Your questions, answered here

1. Bearing:

• Damaged or worn bearing.

• Improper bearing clearance.

2. Ring die:

• Clogged or out-of-round ring die.

• Worn press roller or damaged bearing.

3. Unbalanced coupling Inaccurate coupling calibration.

4. Main shaft Loose main shaft. 

5. Worn gear Worn gears and pinions or improperly replacement.

6. Conditioner Uneven discharge of the conditioner outlet.

7. Mismatch between the new ring die and the press roller The new ring die is not equipped with a new press roller.

8. Improper control of raw material moisture Improper control of raw material moisture: Whether too dry or too wet, it will cause abnormal discharge, make the pellet mill work abnormally and cause vibration. 

9. Insecure steel frame structure The support strength of the steel frame structure is not enough. 

10. Poor fixing of the tail of the conditioner Wobbling of the tail of the conditioner produces resonance. 

In general, the vibration problem of a pellet mill is a complex mechanical failure phenomenon, involving many factors. From the above analysis, it can be seen that any negligence in any part of the process, from the bearings to the ring die, from the conditioner to the raw material control, and to the overall structure of the machine, can be a potential cause of vibration.

1. Equipment structure factors:

• The assembly problem of screw, extruding chamber and shear block.

• Improper matching of die holes’ open area and length-diameter ratio.

• Cutter structure.

2. Operating parameter settings:

• Poor conditioning: inadequate control of temperature, time and moisture in wet and heat steam conditioning.

• Extruder running speed: Too fast or too slow running speed will affect the stability of the extruder, and then produce vibration.

3. Changes of raw material characteristics:

• Starch and crude fat content: Unreasonable starch and crude fat contents will affect the extruding effect of the material.

• Unreasonable grinding fineness.
  

4. Unplanned maintenance and wear If not repaired or maintained in time, the accessories are abnormally worn, resulting in mechanical failure and vibration. 

5. Environmental factors Whether the ground where the extruder is located is solid and horizontal, and whether there are other vibration sources to interfere.

In addition, after understanding the above reasons, here are some suggestions and precautions to reduce or eliminate the vibration problem of the extruder in operation: 

• Regularly inspect and maintain the key components of the extruder to ensure that they are in good condition. 

• Optimize the production process and select the appropriate screw configuration and operating parameters. 

• Improve training and skill levels of operators and standardize operating procedures. 

Adopt appropriate anti-vibration measures, such as the use of shock-absorbing pads. In general, the reasons for the vibration of the aqua feed extruder in operation are complex and diverse, involving the structure of the equipment itself, operating parameters, raw material characteristics, operating skills and other aspects. Through the comprehensive analysis and control of these factors, the vibration problem of the aqua feed extruder can be effectively reduced to ensure the efficient and stable production.

1. Optimize the moisture content of the material before it enters the dryer:

• Reduce the moisture content of the material to be dried: Reduce the moisture content of the material on the premise of ensuring the quality of the product.

• Control the difference in material moisture: Try to keep the difference within 2%. 

2. Improve the operating conditions and settings of the dryer:

• Thickness of the material layer and uniform distribution: The distributor should evenly distribute the material to ensure the equal thickness of the material layer.

• Reasonable control of air volume and temperature: According to the production requirements, set the parameters reasonably.

• Sealing performance inspection: Avoid wasting energy caused by thermal short-circuiting. 

3. Improve operating skills and management:

• Skill training and production planning: Improve workers’ operating skills, rationalize production scheduling, and reduce the time and frequency of changing variety.

• Steam inspection: Regularly check the steam leakage, especially the leakage of the steam trap. 

Attention also needs to be paid to daily maintenance and management, such as regularly cleaning the anti-dust net of the heat exchanger and the residues in the dryer. In general, the implementation of the above comprehensive strategy can not only effectively reduce the energy consumption of the feed steam dryer, but also improve the overall production efficiency and product quality.

As the key equipment in the feed production line, the performance and state of mixers directly affect the mixing homogeneity and production efficiency of feed. Here are some practical solutions and suggestions.

1. Check and replace the sealing strip:

• Check sealing: Check if the sealing strip is damaged or aged.

• Replace the sealing strip: If the sealing strip has been damaged or deformed, it should be replaced promptly. 

2. Adjust and optimize:

• Check the air source pressure: Make sure the air source pressure is more than 0.6mpa.

• Adjust with shims: Use the adjustment shim to adjust the gap between the sealing strip and the door body.

3. Maintenance and care:

• Clean up the accumulated materials: Regularly clean up the accumulated materials of the discharge door.

• Check flexibility: Check whether the discharge door opens and closes smoothly.

• Regular lubrication: Each bearing and linkage mechanism should be lubricated regularly.

In general, although the problem of mixer leakage is common, in most cases it can be effectively solved by the above measures.

Uneven oil injection of the coater is a common problem in the feed production process, which directly affects the quality and nutritional value of the feed. Here are some possible solutions and suggestions.

1. Inspect and maintain the coating equipment:

• Make sure that the nozzles are not clogged: to ensure uniformity and efficiency of coating.

• Adjust the nozzle position: to ensure that the grease can be more evenly covered on the surface of the feed.

2. Optimize the heating and conveying of grease:

• Proper heating of grease: to reduce the viscosity of the grease and to facilitate flow and material absorption.

• Keep the pipework clean: to ensure continuity and stability of coating.

3. Precise control of the coating amount:

• Adjust the oil injection speed: to ensure the accuracy of the coating amount.

• Use a high precision control system: automatic adjustment of coating parameters, such as flow, pressure, etc., based on real-time monitoring data to ensure uniformity and accuracy of coating.

4. Operating skills and training:

• Enhancement of operator training: Operators are trained and then put on duty.

• Developing detailed operating procedures: reduce operating errors.

In general, the implementation of the above measures can effectively improve the uniformity of oil injection of feed coaters, which in turn improves the overall quality and production efficiency of the feed.

1. Check the feeder:

• Feeding rate adjustment: Adjust the feed rate to stabilize current.

• Air inlet adjustment: Adjust the opening of air inlets to approximately 1/2 to 2/3 of its full range.

• Improper adjustment plate setting: Recalibrate the adjustment or replace it with a new one.

2. Check the air gate of fan:

• Air gate setting: Adjust the air gate opening to ensure the fan's load current reaches approximately 90% of the motor's rated current.

3. Check the feed guiding mechanism:

• Feeding direction: If the feeding direction is inconsistent with the rotor rotating direction, adjust the solenoid valve to make them rotate in the same direction.

• Deflector angle: Adjust the limit board position to achieve the feeding deflector a proper angle that can minimize current fluctuations.

4. Check all hammers and accessories:

• Hammer wearing condition: Make sure the weight differences between each set of hammers are controlled within 5g.

• Hammer arrangement: Usually, poultry feed and livestock feed productions are configured with eight sets of hammers, while aquafeed productions are configured with four sets.

• Hammer-to-Screen gaps are different on both sides: Adjust the position of the rotor-hammer frame plate and the screen support ring to achieve uniform hammer-to-screen gaps on both sides.

• Hammer-to-Screen gaps: It is recommended to adopt a smaller gap.

5. Check the baffle plate and the screen sieves:

• The baffle plate is worn out: Replace it with a new one.

• The screen sieve is worn out or the sieve holes are blocked: replace it with new one.

6. Check the feed recipe:

• Inclusion of some special materials (especial oil-rich materials such as palm kernel meal, etc.): Adjust the formula structure to reduce the inclusion of such materials.

In summary, by implementing the above measures, current fluctuations can be mitigated effectively, thereby improving production efficiency, and ensuring stable and reliable operations.

Hammermill output decline is one of the most common issues in feed mills. It will directly impact the production efficiency and the energy consumption of the whole plant. Followings are some solutions and suggestions for your reference just in case.

1. Check all hammers and accessories:

•  Hammer wearing condition: Weigh all new hammers, spacers, and pin shafts, and make sure that the weight differences between each set of hammers are controlled within 5g.

• Harmer arrangement: Usually, poultry feed and livestock feed productions are configured with eight sets of hammers, while aquafeed productions are configured with four sets.

• Hammer-to-Screen gap: Available of two sizes. The larger gap is recommended for sieve hole diameter≥1.2mm, and the smaller gap is for sieve hole diameter ≤1.0mm.

2. Check all screen sieves:

• Installation direction: Make sure the smooth side of screen sieve faces outward, with the rough side facing inward.

• Sieve hole arrangement pattern: Buy screen sieves from the original manufacturer, and make sure the holes are arranged perpendicular (90°) to the feeding direction.

• Sieve open area: Buy screen sieves from the original manufacturer to ensure grinding output and efficiency with scientific open area.

3. Check the screen pressing plate:

• Baffle wearing condition: Replace with a new baffle if it is worn.

• Wearing condition of screen keeper lip plate: Replace with a new lip plate if it is worn.

4.  Check the feed guiding mechanism:

• Feeding direction: In case feeding direction is inconsistent with the rotor rotating direction, adjust the solenoid valve to make them rotate in the same direction.

• Deflector angle: Adjust the limit board position to achieve the feeding deflector a proper angle that can minimize current fluctuations.

5. Check whether sealing baffle of the screw feeder has fallen off or not. If the welding is detached, perform on-site welding to reattach the sealing baffle.

6. Check feed recipe:

• Raw material moisture content: the moisture content of raw materials to be ground should not larger than 14%.

• Raw material particle size and oil content: Please note that, the larger the particle sizes or the higher the fat content in raw materials, the lower the grinding output.

7. Check the feeder:

• Insufficient feeding rate: Increase feeding rate to ensure the principal machine works at its rated current.

• The opening of air inlet: Adjust the opening of air inlet to approximately 1/2 to 2/3 of its full range.

8. Check the fan:

• Fan rotation: Check on-site to make sure the fan rotates in the correct direction.

• Belt of the fan: The aged belt will cause insufficient air volume. In this case, it is better to replace it with a new V-belt or re-tighten the old one.

9. Check the dust collector:

• Excessive pressure differential: Clean the filter bags if the pressure differential exceeds 1,000Pa; in case the pressure exceeds 1,500Pa, replace the filter bag with a new one.

• Solenoid valve pulse control: Adjust the pulse control settings to a pulse width of less than 1 second, with intervals of 8-12 seconds, and a pressure of 0.5-0.6MPa.

• Weak air jetting: Air leakage or insufficient air pressure of solenoid valve.

In summary, a decline in hammermill production capacity is a multifaceted issue. From the machine's structural integrity to raw material quality and the working condition of wear parts, any oversight in these areas can contribute to reduced performance.