Morbark, LLC

For Syracuse company, it`s all about spec grinding (with a serious twist) yields specialty soil blends for blowing

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Courtesy of Courtesy of Morbark, LLC

To the layman, making a soil capable of being applied by a blower truck would seem fairly rudimentary: take dirt, grind it, screen it and blow it. It's not rocket science, they'd say, and, at times, Cliff White wishes all that were true. The founder and owner of Syracuse, NY-based Ground Effects, Inc., has found - and proves it daily - that creating a soil product to meet a specific need, really is more science than art. His efforts to make that science work for him, however, have paid off nicely: Ground Effects is the premier source for blended soils and their application for almost all of New York State and surrounding areas. Using a specially-equipped Morbark Model 5600 horizontal grinder, some specialty screening, and a fleet of state-of-the-art blower trucks, Ground Effects has built a business which provides not just soil, but the right blend of soil for a range of specific applications. As a result, for a growing number of contractors, municipalities and various State agencies, they've become the go-to source for issues involving erosion control, soil remediation, and more. And White says they've really only just begun.

Making a Change
A tree and landscape professional by trade, Cliff White says he was already looking for something new and creative to add to the business when he stumbled upon an ad in a trade publication.

'Actually it was my girlfriend who was looking through some trade magazines and saw an ad for a blower truck. We had already done some research and knew a soil application business could work well in this area, but I didn't think that particular truck was the right answer. About six months later, she showed me another ad - this time for Express Blower trucks - and that time I felt they had what I wanted. I ordered one and was on my way to an apparent career change.'

Knowing that the basis for any soils creation effort starts with grinding, and already having a Morbark 1100 tub grinder for his existing business, White contacted Dale Webster at L.C. Whitford Equipment, the local Morbark dealer. This time, however, he was in search of a horizontal grinder.

'I needed a larger screen area and more of a direct feed capability, the very things a horizontal grinder offers,' he says. 'So we traded the Model 1100 in on a Model 5600 horizontal and it's been a very good move for us in terms of how well it fits into our operation and in overall production.'

Some Bumps in the Road
Making the transition from landscaper to soils specialist was not entirely painless. There was a learning curve - a steep one, says White - that had to be dealt with before customers could fully place their trust in his product.

'For the markets we serve, the spec is the most important factor and, quite frankly, early on we had some blends that just weren't what we set out to get. However, we worked hard at it, made the necessary adjustments to our process, and today, can provide a consistent blend of soil to meet virtually any spec.'

White says his customers include, among others: private contractors, the State Department of Environmental Conservation (DEC) and Department of Transportation (DOT), and area colleges and universities. Depending on the end use for the material, Ground Effects' products can range from a lightweight soil spec to create a 'green' roof; to a bioretention material for the state's highway department; to a material specially blended to provide good slope capability for the DEC.

'The materials we are called upon to provide differ by mineral content and gradation,' White says. 'A bio-retention material, for example, will be mostly sand, not much organic. A slope material, on the other hand will probably be 90% organic to reduce the chance of it washing away. In fact, we can do a 1:1 slope and guarantee that it won't wash or rill; the material is that stable and takes hold that quickly.'

Breaks: Getting Them, Making Them
As with most businesses, luck has played a certain role in Ground Effects' success to date. For example, their current location, adjacent to one of the busier highways in Syracuse, was something of an unforeseen bonus.

'Not long after we were in full swing, the Federal Government was doing an erosion control job in the area. At the time they were trying to process some huge piles of organic material that were left here by the City of Syracuse for that particular job. They found that they couldn't and asked us to come in and do it. We did and we've been here ever since. We have also been fortunate to have a solid, reliable source for more than 12,000 yards of soiled animal bedding - better than half our yearly volume - the material that serves as the 'feedstock' for much of our soils composting operation.'

That composting operation is, in itself, something of a departure from the norm, a move White says was driven by efforts to keep costs down.

'Every time you touch a material in this business, you add to the cost to process it,' he says. 'I see municipalities that are constantly turning and working windrows and think that doing so makes the process much more costly and inefficient. So I looked for a way to minimize handling during the compost operation and believe we've done that.'

White's approach involves feeding material through the Morbark 5600 and amending it using a specially-designed blending unit attached to the grinder. That newly ground and blended material is then sent to a 60-foot stacking conveyor which creates a huge cone-shaped pile. Unlike conventional composting techniques, however, that pile will not be touched again until it is ready to screened, further amended, if necessary, loaded into the blower trucks and delivered to the customer.

'We monitor the temperatures of the pile, and generally find that we can maintain temps of 150° to 180° and get the soil ready for regrind and amendment. It has been the foundation of almost all that we do here.'

Blow by Blow Success
Once material reaches maturity - White says the process can be shorter than most traditional composting techniques - it is either ready for use as is, or once again reground and amended to create specialty blend soils. Depending on the mix design being called for, the firm will add aggregates of varied sizes as well as different levels of urea, sulfur, water, gypsum, etc., to get the spec they need. They then screen it through an Erin StarScreen 200A finishing screen and load it into one of several blower trucks. Out in the field, an injection system on each truck meters seed and fertilizer into an air chamber, then mixes those with the soil as it exits the blower hose.

'The trucks do the application and they do an excellent job of it,' says White. 'However for us, it's really been the medium that has made the difference. Some people mistakenly describe what we do as Hydroseeding which is simply spraying a mixture over soil . Our process is actually called Terraseeding because we are delivering soil, seed and fertilizer all in one application. Because our soil is so rich, the germination rate is extremely short; we generally have grass out of the ground in seven days. In fact, if we leave soil in the feeders of the trucks overnight, we can usually see white roots in the soil by morning. And, because our piles are managed so well, all the materials are cooked, thereby killing all pathogens or weed seed. The customer gets lush, weed-free vegetation in no time at all.'

Greatly Appreciated
White's products - and his ability to apply them - have found ready acceptance throughout the region. Contractors and city crews alike appreciate the fact that he is able to come in after they've wrapped up and restore an area to even better condition than when they started.

'The trucks make a huge difference in what we are able to do for our customers,' he says. 'I recently had one of our units working in a development where the contractor had just done the blacktop. We came in to backup the curb, that is, fill in the areas between the newly-poured curb and the residents' lawns. The contractor said that, over the years, he has tried using slingers, used a skid steer loader - tried just about everything - and it's always been a nightmare. He couldn't believe how easy we made it look.'

Between the massive overhead with which he has to deal (their current blower trucks cost better than $300,000 apiece with new units pricing out at better than $400,000), and the specs they constantly have to meet and maintain, White says his is a challenging business. 'But I think we've done it the right way. Through a combination of reliable equipment, a willingness to learn, and a good solid customer base we've grown faster than I ever imagined. Most importantly, however, we have not sacrificed on quality one bit. Today we generate between 75,000 and 100,000 yards of product per year, and we are looking into doing some other things such as composting with food waste that will really change things again. But we're no strangers to change; that's just the way we like it.'

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