Common Faults and Solutions for Double Roller Press Granulators
2025/08/12
The double roller press granulator is the core equipment in a fertilizer production line, compressing raw materials into granules. Its stable operation directly affects granule quality and production efficiency. In actual operation, the equipment is prone to various faults. Mastering targeted solutions can effectively reduce downtime.
Poor granule formation and easy breakage are often caused by inappropriate raw material moisture or improper roller pressing parameters. If the raw material is too dry, the granules tend to be loose, requiring additional conditioning moisture to maintain stickiness. If the raw material is too wet, the granules will stick to the roller surface, requiring drying or adding dry material to reduce moisture. If the roller pressure is too low, the granules will be insufficiently dense. Gradually increase the pressure until the granules are smooth and non-brittle. Excessive pressure may cause roller overload and require prompt adjustment. Wear or pitting on the roller surface is often caused by hard impurities mixed into the raw material and damage caused by high-speed extrusion. Enhanced screening before feeding and the addition of a magnetic separator are necessary to remove metal impurities. Minor scratches on the roller surface can be repaired by grinding; severe scratches require replacement, and the roller surface hardness should be checked regularly. Bearing overheating is often caused by poor lubrication or installation errors. Bearing lubrication should be checked regularly, and high-temperature resistant grease should be added according to specifications to avoid grease deficiency or contamination. Eccentric installation can increase friction, so the rollers should be recalibrated for parallelism to ensure a tight fit between the bearings and sleeves. Motor overload can also cause overheating. Check whether the feed rate exceeds the equipment's capacity and adjust the feed speed promptly. Unusual equipment noises are a malfunction warning. A metallic clashing sound may indicate foreign objects lodged in the roller gap; the machine should be stopped and cleaned immediately. Periodic grinding noises are often caused by worn or poor meshing transmission gears. Inspect the tooth surfaces and replace them if severely worn. Ensure adequate gear lubrication. Promptly troubleshooting and resolving these faults ensures efficient operation of the double roller press granulator, consistent fertilizer pellet quality, and reduced production losses.
