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Discussion on the Effect of Ring Die Compression Ratio on Granulator Efficiency and Quality

Time:2020-07-15 11:00

1 Overview
 
This article discusses the big pig pellets. Due to the current fierce competition in the feed market and the change in people's breeding concepts, the market's demand for large pig feed has gradually changed from the past customary use of powder to pellet feed. In order to improve the competitiveness of feed mills, the control of feed costs is particularly important. Therefore, the production efficiency of the pellet machine has become a key point of feed cost control.
 
2 Basic parameters
 
(1) Comparison on the basis of the same formula: corn content in the formula is about 65%, protein raw materials account for about 34%, minerals and other about 1%;
 
(2) The raw materials in the formula are the same batch (moisture, impurities, etc.);
 
(3) The crushing fineness of 2.0mm diameter sieve is crushed and the water content after mixing is about 12.5%;
 
(4) The cylinder pressure is 8 bar before granulation, and the apparent pressure is 5 bar after decompression; the tempering temperature is 80~85℃;
 
(5) The granulator motor is 150KW, and the current is about 230A during actual operation;
 
(6) Particle diameter 4.0mm;
 
(7) The opening of the air door of the cooling fan is unchanged, and the discharge position of the cooler is unchanged;
 
(8) Double-layer sieve (upper 3 mesh, lower 8 mesh).
 
That is to say, the tests between ring dies with different compression ratios were performed under all the same parameters.
 
3 Test pellet machine model (Muyang MUZL610TW)
 
(1) Ring die aperture 4.0mm, compression ratio 1:6, production time 12.6h, actual ingredient amount 200t, powder rate about 5%, average hourly production about 15.9t, finished product moisture about 12.3%, particle hardness not tested;
 
(2) Ring die aperture 4.0mm, compression ratio 1:5, production time 10.1h, actual ingredient amount 200t, powder rate about 5.3%, average hourly production about 19.8t, finished product moisture about 12.4%, particle hardness not tested;
 
(3) The ring mold manufacturer is the same, the material is 4Cr13, and the ring mold opening rate is about 38.6%.
 
4 Comparison of test results
 
(1) Electricity cost when granulating with 1:6 ring mold: electricity consumption=150KW×12.6=1890 degrees, electricity consumption per ton 9.45 degrees, electricity cost per ton is 0.56 yuan/kwh according to normal electricity calculation, that is, electricity cost per ton is about 5.3 yuan;
 
(2) Electricity cost when granulating with 1:5 ring mold: electricity consumption = 150KW × 10.1 = 1515 degrees, electricity consumption per ton is 7.58 degrees, electricity consumption per ton is 0.56 yuan/kwh according to normal electricity calculation, that is, electricity cost per ton is about 4.24 yuan;
 
(3) The ton from the pellet machine efficiency can save about 1.1 yuan in cost;
 
(4) It can be seen from the finished product moisture that it can reduce the loss of about 0.1%, which improves the output rate of the product, indirectly reduces the cost, and produces benefits (according to 3000 yuan/t, it can increase income by about 3 yuan/t);
 
(5) Judging from the comparison results, the cost can be reduced by RMB 4.1 per ton; if the annual output reaches 50,000 tons, then the cost can be reduced by RMB 205,000 per year.
 
5 Discussion
 
According to the results of the experiment, it can be found that the modulation temperature with a small compression ratio can be greatly increased, which can also make the starch in the corn more gelatinized, which can improve the palatability of the feed;
 
For big pig feed, the impact of the compression ratio of the ring die on the production efficiency is obvious without affecting the product quality, and the reduction in feed cost can also be calculated. At the same time, the improvement of the granulation efficiency also drives the improvement of the efficiency of each process link, which can reduce costs in many ways.
 
Of course, due to the limitations of the conditions in this related experiment, we cannot compare the various performances of the feed one by one, but simply start from the power consumption and give us a reference. This will occur in the actual long-term production of large quantities. Such problems are all bottlenecks for us to control costs and are worthy of our study.
 
6 Conclusion
 
The results of the above experiments are much lower than the compression ratio of 1:10-12 used in the past in the industry for large pig pellets. This is closely related to the gradual rationality and improvement of the current breeding industry, which brings to the improvement of production efficiency. Great changes have also played a role in improving the market competitiveness of feed mills.
 

 

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