High-Quality Roller Compactor/Granulator: The Basics

Why compacting?

Granulation or compacting is a technological process that involves particle size enlargement in which dust and powder are molded into shapes through the drying method.

The binding of the product is obtained by mechanical compression through a double roll press.

Furthermore, coagulation involves a chemical process, in which two rollers rotating in opposite directions compresses granular material into a larger chunk.

A decrease in the surface area of the coagulated material leads to a better product, and thus, explains why rough- texture feed is most appealing.

This implies that the large particle size retains a lesser surface area and hence a less work per unit volume is needed.

The high compaction pressure of a quality roller compactor allows the formation of a specialized solid shape product.

To get the best form of compaction, there is a need to partner with a reliable and experienced high-quality roller compactor manufacturer.

Application of Roller Compactor

1. Fertilizer, animal feed, and other micronutrients to give the desired mixture and enhance proper distribution in the soil.

2. Minerals, salt, and organic materials to fine or coarse granules.

3. Improve flow characteristics of fine materials.

The Process

Screening, milling, mixing, de-aeration, and material handling are integral parts of the common compaction and granulation plant.

Depending on the material, there is a need for proper selection of this equipment to ensure optimal operating conditions and excellent product.

The process of compacting or granulating normally follows these steps:

1. Materials from the material silo are fed into the compactor and mixed thoroughly.

The resulting feed materials are then compressed together by high-quality roller compactors.

2. The compacts formed are broken into granules of similar particle sizes as requested.   

Sizes below the required size are returned back into the roller compactor while those that are oversize are fed back for correction on the size.

3. Materials that satisfied the final requirement in shape and size are subjected to finishing processes.

These are drying and the application of anti-caking after which is the final packaging.

Features

· Non- complex  manufacturing process

There is no need for drying stages and humidification after dry-process granulation.

· Minimal change of forms

This system is best- apt to compact materials which are changeable in water or solvent and are thermally unstable.

· High-density products

A granulated powder or material of high density can be produced by a high-quality roller compactor.

· High compression force

Some roller compactor has a large compressive force which allows the formation of high intensity and high-density materials   

Soft granulation

The compression force of the compactor results from the hydraulic cylinder and the operative pressure exerted can be adapted for soft granulation through pressure reduction.

· Incorporation of high-performance screw

The roller compactor has a screw performance that determines and exerts a major influence on its granulating ability.  

The materials to be compacted are usually placed in between the rolls to enhance the process of de-gassing.

Efficient crushing and granulation

With a roller compactor, several types for fine particle and size are found based on the combination of different breakers.

Some have a screen, so as to efficiently get the targeted particle size based on their specifications.

A very important advantage of the high-quality roller compactor is the fact that they are built in a particular design that can operate under various conditions.

Conclusion

A lot of products such as fertilizer and animal feeds need to be thoroughly mixed, blended, and broken into the desired sizes using a roller compactor.

However to get value for money you need to partner with a reliable and trustworthy high-quality roller compactor manufacturer.