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kahl-small-scale-pelleting-press

KAHL small scale pelleting press

You may press finely sized powders together into dosages and quantities using compaction machines. The process separates the fed material into predefined measurements and packs the powders into blocks according to the specified density and shape to accommodate different end products.

Compaction

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.

Pelleting

Using pelleting presses allow you to compact your material granules into a homogenous mass by pushing powder into a pellet die hole and applying pressure with a roller. The compressed material is then cut down to size in equal measurements. Used for numerous applications, pellets vary in consistency and may require further temperature control to achieve the required solidity. In order to improve pellet quality, conditioners are an important part of the pelleting press process. This step treats the powders and raw materials hydrothermally, before being pressed, in order to achieve high quality pellets.

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

In order to produce items of a uniform shape and size, you will typically use an extruder machine that presses a fluid or solid material through a die. Depending on your use case, extruders adopt single- or twin-screw systems to push the mixture, first through a barrel that forms the items and, then, through a knife head that cuts them into your designed shape.

Extrusion

solid

Many industries that process materials in pellet, powder, or crumble form need a closely controlled drying and/or cooling process to ensure product quality. This line of cooling/drying conveyors provides this function in a highly flexible, modular design configurable to any industry.


<h2>A completely modular line of drying and cooling conveyors</h2>
Amandus Kahl’s line of cooling /drying conveyors is configurable to meet the cooling and drying needs of any industry that deals with pelletized or granular dry bulk material. Process air is drawn through a layer of the customer’s bulk product as it travels along a conveyor. The conveyor bed is either composed of slotted plates attached to driven chains, or a full fabric belt depending on the characteristics of the product being cooled or dried. The belt speed is adjustable and used along with configuration of the overall belt length to precisely determine the product retention time. For enhanced drying, process air can be heated to 200 C, but drying can also be achieved using only air at ambient temperature. Cooling is also controlled and enhanced by the characteristics of the process air and overall product retention time. The modular design of the line allows the use of several layers of belts to be stacked on top of one another and a wide variety of belt widths and lengths are available. Airflow through the array of belts can also be uniquely configured to accommodate a wide variety of process needs.

Belt dryer/cooler for pellets and granules

Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries. Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water.

Cooling

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. Drying technology exploits the modes of industrial heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

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

Milling &amp; grinding technologies are used to reduce the particle size of your product while preserving its essential properties. The choice of a suitable solution depends on your product feed, desired particle size distribution as well as your production volume.

Milling

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

Control the quality of your pelletizing processes using a pellet hardness tester. Pellet hardness is one of the most critical characteristics indicating process quality, and it is essential to ensure a desirable product and efficient downstream processes. The hardness can now be measured right after the pellets have left the cooler.
<h2>Monitor your pelletizing process with a hardness tester</h2>
Amandus Kahl’s pellet hardness tester is a hand-held device that allows the user to quickly and easily monitor the quality of their pelletizing process at the source without the need for laboratory equipment. Hardness/softness is a good measure of overall pellet process quality. Using this device allows the customer to test pellet softness and immediately adjust the process parameters to achieve the desired results without delays and lost production time caused by waiting for more sophisticated laboratory equipment.

The pellet hardness tester allows a simple in-the-field quality control for the pelletizing process. The pellet tester comes in two versions, manual and automatic. An operator can periodically rotate the adjusting screw on the manual version at different speeds to retrieve multiple readings. The automatic unit is motorized and works independently, offering more consistency and better comparison of the hardness values taken by different operators due to potential variation in operator handling of the manual version.

Pellet hardness tester

A crucial step before your products leave the production line is a quality check for dosage and standards. Equipment for measurement and control employs a range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized systems allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

Drawing samples and testing them for conformity with preset quality standards allows manufacturing units to produce a consistent quality of the product. In a batch process, sample testing ensures that each batch meets the specified standards. In a continuous process, product testing helps in the early identification of quality issues, saving significant time and resources, and preventing a sub-standard product from reaching the market. The selection of testing equipment depends on the identification of key quality parameters. These parameters may include volume, weight, viscosity, hardness, particle size distribution, sterility, and containment, among other parameters.

Testing

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

Food and feed industries require the highest standards of hygiene and sanitation. This entails frequent cleaning and inspection. There is also a need to closely control the cooling process in these industries to ensure product quality. A simple yet state-of-the-art pellet cooler can help improve sanitation standards, product quality and reduce Total Cost of Ownership.


<h2>Provides the cleanest and most efficient cooling technique</h2>
Geelen Counterflow’s Sanitary design cooler has been configured to meet the cooling needs of any industry while maintaining the highest standards of hygiene. It is especially useful in the cooling of animal feed and oilseeds as it is designed to allow easy access for inspection, the lowest need for cleaning, and the fastest cleaning times.

The cooler’s hood with a rounded top prevents the accumulation of liquids/solids and allows cleaning liquids to be drained off. Its new and smart design allows round air discharge thus eliminating low spots for fines or moisture build-up. There is also a collection trough that safely accumulates and channels the cleaning liquid into the floor drain.  It is also equipped with big access doors in bin walls and collecting hopper enabling fast and easy inspection and cleaning, without entering the cooler. There are no hollow spaces avoiding the risk of build-up in places that can not be accessed or cleaned.

The Counterflow Pellet Cooler provides full control over air volume, air quality, process time, relative humidity, temperature, and moisture. It also offers several upgrades with respect to your specific industry requirements.

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Counterflow pellet cooler

Cooling is a very important and critical process for feed hygiene and pellet durability index. Pellet formation mainly requires this process to withdraw heat and moisture from dense mass to form shaped mass and maintain product quality. Thus, a more specific solution is necessary for pelleted products with good flowing capabilities.


<h2>Saves downtime while ensuring smooth discharge of cooled product into the hopper</h2>
Geelen Counterflow’s triple grid cooler is typically used for the cooling of feed pellets, wood pellets, pulp pellets, etc. It is available in multiple sizes, each with different cooling surface areas. In combination with your process details, the cooling surface determines the air volume that is required for proper cooling.

It is equipped with an Air Flow Control Valve, which helps control the air volume accurately. It also stabilizes air volume automatically irrespective of the product bed depth. Its triple grid discharger ensures smooth discharging of cooled product into the hopper.  The required air volume can be recipe-dependent.

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Continuous pellet cooler

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

Pelleting Presses

The classification of sunflower seeds changes according to the pattern of its shell or hull. If the shell is solid black, it is an oilseed sunflower. With these, you produce sunflower oil. If the shell is striped, it is a non-oil sunflower seed or confectionery sunflower seed. These usually become snack food products. Whether to make them as snacks or oil, processing sunflower seeds include steps like drying, screening and cleaning, grading, roasting and de-hulling, flavoring, grinding, pressing, refining, and packing.

Sunflower seeds

Laundry detergents are currently on the rise due to increasing urbanization and the need for automation. The global market will reach $98,139.7 million by 2030 from $61,711.0 in 2020, influencing the demand for laundry detergent equipment. Unlike in Western countries, powdered detergents are more popular in Asia and China because they’re cheaper.

Laundry detergent

Powder detergent is one of the most widespread washing solutions used in the laundry of fabrics. Since they contain no water, powder detergents are lighter than liquid detergent or pods, which results in cheaper transport and, thus, a more affordable choice for the end consumer. Although manufacturers can formulate their powder detergents differently, the detergent powder production process relies on a combination of builders, surfactants, and enzymes.

Powder detergent

Growing populations and intensive farming in the last centuries reduced soil nitrate levels. Aware of the risks to food security, chemists Fritz Haber and Carl Bosch developed a way to industrialize synthetic nitrogen fertilizer production. They created the Haber-Bosch process for ammonia synthesis which is still used today. Manufacturers produce over a hundred million metric tons of nitrogenous fertilizers every year.

Nitrogen fertilizer

Phosphorous is literally at the root of the food industry. An essential ingredient in agriculture, it contributes to plant seed formation and root development. But farmers do not simply give their soil a dose of the chemical element. Instead, phosphorous fertilizer processing equipment blends it with other materials to manufacture effective formulas.

Phosphorus fertilizer

Unlike natural resins, synthetic resins produced in the industry make up 30 to 60% of plastic composition. Silicone resins, gum arabic, epoxy resins, acrylic resin and carrageenan are some of the different types of synthetic resins that exist. You manufacture them using the chemical polymerization process. Synthetic resin making equipment can help you with that.

Synthetic resin

Poultry feed

Fodder

In the feed sector, it's common to talk about feed as balanced, compound, or concentrate. Many people use one of these terms to refer to any feed mill product. However, the processing of feed concentrates, only requires grinding and mixing. The further transformation into pellets adds is an added value for the market.

Feed concentrates

Feed premix delivers a quality blend of macro and micronutrients to meet the overall growth and health needs of animals. Although they constitute a small portion of the feed, they provide enormous benefits by adding a balanced, nutrient-rich feed that supports the animal health. Feed premix making equipment ensures a proper combination of important ingredients to generate a perfect blend.

Feed premixes

Cotton has been used for about five millennia in ancient civilizations in America, Africa, and Asia. But up until the nineteenth century, cottonseed was not considered a product of value. The first cottonseed oil production started in 1833, consequently forming the cottonseed cake. Nowadays, we know cottonseed meal is a useful by-product for the feed industry and the fertilizer sector.

Cottonseed meal

There are two misconceptions about floating pellets. The first one is that they are made with a pellet mill, when the proper floating pellets-making machines are extruders. The second misconception is that floating feed is only used for fish. However, many other species consume feed on the water, such as crocodiles and birds.

Floating pellets

In aquafeed, you can find three types of pellets: floating pellets, sinking pellets, and slow-sinking pellets, because not all aquatic species eat at the same height of the water column. In the case of bottom feeders such as shrimp, river crab, sea bass, and some species of catfish, they eat sinking pellets. Contrary to tilapia and carp that feeds from the surface with floating pellets. Sinking pellets production must control water stability to preserve the quality and form of the pellets, avoiding nutrients' dissolution in the water.

Sinking pellets

Limestone

Kaolin, also called china clay, is made from natural rock composed of aluminosilicate clay or kaolinite. Kaolin has wide applications in different industries. Moreover, their classification depends on their industrial use, which includes film formation, fiber extension, polymer extension and chemical composition. Choose a kaolin processing machine to help you make kaolin for beauty products, paper filler, coating, ceramics and even medicine.

Kaolin

Chicken manure

Building a fire with wood sticks and logs is one of the most wholesome experiences. But it would take a lot of trees to heat up our homes. Instead, the fire-stoking power of plant material can be concentrated in a wood pellet, boosting its burning efficiency. However, wood pellet making machinery involves more than just the compaction of sawdust. Processing high-quality pellets from biomass can be as intricate as loading a fire-lay.

Wood pellets

Straw

Plant waste

Pellet fuel is an alternative to renewable energy sources made from recycled biomass such as wood waste (wood chips and sawdust), wastepaper, agricultural residues (straws, corn stalks, and other residual crops). Raw biomass is usually collected for recycling and pre-treated before being manufactured into pellet fuels to increase its burn efficiency. Pellet fuel is made uniformly in terms of size, shape, moisture, density, and energy content so it is easy to transport, store and feed into heat and power generation units.

Pellet fuel

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