The flat die extrusion granulator is widely used in organic–inorganic compound fertilizer production. It forms pellets by forcing materials through a flat die under mechanical pressure, unlike rolling granulation. The machine produces dense cylindrical pellets and works well with high-fiber materials.
The extrusion granulator can achieve a granulation rate above 95%. Most powder materials are formed in one pass. Screening and material recycle are usually unnecessary.
Adjustable Pellet Size
Different die plates can produce cylindrical pellets with diameters of 2–10 mm. The built-in cutting device adjusts pellet length according to market requirements.
Binder-Free Granulation
Organic materials often contain natural fibers. Under high pressure, these fibers interlock and form pellets without additional binders. This allows 100% pure organic granulation.
Low Moisture Requirement
The extrusion process requires much less water than wet granulation. Many materials can be pelletized without a drying stage.
Low-Temperature Pelletizing
The machine uses a cold extrusion process. Pellet temperature usually stays below 30°C. This helps protect heat-sensitive components such as beneficial microorganisms in bio-organic fertilizers.
High Pellet Strength
Strong mechanical compression creates dense pellets. The granules have high strength and good resistance to breakage during transportation and application.
Structure
Flat Die Plate
The flat die is the key working component. It contains multiple extrusion holes. Material is pressed through these holes to form pellets.
Press Roller
The press roller rotates over the flat die surface. It compresses materials into the die holes under high pressure.
Feeding System
The feeding device distributes materials evenly across the die surface. This ensures stable extrusion and consistent pellet formation.
Cutter Device
A cutting blade is installed below the die. It cuts the extruded material into uniform pellet lengths.
Drive System
The drive system includes a motor and reducer. It provides the torque required for the roller and die rotation.
Machine Frame
A reinforced steel frame supports the whole machine and maintains structural stability during operation.
Principle
The flat die extrusion granulator works on the principle of mechanical compression. The raw material is fed into the granulation chamber and spreads evenly across the flat die.
As the main shaft rotates, the pressing rollers roll over the material. The intense pressure forces the material into the holes of the die. On the other side of the die, the material emerges as solid columns. Finally, the cutting blades slice these columns into uniform cylindrical pellets.
Application
Organic Fertilizer Production
Widely used for granulating fermented manure, compost, sludge, and agricultural waste.
Biomass Pellet Production
Suitable for biomass materials such as sawdust, straw powder, rice husk, and wood powder.
Compound Fertilizer Materials
Can process some powder fertilizer mixtures that require extrusion forming.
Feed Additives
Used for pelletizing feed premixes and additive powders.
Recycling Materials
Applicable to pelletizing industrial powder materials for recycling and reuse.
Advantage
Wide Material Adaptability
The flat die extrusion granulator can process many materials. These include fermented manure, straw powder, high-fiber organic matter, compound fertilizers, and some chemical powders.
Simple Structure and Easy Maintenance
The machine uses a flat die and press roller structure. Maintenance mainly focuses on the rollers, die plate, and cutting device. Operation and servicing are simple.
Easy Die Replacement
The flat die is designed for quick replacement. Dies with different hole sizes can be installed to produce different pellet diameters.
High Durability
The rollers and dies are made from wear-resistant alloy materials. Heat treatment improves hardness and extends service life.
Stable Operation and Low Energy Consumption
The machine structure is reliable. It runs smoothly with low vibration. Mechanical extrusion also keeps power consumption low.
Low Dust and Clean Production
Compared with rolling granulation, the extrusion process generates very little dust. The working environment remains cleaner and more environmentally friendly.
Technical Specifications
Model
Production (t/h)
Granulating rate (%)
Granule temperature rise (°C)
Power (kW)
SYM-150
0.08-0.1
>95
<30
5.5
SYM-250
0.5-0.7
>95
<30
15
SYM-300
0.8-1.0
>95
<30
18.5
SYM-400
1.1-1.8
>95
<30
22
SYM-550
1.5-2.5
>95
<30
33
FAQ
1. Does extrusion granulation require binders?
It depends on the material formula. Many organic materials contain natural fibers and can form pellets without binders. Some chemical formulations may require a small amount of moisture or lubricant.
2. How does it compare with a double roller granulator?
The flat die extrusion granulator is better for high-organic or high-fiber materials. Double roller granulators are more suitable for dry chemical fertilizers. Extrusion granulation produces stronger cylindrical pellets for mixed formulations.
3. Can different materials use the same die?
Some materials can use the same die. However, different materials may require different hole diameters or compression ratios for optimal pellet quality.
4. How should the machine be cleaned when changing materials?
Run dry powder materials or materials mixed with a small amount of vegetable oil through the machine. This helps purge residual material from the die holes and prevents blockage during the next production batch.
