Uneven discharge in flat die granulators during production is a frequent problem. It not only reduces efficiency but also leads to inconsistent product quality. Below are common causes and quick solutions:

Common Issues

1. Material Issues

Uneven material moisture can lead to uneven discharge. If some parts are too dry (hard to form) while others are too damp (causing blockages).

Inconsistent particle size mixes large and small granules unevenly, affecting material flow during pelleting and resulting in irregular discharge.

2. Die Problems

The die of the flat die granulator is severely worn, causing the shape and size of the die hole to change, resulting in uneven extrusion. For example, worn die edges create varying resistance for material passing through.

Clogged die holes are common. Impurities or sticky substances in the material can block holes, preventing normal discharge.

3. Equipment Settings

Unstable screw speed causes uneven material pushing. Overly fast or slow screw speed disrupts coordination with the flat die, affecting discharge.

Quick Fixes

1. Adjust Material Properties

For uneven moisture: Remix and adjust moisture to optimal levels. Add water or dry the material as needed. For inconsistent particle size: Screen or premix the material.

2. Maintain the Die

Regularly check die wear and replace heavily worn dies. Clear clogged die holes with specialized tools (such as needle-like tools). Avoid hard tools that might damage holes.

3. Optimize Settings

Ensure stable screw speed by checking the screw drive mechanism. Adjust the speed based on material properties and production needs to match the die’s working state.

By addressing these common issues with the above fixes, uneven discharge in flat die granulators can be effectively resolved, boosting both efficiency and product quality.