1 Material Factors 1.1 Material Volume Quality In general, the greater the volume and mass of the material, the higher the granulation yield. Therefore, formula personnel should consider the bulk density of the material in addition to the nutritional requirements when selecting raw materials. 1.2 Particle size Fine particle size, large specific surface area, rapid vapor absorption, is conducive to moisture regulation, granulation yield. However, when the particle size is too small, the particles are fragile and affect the quality of the particles. If the particle size is too large, the wear of the die and the pressure roller will increase, the energy consumption will increase, and the yield will decrease. Generally, the size of the pig material should pass a 3 mm sieve, and the chicken material size should pass a 3.5 mm sieve, and at least 80% of it should pass a 1.18 mm sieve. 1.3 Material moisture The moisture content of the material is too high, reducing the amount of steam added during granulation, affecting the increase of granulation temperature, thereby affecting the pellet feed production and quality. At the same time, the moisture content of the material is too high, the conditioning is difficult and the material may easily slip between the inner wall of the ring die and the pressure roller, resulting in blockage of the annular die hole. It is generally required that the moisture content of the material before and after quenching should be below 13%. 1.4 Material Components 1.4.1 The protein content of the protein material is high, and the plasticity of the material after heating is large, the viscosity is increased, and the granulation yield is high. However, when the non-protein nitrogen (such as urea, etc.) is high, the granulation yield is reduced. 1.4.2 Starch Cereals have high starch content and are easily granulated under high temperature and high moisture. The yield is also high. At this time, the moisture content is required to be between 16% and 18%, and the tempering temperature should be above 80°C. Otherwise, the degree of gelatinization of the starch is poor and brittle granules are produced, which may not even be formed. If the grain has matured before and after conditioning (eg, dried corn), the pellet production will decline. Therefore, it is better to choose not to dry when purchasing raw materials. 1.4.3 Add a small amount of grease (0.5% to 1%) to the grease, which will help reduce the wear of the machine components and allow the particles to easily pass through the die holes and increase the granulation yield. However, when the addition amount exceeds 2%, the particles are loosened and it is difficult to form. Therefore, when adding high-dose grease, it is advisable to add the full amount of 30% at the mixer and 70% of the total amount at the granulator. 1.4.4 Crude fiber The appropriate crude fiber content (3% to 5%) is conducive to the bonding of granular materials, reducing the rate of particle pulverization, and improving the granulation yield. However, when the crude fiber content exceeds 10%, the hardness and the forming rate of the granules are affected due to the poor adhesion, the mechanical abrasion is increased, and the granulation yield is reduced. 1.4.5 Minerals Inorganic feeds have almost no cohesive force and poor granulation performance, affecting the granulation output. Therefore, when the inorganic content is high, a small amount of binder (such as molasses) is generally added to the material to improve the granulation performance and increase the yield. 1.4.6 Heat Sensitive Feed Lactose, whey powder, etc., increase in viscosity after heating, is conducive to increase production, but the temperature exceeds 60 °C, it is prone to coking, plugging die holes, affecting the granulation yield. Therefore, warm water can be used for this type of feed conditioning. 2 Operational Factors 2.1 Conditioning After the moisture content of the material is adjusted, the appropriate moisture content should be between 15.0% and 16.5%. It is advisable to determine the amount of moisture that can be dispersed by hand and then loosen. When the tempered moisture exceeds 18%, the material easily slips between the inner wall of the ring die and the pressure roller, and even the pellets cannot be pressed and the granulation yield is reduced. If the conditioning moisture is less than 14%, the friction between the material and the machine is severe and the granulation yield is reduced. 2.2 Roll, die spacing The gap between the press roller and the ring die has a great influence on the pelleting quality. Generally the gap should be between 0.05 and 0.3 mm. When the gap is greater than 0.3 mm, the material layer is too thick and unevenly distributed, reducing the granulation yield. When the gap is less than 0.05 mm, the machine wears badly. Roller, die spacing judgment method: Generally, when turning on the pressure roller, it is better to hear the squeak when it is not turning or hand throwing into the granulator. 2.3 Mold finish New ring mold Since the inner wall of the mold hole is covered with iron scraps, oxides, etc., it should be polished before use to make the inner wall of the mold hole smooth, reduce frictional resistance, and increase the granulation yield. The polishing method is as follows: 1) Cleaning the plugging holes with a hole smaller than the hole diameter of the die hole. 2) Install the ring mold, apply a layer of grease on the feed surface, and adjust the roller and mold spacing. 3) After mixing with 10% fine sand, 10% soybean meal, and 70% rice bran, mix 10% of oil with abrasive, turn on the abrasive, and treat for 20-40 minutes. With the improvement of die finish, the particles will loosen gradually. According to this point to determine the degree of polishing, and should be more than 90% of the die hole discharge. 2.4 Feed Scraper For long-time granulators, the feed squeegee wears heavily, which reduces the amount of feed that enters the roll and the mold, thereby reducing the output of the granulator and increasing the flour content. 2.5 Blockage of die holes is mainly caused by materials with poor granulation performance or new molds that are not caused by the polishing treatment or after the granulation is not cleaned by oily materials. It was found that the die hole was blocked and the drill bit was used to open the hole. The ring die should be immersed in an iron box containing organic oil, and the iron box was heated. When the ring was heard, it could be directly used for granulation. 2.6 Friction coefficient of materials and rollers and molds When the friction coefficient between the material and the inner surface of the press roller and the ring die is small, the material is easy to slip, thus reducing the output. If the friction coefficient between the material and the inner wall of the die hole is too large, the material will not be pressed out of the die hole and the pellet production will be reduced. The factors affecting the friction coefficient include formula, quality adjustment, and mechanical itself. 2.7 Feeding volume reduction The feed volume is reduced. Even if the operator's tempering level is higher, it is impossible to increase the output. 2.8 Cooling pellets Insufficient cooling of the feed, loose particles, and increased powder after being lifted by the elevator. After passing through the sieve, the powder is re-granulated to reduce the granulation yield. This effect is particularly prominent when the pellets are to be broken, and can be adjusted by adjusting the amount of cooling air and cooling time. General requirements, the particle temperature after cooling can not be higher than room temperature 3 °C. 3 Machine installation and accessories selection factors 3.1 Open rate The open rate of the ring die has a great influence on the production. In order to ensure the strength of the ring die, the hole diameter is generally high, and the granulation yield is also high. 3.2 Modular hole-shaped straight hole ring die is more suitable for processing compound feed, but for some lower-grade feed, because of its high crude fiber content, processing with straight hole ring die will greatly reduce the output. At this point you can use external tapered ring die processing. 3.3 Die, roller diameter ratio on the basis of the large ring die diameter, the larger the diameter of the roller, the smaller the angle of the material into the pressing zone, the less likely the material will be squeezed back, which will help improve the production of pellets. Generally, the ratio of the diameter of the roller and the die must be greater than 0.4. 3.4 Scraper Position Feeding squeegee is not properly installed, the material is ejected from the ring die, resulting in low yield and more powder. The correct installation shall be that the edge of the upper part of the feeding squeegee is 2 to 3 mm away from the ring mold and the ring mold cover, and the depth of the top of the squeegee shall not exceed the depth of the mold hole. 3.5 The ring mode with a large pore size and a large diameter-to-aperture ratio has a high granulation yield, but a suitable ratio of depth to diameter should also be selected. The thickness of the die hole is too large, the yield is low, and the hardness is high; when the die hole thickness is small, the particle hardness is small and the quality requirement cannot be achieved. Taking the 4.0 mm hole diameter as an example, the ratio of the depth to the diameter ranged from 9.5 to 12.5 for feeds with high cereal content and 4.8 to 8.0 for heat-sensitive materials. Large values ​​should be used when adding 1% to 2% of fat. 3.6 Ring Die Mounting Errors Misalignment of the ring die position can cause uneven wear and uneven granulation, and even ring motion can reduce the pelleting yield. 3.7 Cutting knife The knife is located too close to the ring mold, causing more powder and affecting the granulation yield. Should be adjusted during the granulation process, with a particle length to particle diameter ratio of 1 to 2: 1 is appropriate. 4 other factors 4.1 steam quality steam in the boiler under a given pressure is saturated steam into the pipeline, in the transmission process will lose energy to produce condensed water into unsaturated hot and humid steam, to adversely affect the quality adjustment. Therefore, condensed water should be discharged before conditioning, and it can be changed to low-pressure dry hot steam through a pressure reducing valve to improve the quenching effect. After the decompression, the vapor pressure is not lower than 0.2 MPa and the temperature is not lower than 120°C. 4.2 The voltage, current, and feed stability all have a significant effect on the granulation yield. In short, in the granulation process, the problem of unsatisfactory yield is often encountered, but as long as the granulator can find a solution according to the specific situation, the granulator can be operated efficiently.
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