Flat Film Feed Pellet Machine has become the preferred equipment for small and medium-sized farms and feed processing plants due to its simple structure, low cost, and adaptability to high-fiber raw materials. However, common problems such as output fluctuations, reduced pellet quality, and mechanical failures during equipment operation often lead to reduced production efficiency and increased maintenance costs. This article combines industry data and technical practices to systematically analyze the core fault causes and solutions of flat film pellet machines to help users achieve efficient and stable equipment operation.
Insufficient output or no pellets
1. Improper raw material pretreatment
Cause analysis:
- Abnormal moisture content: Too high moisture content (>20%) of raw materials can easily lead to material adhesion and blockage, while too low moisture content (<10%) cannot form.
- Too coarse pellets: Raw materials such as straw and rice husks are not crushed to less than 2-3mm, or are mixed unevenly, resulting in blockage of die holes.
Solution:
- Humidity control: Use a moisture detector for real-time monitoring. The recommended moisture content for high-fiber raw materials is 12%-18%, and for cereals, it is 8%-12%.
- Crushing optimization: Configure a hammer mill with a screen aperture of ≤3mm to ensure uniform particle size of the raw materials.
2. Wear of the mold and the pressure roller
Cause analysis:
- Mold blockage: The mold was not fully ground when it was first used, and the mold hole finish was poor; after long-term use, the residual material was carbonized and blocked.
- Abnormal gap: The gap between the pressure roller and the flat die is too large (>1mm), resulting in the inability to effectively squeeze the material.
Solution:
- Grinding treatment: Before using a new machine or a new mold, grind it with oil-containing materials (such as bran + cooking oil) for 10-15 minutes to improve the finish of the mold hole.
- Gap adjustment: Adjust the gap to 0.2-0.5mm by tightening the bolt, so that the pressure roller and the flat die are almost touching but not touching.
3. Transmission system failure
Cause analysis:
- Belt slippage: V-belt aging or insufficient tension leads to power transmission failure.
- Motor overload: unstable voltage or excessive material feed, triggering overload protection shutdown.
Solution:
- Belt maintenance: Regularly check belt wear, replace belts of the same specification, and adjust the tension to 10-15mm under finger pressure.
- Motor optimization: Ensure voltage stability (380V±10%), use variable frequency speed regulation to control feed volume, and avoid instantaneous overload.
Pellet quality defects
1. Pellets are fragile or contain too much powder
Cause analysis:
- Raw material formula problem: The proportion of high-protein raw materials (such as soybean meal) is too high, lack of binder; or insufficient fiber content.
- Insufficient pressing pressure: Severe wear of the pressing roller, or mismatch of the compression ratio of the mold (such as compression ratio < 4:1).
Solution:
- Formula adjustment: Add 3%-5% bentonite or molasses as a binder, and control the fiber content at 15%-25%.
- Mold upgrade: Use 4Cr13 alloy steel mold, compression ratio 4.5:1-6:1, and increase the particle density to 1.2-1.5 g/cm³.
2. The surface of the particles is rough or hollow
Cause analysis:
- Uneven moisture: The amount of steam added during the conditioning process is unstable, resulting in local over-wetting or over-drying of the material.
- Mold wear: The inner wall of the mold hole is worn to form burrs, or the surface of the pressing roller is uneven.
Solution:
- Steam control: Use dry saturated steam, pressure 0.1-0.4 MPa, tempering temperature 60-85℃ to ensure uniform moisture content of the material.
- Mold repair: Use laser cladding technology to repair worn parts, or replace tungsten carbide coated molds, which can increase the lifespan by 3-5 times.
Mechanical failure and abnormality
1. Equipment vibration or abnormal noise
Cause analysis:
- Bearing damage: Long-term lack of lubrication or dust intrusion leads to bearing wear.
- Foreign matter stuck: Metal impurities or hard objects enter the pressing chamber and damage the mold or pressing roller.
Solution:
- Lubrication maintenance: Clean the bearing every 3-10 working days and add high-temperature resistant lithium grease (such as Mobil XHP 222).
- Impurity filtration: Install a permanent magnetic cylinder or iron remover at the feed inlet and clean foreign matter regularly.
2. Motor overheating or shutdown
Cause analysis:
- Poor heat dissipation: The motor fan is blocked or the ambient temperature is too high (>40℃).
- Winding short circuit: Long-term overload operation causes the insulation of the motor winding to age.
Solution:
- Heat dissipation optimization: Clean the motor fan and heat sink, keep the equipment well ventilated, and install a cooling fan if necessary.
- Motor maintenance: Regularly check the insulation resistance (≥0.5 MΩ) to avoid long-term full-load operation.
Common Misunderstandings and Pitfall Avoidance Guide
Blindly Pursuing High Output:
Overloading of small equipment may shorten the life of the mold by more than 50%.
Ignoring Raw Material Pretreatment:
Direct pelletizing of uncrushed straw increases the probability of blockage by 40% and energy consumption by 30%.
Low-Price Mold Trap:
Poor-quality molds are easy to wear, and the replacement cost may exceed the initial investment of high-quality molds. We recommend Huaxin Machinery’s flat film feed pellet machine, which uses high-hardness alloy steel molds (Cr4W2MoV) with a life of up to 800-1000 hours.
Summary: Efficient Operation and Maintenance Formula
Equipment Efficiency = Raw Material Compatibility × Mold Life × Maintenance Frequency × Energy Consumption Optimization Through systematic troubleshooting and preventive maintenance, the comprehensive operating cost of the flat die pellet machine can be reduced by 20%-30%, and the pellet qualification rate can be increased to more than 95%.
