredding machines

Terminator

Low-speed single-shaft shredder for all types of waste and wood

Crambo

Low-speed dual-shaft shredder for all types of wood and green waste

Chippo

Mobile drum chipper for wood logs and pruning

Axtor

High-speed universal shredder for green waste and wood

Screening machines

Primus

Mustang S

Drum screen for smaller and mid-sized composting plants

Multistar L3

Cribus 3800

Drum screen for large plants needing New generation of mobile drum screen, higher throughput and material quality with the ultimate functionality and operating efficiency

All-round star screen with high performance, wide range of applications and high operating efficiency

Multistar XL

Star screen for large plants and contractors, also ideal for preparation of biomass

Multistar XXL

High-performance star screen for demanding requirements

Magnum

Our largest mobile drum screen, with performance rivaling stationary plants

Multistar XXXL

Highest-performance star screen for very demanding requirements

Turning and sifting machines

Topturn X53

Compost windrow turner

Topturn X60

Higher-capacity compost windrow turner

TopturnX67

High-throughput compost windrow turner

Hurrikan

Windsifter for separation of11plastic, stone, metal from screening residues

Komptech USA is growing fast!

We are actively seeking qualified personnel for Sales and Service.

Please contact us at

info@komptechusa.com

Komptech USA Inc. [P] (720) 890-9090 [F] (720) 890-5907 info@komptechusa.com www.komptechusa.com

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