The flat die pelleting machine is a piece of equipment that utilizes an extrusion molding process to directly press fermented organic materials into cylindrical granules. It is widely used in the organic fertilizer processing sector, making it particularly suitable for small-to-medium-sized livestock farms, organic fertilizer processing facilities, and family farms. The machine operates by rolling pressure rollers over a horizontal die plate, forcing the material through the die holes to form granules. It features a compact structure, ease of operation, and excellent material adaptability; it performs reliably—especially when processing high-fiber organic materials such as fermented chicken, sheep, or cattle manure. The flat die pelleting machine requires no water conditioning or steam heating, operating on a "dry-in, dry-out" basis at ambient temperatures. The moderate extrusion temperature minimizes damage to beneficial microorganisms in the organic fertilizer, making it an ideal choice for bio-organic fertilizer production.
Working Principle of Flat Die Pellet Machine
Material is forcibly fed from the hopper into the granulation chamber, which houses a horizontally mounted circular die plate perforated with holes; two to four freely rotating pressure rollers are positioned above the die. The rollers press the material firmly against the die surface, and as the die or rollers rotate, the material is continuously crushed and forced into the die holes. After undergoing compression and shaping within the holes, the material is extruded from the underside of the die as cylindrical strands. Once the strands reach the preset length, a cutter mounted beneath the die severs them, creating uniform cylindrical granules. The entire granulation process relies on purely mechanical extrusion; while the material temperature rises naturally, it does not become excessive. The process accommodates a wide range of moisture content levels and allows for pellet formation without external binders. Granule diameter is determined by the die hole size, while length is adjusted via the cutter position, making the granulation process simple and straightforward.
Structural Components of
Frame: Constructed from welded steel plate, the frame offers high overall rigidity, absorbs operational vibrations, and ensures the stable functioning of the granulation components.
Die Plate: A horizontally mounted annular or disc-shaped die forged from high-quality alloy steel. The surface undergoes heat treatment to ensure high hardness and excellent wear resistance. Die hole diameters range from 2.5mm to 12mm, with the hole size determining the thickness of the finished granules.
Roller Assembly: Two to four rollers are symmetrically arranged above the die plate; their surfaces feature anti-slip serrations. Mounted on shafts via bearings, the rollers rotate passively as the die plate turns, crushing and pressing the material into the die holes.
Drive System: The main motor drives the main shaft through a gearbox, which in turn rotates the die plate. The drive train is short and compact, resulting in fewer potential points of failure.
Feeding Device: A feeder connected beneath the hopper forces material into the granulation chamber, preventing bridging or clogging (especially with fibrous materials) and ensuring a continuous, uniform feed.
Cutter Assembly: An adjustable cutter is mounted beneath the die plate; the blade height can be modified to control the length of the extruded granules. The cutter is sharp, durable, and easy to replace.
Discharge Device: Cut granules fall into a collection hopper or onto a discharge conveyor belt for transport to the next processing stage. The discharge outlet is strategically positioned to facilitate connection with screening or packaging equipment.
Performance Characteristics of
High Suitability for Organic Fertilizer: Effective for processing high-fiber fermented organic materials (such as chicken, sheep, and cattle manure, or straw powder). Materials can be granulated without excessive pulverization, accommodating the uneven particle sizes typical of organic fertilizer raw materials.
Ambient-Temperature Dry Granulation: No water conditioning or steam heating is required; materials enter and exit the machine at ambient temperature. This preserves the activity of beneficial microbial flora in bio-organic fertilizers, resulting in high biological potency.
Uniform, Durable Granules: Extruded cylindrical granules are dense and strong, resisting breakage and crumbling, which facilitates mechanical application and long-distance transport. Granule length is adjustable, ensuring a neat, consistent appearance.
Low Energy Consumption and Cost-Effectiveness: The flat die pelleting machine has low power requirements; for the same production capacity, electricity consumption is lower than that of double roller press granulators. Its simple structure and low initial investment make it an ideal starting point for small and medium-sized users.
Easy Operation and Maintenance: The equipment features a moderate level of automation, allowing operators to start work after simple training. Routine maintenance primarily involves cleaning die holes and replacing worn rollers, resulting in minimal maintenance effort and low costs.
Application Fields for
Organic Fertilizer Processing: Granulation of fermented livestock and poultry manures (such as chicken, pig, sheep, and cattle manure) and agricultural wastes (such as powdered straw and rice husks) into fertilizer pellets.
Bio-organic Fertilizer: Ambient-temperature granulation of bio-organic fertilizers enriched with functional microbial agents, ensuring high viable bacterial counts in the granules.
Feed Processing: Pelletizing of compound feeds and concentrated feeds; production of aquatic feed pellets.
Chemical Industry: Extrusion granulation of certain chemical powders; production of biomass fuel pellets from materials such as lignin and sawdust.
| 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 |
