Pellet mills: Scaling-up to boost operational efficiency

by Famsun, China

October 6th, 2020 – Famsun recently rolled out a 70t/hr pellet mill to help feed producers tackle sustainability challenges. To feed the anticipated human population of 9.8 billion by 2050, we need to promote sustainable consumption and responsible production patterns in the global food production system. As a solution-focused processing partner from farm to table, Famsun strives to be forward-thinking and is always considering how to improve production systems through better utilisation of natural resources, for example, by reducing raw material waste and energy losses.

Due to proven animal growth and feed efficiency results, the pelleting process has been a very popular processing solution in the feed industry for many decades. However, improving the pelleting line’s yield efficiency is an essential design objective to help feed factories operate more sustainably. The new Famsun K70 Pellet Mill is such a machine using this design principle. The gear driven K70 design boosts capacity while also improving energy efficiency and operational reliability, which seeks to minimise line interruptions that can create substantial raw material waste.

This giant machine is a new member of the Famsun K-Series pellet mill family, which includes the K15, K15X, K20, K25, K35, and K50. Since the initial introduction of the first K-Series model in 2014, over 350 units of this gear-driven pellet mill are now in operation around the world. The popularity of this line of pellet mills is a result of its excellent reputation to perform reliably, its ability to control product quality, and for its ease of maintenance.

The K70 Pellet Mill was developed not only by scaling-up the machine’s size from its existing models but also by incorporating the latest innovations and design considerations. By introducing this new unit, the Famsun company can help feed producers become more sustainable and allow them to continue leading the market well into the future.

Geardrive to maximise power utilisation

The gearbox is more compact, efficient, and has a long service life. Famsun gear drive pellet mills are equipped with either a German SEW or an American Rexnord gearbox, ensuring efficient power transmission. The design of the large gearbox ensures stable and trouble-free running with minimal vibration and noise (< 95 decibels). Also, the gears and bearings are designed for a service life of one million hours or more to ensure a long and stable running performance, considerably reducing downtime, maintenance, and operational costs.

Optimised design to boost capacity up to 70 t/h

The K70 drive motor can be as large as 500kW and it uses a ring die of 1,070mm in diameter. The feeding and compression structure were also optimised in this new pellet mill.

The new design optimises the working area and linear velocity of the ring die. The optimised power per unit area is between 15-to-25 percent higher than that of regular ring die. Therefore, it has dramatically increased production output. The improved feeding scraper size and angle evenly spread the mash into the compression area between the ring die and press rollers. Thanks to uniform feeding, the pelleting process is more stable, minimising trouble-related downtime, while the pelleted product is of more consistent quality.

Automated tools for smooth operation

Famsun provides powerful automation with the K70 to help operators manage this massive machine with ease. The clamp installed ring die and the unique die and roller replacement assist tool make convenient replacement possible. The automatic roller adjustment system can achieve the target gap quickly and efficiently. The distinct drive shaft end coupling has ample space to ensure the motor doesn’t need to be disassembled for maintenance. The roll-speed slip detection device also alerts the operator of any potential die blockage risks in advance.

CE standard details to ensure the safety of man and machine

Over many years of closely collaborating with customers all over the world, Famsun researchers have established the principle of adopting CE safety standards and Famsun’s principles of ergonomic design into every new product. Factors such as the safety of the equipment and operators and requirements regarding a safe working environment are taken into consideration in developing the K70 pellet mill. All these details have ensured man and machine safety, thus improving productivity.

For equipment protection, the K70 includes a shear pin, a gearbox oil level monitoring system, and a gearbox cleaning and de-ironing design that ensures a very long, reliable, continuous, and stable operation.

Strictly following CE safety standards, safety shields are equipped at the observing outlet, air cylinder, gearbox coupling, shear pin disc and a power-off limit switch on the pellet mill access door ensures additional reassurance of total safety. The shields not only prevent dust but also protect the personal safety of operators. The safety shield at the discharge chute prevents the return of feed mash and steam and stops the operator from reaching the internal part of the hopper. A safety shield also prevents pieces of broken shear pins from being hurled into the factory. All of this reflects the engineering innovation of the K70 Pellet Mill.