The disc pelletizer, or pan granulator, is the device of choice for processing powdered bulk solids and fines into rounded, dust-free granules, improving handling and transportation qualities, enhancing performance, and creating a premium product.
As with most process equipment, choosing the right manufacturer can quickly become overwhelming. Here are a few considerations to keep in mind during vendor selection to ease the decision-making process and ensure a good fit.
Testing Capabilities
Unless the project at hand is a carbon-copy replacement of an existing system, select a manufacturer with on-site testing capabilities. A thorough testing program is often vital to the successful commercialization of a pelletizing process for two reasons:
- To confirm (or deny) feasibility: Not all materials respond favorably to agitation agglomeration. Some readily pelletize, while others take a little coaxing, and still others refuse. Ensuring the intended process is physically and economically feasible up front saves many costs and headaches in the long run and significantly de-risks the path to commercial-scale production.
- To develop and refine the process: Whether working with a new process or a well-established one, process development testing is often essential to gathering and refining process data for commercial scale-up.
This is because some variations in a material’s physical parameters or chemical composition can cause it to respond differently to the agglomeration process. A common example of this is limestone; while limestone is widely pelletized, the variation it exhibits across sources makes testing essential to engineering a process that can consistently and reliably produce on-spec product.
Further, testing reveals potential process challenges, allowing them to be addressed through the equipment design or planned for in the process flow.
For these reasons, FEECO typically recommends customers go through testing in the FEECO Innovation Center prior to equipment design. In addition to informing on equipment decisions, such testing can also help determine if and what type of preconditioning may be necessary, as well as drying parameters for reaching the intended specifications of the end product. Here, both batch and continuous pilot plant testing are available.
Feasibility testing on a batch disc pelletizer (pan granulator) in the FEECO Innovation Center
Material Experience
Past experience with the material at hand, or an extensive background of experience working with different materials can be a valuable asset to a project. This type of experience gives manufacturers a solid understanding of where potential challenges might exist or where modifications to equipment or the process may be necessary.
Synthetic gypsum pellets produced on a FEECO Disc Pelletizer
Ongoing Support
Avoid manufacturers that do not provide parts and service support. Support after the sale of the equipment is often just as imperative as the equipment itself.
While this is true of many types of process equipment, it is particularly true of disc pelletizers. In addition to providing spare parts, after-sale support is crucial to getting the process up and running. The finicky nature of the pelletizing process can make reaching the desired capacity a challenge during the start-up process. As such, buyers should select a manufacturer that, in addition to providing spare parts, is also capable (and willing) to work with the buyer through the start-up process to reach rated capacity as quickly as possible.
This type of support is also a lifeline in the event that process conditions or feedstock characteristics change, allowing the producer to get back to a stable and consistent operation as quickly as possible.
A FEECO Disc Pelletizer on service visit
Training
One of the major reasons for which the disc pelletizer is chosen for an operation is that it provides ample opportunity for fine-tuning granule characteristics and responding to changes in process conditions through several adjustable variables. This advantage, however, means that operators must be trained not only on the mechanics and operation of the disc pelletizer, but also on the principles behind agitation agglomeration.
Operators unfamiliar with how this type of agglomeration works are likely to struggle to produce on-size product, as well as granules of the desired quality. Select a provider that can provide pelletizing process training to operators for best results.
A Process Expert studying a disc pelletizer in the FEECO Innovation Center
Complete Disc Pelletizer System Suppliers
While the disc pelletizer can serve as a stand-alone agglomeration device, it does not operate in isolation; it is part of a larger granulation system that incorporates feeding, drying, screening, and recycle at a minimum.
Depending on the manufacturer, these different parts of the process may require sourcing from multiple vendors, leaving the buyer to integrate the process into a continuous operation. By selecting a manufacturer that can provide the complete pelletizing plant, buyers can avoid the headaches associated with piecemealing the system.
The diagram above illustrates a typical disc pelletizing setup with preconditioning, drying, cooling, screening, and recycle.
High-Quality Pelletizer Design Fabrication
The value of proper disc pelletizer design and fabrication should not be underestimated. Manufacturers commonly make the mistake of under-sizing the pelletizer, tying the hands of operators to produce product at the desired capacity. Further, several aspects of the design and fabrication process can influence the performance and longevity of the unit. Selecting proper materials of construction, fitting assemblies to avoid interference, and abiding by strict quality standards, should all be expected of a disc pelletizer manufacturer.
FEECO Disc Pelletizer in fabrication
In vetting manufacturers, be sure to ask for disc pelletizer project profiles and references that demonstrate experience.
Conclusion
Selecting the right disc pelletizer manufacturer for a given job can be a challenging undertaking. By considering factors such as on-site testing facilities, material experience, ongoing support, training, and high-quality design and fabrication, however, the process can be made much more simple.
FEECO is the world’s leading provider of disc pelletizers for industries ranging from fertilizers and soil amendments, to specialty chemicals and ores. We offer batch- and pilot-scale testing in our Innovation Center and have a comprehensive parts and service program to support all of your disc pelletizer needs – including training. All FEECO disc pelletizers are designed and manufactured to the highest quality standard for an efficient and reliable result, and can be provided as a stand-alone unit, or as part of a complete pelletizing system. For more information on our disc pelletizers, contact us today!