The replacement cost of the consumable parts (flat die and roller cover) of a flat die granulator accounts for over 70% of the total equipment operation and maintenance costs. Proper daily maintenance directly impacts the life of these consumable parts.
- Precise Maintenance of the Flat Die
After each production run, the surface of the flat die granulator and the die holes must be cleaned of any residual raw material. Compressed air can be used to blow out the die holes, followed by a soft-bristled brush to clean the surface of the flat die to prevent scratches caused by hardened raw material during the next machine start-up. If one side of the flat die is severely worn, the die can be flipped over and used. Minor chipping of the die holes can be repaired with a grinding wheel to reduce the frequency of replacement.
- Regular Inspection and Adjustment of the Roller
Check the roller cover weekly during flat die granulators shutdown to check for wear. Replace any noticeable grooves or cracks. Also, adjust the gap between the roller and the flat die using a 0.2-0.4mm feeler gauge inserted between the two to ensure a uniform gap. Excessive gaps can lead to loose pellets, while too small a gap increases friction between the roller and the flat die, shortening their lifespans.
- Drive and Lubrication System Maintenance
Check the drive belts between the motor and roller monthly. If the belts are loose, adjust the belt tension. Lubricate the roller bearings with special grease every two weeks. The amount of grease should be sufficient to allow a small amount to overflow from the bearing gap. Excessive grease will result in poor heat dissipation from the bearings.
