Overview
We started toll manufacturing / contract manufacturing many years ago to assist customers make products while their purchased unit was built and installed. From that initial beginning, We have continued to develop processing capabilities to assist in our customer’s product success. There are many reasons to consider contract manufacturing like new product development, raw material formatting, fluctuating demand, product recovery/restoration, supplemental manufacturing capabilities, develop operating techniques to support machine sale, and the initial reason of getting a product produced while your system is being built.
Capabilites
Our advanced facility offers clients the opportunity to test and develop new product without the same capital commitment associated with purchasing machinery. Our facility has 8 full scale bays dedicated to toll manufacturing while having the technical experience and know how to get jobs done quickly and efficiently. The massive facility can handle orders from 100lbs to up over one million pounds of product! Whether it be screening, grinding, air classifying, mixing/blending, packaging and repackaging, magnetic separation or anything else you may need done, we have the solution. Call today to find out how toll manufacturing can help you get the most out of your product.
TOLL SCREENING
Our state of the art toll processing facility features 8 bays dedicated to toll screening and 2 bays for our new line of fine grinding equipment which includes a jet mill and a sieve mill. In addition, we have an Electro Magnetic Separator, bulk-to bag packaging area, blending and mixing machinery. We have also recently installed and commissioned a SDF 200 Air Classifier. All of the equipment that we offer for sale is available for use in our facility. This features the Hi Sifter, Rhewum, Vibrowest and Minox lines of screeners and the entire STM Micron line of grinding equipment.
Unlike most OEMs, we run these machines in our factory every day. This daily practice has given us the hands-on experience and know-how that is invaluable to our customers. By the time our customer purchases equipment for their factory to run products they were tolling with us, the bugs are all worked out and the problems are eliminated. Quick and easy start-ups are the norm for our customers.
We have the most advanced screening machines in the world and our capabilities far exceed other screening companies. The combination of advanced technology and seasoned techniques provides solutions to the most difficult to screen products. We can make products separations as fine as 10 microns but has also provided cuts as coarse as 10mm! Our large facility has the capacity to handle from 100 pounds up to a million pounds and we can take in material by the truckloads! Our grinding business is just starting up and will be fully operational this year.
Our initial work in tolling was the result of customer requests to match the lab work we performed for them. Once the end customer saw the results from our testing, they demanded more sellable product immediately. It could take months before the machinery bought from Elcan could be installed so we offered to toll the product until their plant was built. We didn’t even know what tolling meant then!!
Our first jobs ranged from crumb rubber to TEFC. We quickly moved to a larger facility and were then able to process truckloads of aluminum powder, glass flake, plastic and glass beads and various metal powders like Zinc, Nickel, Chrome Oxide, Iron Pyrite and Stainless powders. We even do the separation of hollow glass spheres used to lighten the wings on commercial jets.
Our reputation spread and we expanded again in 2012 to our current 20,000 sq. /ft. facility in Tuckahoe, NY. We then added complimentary lines of services and are will to add any equipment to help our customers. We have packaged dozens of truckloads of persulfates and alumina for computers.
This move has allowed us to process 4 million pounds of recycled fluorescent light bulbs, boatloads of polymers and catalysts, tons of glass flake for the high-end electronic industry and even chrome-oxide screened, de-magged and packaged into 10 pound bottles. Ongoing campaigns of diatomaceous earth, glass beads, graphite and sands flow into our facility daily.
Our in-house laboratory is now undergoing an upgrade and we have added the Malvern Mastersizer 3000 recently to provide our customers with better analysis. The Malvern is also available for toll work. The new lab includes a Nisshin Air Classifier, a V-blender, Air-Jet Sieves, Rotap as well as dryness and density analysis. Lab-sized grinding machines are scheduled for later this year.
TOLL GRINDING AND CLASSIFYING
In addition to toll screening, we also offer customers the opportunity to toll grind and classify with us as well on our line of STM Micron equipment. All of the equipment in our facility is available for both testing and toll processing.
We have a SDF Series Dynamic Air Classifier installed in our plant. The ultra-high efficiency dynamic air classifier is equipped with a two-stage, dual air intake and a centrifugal type rotor to accurately classify the entrained powder. The precision engineering of the SDF Series prevents unwanted particle bypass to ensure that only the desired fraction is collected. The desired fineness is easily adjustable and assembly, maintenance and cleaning operations are extremely simple. These features allow the classifier to make precise separations at very small micron sizes.
We also have installed a sieve mill, which is similar to a hammer mill except it uses a screen to determine particle size. Within the sieve mill, the grinding is achieved by the material impacting the grinding tools mounted to the grinding disc. The grinding disc rotates around the grinding track, which includes the sieve itself. The sieve acts like a classifier as it determines the particle size according to its hole diameter. Final particle size is determined by a number of different factors that are adjusted based on each specific product’s sizing requirements. The machine has a simple design with a wide range of accessories and this along with numerous grinding disc designs and different sieve sizes make it suitable for virtually every purpose.
We are currently in the process of installing an MJS Fluidized Bed Jet Mill, which will be operational by the end of 2017. The MJS Jet Mill consists of a grinding unit which uses high pressure gas and a variable rotary classifier for precise selection of particle size. The high impact speed and accelerated air flow from the nozzles produce a high collision speed and allow for very efficient grinding. These advanced features enable the mill to pulverize extremely hard, abrasive products. Inside the unit, a turbine classifier is used for ultra fine powders, which results in a very precise selection and a tight curve of particle size distribution. The design of the machine allows for easy cleaning and the quality of the construction of the machinery eliminates the possibility of iron contamination as a result of wear and tear. The equipment features a completely automatic operation, which eliminates the need for constant supervision while in use.
MIXING AND BLENDING
We have expanded our corporate capabilities to include mixing and blending in addition to their extensive line of screening, grinding, and toll processing services.
We have a number of double ribbon blenders that keep the product in a constant motion and has ribbons that move in opposite directions providing counter directional flow.
We have a paddle ribbon blender, which works great with products that are difficult to blend. We also have double conical blenders for thorough mixing of dry metal powders.
We have used this equipment to blend not only metal powders, but to create blends of product for customers using multiple additives. For mixing and blending, we have the capabilities of handling truckloads of material if need be.
PACKAGING AND REPACKAGING
After a customer inquiry to help them through a period of downtime while they modernized their packaging facility, we dedicated 2 entire bays, installed a brand new packaging line and learned how to take the customer’s product from supersacks into 25kg bags that had to be sewn shut. This allows customers the opportunity to have bulk sacks repackaged into smaller sellable bags. The bagging machine has load cells, which allow for the bag to be released exactly at the right weight. Then the material travels down the conveyor to be sewn and then palletized. This allowed the customer to continue shipping their product without any disruption while they installed the new equipment they purchased for this function over a 2 month period.
Over our 25 years of toll processing, we have packaged and repackaged material in every combination possible. We can pack out material after being screened to meet any customer’s specifications. Whether it is from supersack to 10 kg bottles, boxes to drums or drums to bags, we have the ability to get the job done. No matter what your repackaging needs, we have you covered.
MAGNETIC SEPARATION
In 2012, a customer approached us with a dilemma, they had jointly purchased a magnet with another tolling company to pass their material through to remove contamination. The machine was the Eriez DVMF Electromagnet. Unfortunately, the machine was never able to be run properly because it was too complicated for the original toller. The customer then made a deal to have us take the magnet, get it running and work off the purchase by running the customer’s product at a discount.
We have teamed up with the manufacturer of magnets. In a short period of time, the unit was installed and running for the customer. The magnet is perfect for companies looking to remove metal contaminants from a product. We have assisted numerous companies removing ferrous material from their product using this magnet as well. The equipment passes a current through the coil within the machine creating a magnetic field. This in turn magnetizes the steel matrix inside the machine. As material passes through the magnetized matrix, any magnetic material gets caught and the non-magnetic material passes through. Once the matrix is full, the material is removed and the process continues. We have this equipment available for testing and toll processing.