The flat-die pellet machine is a piece of machinery that utilizes extrusion technology to process powdery or fibrous materials into cylindrical pellets. Primarily used in sectors such as organic fertilizer production, feed processing, and biomass pellet manufacturing, it is characterized by a high pelletizing rate, good pellet strength, minimal temperature rise during processing, relatively simple operation, and a wide range of applications.
The flat die pellet mill primarily consists of the following major components:
Flat Die (Template): A horizontally positioned circular steel disc featuring evenly distributed die holes; it is the key component for material shaping. The die hole diameter can be customized based on the required finished pellet size, typically ranging from 1.5 mm to 20 mm.
Pressure Rollers (Crushing Wheels): These rotate around the main shaft, applying high pressure to the material and forcing it into the die holes. Usually made of wear-resistant alloy, they come in two types: conical rollers and cylindrical (straight) rollers.
Drive System: Comprising the electric motor, gearbox, main shaft, gears, and other parts, this system transmits power to the pressure rollers or the flat die.
Feeding Device: Uniformly delivers material into the space between the flat die and the pressure rollers.
Discharge Mechanism: Includes cutters and scrapers responsible for cutting the cylindrical material extruded from the die holes into pellets of the desired length.
Frame and Housing: The overall structure that supports and houses all the components.
The flat die pellet machine operates based on the principle of extrusion molding using a die and rollers.
The process is as follows: An electric motor drives the main shaft through a gearbox, causing the pressure rollers to rotate over the flat die. Material enters from the hopper and is evenly distributed across the surface of the flat die by gravity and a material-spreading mechanism. The rotating rollers continuously roll over the material layer, forcibly pressing the material into the die holes. Inside the holes, the material undergoes compression, shaping, and consolidation before being extruded from the bottom; a cutter then slices the extrudate into cylindrical granules of a specific length.
The entire process is a dry extrusion method performed at ambient temperature; it requires no heat, water, or binders, relying solely on physical pressure to shape the raw materials. This makes the flat-die granulator particularly suitable for producing bio-bacterial fertilizers, as the ambient-temperature molding process does not kill the live bacteria.
Flat-die pellet machines are highly adaptable to various raw materials and can be widely used in the following fields:
Organic fertilizer production: Suitable for granulating bio-organic fertilizers and organic-inorganic compound fertilizers. The low-temperature extrusion process meets the requirements for granulating bio-bacterial fertilizers at ambient temperatures.
Feed processing: Capable of producing feed for poultry (such as chickens, ducks, and geese) and livestock (such as rabbits, cattle, sheep, and pigs), as well as feed for aquaculture (such as fish and shrimp). It is suitable for use by home-based breeders, professional farmers, and small-to-medium-sized feed processing plants.
Biomass fuel: Can process agricultural and forestry waste—such as sawdust, straw, rice husks, cotton stalks, peanut shells, and bamboo powder—into biomass fuel pellets.
Chemical and other industries: Can also be used to granulate powdered materials such as compound fertilizers, additives, catalysts, pesticides, clay, lead oxide, and zinc oxide.
The flat die pellet machine typically serves as the core forming equipment within the production line. The complete process flow for organic fertilizer production using a flat-die pellet machine comprises the following stages:
Raw material pretreatment ——Crushing ——Batching and mixing ——Flat-die extrusion granulation——Drying (depending on material moisture content) ——Cooling ——Screening ——Packaging of finished product
A significant advantage of the flat-die granulator is that raw materials do not require drying or crushing prior to granulation; cylindrical granules can be produced directly from the mixed ingredients, resulting in substantial energy savings. The resulting granules typically have a moisture content of less than 15%, allowing them to proceed directly to the cooling and screening stages and eliminating the need for expensive drying equipment.
When selecting a flat-die pellet mill manufacturer, you should comprehensively evaluate them based on the following criteria:
Compatibility between equipment and materials: Does the manufacturer understand the characteristics of the materials you process (such as moisture content, fiber content, and viscosity), and can they provide a tailored equipment solution?
Materials and manufacturing processes for core components: High-quality flat dies utilize high-strength, wear-resistant materials——such as high-chromium alloy or high-manganese steel—achieving a hardness of 55-60 HRC. When purchasing, pay close attention to the materials and heat treatment processes used for the dies and rollers.
After-sales service capabilities: This includes installation and commissioning, technical training, maintenance and repair services, and the availability of spare parts. Blindly prioritizing low prices can lead to skyrocketing maintenance costs and failure to meet production targets.
Industry reputation and experience: Prioritize manufacturers with extensive experience and a strong market reputation in sectors such as organic fertilizer, animal feed, or biomass processing.
Zhengzhou Huaqiang Heavy Industry has specialized in fertilizer production equipment for over twenty years and is a reliable manufacturer in the field. We welcome your inquiries.
| Model | KP-210 | KP-260 | KP-400 | KP-500 |
| Capacity (t/h) | 0.2-0.3 | 0.4-0.5 | 1-1.2 | 2-5 |
| Pelleting Rate (%) | >95% | >95% | >95% | >95% |
| Rotation Speed(r/min) | 370 | 260 | 260 | 125 |
| Power(Kw) | 7.5 | 11 | 30 | 55 |
