In the production of granulating machine pellets, sometimes irregularly shaped pellets may occur, and experienced feed manufacturers will know what the cause of the situation is and can be quickly eliminated, for inexperienced or new feed production. Manufacturers, sometimes can not find the crux of the problem, only ask the outside world or the help of the granulator manufacturer. The following are the reasons and improvement methods for the seven common abnormal material particles. This is the author's work experience in the development and commissioning of granulators for many years, for comparison and reference in feed production.
1. The phenomenon that the pellets are curved and exhibits many cracks on one side is usually produced when the pellets leave the ring mold. In production, when the position of the cutter is adjusted far from the surface of the ring mold and the edge is blunt, the particles are broken or torn by the cutter instead of being cut when being extruded from the die hole. There are many cracks on one side and the other side. Such pellets tend to break from these cracks as they enter the cooler for cooling or transportation, resulting in excess pellets produced.
Improvement method:
a) increasing the compression force of the ring mold on the feed, that is, increasing the compression ratio of the ring mold, thereby increasing the density and hardness value of the pellet material;
b) The feed ingredients are pulverized more finely. If molasses or fat is added, the uniformity of molasses or fat should be improved and the amount added should be controlled to increase the compactness of the granules and prevent the feed from becoming soft;
c) adjust the distance of the cutter from the surface of the ring mold. Usually, the distance from the outer edge of the cutter to the outer surface of the ring mold is not greater than the diameter of the feed pellets produced, or the sharper cutting blade can be replaced. For small diameter pellets, it can also be used. Thin blade and make the thin blade close to the surface of the ring mold;
d) The use of a bonding granulation aid helps to improve the bonding force inside the particles.
2. The horizontal crack across the entire pellet is somewhat similar to the phenomenon in Case 1. The crack occurs on the cross-section of the particle, but the particles are not bent. This can happen when granulating fluffy feeds containing more fiber. Such pellets tend to be granules in the cross-section of the cross-section due to the expansion of the fibers when the pellets are extruded into the granulation pores of the ring mold. Produces a bark-like appearance of the feed.
The improved method is to increase the compression force of the ring mold on the feed, that is, increase the compression ratio of the ring mold; control the fineness of the fiber, and the large length of the zui cannot exceed one third of the particle size; reduce the yield to reduce the feed through the mold. The speed of the hole increases the density; the length of the conditioning is increased, and the multi-layer conditioner or the kettle type conditioner is used; when the powder moisture is too high or contains urea, it may also produce a bark-like feed. Appearance should control the added moisture and urea content.
3. The vertical crack of the granular material contains fluffy and slightly elastic raw materials in some feed formulations. This raw material will swell and swell when it is tempered by the conditioner, and will be hydrated after being compressed by the ring mold. The effect and the elasticity of the raw material itself bounce open, resulting in vertical cracks.
The improvement is to change the formula, but it is possible to increase the cost of raw materials; to control the quality of the steam used in quenching and tempering, to use as much saturated steam as possible, so that the added water is reduced to as low as possible; Or increase the effective length of the die hole, as much as possible to increase the retention time of the feed in the die hole; adding adhesive also helps to reduce the occurrence of vertical cracks.
4. The granules produce a radiant crack from a source. This appearance indicates that the granules contain large granules. When these granules are tempered, it is difficult to fully absorb the water and heat in the water vapor, unlike Other finer raw materials are so soft to soften, and when cooled, due to the difference in the degree of softening, the difference in the amount of shrinkage is caused, so that radiant cracks are generated, so that the pulverization rate is increased.
The improvement method is to properly control the thickness and uniformity of the powdery feed material, so that all the raw materials can be fully and uniformly softened during the quenching and tempering.
5. The surface of the granular material is uneven. This is because the powder used for granulation contains large granules which are not pulverized or partially pulverized. Since the granules are not sufficiently softened during the tempering process, the granules are relatively hard and large. When passing through the die hole of the granulator, it is not well combined with other raw materials, making the particles appear uneven. Another situation may be that the quenched and tempered raw material is mixed with steam bubbles, and the steam bubbles cause the air bubbles to be generated during the pressing of the feed into the granules. When the granules are extruded into the ring mold, the bubbles rupture due to pressure changes. And unevenness occurs on the surface of the particles. This can happen with any fiber-containing feed.
The improvement method is to properly control the thickness of the powdered feed, so that all the raw materials can be fully softened during quenching and tempering; for the raw materials containing more fiber, it is easy to be mixed with steam bubbles, so do not add too much in this formula. Steam.
6. Whisker-like pellets When the pellets are produced, if too much steam is added, too much steam will accumulate in the fibers or powders, and when the pellets are extruded into the ring mold, the pressure changes sharply. The particles burst and the fiber or granule raw material protrudes from the surface to form a whisker, especially in the production of high starch, high fiber content feed, the more steam is used, the more serious the situation.
The improvement is in good quality. When we granulate high-starch, high-fiber feed, low-pressure steam (0.1-0.2Mpa) should be used to allow the moisture and heat in the steam to be fully released into the feed. If the steam pressure is too high, or the downstream pipeline after the pressure reducing valve is too short from the conditioner, generally greater than 4.5m, the steam will not release the water and heat well, so there is part of the steam accumulation. In the tempered feed ingredients, when the granulation is carried out, the whisker-like particle effect described above is caused. In particular, special attention should be paid to the pressure regulation of the steam and the installation position of the pressure reducing valve.
7, individual particles or individual particles are inconsistent in color, commonly known as "flower material"
This situation is more common in the production of aquafeeds, mainly because the color of individual particles extruded from the ring die is darker or lighter than the color of other normal particles, or the surface color of individual particles is inconsistent, thus affecting the appearance quality of the whole batch of feed. . The reasons for this phenomenon are mainly the following:
a) Due to the complex composition of aquatic feed ingredients, there are many kinds of raw materials, and some ingredients are added in a small amount. When mixing raw materials, if the mixing effect of the mixer is not ideal, it is difficult to ensure that the mixed raw materials entering the granulator are uniform. Therefore, in the process of quenching and tempering, under the combined action of moisture, temperature and pressure, physical and chemical changes occur in the raw materials, resulting in inconsistent color changes of raw materials of different components, resulting in "flowers". It is more prominent when the feed formulation contains sensitive changes in temperature and moisture.
b) The moisture content of the raw materials used for granulation is inconsistent. In the aquatic feed production process, in order to compensate for the loss of raw water after ultrafine pulverization, a certain amount of water is added to the mixer, and then mixed into the conditioner for quenching and tempering. Some feed manufacturers have a simpler process. Instead of using a special nozzle to evenly inject a certain amount of water directly into the mixer, it is difficult to evenly distribute the water after mixing. When the mixed raw material enters the conditioner to adjust the quality, it is impossible to further distribute the water evenly in a short time due to the conditioner. Under the action of steam, the ripening effect of each part of the feed after quenching and tempering is inconsistent, granulation. After the color change is also inconsistent.
c) Recycled material with heavy replicated particles in the granulation bin. After the granulated granules are cooled and sieved, they can become finished materials. The fine powder or small granules after sieving often enter the process and re-granulate, usually into the mixer or the granulation bin. Since this kind of returning material is re-tempered and granulated, if it is mixed unevenly with other raw materials after quenching and tempering or mixed with small pellets, sometimes "flower material" will be produced for some feed formulations.
d) The inner wall finish of the ring mold aperture is inconsistent. Due to the inconsistent mold hole finish, the resistance and squeezing force of the granules during extrusion are different, and the color changes are inconsistent. In addition, some of the ring mold holes have burrs on the wall, and the particles may scratch the surface when extruded, so that the surface color of the individual particles is different.
For the four reasons for the "flower material" listed above, the improvement method is clear, mainly to control the mixing uniformity of the components in the formulation and the mixing uniformity of the added water; improve the quenching and tempering performance, If necessary, control the quenching and tempering temperature, use a lower quenching and tempering temperature to reduce the color change; control the returning machine material, for the formula that is easy to produce "flower material", try not to return the machine material directly to granulate, should return the machine material and After the raw materials are mixed, the pulverization is repeated; the ring mold with a guaranteed quality is used to control the smoothness of the die holes, and if necessary, the die holes are sanded and then used.
In summary, for the unusual appearance of pellets in feed production, seven representative expressions are discussed above, and some of the appearance anomalies of the particles are not representative and are not listed here. As can be seen from the above discussion, the reasons for these phenomena are multifaceted and not completely isolated from each other. This requires us to analyze and grasp the key issues when dealing with such problems in actual work. Only then can solve the problem. I hope this article can help everyone.
(Source: Agricultural Network)
1. The phenomenon that the pellets are curved and exhibits many cracks on one side is usually produced when the pellets leave the ring mold. In production, when the position of the cutter is adjusted far from the surface of the ring mold and the edge is blunt, the particles are broken or torn by the cutter instead of being cut when being extruded from the die hole. There are many cracks on one side and the other side. Such pellets tend to break from these cracks as they enter the cooler for cooling or transportation, resulting in excess pellets produced.
Improvement method:
a) increasing the compression force of the ring mold on the feed, that is, increasing the compression ratio of the ring mold, thereby increasing the density and hardness value of the pellet material;
b) The feed ingredients are pulverized more finely. If molasses or fat is added, the uniformity of molasses or fat should be improved and the amount added should be controlled to increase the compactness of the granules and prevent the feed from becoming soft;
c) adjust the distance of the cutter from the surface of the ring mold. Usually, the distance from the outer edge of the cutter to the outer surface of the ring mold is not greater than the diameter of the feed pellets produced, or the sharper cutting blade can be replaced. For small diameter pellets, it can also be used. Thin blade and make the thin blade close to the surface of the ring mold;
d) The use of a bonding granulation aid helps to improve the bonding force inside the particles.
2. The horizontal crack across the entire pellet is somewhat similar to the phenomenon in Case 1. The crack occurs on the cross-section of the particle, but the particles are not bent. This can happen when granulating fluffy feeds containing more fiber. Such pellets tend to be granules in the cross-section of the cross-section due to the expansion of the fibers when the pellets are extruded into the granulation pores of the ring mold. Produces a bark-like appearance of the feed.
The improved method is to increase the compression force of the ring mold on the feed, that is, increase the compression ratio of the ring mold; control the fineness of the fiber, and the large length of the zui cannot exceed one third of the particle size; reduce the yield to reduce the feed through the mold. The speed of the hole increases the density; the length of the conditioning is increased, and the multi-layer conditioner or the kettle type conditioner is used; when the powder moisture is too high or contains urea, it may also produce a bark-like feed. Appearance should control the added moisture and urea content.
3. The vertical crack of the granular material contains fluffy and slightly elastic raw materials in some feed formulations. This raw material will swell and swell when it is tempered by the conditioner, and will be hydrated after being compressed by the ring mold. The effect and the elasticity of the raw material itself bounce open, resulting in vertical cracks.
The improvement is to change the formula, but it is possible to increase the cost of raw materials; to control the quality of the steam used in quenching and tempering, to use as much saturated steam as possible, so that the added water is reduced to as low as possible; Or increase the effective length of the die hole, as much as possible to increase the retention time of the feed in the die hole; adding adhesive also helps to reduce the occurrence of vertical cracks.
4. The granules produce a radiant crack from a source. This appearance indicates that the granules contain large granules. When these granules are tempered, it is difficult to fully absorb the water and heat in the water vapor, unlike Other finer raw materials are so soft to soften, and when cooled, due to the difference in the degree of softening, the difference in the amount of shrinkage is caused, so that radiant cracks are generated, so that the pulverization rate is increased.
The improvement method is to properly control the thickness and uniformity of the powdery feed material, so that all the raw materials can be fully and uniformly softened during the quenching and tempering.
5. The surface of the granular material is uneven. This is because the powder used for granulation contains large granules which are not pulverized or partially pulverized. Since the granules are not sufficiently softened during the tempering process, the granules are relatively hard and large. When passing through the die hole of the granulator, it is not well combined with other raw materials, making the particles appear uneven. Another situation may be that the quenched and tempered raw material is mixed with steam bubbles, and the steam bubbles cause the air bubbles to be generated during the pressing of the feed into the granules. When the granules are extruded into the ring mold, the bubbles rupture due to pressure changes. And unevenness occurs on the surface of the particles. This can happen with any fiber-containing feed.
The improvement method is to properly control the thickness of the powdered feed, so that all the raw materials can be fully softened during quenching and tempering; for the raw materials containing more fiber, it is easy to be mixed with steam bubbles, so do not add too much in this formula. Steam.
6. Whisker-like pellets When the pellets are produced, if too much steam is added, too much steam will accumulate in the fibers or powders, and when the pellets are extruded into the ring mold, the pressure changes sharply. The particles burst and the fiber or granule raw material protrudes from the surface to form a whisker, especially in the production of high starch, high fiber content feed, the more steam is used, the more serious the situation.
The improvement is in good quality. When we granulate high-starch, high-fiber feed, low-pressure steam (0.1-0.2Mpa) should be used to allow the moisture and heat in the steam to be fully released into the feed. If the steam pressure is too high, or the downstream pipeline after the pressure reducing valve is too short from the conditioner, generally greater than 4.5m, the steam will not release the water and heat well, so there is part of the steam accumulation. In the tempered feed ingredients, when the granulation is carried out, the whisker-like particle effect described above is caused. In particular, special attention should be paid to the pressure regulation of the steam and the installation position of the pressure reducing valve.
7, individual particles or individual particles are inconsistent in color, commonly known as "flower material"
This situation is more common in the production of aquafeeds, mainly because the color of individual particles extruded from the ring die is darker or lighter than the color of other normal particles, or the surface color of individual particles is inconsistent, thus affecting the appearance quality of the whole batch of feed. . The reasons for this phenomenon are mainly the following:
a) Due to the complex composition of aquatic feed ingredients, there are many kinds of raw materials, and some ingredients are added in a small amount. When mixing raw materials, if the mixing effect of the mixer is not ideal, it is difficult to ensure that the mixed raw materials entering the granulator are uniform. Therefore, in the process of quenching and tempering, under the combined action of moisture, temperature and pressure, physical and chemical changes occur in the raw materials, resulting in inconsistent color changes of raw materials of different components, resulting in "flowers". It is more prominent when the feed formulation contains sensitive changes in temperature and moisture.
b) The moisture content of the raw materials used for granulation is inconsistent. In the aquatic feed production process, in order to compensate for the loss of raw water after ultrafine pulverization, a certain amount of water is added to the mixer, and then mixed into the conditioner for quenching and tempering. Some feed manufacturers have a simpler process. Instead of using a special nozzle to evenly inject a certain amount of water directly into the mixer, it is difficult to evenly distribute the water after mixing. When the mixed raw material enters the conditioner to adjust the quality, it is impossible to further distribute the water evenly in a short time due to the conditioner. Under the action of steam, the ripening effect of each part of the feed after quenching and tempering is inconsistent, granulation. After the color change is also inconsistent.
c) Recycled material with heavy replicated particles in the granulation bin. After the granulated granules are cooled and sieved, they can become finished materials. The fine powder or small granules after sieving often enter the process and re-granulate, usually into the mixer or the granulation bin. Since this kind of returning material is re-tempered and granulated, if it is mixed unevenly with other raw materials after quenching and tempering or mixed with small pellets, sometimes "flower material" will be produced for some feed formulations.
d) The inner wall finish of the ring mold aperture is inconsistent. Due to the inconsistent mold hole finish, the resistance and squeezing force of the granules during extrusion are different, and the color changes are inconsistent. In addition, some of the ring mold holes have burrs on the wall, and the particles may scratch the surface when extruded, so that the surface color of the individual particles is different.
For the four reasons for the "flower material" listed above, the improvement method is clear, mainly to control the mixing uniformity of the components in the formulation and the mixing uniformity of the added water; improve the quenching and tempering performance, If necessary, control the quenching and tempering temperature, use a lower quenching and tempering temperature to reduce the color change; control the returning machine material, for the formula that is easy to produce "flower material", try not to return the machine material directly to granulate, should return the machine material and After the raw materials are mixed, the pulverization is repeated; the ring mold with a guaranteed quality is used to control the smoothness of the die holes, and if necessary, the die holes are sanded and then used.
In summary, for the unusual appearance of pellets in feed production, seven representative expressions are discussed above, and some of the appearance anomalies of the particles are not representative and are not listed here. As can be seen from the above discussion, the reasons for these phenomena are multifaceted and not completely isolated from each other. This requires us to analyze and grasp the key issues when dealing with such problems in actual work. Only then can solve the problem. I hope this article can help everyone.
(Source: Agricultural Network)
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