The disc pelletizer, also known as a pan granulator, is the preferred stirred agglomeration (wet granulation) method for soil amendment producers, mineral processors, and chemical manufacturers, and is prized for its high size yield, ability to fine-tune products Favored, and the high-quality round pellets it produces.
While this versatile machine is relatively low-maintenance, it does require some routine maintenance and periodic inspections as part of a preventive maintenance program.
Adopting proper maintenance procedures will help ensure that the disc granulator continues to operate as designed, thereby improving process efficiency, product uniformity and equipment lifespan. This proactive maintenance approach also creates a safe working environment and helps avoid costly downtime.
General safety precautions
Before performing any type of maintenance on your granulator equipment, be sure to keep the following safety precautions in mind:
Stay alert for excessive wear, damage, or malfunction of equipment. This may include unusual smells, noises, or other abnormalities. Do not operate the equipment if any component is worn, damaged, malfunctioning, or appears in any way abnormal.
Granulator maintenance should only be performed in accordance with the original equipment manufacturer's instructions.
All maintenance related procedures should be documented. It is important to record details such as the date, supply and condition of each part and the person who performed the work or inspection. This can aid future troubleshooting activities and provide necessary baseline data for maintenance planning.
Shut down, lock out, tag out, and test run all machine controls before performing any maintenance work, including inspection, lubrication, or adjustments.
Basic maintenance of disc granulator
Following the maintenance procedures established by the OEM is the best way to prevent wear or component failure on any type of equipment, including disc granulators. This is also a great way to catch potential component problems early and resolve them before more serious problems occur. The following information outlines basic maintenance procedures for a disc granulator.
Regular inspection of disc granulator
Operators and maintenance personnel should regularly inspect equipment for any wear and tear as well as visual or auditory abnormalities that may indicate a problem.
Ensure proper lubrication
Bearings, reducers and motors should be lubricated regularly in accordance with OEM guidelines. Frequency of lubrication, as well as lubricant type, may vary depending on the equipment's custom specifications, so manufacturer guidelines must be followed.
Perform reducer maintenance
In addition to lubrication, it is also important to keep the reducer vents clean and free of material buildup. The oil in the reducer must also be maintained at the correct level. In addition, the reducer must be drained of all oil, flushed and refilled with new oil after six months of operation. Always refer to the reducer manufacturer's maintenance recommendations to ensure all maintenance procedures are completed correctly. It's also a good idea to send a sample of your reducer oil to a third-party testing facility to evaluate possible contaminants present in the oil, as this could be a sign of wear on internal components.
Perform spray system maintenance
Spray systems require regular inspection and cleaning, as the nozzles can become clogged if not checked and cleaned regularly. A clogged nozzle usually manifests itself as an irregular spray pattern. The spray system manufacturer's maintenance recommendations should be followed as outlined in the pan granulator manual.
Monitoring and handling of granulator plows/scrapers
The scraper plow is responsible for keeping the disc bed clean and flat. Damage/wear to the scraper plow can result in reduced granulator performance. It is vital that the granulator plows are all mounted at the same offset from the disc bed to ensure a flat and uniform surface for the granulation process.
Worn scrapers should be replaced as needed because they can cause uneven accumulation of material on the disc surface, causing the disc to run unbalanced and thus putting undue stress on the reducer.
Squeegees may wear out faster when using abrasives, so it's a good idea to keep spare scrapers and extra scraper bars for quick replacement.
Minimize material accumulation
Material tends to accumulate at multiple locations in the granulator. The most common places include: discharge chute, granulator plow, granulator disc edge and granulator feed chute.
Material buildup can impede material flow and reduce the efficiency of the granulator and, in some cases, reduce throughput. Excessive buildup can also cause further problems if large amounts of buildup break off and move along the production line.
Maintain expanded steel mesh
For disc granulators using porous metal liners, operators and maintenance personnel should pay close attention to the condition of the lining. Worn liners can cause inconsistencies across the entire disc surface, affecting overall efficiency and product quality.
Keep spare parts on hand
It is recommended to keep a stock of spare parts on hand, including extra nozzle tips and scrapers, in case damage to either component occurs.
Follow a disc granulator maintenance schedule
A typical maintenance schedule is outlined below. The operating conditions of the disc granulator and its operating level may require a more stringent schedule. It is recommended to work with the OEM to develop a schedule based on your factory's specific needs.
Weekly: Check the lubrication of drive components and lubricate as necessary.
Every two weeks: Check for abnormal wear. If found, identify the cause and correct it.
Monthly: Check parts for cleanliness; remove any accumulated material or foreign objects.
Every six months: Perform the above inspections to check the condition of the lubricant, send oil samples for third-party testing, and drain and refill the oil if necessary.
Main points of disc granulator maintenance
Always perform necessary safety checks and procedures before performing any maintenance.
Check all parts regularly for wear or abnormalities. This should include scrapers, nozzles and expanded metal mesh (if applicable).
Minimize material buildup on components.
Check and clean nozzles regularly to avoid clogging and inconsistent adhesive supply.
Follow the manufacturer's guidelines for maintenance procedures and lubrication requirements.
Keep the reducer vents clean and ensure the oil is at the proper level at all times.
Keep spare parts in stock.
Consider conducting a process audit to improve efficiency and resolve operational issues.
Ensure operators and maintenance personnel receive appropriate training.
In conclusion
While disc granulators do not require extensive maintenance, proper inspection and maintenance of the equipment is critical to increase longevity and reliability.
As a leading manufacturer of disc granulators, Bolong can support disc granulator operations with installation support, spare parts, routine maintenance, inspections and training.
To learn more about our disc granulator maintenance services, contact us today!
