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pelletmills

Pellet-mills

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

Cereals are also defined as breakfast food made from roasted grain and typically eaten with milk or yogurt. Cereal grain is a small, hard, and dry seed, which mainly harvests for human or animal consumption, like wheat, maize, or rye. Processed from the edible components of the grains, breakfast cereals contain rich nutrients and usually serve as the main course during breakfast meals. Different cereal manufacturing equipment allow various options to appear on the market, ranging from cereals, granola, and muesli. Granola and muesli can be converted into cereal bars. The healthy, on-the-go snack bar shows a growing trend due to its nutrient content and convenience.

Breakfast cereal

With the increase in the world population and rising concerns for environmental sustainability, the market for suitable new protein sources is expanding rapidly. Traditional agricultural methods alone can’t deliver sufficient protein to meet the projected food demand over the next decades. Insects provide an alternative source of nutrients. But insect protein does not mean direct insect consumption. Extracting protein and amino acids from farmed insects is more sustainable and efficient. Specialized insect protein processing technology is driving the transformation toward new protein sources.

Insect protein

We continuously talk to suppliers of feed processing technologies that have important know-how on how to create the smarter, better, and greener feed products we need to kickstart a better tomorrow. Are you into making animal feed or pet food and looking for ways to improve your production process? Let’s navigate the world of feed production technologies together!

Feed

Feed ingredients

Aquaculture feed is used when rearing marine livestock such as fish, shellfish, and algae. Quality nutrition is needed for healthy growth and reproduction and feed usually consists of fats, carbohydrates, protein, vitamins, and minerals. Extruded aquaculture feed floats on the water surface and pressure-pelleted feed will sink to the bottom.

Aquafeed

A pellet mill is a type of mill used to make small, round, compressed, pellets from powdered materials. Selection of a suitable pellet mill requires consideration of the desired pellets size and shape, nature of the material to be processed, ease of cleaning, and the scale and mode of pellet production. In the animal feed and pet food industries, pellet presses are used to combine various nutritional ingredients into each pellet. In biomass combustion, a pellet mill is used to increase bulk density and provide a consistent, easy-to-handle input product made from raw materials such as sawdust.

Continuous

Form pellets with the uniform length for a dust-free, cylindrical granulate, pellets with smooth surface and high stability of the granulate.


<h2>Stable pelleting with uniform length</h2>
The Gear pelletizer from Hosokawa Alpine is also known as the low-pressure extruder or pelleting machine. This process is known as extrusion, and helps to get stable pellets with uniform length are formed. The extrusion takes place by a pair of counter-rotating hollow toothed rollers. The product is drawn in by the rollers and pressed by nozzle bores or press nozzles.

The compression is determined by the relationship of the nozzle diameter to the nozzle length. The nozzle diameter is within the limits of 1 to 10 mm.

The Gear Pelletizer can be run dust and gas-tight. Operation with inert gas and solvents it’s possible without any problem.

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Pelleting machine

Compaction machines and technologies crush or compress materials and make them denser. Compaction can be used to simply save space or to shape materials into a desired form or format. Tablets, pellets, or briquets are formed by compactors but powder presses also help form cosmetic eyeshadow or face powder.

Compaction

Pelleting equipment transforms powdered, mashed, or grounded material into a denser cylindrical shape. Pellet processing compresses the fine material against a perforated die, where it will be shaped and cut. Although granulating and extrusion also produce pellet-like products, manufacturing pellets is a distinct process.

Pelleting

solid

Utilization of biomass for energy and other applications requires consistent and reliable compaction to increase bulk density and provide a consistent an easy to handle input product to subsequent processes such as combustion. This line of pelleting presses has been under development since the energy crisis of the 1970’s and is well suited for today’s renewable raw materials industry needs.


<h2>Robust biomass pelletizers with impeccable pellet quality and high up-time</h2>
Amandus Kahl produces pelletizing presses with proven success for many types of biomass including wood, straw, dried forage, and agricultural byproducts among many others. The presses use pan grinder rollers to compact the biomass and force it through a flat pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives. The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimized generation of noise and heat.

The grinder roller gap and strand cutter are adjustable for optimized pellet quality for the customer’s particular needs.  The presses are designed for maximized plant up-time and include reinforced press chamber, die supports and cutting knives, oversized and permanently lubricated roller bearings, and active gearbox lubrication. The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses. Amandus Kahl has pelletizing presses with capacities from 300 Kg / h to 8,000 Kg / h.

Pelleting press for biomass

Grinders use a spinning blade or rotating abrasive elements to reduce the size of various materials. The specifications, RPM and grit of the engineered grinder, will result in various particle sizes. As a result, what you want to make will determine the type of grinder you need. Grinding is used for improving the texture and flow properties of various products and to enhance the flavor of food products such as coffee, spices, sugar, nuts, sesame, poppy seeds, lentils, wheat, and rice. Choosing the right rotational speed, grinding elements, and processing power allow the grinding and shredding of a wide range of materials into coarse or fine powders. Popular types of heavy duty grinders in food processing include angle grinders, bench grinders and meat grinders.

Grinding

The production of agricultural feed and pet food products requires machines and plants that supply stable-abrasion resistant pellets tailored to the customer’s needs. A proven, robust press design is required to ensure a consistent, high quality product and efficient operation.


<h2>Robust feed pelletizers with a proven design from an industry leader</h2>
Amandus Kahl produces pelletizing presses with proven success for many types of animal feed including compound feeds for all species, raw components, mineral mixtures, dried forage and straw mixtures. The presses use pan grinder rollers to compact the input material and force it through a flat pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimized generation of noise and heat. The grinder roller gap and strand cutter are adjustable for optimized pellet quality for the customer’s particular needs. The presses are designed for maximized plant up-time and include reinforced press chamber, die supports and cutting knives, oversized and permanently lubricated roller bearings, and active gearbox lubrication. The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses.

Amandus Kahl works with customers to combine pelletizing machines and other supporting equipment including conditioners, coolers, dryers, and a coating system to provide an optimized plant solution for producing the customer’s product.

Pelleting press for feed and petfood

Batch

The production of pelletized or granularized food products requires hygienic presses designed for high quality output and robust efficient operation.


<h2>Robust food pelletizers with a proven design from an industry leader</h2>
Amandus Kahl produces pelletizing presses with proven success for many types of food products including those with powdery or lumpy input products.  The presses use pan grinder rollers to compact the input material and force it through a flat pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimized generation of noise and heat. Temperature is monitored and the grinder roller speed is infinitely adjustable. The grinder roller gap and strand cutter are also adjustable for optimized pellet quality for the customer’s particular needs. The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses.

The hygienic presses are also designed for easy cleaning and meet GMP guidelines for food processing equipment. Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customers in developing a process that is optimized for their product.

Hygienic pelleting press

Many industries require reliable pelletizing equipment with smaller scale production capacities. These industries include chemicals, pharmaceuticals, synthetic material manufacture, waste disposal and recycling, minerals, and energy where compaction and uniform output are important but high volume production of a pelletized product is not necessarily the industries’ focus.


<h2>Robust smaller scale pelletizers with a proven design from an industry leader</h2>
Amandus Kahl produces smaller scale pelletizing presses with proven success for many types of products that often do not require the high volume production of larger presses. This line of presses uses the proven technology of Amandus Kahl’s larger sized presses in a scale more appropriate to the smaller production volumes. The presses use pan grinder rollers to compact the input material and force it through a flat pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimized generation of noise and heat. The grinder roller speed is infinitely adjustable. The grinder roller gap and strand cutter are also adjustable for optimized pellet quality for your particular needs.

The flat die design ensures even distribution of feed material and optimized pressure in a more compact package than traditional ring die type presses. Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customer in developing a process that is optimized for their product. Amandus Kahl variable speed proportioning screw is often used in conjunction with these units to ensure consistent and uniform feeding of raw materials.

Small scale pelleting press

Production of certain pelletized products requires working with output products of a pasty consistency. These products include pigments, clay, detergent additives, vitamin products, and many other products where problems of adhesion of fresh pellets are often encountered. Processing of these types of products requires a pelletizing press that allows the fresh pellets to be directly deposited on a gently transporter such as a conveyor.


<h2>A pelletizing press for depositing pellets directly onto your conveyor</h2>
Amandus Kahl produces pelletizing presses with overhead drives that allow pellets to be deposited directly onto a conveyor from above-eliminating the adhesion issues of fresh pellets often encountered with pasty products. This line of presses uses the proven technology of Amandus Kahl’s other pelletizing presses but the drive unit is above the pelletizing die rather than below it allowing gentle direct deposition of the fresh pellets onto a conveyor. The presses use pan grinder rollers to compact the input material and force it through a pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimizing generation of noise and heat. The grinder roller speed is infinitely adjustable. The grinder roller gap and strand cutter are also adjustable for optimized pellet quality for the customer’s particular needs.

Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customer in developing a process that is optimized for their product. A Kahl variable speed proportion screw is often used in conjunction with these units to ensure consistent and uniform feeding of raw materials.

Pelleting press with overhead drive

Manure fertilizer needs to be made marketable by making them visually attractive, with high level of hygiene frequently required for export. A full processing line can provide a cost-efficient, start-to-end solution to form pellets, which are uniform with smooth surface and high stability of the granulate, ready for transporting.


<h2>Reliable, standardised system focused on processing poultry manure</h2>
Dorset’s Pelleting line is a fully equipped standardised pelleting line, dedicated for volumes of 400 Kg/H or 800 Kg/H. It is a full processing line, mounted on a steel platform. It includes all the parts required for pelleting dry poultry manure: a crusher, dosing system, pellet press, dust sieve, cyclone, sanitation and a cooling system.

Most wastewater treatment plants processing slurry use techniques that result in waste streams which by itself have little or no value and are difficult to process further. However, this pelleting line for manure fertilizer combines these substances for effective and configurable production of green chemical fertilizer. This results in a customer specific supply of fertilizer to the end-user.

Pelleting line for manure fertilizer

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

Seed pelleting or encrusting is the addition of materials like powders and liquids to seeds to increase their size, shape, and weight. These processes are usually used for irregularly shaped or small seeds, such as carrots, onions, and lettuce to make planting easier and more efficient. Along with enhancing seed quality, the process also reduces seed production cost. However, there are very few seed pelleting machines that ensure uniform, heavy, and perfectly round seeds for precision-sowing in the field.


<h2>Achieve a more efficient seeding process</h2>
The Seed pelleting machine by Seed Processing Holland is ideal for the conventional pelleting of seeds to make them better to sow. In other words, turning an oddly shaped seed into a perfectly shaped seed ready for germination and growth. By adding liquid and powders, the seeds are made more uniform, heavier, and as round as possible.

Boasting a polished stainless steel pan, this unit is designed with an opening that enables operators to visually follow the entire process and feed the necessary liquids and powders. A light fixture is further mounted in the pan to enhance its visibility. In order to ensure proper ventilation, a transparent dust suction hood is designed at the opening as well.

A compressed air spraying nozzle is also positioned near the opening of the steel plan, allowing operators to spray liquids on the seeds. Lastly, this unit boasts a maximum capacity of 1,000,000 pellets of 3.5mm and is suitable for different kind of seeds, including small flower seeds and larger vegetable seeds.

Seed Pelleting Machine

When producing customized flakes, pressed cakes, or other oilseed products, the oilseed preparation value chain differs from one seed to the other. For example, soybean treatment asks for different processing compared to a sunflower seed or rapeseed.


<h2>Cleaning and dehulling seed for further processing in extraction plants</h2>
An oilseed preparation plant by Andreotti Impianti has a specific sequence of activities that meets the specific business needs of the following process plants of, for example, biofuel production. First, depending on the type of seed processed, the preparation plant handles the weighing of the seeds to stabilize the flow at the plant's inlet. The process then continues with removing any coarse particles from the raw material, and further cleaning consists of destoning where stones and other impurities are removed. After this, the material is then conditioned to reduce the viscosity and adjust the moisture content to desired levels. The oilseeds now need to be further reduced in size, which happens by cracking them. Finally, the seeds are dehulled to modify the final meal protein content, leaving a material with a higher protein density.

Take, for example, sunflower seed processing. The dehulling directly impacts the protein levels of the end product for this type of seed. Therefore, there is the option for one-stage or two-stage dehulling, meaning that for the one-stage dehulling, the product contains less than 16 percent residual hulling fragments. The dehulling process can reduce this percentage to 11 percent with a second round, which will lead to an even higher protein level in the dehulled product.

The main goal of the preparation plant is to have the raw material, the seeds ready and modified for further processing by solvent extraction or mechanical pressing. After dehulling, as mentioned above, seeds can be flaked to improve extraction performance for solvent extraction in an extraction plant. In addition, sunflower seed and rapeseed need to be pressed to improve extraction performance. Other process steps in the preparation plant might include milling to homogenize the size of the meal and pelleting for the logistics of the final product.

Oilseeds preparation plant

Industrial cleaning equipment is used to wash or disinfect machinery and the production/warehouse area. It may also be used to sterilize the product, equipment, tools, floor or work surfaces and to purify or clean the product by removing impurities. Choosing a suitable cleaning system depends on the type of product or equipment to be cleaned, the sensitivity of the product to heat, pressure, and chemicals, and the level of sterility desired.

Cleaning

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

Almost all manufacturers will require industrial storage systems and solutions at some point during their production process. The raw materials that go into your products need dedicated storage solutions to protect them from spoilage and contamination before they enter the manufacturing cycle. Storage usually refers to particular storage space. For example, having enough warehouse storage. Or clearing out a production facility for more floor space.  However, in this case, we are referring to the equipment and solutions that make storage manageable and easier. Such equipment includes solutions such as storage racks, pallet racks and shelving systems. These are just some of many storage options available to manufacturers. Advanced technology facilitates the management of heavy duty and high density tank and silo systems by automating the delivery system and linking it with the rest of the production line.

Storage

liquid

When pelleting large batches of seeds like flower, vegetable, or agricultural types, it is important for manufacturers to achieve uniformity of product size and shape. Through accurate dosage of coating elements and proper movement during the coating process, pellet products of consistent size and shape can be achieved.


<h2>Coating seeds through a rotating chamber with accurate dosage of coating mixture</h2>
The PRM-4210 Rotary Pelleting Machine from Seed Processing Holland is a system that coats seeds to produce pellets. The process starts with feeding the seeds into a weighing bin from two vibratory feeders –one for course dosage, and the other for fine dosage, until it reaches the desired weight. Then it is fed into the pelleting chamber where it is constantly rotated, with the use of a rotor. In the meantime, a preset amount of liquid and coating powder is dosed automatically until the desired pellet size is achieved. The 3-dimensional movement of the seeds from constant rotation allows for a good build-up of the pellets.

The system features a high-pressure fan where the air is blown under the rotor to avoid clogging between the rotor and chamber wall. The speed of the rotor can also be adjusted by the operator. The system is equipped with a transparent plastic hatch cover with a grip for easy visibility. Seed calibration and drying processes can be added optionally.

Rotary Seed Pelleting Machine

To coat your consumer products with color or taste-enhancing substances, specialized technologies are available that ensure all the contents are individually and evenly covered. The process starts with loading your goods onto rotating drums, exposing the products to spray nozzles that treat them with your prescribed coating formula.

Coating

At the industrial level, the application areas of pellets range widely in fields such as feeds, biomass, wood chips, sawdust, and other renewable raw materials. To adapt to the most diverse requirements, the pelleting presses must have a modular design while keeping maintenance costs low and providing a long service life.


<h2>Producing pellets using a modular pelleting press with an energy-efficient direct drive</h2>
The MAXIMA Pellet Mill from SALMATEC is an industrial-grade pelletizer capable of producing pellets for various applications like feeds, woodchips, recycled plastics, and many more renewable raw materials. The system has a vertical ring die with optional 2 or 3 rollers that can be equipped with a cooling system. The rollers press the product through the ring die at the highest possible pressure before cutting it down to the right size with its adjustable knife. The system has a lifting frame to support heavy parts such as rollers and dies removed during maintenance.

The unit has a central lubrication system that automatically lubricates the rollers and the main bearings. A maintenance drive is equipped inside a well-ventilated housing for larger units to ensure slow and safe die rotation for work on the press tools. The system is made from high-quality materials and complies with the latest safety standards and guidelines. The Maxima provides energy efficiency and equal power transmission thanks to a one-step operated v-belt drive. The system is available in various capacities of up to 50 tons per hour, depending on the type of machine and product application.

Industrial pellet mill

Large industries are shifting towards more environment-friendly technology, such as recycling wastes and utilizing them as an alternate energy source. For instance, sawdust and wood chips from wood mills are collected and processed into pellets which can be used in households or large industrial plants as a source of energy for heating systems. Plastic waste can also be recycled and made into pellets. Later these will be used in injection and molding machines to produce bottles, containers, or bags.


<h2>Turning wood and plastic byproducts into uniform pellets using a complete pelletizing system</h2>
The Complete Pellet Line from SALMATEC is a pelletizing system that includes multiple processes from conditioning raw materials and turning them into uniformly sized pellets. The entire system is specifically designed for the required product specifications. The conditioner helps the products achieve the optimum amount of moisture before feeding them to the pelletizer. The moisture content of raw materials can be controlled through a conditioning system in which the product moves inside a chamber while steam is also injected.

The pelletizer can be equipped with 2 or 3 rollers and multiple knives to cut the extruded products from the die into the necessary pellet size. The pellets then go to the cooler to prevent them from sticking to each other before storing them for at least one day in the silos. This process allows the structure of the pellets to stay intact and prevents them from breaking into tiny particles. Each complete system is designed according to the desired production capacity, raw material input, and high safety standards.

Complete pellet line

Pellet Mills

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