A pellet mill die has become a necessity for manufacturing a variety of items. The fact is that a roller and die form the main part of the pellet machine and determine the pellet quality and forming rate. However, they are also considered to be the most wearable parts. If you want to learn more about a pellet mill die, you have come to the right place. This post aims to provide you with all the information you need about the machine. So, what are you waiting for? Let’s get started.
Pellet Mill Die
A pellet mill die machine is a machine that has a die with many holes on it. The die is actually a disc that is made using ductile cast iron. After it receives quenching and carburizing treatment, it achieves hardness of 55 to 60 HRC. As for the size of the holes, they range from 2.55 mm to 10 mm. Generally, the most popular sizes include 10mm, 8mm, and 6mm. The thickness and machine whole sizes tend to be different to adapt to different production and material requirements. Most flat dies have a working life of anywhere from 300 to 500 hours.
When one side gets worn out, it will be used for the other side. The size and length of the hole is designed according to the number of experiments. However, the best compression ratio that should be achieved is for 30 biomass materials. In order for the pellet mill to continue to operate at optimal, the flat die along with rotary dryer parts must be replaced before they wear out entirely. Besides, it is not that difficult to replace the flat die after it wears out. All you would need to do is loosen the lock nuts from both sides and remove the upper chassis to take out the flat die and roller. You can get the best pellet mill die from Bio Pellet Machine. It is a company that provides a pellet mill, rotary dryer, and even rotary dryer parts.
Rollers in Flat Die Pellet Machine
The rollers are installed in a flat die pellet machine on the main shaft. A roller shaft connects the rollers together. The rollers are actually cylinders that feature skid-proof ace on their surface. The roller shaft rotates during work around the main shaft. Then, the rollers rotate along the main shaft as well. As for the diameters of the rollers, they vary based on the production capacity. As the hardness of rollers tends to be much lower, it is possible to reduce the wear of the flat die to prolong its working life.
In order to ensure uniform performance, all rollers must have the same clearance when it comes to the flat die. It should range between 0.1 mm to 0.3 mm. For ensuring that the rotating speed at the two ends remains the same, the roller adopts tapered shape. Such a design avoids slipping of the roller itself which helps reduce the wear of the flat die along with the energy waste. Moreover, it adopts screw central pressure adjustment equipment for adjusting the clearance between the die and roller. This allows for different materials to be adopted to ensure molding effect.
How Do the Flat Die and the Roller Work?
As raw materials are fed into the pellet machine from the hopper, they make their way onto the flat die and roller. Then, the roller rotates as driven by the main shaft itself and distributes the raw materials evenly onto the flat die. While rotating, the flat die and the roller form a strong fraction and pressure. Thus, they would heat up the compression chamber and lead to the materials softening and being easy to mold. As for the downward pressure from the roller, it squeezes the raw materials of the flat die into the holes. These are then transformed into cylindrical strips which become longer and continue squeezing the raw materials. As the strips come off from the bottom of the holes, a slicer cuts them off which causes the strips to fall out of the outlet. These strips are known as wood pellets.
Ring Die and Flat Die Mill Comparison
The fact is that a flat die pellet machine is more geared towards domestic use as well as for small workshop productions as it costs less. Moreover, it has a smaller size and offers lower productivity levels. On the other hand, a ring die pellet machine is designed for large scale production and offers plenty of advantages. It also has a greater production capacity and ensures lower power consumption. However, the cost and size are much higher. The shape of the dies is what differentiates a ring die pellet machine from a flat die pellet machines. Another notable difference between the two is the position of the rollers itself.
Ring Die in Pellet Machine
The truth about a ring die is that it is annulus that has many holes in it. It is made using carbon steel along with stainless steel. It undergoes cutting, stamping, drilling, and heating treatment. The number of holes of the die influence its strength. Generally, the bigger the size the holes the fewer their number.
Ring Die Pellet Machine Rollers
Chilled cast iron or high-carbon steel is normally used to produce the rollers of the ring die pellet machine. It boasts a greater hardness when compared to the ring die which means that one gets to benefit from uniform abrasion and the best compression effect. The suitable clearance between the ring die and the rollers is around 0.1 mm to 0.4 mm. To grab new materials, there are axial grooves on the roller’s surface.
After you have finished reading the post, you will know everything there is to know about a pellet mill die. There are plenty of reasons to invest in one which is why you need to consider getting one from Bio Pellet Machine as it provides top quality machinery.