Design of flat die pellet mill,the expert of animal feed production
The feed pellet mill is designed in the early 20th century, which is designed to process feed pellets for livestock such as cattle, pig, chicken, etc. The purpose of pelleting is to improve feed handling and acceptance by our livestock. It can be divided into two types: flat die pellet mill and ring die pellet mill. Compared with ring die pellet mill, it have a high level of tolerance as compared to round die pellet it. Their tough design and body structure able to produce pellets of different raw materials that have variable characteristics.It features small volume, simple design and low capacity, so it is suitable for home use and small-scale production.
Structure of flat die pellet mill
Flat die pellet mill is mainly composed of press roller, flat die, feeder, gear bearings and power source.To be specific, a flat die pellet mill is constituted by a feed hopper, upper box body, adjusting nut, pellet outlet, spindle box, gear box, transmission shaft, foundation, wheels, electric motor, electric control cabinet. Meanwhile, the electric motor can be replaced by diesel engine, gasoline engine.
The design of flat die pellet mill
As the name implies, the pellet mill die is flat comparing with the ring die pellet presses.When you feed raw materials into the hopper of pellet mill, The pelletizing chamber distributes the feed stocks evenly across the face of pellet die.Pellet dies work along with the roller to execute the pellets during the process of pelletizing.The force of the roller acts on the feed stocks in contact with the die.This is where the rollers and the cross face of pellet dies press the feed stocks, consequently forcing them through the die holes to mold pellets. The pellets are usually cut off and shaped when extruded out of the pellet die.
There are two different working ways of flat die pellet mill: roller-turned type and die-turned type. The former one works as the roller rotates and the flat die keep still, while the second one works as the roller keep still and flat die rotates. Adopting vertical principle, raw material drops down into the working chamber depending on its own weight. When falling into this area, materials will naturally be compressed into pellet form between rollers and die through the die holes.Both of them are able to make qualified feed pellets. But Roller turned type adopts smarter structure and superior gearbox, so it has higher power and capacity, and the cost is higher.
Features of flat die pellet mill
Roller and flat die are the core part of flat die pellet mill. The roller is made of superior alloy steel. Its hardness is 55-60HRC, lower than that of flat die so as to prolong the working life of flat die. The roller is installed on a roller shaft which it also rotates around. The larger the diameter of roller, the larger the grabbing force it has on the raw materials. Meanwhile, the materials layer can be thicker to improve the production. The roller shaft has two roller on both ends, their clearance with the flat die should be the same. The equipment adopts screw central pressure adjustment device. You can change the clearance between roller and flat die to adapt to different materials so as to ensure the pelletizing effect. Zeno brand pellet mill adopts large-size and wide-slot rollers. They are durable with high loading capacity. To match up with the roller, the bearings are also enhanced with higher capacity. In this way, we prolong the working life of rollers bearings and reduce the production cost.
The core par is a disc flat die which is made of ductile cast iron,it with multiple holes and a roller with slots on the surface,the thickness, hole size and quantity have huge effect on the production quality and capacity. Flat die holes size should be chosen depending on desired pellet diameter. Each pellet mill can match a bundle of flat dies with different holes size, which allows to produce pellet with different diameters. The hole sizes of flat die are from 2.5mm to 10mm, and the 4mm,6mm, 8mm and 10mm are the most popular. They apply to different types of materials. You can make pellets of different diameters with flat die of different hole sizes.
Flat die pellet mill has simple structure. It is small, light and portable. The cost is much lower than ring die pellet mill. It is easy to operate and maintain. You can observe the pelletizing process and solve any fault in time. So it is popular with farmers, home users, and small feed production plant. The flat dies are wearing parts, the user need to replace it regularly. But this parts can be used with both sides. You can turn it over when one side has worn out. You can extend their working life and reduce cost of feed production. On the other hand, the moving distance are different in the inner and outer side of roller, which cause the slide of rollers and abrasion on the flat die. Currently, many flat die pellet machine adopt tapered roller to solve this problem. Zeno brand flat die pellet mill adopts tapered roller and superior alloy steel in the flat die. Due to the structure of the machine, rollers, and die, flat die pellet mills are easy to be washed, cleaned, and looked after as compared to the other types of pellet mills where you would have to put extra care and attention to clean the whole apparatus. Pelletizing chamber can be easily observed which makes it more convenient for the workers to observe the whole process of pellet formation. If a flat die pellet mill is not producing pellets or is producing a very small amount of pellets even after adding enough amount of raw materials, They don’t have to open the whole machine to observe the process, the workers can easily determine whatever the fault is in the machine.
The contact area of roller and flat die is smaller than ring die pellet mill, so the production capacity and forming rate is lower. Ring die pellet mill production capacity is from 800kg to 20t per hour. As for flat die pellet mill, the capacity is from 100kg/h to 1t/h. If you production requirement is under 1000kg, you’d better choose flat die pellet machine.For the capacity more than 1000kg/h , ring die pellet mill is more suitable.