1. Product Introduction

The Flat Die Granulator utilizes a horizontally positioned circular mold (the Flat Die) and press rollers to form pellets. Originally developed for feed processing, its use has expanded significantly into resource recycling and the fertilizer industry.

• Key Applications: Especially suitable for processing materials with high crude fiber content, such as straw, sawdust, peanut shells, and cotton stalks. It is also widely used for organic fertilizers (chicken/pig manure) and refuse-derived fuel (RDF) pellets.

• Output Form: Produces cylindrical pellets with a wide range of diameters, typically between 2.5mm and 30mm.

2. Performance Features

The Flat Die Granulator is known for its robust physical characteristics, offering unique advantages over Ring Die models in specific sectors:

• Powerful & Uniform Pressure: Unlike other designs, the roller diameter is not restricted by the mold size, allowing for larger bearings and higher crushing pressure. This results in a superior shaping rate when processing tough biomass fibers.

• Wide Material Adaptability: It is more tolerant of varying moisture levels and can effectively handle raw materials with poor natural binding properties.

• Simple Operation & Maintenance: The intuitive horizontal structure makes it easy to adjust the gap between the rollers and the die. Replacing wear parts (the die plate) is faster and more convenient than in Ring Die systems.

• Easy Monitoring: The open design of the granulation chamber allows operators to observe the material flow and formation in real-time, facilitating quick troubleshooting.

• Smooth & Dense Pellets: The forced extrusion mechanism ensures high pellet density and a polished surface finish.

3. Working Principle

The operational logic of the Flat Die Granulator is based on "Friction-Extrusion under Relative Motion."

Core Process Stages:

1. Vertical Feeding: Material enters the granulation chamber vertically, aided by gravity. Since the die is horizontal, the material spreads evenly across the surface of the die plate.

2. Forced Compression:

   • Rotating Die Type: The die plate rotates, causing the rollers to spin and generate pressure.

   • Rotating Roller Type (Mainstream): The die plate remains fixed while the rollers revolve around the central axis. Under intense rolling pressure, the material is forced into the dense matrix of holes in the flat die.

3. Thermal Compaction: The friction generated during extrusion creates instantaneous temperatures of 60°C to 80°C. This heat softens the lignin in biomass fibers, acting as a natural "glue" that binds the particles tightly together.

4. Cutting & Discharge: As the cylindrical strands are extruded from the bottom of the die, they are cut to a uniform length by a rotating knife. The finished pellets are then discharged via the slinger plate.