Feed production process factors causing mildew
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July 05 13:48:21, 2025
The granulation process is known for its fast particle size production and excellent results. A specially designed filter screen ensures precise sieving, while the friction filter rod helps crush the solid particles. This technology is widely used in the pharmaceutical, chemical, and food industries. The machine can replace traditional swinging pellet machines, offering a more advanced and efficient solution for pellet production. However, during the granulation process, some particles may exhibit abnormal appearances. For less experienced or new feed manufacturers, identifying these issues can be challenging. In this article, we will discuss seven common problems with granular materials and provide practical solutions to help improve quality and efficiency in feed production.
1. **Pellets are bent with cracks on one side**
This issue typically occurs when the pellets exit the ring die. If the cutter is positioned too far from the ring mold surface or if the blade is dull, the particles may be torn rather than cut as they pass through the die holes. This leads to cracks on one side, which can cause the pellets to break further during cooling or transportation, resulting in excessive fines.
Improvement methods include:
a) Increasing the compression force of the ring mold to enhance pellet density and hardness.
b) Ensuring finer grinding of ingredients and improving the uniformity of molasses or fat addition to increase compactness.
c) Adjusting the distance between the cutter and the ring mold, or replacing the blade with a sharper one.
d) Using a bonding agent to strengthen internal adhesion.
2. **Horizontal cracks across the entire pellet**
Similar to the previous issue, but without bending. These cracks often occur in fibrous feeds where fibers expand during extrusion, creating a bark-like appearance.
To address this, increase the compression ratio, control fiber length, reduce production speed, extend conditioning time, and manage moisture and urea levels appropriately.
3. **Vertical cracks in the pellet**
Some elastic raw materials may swell during tempering, leading to vertical cracks after compression. This can be mitigated by adjusting the formula, using dry steam, increasing dwell time in the die, or adding a binder.
4. **Radiating cracks from a central point**
These cracks indicate the presence of large particles that do not soften evenly. Controlling ingredient particle size and ensuring even moisture distribution can help prevent this issue.
5. **Uneven surface on pellets**
This usually happens when coarse particles are not fully softened during tempering, or when air bubbles form due to excess steam. Proper conditioning and controlling steam usage can improve surface consistency.
6. **Whisker-like pellets**
Excess steam can cause pressure changes, leading to bursting and the formation of protrusions on the pellet surface. Using low-pressure steam and ensuring proper steam release can minimize this problem.
7. **Inconsistent color (flower material)**
This occurs when individual particles vary in color, often due to uneven mixing or temperature differences during processing. Ensuring consistent formulation and proper conditioning can help achieve a uniform appearance.
By understanding these common issues and applying the suggested improvements, feed producers can significantly enhance pellet quality, reduce waste, and improve overall efficiency in their operations.