A publication from Gencor Industries, Inc.

Fall 2008

COLD-WEATHER CHECKLIST Steps to take before winter’s arrival 6

D. Crupi & Sons Switching from a batch plant to an Ultradrum 16

Carrolls make a key purchase to preserve family businessFAMILY DISCUSSION

Innovations™ is published by High Velocity Communications Inc.. Publisher, Ken Snover • Editor, Pete Kennedy • Art Director, Jason France • Director of Client Services, Kris Matz. Every attempt has been made to ensure specifications are accurate. Because specifications are subject to change without notice, check with us for the latest information. Some photography provided courtesy of Gencor Industries Inc. Gencor, its respec-tive logos and corporate and product identity used herein and Innovations are trademarks of Gencor Industries Inc. and may not be used without permission. Phone (407) 290-6000. High Velocity Communications Inc., 2444 North Grandview Blvd., Waukesha, WI 53188. Phone (262) 544-6600. © 2008 Gencor Industries Inc.. All rights reserved. Printed in the U.S.A. Volume 2 Number 3.

3

IN THIS

ISSUE

6

8

16

2

MANAGEMENT MESSAGE

Principled ownersIn today’s modern hot mix industry, we can learn a lot from traditional firms like F.R. Carroll and D.

Crupi & Sons, featured in this issue of Gencor Innovations. They raise issues that apply to most of us who are involved in family businesses—no matter what generation we belong to.

In the case of F.R. Carroll, they stuck to their principles of recognizing the need for long-term growth but doing so in a methodical and responsible manner. You might call it ultra-conservative in today’s modern age of fast-paced big business, but the outcome was all they expected and more, eventually investing in a new Gencor plant and never looking back.

D. Crupi & Sons is another valued Gencor customer—and another family business, now being run by second- and third-generation family members. Crupi recently switched from a batch plant to a drum plant—no small undertaking—and now are enjoying the benefits.

The leaders of these companies don’t make hasty decisions. They research, evaluate and analyze—and then make sound business decisions they know are going to pay off big down the road. Being selected as the plant manufacturer of choice for these firms with such extensive industry knowledge is a great source of pride for all of us at Gencor.

We also feel a certain kinship with these companies because Gencor, too, is a family business in many ways. We still face the same types of challenges that so many of our customers encounter. When do we invest in new technology? Where will the industry be in five years, ten years, twenty years—and how do we prepare our operations?

Those can be awfully tough questions, but the answers get a little easier when guided by a strong set of principles and the desire to seek expert advice from professionals who can help guide you through the process.

As Cosimo Crupi said of his father, and the business’ founder, “He believed in providing good work, paying your bills and always looking ahead—always progressing. Those are principles we follow to this day.”

There is no question that the hot mix industry has evolved in the last couple of generations, but one thing that hasn’t gone out of style is a strong set of traditional business principles.

I like to think of it as just good business.

Marc ElliottPresident

Gencor Inc.

DEPARTMENTS Gencor News 4

6 Cold-Weather Checklist

Steps to Take Before Winter’s Approval

8 Family Discussion

Purchase Helps Carrolls Grow Business

12 A ‘Green’ Solution

Systems Reduce Emissions and Fuel Consumption

15 Tons of Attention

Pink Truck Raises Eyebrows—and Money

16 Still Looking Forward

Crupi Benefits from New Technology

and Old-Fashioned Beliefs

GENCOR INNOVATIONSFall 2008

NEW AND IMPROVED

4

GENCOR NEWS

4 5201 North Orange Blossom Trail Orlando, Florida 32810 T 407.290.6000 www.gencor.com

S.W.A.TSUCCESS WITH ADVANCED TRAINING

SECURE YOUR POSITION NOW! CLASS SIZE IS LIMITED.

OPERATION: TRAINING

Be prepared. Be equipped. Be ready. Achieve success for your plant by making sure your team attends the Gencor Advanced Training School 2009. Our expert instructors provide step-by-step comprehensive and concentrated training on our state-of-the-art control simulation and plant equipment. Benefi t from our advanced knowledge and expertise in the science and technology of hot mix asphalt production. Then get ready for success!

BE AWARERegistration due by December 19, 2008. Classes begin on January 12, 2009.

BE INFORMEDAll details can be found at www.gencor.com/SWAT2009407.290.6000 x342

2009 CLASSES:Week 1 Basic Course: Jan. 12-15, 2009

Week 2 Advanced Course: Jan. 19-22, 2009

Week 3 Advanced Course: Jan. 26-29, 2009

Week 4 Advanced Course: Feb. 02-05, 2009

117980_GencorTrainingAd_V2.indd 1 10/20/08 5:39:22 PM

Gencor Board

The Board of Directors of Gencor Industries Inc. has elected Dennis Hunt to the position of Senior Vice

President over Sales and Marketing.Hunt joined Gencor in January 2005

as Vice President and was responsible for developing and strengthening relations with customers. He also led efforts to aid producers in reducing

energy costs during this time of soaring energy prices.“Dennis has done an outstanding job of creating a nationwide

awareness in the roadbuilding industry of the importance of energy conservation and good practices in the operation of asphalt plants, showing operators how to reduce energy consumption, improve the quality of hot mix asphalt for our highways, extend the life of the plant equipment, and significantly reduce the environmental

impact of asphalt plants,” said Marc G. Elliott, President of Gencor Industries. “Dennis has been addressing plant production and energy conservation issues, as well as the introduction of Warm Mix Asphalt, with the passion of a ‘True Green Missionary.’”

Hunt brings to Gencor over 30 years of experience in all-around operations, sales, and management—all areas related to Gencor’s core business and markets. Before joining Gencor, Hunt served as Vice President of Asphalt and Readymix Operations for Vulcan Materials Company, Western Division, with headquarters in Los Angeles, and was a principal and officer with Industrial Asphalt Corp.-Calmat.

He also has served as Chairman of the Northern California Asphalt Producers Association. Hunt’s grandfather, Wallace E. Hunt Sr., founded Industrial Asphalt in 1941, and the Hunt family built Industrial Asphalt into one of the largest producers of hotmix asphalt in the United States.

GENCOR.COMOur website is new and improved—and

designed to make useful information even easier for you to find. If you’re on the hunt for top-quality equipment,

there is a complete listing of new products—plus a comprehensive list of used equipment.

The site provides you with effortless navigation to parts, service and Gencor Green products. Another feature is an easy-to-locate link to our popular training program. And, last but not least, you can register to receive your free copy of the quarterly Gencor Innovations when you visit the site.

Stop by Gencor.com and see how new and improved we are.

ELECTS VICE PRESIDENT

Steps to take before winter’s arrival

76

PRODUCT SUPPORT

For many contractors, the end of the year means shutting down the plant and preparing for a long winter ahead. But, before this shutdown process can begin—and while the plant is still operating—a good

maintenance practice should involve an equipment checklist to aid in a quicker spring start-up.

Equipment that has deteriorated due to age and wear will need to be replaced before spring startup, and now is a good time to order and have the materials on hand—possibly at a better price today, as steel prices are still fluctuating.

Also, consider the toll that the year-end push has taken on equipment. Items that were new at the beginning of the season might need to be replaced, especially where hard aggregates are used as normal course. Not replacing wear items in a timely fashion can cause undo wear on other components. You are typically ahead to change wear parts that have less than 50 percent life rather than risk a breakdown mid-season.

A thorough look back to the beginning of last spring is always a good place to start. Think about the areas of the plant that needed attention so you can hit the ground running when the weather warms up. Here are some common steps that we recommend when winterizing your plant:

n Place low-cost shrink-wrap plastic and grease on all exposed unpainted metals such as air rams, motor shafts and other components.

n Take a look at above-ground wiring, making sure it is still properly protected. Portable plant cable should be stored in neat coils with plywood beneath the wires. Cover the wires with a canvas or plastic tarpaulin. Also cover the plug connectors from the elements. (Tip: plastic wire markers OEM style can be ordered from our parts department.)

n Underground wires should not be near trapped water and should be covered to prevent ice from forming.

n Equipment junction boxes should have a weep hole in the bottom to prevent water from condensing inside. Special cone-shaped screens are available that allow for a bigger opening and keep rodents and pests out.

n Gearboxes (and any other equipment on the plant that has a large amount of airspace) should be drained. This can prevent problems such as seal leakage and gear reducer failure. Adding a vapor phase corrosion inhibiting

CHECKLIST oil, such as the VCI-105 oil by Daubert Chemical Co., can be helpful. Once again the plastic shrink-wrap and grease or a waxy alternative should be used to seal out moisture. The VCI oil does not need to be removed before refilling the reducer with oil in the spring.

nPut plywood over the exhaust stack to prevent rain and snow from entering the stack and exhaust fan. Also make sure the drain plug on the exhaust fan is open.

nCheck the rain cover on the hot oil heater exhaust stack.

Other maintenance preparations

Some of the lesser-known preventative measures and observations include:

nA temperature reading of all bearings (regardless of size) at the plant.

nA vibration analysis on key components.

nUse a thickness gauge on silo sidewalls and cones to determine metal thickness. Do the same for dryer shells.

COLD-WEATHER

nDue to the high price of asphalt cement, many contractors fill their AC tanks in the fall for spring use. Is there room for expansion? Also check the hot oil or electric heat elements for proper operation.

nFuels and lubricating oils are susceptible to water. Some waste oils can have small amounts of water in them, which separates over time. Water will need to be drained from the fuel lines and storage tanks in the spring (if it’s stored over the winter). An alternative would be storing #2 diesel for start-up, then switching back to waste oil— though water would still have to be drained.

n Test the components. When purchasing a “spare” component, either electrical or mechanical, install it or test it to make sure the part being stored works. This will ensure you have a properly working part when you need it, and also allow you to take advantage of any warranties—should the part fail.

Do you have questions, or want some help? Contact our parts and service switchboard at 407-290-6000 ext. 322. Literature for your specific product also is available.

By John Hynes Product Support TechnicianGencor Inc.

Are you planning to paint this year? Make sure your peeling paint isn’t a sign of bigger trouble—and that the new coat will last.

Peeling paint in horizontal ductwork on parallel flow plants is an indication of a blockage—especially if the paint is peeling on one side. If you’re putting a new coat over a blocked area, you could be masking a problem, and creating more work because the fresh coat will peel.

Another reason for the peeling could be improper heat transfer. It can show up in other areas such as breechings and transitions.

Keep a close eye on peeling surfaces and you’ll have a better working, and better looking, plant.

BEFOREYOU PAINT

MAINTENANCE TIP

Carrolls make a key purchase to preserve family business

9

Eventually, all three Carrolls agreed to investigate the purchase of a new asphalt plant. They evaluated and settled on equipment in the same deliberate fashion in which they conduct all their business. “We take our time and do it right,” Frank II said.

Growth increases demandThe discussion began in the late 1990s. The asphalt division

of the company had started in 1986, shortly after Frank II arrived at the business. The division originally supplied materials to outside customers, but that changed with an acquisition that gave the firm a paving crew.

“We had a two-ton plant,” Frank II said. “It was fine before we had the crew. But the crew was successful, and we started getting more and more business—and started doing DOT work, which

Continued on page 10

8

CUSTOMER PROFILE

FAMILY DISCUSSION

In some circumstances, it would have been a generational clash with a less than positive outcome. Instead, it became a collective decision that will

help preserve a family business for years to come.

Frank Carroll, the founder of the company that bears his name, had built a successful business from scratch. He had done so slowly and steadily, so he needed some convincing when his son, Frank Carroll II, said it was time to buy a new plant.

“We’re a small business, we don’t have the deep pockets that some do,” said Frank II. “We had to strategically plan.”

The Carrolls—including another son, Michael—addressed the issue. It took some discussion, but Frank Sr. was persuaded.

Ultimately, he also realized the company was at a crossroads. Its asphalt lay-down business had grown substantially, meaning outside customers were having mix supply problems. More urgent was the situation with company crews, which were putting in longer days because of the existing plant’s limited capacity.

“My father would tell me I had to go home and not work all day, and that the crew should go home too,” Frank II said. “I would tell him that wasn’t efficient.”

In many instances, the crew would be in the middle of a job that only needed another 100 tons or so to complete the work. “I wasn’t going to knock off and then go back the next day and lay 100 tons,” Frank II said. So the work continued, late, until the job was done.

Location: Limerick, Maine

Employees: 65

Business: The company is a manufacturer of Redi-Mix Concrete, asphalt and aggregate materials.

History: F.R. “Frank” Carroll and his wife, Barbara, started the business in 1952. Frank still works at the business, as do three of his children: Michael, F.R. Carroll II and his youngest daughter, Kathleen Colby.

On the Web: frcarroll.com

F.R. Carroll Inc.

The Carrolls: Michael, Frank and Frank II

At AglANce

““

1110

CUSTOMER PROFILE

required a lot of Superpave. Changing mixes became more of an issue, and we ended up hogging our own plant.”

By 1999, the laydown business had grown by 50 percent. “We still had a two-ton plant,” Frank II said.

That’s when the Carrolls started to discuss expanding.

The decisionThe Carrolls agreed there were

some advantages to expanding. A larger plant could more quickly provide material for the crews and reduce the length of the work days.

“My father realized I probably wasn’t going to change my ways,” Frank II said. “I wasn’t going to start carrying 100 tons over to the following day. It didn’t’ make sense.” The way to make the crews more productive was to deliver more asphalt during the course of the day. This would keep the paver moving more steadily and end the work day sooner.

There were other advantages to finishing jobs more quickly for F.R. Carroll crews. The Carrolls felt confident they could sell more mix if they could produce it.

“We all could see the need,” Frank II said. “It was just a matter of us being a small company. But we asked ourselves, ‘Where are we heading, and what are we going to do?’”

They decided to explore a purchase. They looked at a new plant, but also evaluated what other areas of the business would be affected.

“Internally, we had to restructure crushing so we could feed aggregate to a bigger plant,” Frank II said. “That took about three years.”

Next, the firm “took a break financially,” Frank II said, and built up cash for another three years.

Meanwhile, they thoroughly examined their plant purchasing options. They found some manufacturers were more interested in pushing products rather than helping the Carrolls find the right equipment.

Sticking with a batch plant“We wanted a batch plant,” Frank II said. “We

change mixes a lot. It’s not uncommon to have two crews out there and run four or five mixes a day.”

The company and its employees also were comfortable with a batch plant—and it showed. “We were very successful with our early batch plant,” Frank II said. “Our paving crews regularly earned bonus pay for hitting specs, and that starts with a quality mix.”

Other companies repeatedly tried to push a drum plant. The Carrolls listened to the sales pitches for a while, but eventually grew weary of trying to convince a sales rep that a batch plant was the way to go.

“Gencor never did that,” Frank II said. “They

understand the business enough to know that there are times when a batch plant is the best fit, and they sold us one.”

The knowledge didn’t end with the sale. Gencor found a way to make the larger plant (4 tons) fit on the existing footprint.

The plant went online in June 2007, about eight years after the discussions began. “The transition was very good,” Frank II said. “Gencor provided four really good installation specialists

with outstanding knowledge and a great work ethic. They got us up and running.”

An unqualified success“It’s working well,” Frank II

said. “We love it. It’s given us the production we’re looking for and shortened our days. Before we weren’t getting asphalt to the jobsites fast enough. Now we are. Instead of producing 1,200 tons a day, you can deliver 1,800 tons to

the crew—in about the same time.”Just as important, F.R. Carroll Inc. is once again meeting

the needs of its outside customers. “We lost some business because we couldn’t supply them,” Frank II said. “Now we have them back.”

The increased crew productivity, combined with the outside sales, is making the investment pay off quickly. “Last year was our biggest ever in terms of customer sales,” Frank II said.

Not too many years ago, the Carrolls were debating whether to expand. Their internal discussions now don’t include a debate over whether they made the right move—all agree they did. “My father will tell you it’s the best thing we ever did,” Frank II said.

The Gencor batch plant F.R. Carroll Inc. began operating in June 2007 offers many benefits. Among them:

nBetter Built. “There are great improvements in engineering,” said Frank Carroll II, vice president of the asphalt division of the company. A new style baghouse features counter-flow cleaning air. “That gives the plant more air to run,” Frank II said. “We also don’t have compressed air lines freezing up in the cold weather.”

nFuel eFFiciency. “The burner is fuel-efficient and user friendly,” Frank II said. “It’s at least 20 percent more fuel efficient than our old burner.”

nreDuceD eMiSSiOnS. Gencor products have come a long ways in terms of reducing emissions as well. “We run a clean operation, and want to be a good neighbor,” Frank II said. The lower emissions also make business sense. “When you’re a good neighbor, you don’t get any trouble,” he said. In fact, the company had no problems when it recently applied for air emissions licensing.

BeNeFITSNeW PlANT

of the

nDOwntiMe avOiDeD. “We can’t afford downtime,” Frank II said. “We literally shoot to lose only a few hours throughout a year, not days, and this plant is reliable.”

nQuiet. “This new plant is a lot quieter,” Frank II said. “We insulated the dryer shell. That prevents heat loss and reduces noise. The baghouse doesn’t use compressed air to clean the bag, so there is no sound of air blasting. “The burner is quieter too. The whole plant runs quieter. People notice—it’s one of the most frequent comments I receive.”

nPrOPer training. Gencor training opportunities have helped crews take advantage of the new equipment. “We ran our plant for a year, and then went to Gencor’s training school,” Frank II said. “Based on that experience, we could ask better questions and come back with a lot more knowledge. I highly recommend going to a Gencor training school.”

“We change mixes a lot. It’s not uncommon to have two

crews out there and run four or five mixes a day.”

An F.R. Carroll truck filling up with

fresh warm mix from the new

Gencor plant.

GEncOR ULtRADRUM™

The Ultradrum has allowed

Frank Carroll Inc. to crank out

up to 1,800 tons of asphalt

each day. This allows them

to take on more business

and keep their own crews

working more efficiently.

Equinox™ and Vector™ systems reduce

emissions and fuel consumption

1312

NEW TECHNOLOGY

By Joe Mollick Manager, Mechanical EngineeringGencor Inc.

A ‘GREEN’ SOLUTIONWITH AN ADDED BENEFIT

It doesn’t get much tougher than meeting the ultra low NOx requirements of Southern California. Yet the Gencor Equinox™ Burner System, combined with the new Vector™ Burner Control, does just that. If that

combination can pass the tough emissions requirements of Southern California, it no doubt can do the same at your location.

The Equinox Burner and Vector Control provide the most environmentally advanced system available. Key to the “green” component of the system is burning less fuel—which also reduces your operating costs. In other words, the Equinox and Vector can make your operations more green while reducing energy costs at the same time.

The Equinox combustion system can be used in any rotary drying process that requires between 23 million and 200 million Btu/hr of heat release. The magic in NOx reduction involves either reducing flame temperature or reducing

the amount of time that a flame remains above a certain temperature. Most conventional HMA burners require large volumes of Flue Gas Recirculation (FGR) to effectively lower peak flame temperatures, which can reduce usable plant exhaust capacity by as much as 20 percent. In addition, the introduction of FGR also increases drum gas velocities that result in increased fines carry-out, overloading the exhaust system and prematurely wearing out plant components.

The Equinox combustion system is designed to significantly reduce (or even eliminate) the need for FGR through a patented two-staged process. The unique design of Equinox incorporates a sophisticated pre-mix accumulator that prepares the gas/air mixture, prior to combustion, to ensure a lower peak flame temperature in the combustion zone. The second stage involves the introduction of a very small amount of water, by way of a patented injection system, to the hottest areas of the flame. This feature provides for much more stable combustion through the use of latent heat evaporation, thereby having little or no effect on the plant’s exhaust system.

Control is crucialIn addition, the need for control equipment as up-to-date as

the burner design itself is crucial. A good control system should produce consistent emissions results so the NOx target can be met. It’s not something you can leave to chance anymore.

The operating flame temperature in the HMA process and air-to-fuel ratios will have a significant impact on NOx formation. Control systems simply have to operate with much greater precision than ever before. The Gencor Vector Burner Control system places a servo motor on each of the burner operating mechanisms and maintains constant, exact, repeatable vigilance of the burner—from light-off through high-firing and full plant production.

The Vector can digitally set the physical minimum and maximum positions for each servo-positioner, for both air and fuel. This feature enables the operator to set the optimum air-to-fuel ratios through 10 user programmable points, creating characterization sets across the entire plant operating range. The Equinox and Vector work in concert to achieve the lowest NOx target mandates, but in a consistent repeatable manner. “Repeatability” is where most low NOx burners fall short.

Fuel efficiency can be maximized because of a systematic approach that ensures emissions are not only consistently low, but maintained between tune-ups.

Continued on page 14

Factoring in COThe air quality districts of California not only require low

emissions of NOx, but carbon monoxide (CO) as well. You likely already are, or soon will be, facing similar regulations.

To produce minimal NOx emissions, plants must produce minimal carbon monoxide emissions. The burner and control system will deliver the required emissions, but the asphalt plant must be in good operating order to allow the system to make it happen. The Gencor approach is to look at the HMA plant as a complete system. The plant equipment must have the ability to make hot mix and carry away the steam and products of combustion that are produced by the burner inside the rotary dryer.

It’s always a good idea to perform the following plant equipment review:

Plant exhauSt SySteM. The plant air flow needed must match plant production. Adequate exhaust is needed on the rotary dryer to insure the atmosphere inside can be maintained at a negative pressure—in turn ensuring the products of combustion and steam can be carried away. The plant exhaust system must be sized sufficiently to meet the expectations of the operator for producing mix at the rate desired based on the moisture of the aggregate materials. A baghouse and exhaust fan in good working order is one of the main components of a successful low NOx system.

Plant exhauSt DraFt cOntrOl. The plant exhaust fan damper or VFD control must

be in good working order in automatic mode. All burners and especially a

burner system that is designed to ensure low emissions can only operate successfully as

long as a consistent plant draft is maintained inside the rotary dryer.

GEncOR EqUinOx™ BURnER SyStEM

15

L IFESTYLE

14

PRODUCT SUPPORT

cOMBuStiOn vOluMe. The rotary HMA plant dryer must be able to allow adequate combustion volume for complete burning of the fuel to insure maximum fuel utilization and reduce the CO emission. This concept has been preached for years, but is now more important than ever. If not, aggregates falling through the fire produced by the burner may interfere or stop the combustion process, causing the production of CO. The result is wasted fuel. In order to maintain low emissions of NOx, low emissions of CO are mandatory. Keep in mind, dust causes CO formation in HMA dryers as aggregates interfere with the sensitive combustion reactions taking place in the rotary dryer. It is impossible to completely eliminate dust interaction with the combustion process, but one must make every effort to insure adequate combustion volume is available to facilitate complete burning of the fuel. Also, there is an added benefit: You will save money on fuel costs.

cOMBuStiOn vOluMe FlightS. The design theory of combustion volume flights deviates when dealing with low CO formation to achieve low NOx emissions. As mentioned in the above reference, dust produces CO when it mixes with the combustion reaction. Therefore, the combustion flight desired in the sensitive area of combustion reaction should be one that does not stir up dust. Many of the existing combustion volume flights presently in dryers can be modified to achieve this result. Gencor’s low NOx combustion flight can be installed into the combustion zone of any dryer to reduce the interference of dust with the combustion reaction.

DruM DiScharge FlOP chuteS On Batch PlantS. When a low NOx burner system is installed onto an HMA batch-type plant, it is imperative to make sure the drum material discharge chute is equipped with a working flop chute. If not, hot dust can be pulled up the discharge chute by the plant exhaust system. This dust will interfere with the combustion process, which is in close proximity.

natural gaS regulatOr. The natural gas piping and regulator needed to deliver gas to the burner system must be properly installed and capable of holding a constant supply pressure to the burner head. Pressure fluctuations will cause spikes in emissions of both CO and NOx.

Burner cOntrOl SySteM. Whether a new control system is added, or an existing control is utilized, it must be in good working order when a new low NOx burner is installed. Carbon monoxide emissions occur when a burner is in firing rate transition. Every time a change in burner position or firing rate occurs, the combustion process is interrupted, causing a momentary increase in the emissions of CO. The combustion control should not be fluctuating, and every effort to tune the control so it draws a straight line on the temperature chart is required. Remember, CO emissions affect the ability to control low NOx emissions.

Following the fundamentals of low NOx and CO are universal when it comes to HMA facilities and can bring added economic benefits to the operating performance of your overall plant while meeting new emission requirements. Gencor’s experience and know-how in this area is extensive, and we have successfully installed Equinox burner systems in the most stringent states meeting the lowest NOx and CO requirements.

Gencor’s continued commitment to innovation is what has led to developments such as the Vector and the Equinox combustion system. The renewed movement toward “green” technologies will continue to benefit HMA producers through improved fuel efficiency, higher production and the lowest possible operating costs.

VEctOR BURnER cOntROL

TONS of ATTENTIONPink paving truck helps firm raise thousands for charity

A business going “green” is one thing. But going pink?Gazzola Paving Ltd. did exactly that when it had a tri-axle dump truck painted pink to raise money to fight breast cancer.

“It got a lot of attention,” said Virgil Gazzola, operations manager of the company, with headquarters in Etobicoke, Ont.—near Toronto. The stares came from both inside and outside the company. “When the guys first saw it, everybody was shocked,” Virgil said. “Then it was positive. Everybody loved it.”

The colorful fund-raising effort started a few years ago, when Pam Gazzola, the wife of vice president Vern, and their daughter Virginia walked to raise funds as part of “The Weekend to End Breast Cancer.” During the walk, Pam and Virginia talked about ways to get others involved. By the time the ideas had been bounced around, an attention-grabbing plan emerged.

“They wanted to paint a truck pink,” Virgil said. “We thought it was a great idea.”

The walkers thought a salt truck would be a nice touch, but Vern had a bigger target in mind and gave orders that the tri-axle undergo the paint job.

“He just put his foot down,” Virgil said of Vern. “He’s a pretty demanding guy. He sent it to the body shop and painted it pink.”

The truck returned to the company, and at first “nobody could figure it out,” Virgil said.

Eventually they learned of the plan, as did those who do business with Gazzola Paving. Company officials asked business associates to donate $2,000 to “The Weekend to End Breast Cancer” cause. Companies that made the donation were

rewarded by having their logo placed on the pink truck—a most visible site as it traveled from one job to another.

It wasn’t long before the truck was doing most of the heavy lifting for the fund-raising. “Everybody started calling me and asking about it,” Virgil said. “Everybody wanted to know what it was.”

Those inquiring were told how they could help the cause—and many did. By the time the fund-raising was over, Gazzola Paving was able to send a check for $64,000 to the Princess Margaret Hospital Foundation in Toronto—the organization charged with turning “The Weekend’s” proceeds into results.

The efforts were fun and helped a good cause, but Virgil said the company wouldn’t make a habit of it—though it continues to donate to many other charities. “It was a one-off thing,” he said. “We don’t want to keep asking for contributions every year. It was sort of a novelty, doing it that once, and it got a lot of attention.

“The response was great, and we appreciated the participation by the other companies who paid to have their logos on the truck. While we won’t be asking them for more contributions, we’ll continue to support a variety of charitable organizations—even if you don’t see a pink truck driving around town.”

GAzzOLA PAVinG LtD. PLAnt in EtOBicOkE, OntARiO

The Vector Burner Control

is the most environmentally

advanced combustion

system, satisfying the most

stringent HMA facility NOx

emission requirements of

Southern California.

A company rich in history ready for change

16

CUSTOMER PROFILE

17

COMING A LONG WAYAND STILL LOOKING FORWARD

Asphalt manufacturer D. Crupi & Sons has come a long way, as proven by the company’s most recent plant purchase. “We had to close down an older plant, and needed a modern facility,” says Cosimo Crupi,

president of the company.Modern is what they got. The purchase was a departure

from the batch plants they had operated since 1971. It comprised a state-of-the-art facility, including a new 400-ton Gencor Ultradrum, Gencor baghouse and cold-feed system. The new plant also featured seven silos. One of the silos is the QuikDraw, which drops three loads of mix simultaneously, saving time for both plant operators and truckers.

It’s an impressive plant, as any visitor can tell you. But what might be most impressive is how far the company has come. “Celebrating 50 years in business is a great tribute to my father, Dominic Crupi,” says Cosimo.

Headquarters: Toronto, Ont., Canada

Founded: 1951, by Dominic Crupi

Plants: Four in the greater Toronto area

Employees: 300

Business: Specializes in road construction, crushed concrete, aggregate sales, asphalt sales, paving services and large-space snow removal

The journeyDominic Crupi arrived in Canada during 1949. “He was

virtually penniless and spoke no English at all,” Cosimo says. “But he had an idea, he had the drive and the energy, and he had the support of his wife, Maria. With all that, he was able to start a company that has grown in size and stature.”

Maria’s support was crucial. Dominic left for Canada in 1949, and she and their three children stayed behind in Italy

until Dominic could get on his feet. “It would be two years before he saw his family again,” Cosimo says.

Dominic worked on his uncle’s farm near Toronto. The city was growing, and he soon found a side job taking on concrete work. “He traveled to each new job in a streetcar,

carrying his tools in a sack,” Cosimo says.In 1951, a few months before his family arrived, Dominic

bought a used GMC dump truck. “It would be some time later before Dominic decided that he needed to get a driver’s license to go along with the truck,” Cosimo says. Regardless, the purchase was made and D. Crupi & Sons was born.

The concrete work continued, as did another specialty: raising houses to add a basement. It was dangerous work—and another sign that Dominic could spot a business trend.

Customers began to ask Dominic to pave their driveways. He soon bought a half-ton roller and, from that point on, asphalt paving increasingly became the business focus.

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D. Crupi & Sons

At AglANce

cOSiMO AnD DOMinic cRUPi

A true family businessDominic continued to grow the business. Maria, meanwhile,

handled the books and kept an eye on the children (there now were five). The two older sons, Cosimo and Mike, helped their father on weekends.

Cosimo, now the company president, joined the firm full-time in 1963, while Mike came on board in 1965. The two were involved as the company began to acquire more equipment and land. In 1971, they opened their first asphalt plant—a 5,000-pound batch plant operation.

The growth continued, with more plants added along the way. It’s a trend that has carried on to this day, with the purchase of the Gencor Ultraplant a few years ago. Today, Crupi & Sons owns four plants, is owned by Cosimo, and employs two family members: Cosimo’s son Dominic, and oldest daughter, Maria. They carry the name of the business’ founder—and his wife.

The younger Dominic likes the family business, and

continuing the traditions started decades earlier. “I’ve worked really closely with my father, and he has to be one of the best people in the industry to learn from,” Dominic says. “There aren’t many people who can teach like he can. He always has

something to share, and all kinds of tips and advice to give on the way we operate between the plants and the jobs.

“It’s a company with experience, and it helps our business. It’s an advantage.”

Dominic Crupi the founder continued to share his experience by visiting the plants and offices until he died in 1989 at the age of 77. Some of the operations, including the new plant, obviously look quite different today. Yet Dominic Crupi

the founder would still recognize his company because of its commitment to the principles he established a long time ago.

“He believed in providing good work, paying your bills and always looking ahead—always progressing,” Cosimo said. “Those are principles we follow to this day.”

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CUSTOMER PROFILE

Wondering whether you should make the switch from a batch to a drum plant? D. Crupi & Sons recently did just that. The benefits make a difference on a daily basis, says Dominic Crupi.

1. Higher production at a lower cost.If you’re looking for the most tonnage at the lowest cost, the

drum plant is the way to go, Dominic says.The firm can produce 400 tons per hour in its Ultraplant.

“In terms of cost, I know a batch plant would cost significantly more for the same production,” Dominic says. “You’d also be looking at a very large batch plant in terms of area. With the continuous flow drum, you’re keeping all that mixing area in one small compartment of the drum. It’s a more efficient use of space.” And a lower cost.

2. Better integration of RAP.A continuous flow drum can better utilize recycled asphalt

(RAP) and create a more consistent product, Dominic says. “With the continuous flow, the RAP is given a longer mixing time with the aggregate and virgin AC. This gives you a more consistent mix when you’re using RAP.”

3. Efficient, consistent mixing.“The production rate, the space, the method of storage, are

all more efficient with the drum,” Dominic says. “You also end up with less segregation when you’re not doing a drop from a pug mill to a conveyor.

“You end up with more consistent mix in the silos, and you can get ahead of the job faster and keep a better inventory in your silo system.”

Making the switch? Consider these tips:nGet help from the experts. “For the most part, it was a pretty smooth transition,” Dominic says. Still, it was a big undertaking—and wouldn’t have gone quite so well without the proper experts on-site. “We had a really good startup pro from Gencor, and he helped us out a lot with that,” Dominic says. “We also had an operator who had dealt with Gencor plants at another company. Both made a big difference.”

nHaving another batch plant on site, or nearby, creates flexibility. While this isn’t always possible, D. Crupi & Sons’ business has benefited from having both types of plants. “It can be hard, with a drum plant, when you have a customer come in who wants a few tons,” Dominic says. “We tend to send our customers who are just doing a driveway to our batch plant. The customers who are doing larger jobs, 400 metric tons or more, we encourage them to utilize the drum plant. If they give us enough warning, we can store the materials and they don’t have to wait.”

nConsider buying the “options.” “I would advise taking a close look at all the options available with a plant, really weigh whether the options are worth the money,” Dominic says. You might be surprised at how many are. “There are some options that, looking back, we probably should have picked up,” Dominic says. “For example, the 0-speed switch in a few more locations, and vibrators on bins. “They’re little things, but the little things can add up. The best time to take advantage of those options is when you’re purchasing the plant.”

MAKINg SWITcHtheWhile there now are hundreds of employees, including the members of this asphalt paving crew, D. Crupi & Sons has maintained a family-type atmosphere since it was founded in 1951.

5201 North Orange Blossom TrailOrlando, Florida 32810

(407) 290-6000gencor.com