Capacity: 0.1-5 tons/hour
Granulation Type: Dry Granulation
Pellet Characteristics: Uniform cylindrical shape
Pellet Formation Rate: 95%
Suitable Materials: Suitable for dry or semi-dry powders (such as traditional Chinese medicine residues and dried, composted mushroom residues). Low hardness requirements are required.
The flat die is a horizontally placed circular steel plate with multiple circular holes evenly distributed across its surface. The inner walls of the holes must be treated with a wear-resistant finish to prevent wear and tear from long-term extrusion, which can cause the holes to widen. The flat die is fixed to the machine base, and some models offer height adjustment to control the gap between the flat die and the pressure rollers.
Press rollers: Rotating components mounted above the flat die in pairs. They are cylindrical or conical in shape, with a smooth or shallowly grooved surface. Driven by a motor and connected to a drive shaft via bearings, the rollers can adjust pressure adaptively based on material thickness.
Feed System: The hopper, located at the top of the machine, holds the material to be pelletized.
The Feed Screw/Dispenser, located below the hopper, uses a screw conveyor or rotating dispensing plate to evenly push the material between the flat die and the pressure rollers, preventing accumulation.
Drive System: The pressure rollers are driven by a motor and a reducer via gears or chains, and can be controlled by a frequency converter. Cutter device: A rotary cutter is installed under the flat die. When the material is squeezed out of the die hole by the pressing wheel to form a columnar strip, the cutter cuts it into particles of a set length.
Working principle of Flat Die Granulator：
Feeding Stage: Powdered or fibrous material enters the gap between the flat die and the compression wheel through a feeding device. Gravity and the push of a feeder fill the gap.
Extrusion Stage: The rotating compression wheel applies radial pressure to the material, forcing it into the die hole of the flat die. During this process, air between the material particles is expelled, and the fibers or powder entangle and bond, forming continuous, columnar strands within the die hole.
Forming and Cutting Stage: The columnar strands are extruded from the die hole below the flat die and then cut into pellets of uniform length by a cutter below. The density and strength of the pellets are determined by the extrusion pressure.
Advantages of Flat Die Granulator:
1. Strong Adaptability:
Suitable for coarse fibers and high-moisture materials, tolerant to small amounts of impurities, and boasts a high granulation rate.
2. Stable Pellets:
High density, resistance to breakage, regular shape, and adjustable density through pressure.
3. Low-Temperature Granulation:
Preserves the activity of microorganisms and heat-sensitive ingredients, making it suitable for organic fertilizers, feeds, and other applications.
4. Easy Maintenance:
Consumable parts (pressing wheel, flat die, and cutter) are easily replaced, resulting in a lower cost than ring die pelletizers.
Model | Capacity(t/h) | Power(kw) | Dimensions(mm) | Pellet Dimensions(mm) |
ASLPM-150 | 0.05-0.1 | 4.5 | 1000x360x550 | 2-10 |
ASLPM-160 | 0.1-0.15 | 5.5 | 1000x360x550 | |
ASLPM-180 | 0.15 | 5.5 | 1000x360x550 | |
ASLPM-210 | 0.2-0.3 | 7.5 | 1250x460x800 | |
ASLPM-230 | 0.3 | 11 | 1300x460x800 | |
ASLPM-260 | 0.5-0.6 | 15 | 1400x480x900 | |
ASLPM-300 | 0.8-1 | 22 | 1500x560x1100 | |
ASLPM-400 | 1.5~2 | 37 | 1850x750x1350 | |
ASLPM-500 | 1.5-2.5 | 55 | 2000x800x1500 |
What materials are suitable for processing? Are there any moisture content requirements?
It is suitable for organic fertilizers (such as straw charcoal and composted manure powder), feeds (such as soybean meal and straw powder), and biomass fuels (such as wood chips and straw). The material moisture content should be controlled between 8% and 15%. A moisture content that is too high can easily clog the die holes and soften the pellets, while a moisture content that is too low can increase pelletizing resistance and wear the die and rollers. High-moisture materials require drying first. Dry materials can be tempered by adding a small amount of water or oil.
Can the length and diameter of the pellets be adjusted?
Yes, they can. The pellet diameter is determined by the die hole size, and can be changed by replacing the die with a different hole size. The pellet length is adjusted by adjusting the distance between the cutter and the die or the cutter speed. It can generally be adjusted within a range of 3-15mm, meeting the pellet size requirements for different applications.
What are common operational faults? How can they be resolved?
Common faults include:
① Die hole blockage (due to high moisture content or impurities in the material); this requires stopping the machine to clean the die holes and increasing material screening.
② Insufficient pellet strength (too little pressure); the gap between the press wheel and the die should be adjusted (reducing the gap increases pressure);
③ Abnormal equipment noise (due to bearing wear or loose parts); the bearings should be replaced and the bolts tightened;
④ Motor overload (due to too hard material or excessive feed); the material should be crushed or the feed rate should be reduced.
Is it necessary to add a binder during the pelletizing process?
In most cases, no. Flat die pelletizers rely on strong extrusion, requiring low material viscosity. Even low-viscosity materials (such as sawdust and fly ash) can be pelletized. However, for extremely loose materials (such as lightweight mineral powder), a binder (such as starch or clay) of 1%-3% can be added to improve pellet strength and reduce breakage.
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