Renews 2 2013

renews Reclaim. reuse. recycle.

Issue VII Volume I

- Turning Waste Into Fuel in BC - Ready for Growth in Texas - Zero Waste in Minnesota

Hand-Picked for Hand Picking

Driven by Efficiency

Green Envy 1

renews Reclaim. reuse. recycle.

Contents Komptech Sales Territories

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New Dealer in TX, OK, AR, LA

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Hand-Picked 5 Crambo Helps Fuel Change in BC 6 Crambo Boosts Efficiency in Sonoma 8 Multistar Gets Selective in Ohio

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Terminator Helps Eliminate Waste in Minnesota

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Product Overview

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Part of the Plan

Komptech Massively Boosting Parts Operation Komptech USA has grown rapidly since its founding less than a decade ago, and there are more and more machines out there working.

That in turn means we need to keep more and more parts ready to service those machines. Komptech is proactively addressing this in two ways – by further boosting its own parts stock, and by helping its dealers with their parts operations.

The goal, according to Parts Manager Tony Pierce, is to “make sure everybody is well stocked, so dealers can support customers smoothly.” To do that, Tony is visiting dealers, training their specialists on the ins and outs of Komptech parts service and finding out from them what Komptech can do to make their jobs easier.

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Tony breaks parts out into highturnover A-list items like oil filters and wear parts, which are stocked centrally as well as by dealers for direct service to customers, and less frequently-needed B-list parts which are kept centrally in Denver.

Komptech is also undertaking a massive expansion of its central parts warehouse in Denver, doubling the space. The existing space was getting crowded, especially since last year we had already doubled our parts stock, and will be adding more this year.

Now with more room to maneuver, as Tony put it, “I can order two parts instead of one when I call in orders, and build up more reserves”

We are dedicated to uptime. We are well aware that for our customers, time is money and downtime equals lost revenue. We have long prided ourselves on the excellence of our service, and are investing to stay ahead of demand and anticipate needs. By further increasing our parts warehouse space and training dealer parts specialists, we are making sure our customers always have the parts they need, when they need them.

Komptech Sales Territories AK

YT NT

NU

BC

NL

MB

AB

ON

NH

WA MT

OR ID

NV

UT

CA

AZ

VT

ND

WY

MN

SD

IL

KS OK

NM TX

WI

PA

OH

IN

MO

WV VA

KY

NC

TN

AR LA

NY

MI

IA

NE CO

NL

QC

SK

MS AL

SC

NS

ME MA RI CT NJ DE

Power Equipment Utah Branch Darek Carnes 2459 S 2570 W Salt Lake City, UT 84119 [t] 1-800-883-9284 [e] dcarnes@power-equip.com [f] 1-303-288-6809 [w] www.power-equip.com

MD

GA

Komptech USA

NB

FL

Powerscreen of Washington Swanston Equipment Midwest ReCon LLC

Columbus Equipment

Bejac Corporation

Powerscreen of Florida

Mid Atlantic Waste

Power Equipment Company

Powerscreen Texas Inc.

Foreman Equipment

Power Screening

Simplicity Engineering

Komptech Ontario

Midwest Re-Con Brad McAlister 1924 Hwy 141 Bayard, IA 50029 [t] 660-295-4661 [e] info@midwestrecon.com [w] www.midwestrecon.com

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

CO

BEJ

C

RP O R A

ON TI

A

Powerscreen Texas Inc. Sam McNabb 2015 West State Hwy 71 La Grange, TX 78945 [t] +1 (800) 255-8628 [e] pwrscrn@powerscreentx.com [w] www.powerscreentx.com

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

Swanston Equipment Mike Mullen 3450 Main Avenue Fargo, North Dakota 58103 [t] 1+ (701) 293-7325 [e] mmullen@swanston.com [w] www.swanston.com

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

Powerscreen Florida Richard Grant P.O. Box 5802 Lakeland, FL 33807-5802 [t] 1+ (863) 687-7153 [e] Richard@powerscreenfla.com [w] www.powerscreenfla.com

Power Screening LLC Jerry King 9725 Brighton Road Henderson, CO 80640 [t] +1 (800) 231-5005 [e] sales@powerscreening.com [w] www.powerscreening.com

Foreman Equipment Ryan Foreman 31244 S. Fraser Way Abbotsford, BC V2T 6L5 [t] 604-852-9021 [e] info@foremanequipment.com [w] www.foremanequipment.com

Vi

le

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

ce

sa s

Re

e N Ta l s s

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Bejac Corporation Robert Cycon 569 S. Van Buren St. Placentia, CA 92870 [t] +1 (800) 77-BEJAC [e] kbarlet@bejac.com [w] www.bejac.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

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Anticipating Growth

Sam McNabb of Powerscreen Texas

Powerscreen of Texas is Komptech’s New Dealer in TX, OK, LA and AR La Grange-based Powerscreen Texas has been in the crushing and screening business for over 45 years, and recently this savvy company added Komptech to its line of machines.

This move was driven by demographics. Texas is growing rapidly – every day 300 more families move to the state, and from today’s population of 37 million Texas is set to top 50 million people by 2040. And naturally, more people means more waste to dispose of.

Texas has not traditionally been a big recycling market like the Northeast and the Northwest, but that is shifting as the population grows.

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Landfill space is starting to get tight, and recycling streams are picking up. By taking on Komptech, Powerscreen is positioning itself to profit from these developments.

In addition, Komptech was an ideal line extension. Powerscreen makes its own trommels for greenwaste, so it made sense to add a line for shredding, grinding, windrow turning and also star screening for wetter materials, all categories that Komptech covers.

As Powerscreen partner Sam McNabb put it, “I don’t want to have to walk out the door when a prospect says, ‘sell me a windrow turner.’ We’re usually first in, and

I want it to stay that way.” By anticipating market needs and taking on the Komptech line, the company looks set to remain that step ahead.

Powerscreen Texas Inc. Sam McNabb 2015 West State Hwy 71 La Grange, TX 78945 [t] +1 (800) 255-8628 [w] www.powerscreentx.com

Hand-Picked

Baltimore Recycling Center uses Terminator as a surge and size solution Jack Hayden knows waste processing.

He’s been in the business for 35 years, and he knows what works. And these days, a Terminator works for him.

Baltimore Recycling Center LLC is a LEED recycling facility for C&D waste that grinds, picks, screens and sifts waste to extract the maximum reusable material. The company pulls metals, wire, cardboard, plastic and clean wood out of waste for resale. Masonry is crushed and sold as recovered aggregate, and clean dirt is landfilled as alternative daily cover. The clean wood goes out for composting.

Like many waste processors, Baltimore Recycling uses a Komptech Terminator, but uses it a little differently.

Hand-picking is a big part of Baltimore Recycling’s operation, since the C&D waste that comes in is commingled.

For picking to be efficient, Jack needed a way to solve two problems – surge and size.

Surge – Pickers need a steady, controlled flow of material so they can do their job. Simply dumping loader bucketfuls on the conveyor leads to surges of material alternating with nothing, and it takes a very skilled loader operator to “trickle” the material onto the belt at just the right speed.

Size – Pickers need the material to be manageable. 10’ pieces of metal are hard to manhandle.

Solution – The Terminator solves both problems. It sizes everything down to 2-3’ minus, and meters the material onto the sorting line. All the loader has to do is keep it full; the Terminator does the rest.

As for the Terminator itself, Jack is nothing less than delighted. In his many years in the industry he’s had some 15 grinders in this size range, but says that none were as reliable or economical to run, and that in just over a year of operation he has had no breakdowns. He attributes this to the Terminator’s ability to protect itself by coming to a gentle stop when it hits something un-shreddable. As he put it, “with other machines there will be damage by the time they come to a stop; not with a Terminator. Others can’t begin to cope with the material we process.”

Now, for this job you wouldn’t expect to see the “F” version of the Terminator.

It’s designed to shred very fine. But Jack chose it because he can take out all but two of the countercomb teeth and get the very coarse product he’s looking for. With that configuration, he can run it on full power but 50% drum speed to feed the material to the picking line at the steady pace and in the size needed.

No two waste processing operations are alike, and each faces different challenges. We’re glad a Komptech Terminator has helped Baltimore Recycling Center solve its particular surge and size challenge.

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Fueling Change

Making Biogas and Compost in Richmond, BC Massachusetts-based Harvest Power is a company deeply committed to change. It helps communities better manage organic waste by shifting those resources from disposal to resource recovery, from landfilling to soil-building, and from energy use to energy production. The company operates 28 locations from coast to coast in the US and Canada, handling over 2 million tons of organic material 6

a year and producing 29 million bags of soil products, and providing the capacity for 65,000 megawatt hours of energy in the form of RDF and biogas.

Biogas – a renewable natural gas Biogas is essentially methane and CO2. It is produced by anaerobic digestion, a process in which microbes break down organic materials in the absence of oxygen. The resulting gas

can be upgraded into pipeline-grade natural gas for electricity production and heating, or CNG (compressed natural gas) for use as a vehicle fuel.

In Europe both uses are common, and biogas is produced at facilities large and small. The potential is enormous, and Harvest is one of the first American companies to make biogas on an industrial scale. At its existing composting site in Richmond BC, it

The Energy Garden Visitor Center

recently set up a new plant called the “Energy Garden” designed specifically to produce biogas.

Harvest’s Energy Garden takes in source-separated organics, such as food scraps and yard trimmings, from residential and commercial customers.

The biogas it produces is used to power a 2 megawatt cogeneration (heat and power) plant, which delivers enough energy to power 700 homes.

A key part of the Energy Garden’s machine park is a Komptech Crambo 3400 stationary shredder. Like Crambos everywhere, its job is to

open up and reduce material to the size necessary for further processing steps. And like Crambos everywhere, it does so dependably, energy-efficiently, and largely without blockages or stoppages – all the reasons so many customers choose the Crambo. Also, in this case Harvest was implementing a technology developed in Europe, and the Crambo has proven itself in exactly this application in Europe many times over. The Crambo in the Energy Garden has a custom touch in that the electric motor is located outside of the building. Harvest runs it with the biocutting screen to open up all the fruit in the feedstock.

The company is proud of this groundbreaking facility and launched a virtual tour of the facility (harvestpower.com/ energygarden), and recently opened an architect-designed visitor center to show interested parties how the process works.

Harvest Power is one of the most committed recyclers in North America, and with this new biogas plant they are taking an important step towards a more sustainable and energyindependent economy. Komptech is very proud to be a part of it.

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“Recycling and efficiency are the motivators”

Curtis Michelini points out one of Global Materials Recovery‘s best assets Global Materials Recovery Services of Santa Rosa CA has long been a pioneer. Ten years ago they became Sonoma County’s first fully permitted C&D recycling facility, and recently they became the first to start shredding waste with a Komptech Crambo shredder.

Wood is an important material for the company. A lot of it comes in, and it is highly marketable. But wood also tends to come in a wide variety of shapes and sizes, including some very un-handy ones that are bad for a sorting line and take a lot of space to store.

To put the scale of this into a little bit of perspective, a county in California isn’t the same thing as a county back east.

At 1768 square miles, Sonoma County is larger than the state of Rhode Island, and almost twice the size of the entire country of Luxembourg. So being the first in Sonoma County is no small matter.

But if you shred wood to a consistent size, everything changes. It’s easier to handle, easier to sort, easier to store, and cheaper to haul. Instead of a truckload of air spaces with some wood around them, like you get with big pieces, you can ship a truckload that is mostly wood – in fact, according to company spokesperson Lisa Hardin, Global Materials needs approximately half the number of truckloads they would need for the same weight of unshredded wood.

In its ten years of recycling C&D waste Global Materials has naturally grown, and capacity and space were starting to become a problem. Also, the company has a custom sort line to separate waste for recycling, and needed something to break down the large items to a manageable size, especially wood.

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The company took their time deciding on the Crambo to take care of their shredding needs, testing it along with several competing models on-site through the good offices of Bejac

Corporation, Komptech’s California distributor. After thorough testing, Global Materials determined that the Crambo offered the best combination of size, performance, throughput and ease of operation. The decision was made all the easier by the knowledge that Bejac stood behind the machine with in-state parts and service.

The company is happy with its decision. According to Lisa Hardin, “the operators love it,” and since acquiring the Crambo the company has been able to increase its recycling rate by 25%. The Crambo is used both to size-reduce material for sorting and to shred wood for sale as biomass.

Global Materials Recovery Services is not a company to rest on its laurels, but instead is working to stay at the cutting edge. As Lisa Hardin put it, “We’re always trying to do more.

Recycling and efficiency are the motivators.” At Komptech, we couldn’t have said it better ourselves.

Everybody Wins

Ohio Company Turns Food Waste Into Top-Grade Soil

Every day, supermarkets across the country throw away produce that is past its sell-by date. Some of it you wouldn’t want to buy, but some of it is fresher than a lot of the things lurking in people’s refrigerators at home.

Regardless, rules are rules and out it goes. Stores do it because they have to, not because they want to – it’s a double financial hit for them. Not only can they not sell the produce they themselves already paid for, they have to pay tipping fees to dispose of it.

Ohio Mulch did some research and development work, and set up a composting operation to use this material. The result was “Green Envy,” an exceptionally rich, allnatural compost. Green Envy is so good that it is gaining national attention, and was recently shown at a Miami home & gardening trade show. Other feedstock suppliers are getting on board, including restaurants like fast-food chain White Castle.

Meanwhile Ohio Mulch, a gardening supply company, had another problem. Most of the soil in Ohio is clay, and to get good soil to sell in their 25 retail stores they had to go out of state.

Ohio Mulch is a well-established, 33 year old company that knows its way around the waste processing business. It has long been making mulch out of green waste and other materials. It even builds its own trommel screens. But for screening Green Envy, the company turned to the Komptech L3 Multistar star screen. The Multistar’s ability to handle heavy, moist material and its precision screening gap control mean it can turn out a consistent product every time. As Ron Frost of Ohio Mulch put it, “It’s phenomenal the way you can program the machine to separate out the exact ingredient you want.”

So Ohio Mulch looked for ways to make their own. Composting was an obvious answer, but where to get a steady supply of the high-quality feedstock it takes to make highly nutritious soil?

The answer was right down at the mall.

Kroger, an Ohio-based grocery chain, had over-aged produce it needed to get rid of. Lots of it. Every day.

Travis Smith and Ron DuPerow with Ohio Mulch‘s new Multistar With the Multistar, Ohio Mulch has been able to get production down to a science. They can fine-tune the quality of Green Envy and get a consistent flow.

Ohio Mulch has 25 retail stores and three production facilities in Ohio, and a fourth production site in Georgia. The company sells Green Envy in its own stores as well as through other retailers – including Kroger. It’s a “virtuous circle” that benefits everybody. The grocery chain no longer has to pay tipping fees for the produce it can’t sell, and can even sell it in another form as compost. Ohio Mulch benefits from a steady source of highly nutritious feedstock for a top-quality product.

The environment and ultimately all of us benefit because the resources that went into growing the produce in the first place are not lost, but instead repurposed as soil for new plants.

Everybody wins!

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The (Nearly) 100 Percent Solution Great River Energy Refuse-Derived-Fuel (RDF) Operation achieves Nearly 100% Zero Landfilling

The co-op’s Elk River Resource Recovery Project is one of the few waste-to-energy operations with an almost 100% recovery rate.

That means that virtually all of the waste taken into the system is either recovered for recycling or burned as RDF to generate electricity. In 2012 only 0.4% of the incoming material was landfilled. This high recovery rate generates income, saves tipping fees, and is good for the environment.

The Terminator shreds incoming waste down to a particle size that allows for complete processing. Before Great River Energy got the Terminator about 8% of incoming waste was landfilled because it was oversize. With its low speed, high torque, and resistance to contraries, the Terminator can handle items that were previously landfilled, like mattresses, carpet, and even large pieces of twisted metal. That was the reason Great River Energy bought the Terminator, and it has succeeded.

As Jack put it, “so far it’s chewed up everything we’ve thrown in. ”The material comes out the right size for the rest of our process, in one pass”.

As a bonus, by shredding previously unshreddable metal items, the Terminator has also increased the metal recovery rate.

This remarkable performance is a result of careful development work and the right equipment. Engineers at Great River Energy tweaked and modified their processes, and recently the co-op also purchased a Komptech Terminator 5000S stationary electric shredder.

According to Great River Processing Plant Supervisor Jack Boogren, the Terminator was “the icing on the cake.”

Working with Komptech, Great River Energy made some modifications to the Terminator; they hardfaced the teeth and rotor, and also put the electric motors and hydraulic pumps on a skid that can slide in and out of the unit to make maintenance easier. (Komptech is a company that has always prided itself on listening to customers, and has adopted the idea for its machines.)

Great River Energy is a cooperative electricity provider serving 28 distribution cooperatives in Minnesota and Wisconsin. As an electric coooperative it doesn’t have customers, it has members. Its business purpose is to supply members with reliable and affordable electricity.

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In general, maintenance is easy, according to Jack, and breakdowns have not been an issue; in over 2000 hours of use the cooperative has not yet run into a stoppage that couldn’t be unstuck simply by reversing the drum in the machine.

Great River Energy originally anticipated running the Terminator about 800 hours in the first year, but has run it more than double that amount. The machine is in use 16 hours a day, 6 days a week. In fact, the Terminator’s ability to handle pretty much anything has encouraged Great River Energy to seek out difficult waste from new sources.

In achieving the near zero-landfill goal, Great River Energy has slashed landfill fees, boosted its income, and taken a major step towards a sustainable future.

Komptech is proud that its Terminator is part of it.

Product overview Shredding

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

Joker

Trommel screen for smaller and mid-sized composting plants

Cribus 2800

Trommel screen for large plants needing higher throughput and material quality

Nemus 2700

New generation of mobile trommel screen, with the ultimate functionality and operating efficiency

Cribus 5000

Our largest mobile trommel screen, with performance rivaling stationary plants

NEW Multistar M2

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

Multistar L3

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

Multistar XXL

High-performance star screen for demanding requirements

Multistar XXL-2

Highest-performance star screen for very demanding requirements

Turning and Separation

Topturn X53

Compost windrow turner

Topturn X67

Higher-capacity compost windrow turner

Stonefex 3000 Stone separator

Hurrikan S

Windsifter for separation of11plastic, stone, metal from screening residues

High Torque = High Profits

The Crambo

Dual-shaft shredder

The Terminator

Single-shaft shredder

The Topturn

The

is

world

getting

greener

Compost turner

Dual Power = Low Cost

The Cribus

Hybrid trommel screen

The Multistar

Hybrid star screen

The Hurrikan

Hybrid wind sifter

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p 720-890-9090 | f 720-890-5907 | e info@komptechusa.com

We make technology for a better environment, with performance and efficiency features others often imitate but never equal. Our build quality and innovations lead the industry, so you can lead yours.

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