Die hole blockage in flat die granulators and its relation to material formulation
Die hole blockage is a common issue in flat die granulators during production, which not only reduces efficiency but also affects product quality. Here’s how material formulation influences this problem:
- Material Moisture
High moisture: Excessively wet materials tend to stick and accumulate in die holes, causing blockages. Adding moisture-absorbing additives like wood fiber can help reduce moisture and improve pellet formation.
Low moisture: Overly dry materials lack fluidity in die holes, leading to clogs. Adding water or moisturizing agents (glycerin) can enhance moisture and flowability.
- Particle Size
Too fine: Fine powders, especially those with sticky components, compact tightly in die holes. Mixing coarse particles (straw granules) can balance particle size distribution for smoother pelletizing.
Too coarse: Large particles create uneven filling in die holes. Further grinding or sieving to remove oversized particles ensures uniform sizing for better processing.
- Material Stickiness
High stickiness: Highly adhesive materials benefit from lubricants like talc powder to reduce friction and ease flow through die holes.
Low stickiness: Non-sticky materials struggle to form pellets. Adding binders (starch) improves cohesion and shaping.
- Material Composition
Impurity removal: Contaminants like metal fragments or sand can block die holes. Screening or magnetic separation ensures cleaner materials.
Functional additives: Ingredients like binders or lubricants can optimize material properties for smoother pelletizing.
In short, changing the material formula can alleviate the problem of die hole clogging of the flat die granulator to a certain extent, but it is necessary to consider many factors comprehensively, weigh the pros and cons, and ensure the efficient and stable operation of the flat die granulator.