Why do the two roller shells used by the pellet machine have inconsistent wear?

During the use of the pellet machine, the two roller shells have different wear. What is the reason? What impact does uneven wear have on pellet machine production? RICHI MACHINERY summarizes its experience and the following is a detailed analysis of possible reasons:

Uneven material distribution

• Irrational design of the feed port:
  If the material enters the pellet machine at different angles, the two roller shells may be subjected to different amounts of material and impact forces. For example, if the material enters from one side at a larger angle, the roller shell close to that side will first contact more material, and will be subjected to greater friction and pressure, thus wearing faster.
• RICHI Machinery recommends:
  Check and clean the feed port to ensure that there are no blockages that affect the uniform distribution of the raw materials. At the same time, consider improving the design of the feed port, such as using a more reasonable diversion structure to allow the raw materials to be evenly distributed between the two roller shells.
• Uneven material itself:
  The flow characteristics of different materials in the pellet machine will also affect the wear of the roller shell. The material on one side may have high humidity or contain more hard impurities. The material with high humidity has strong adhesion to the roller shell during the pressing process, or is easy to adhere to the roller shell at a specific position, increasing the wear of that part. Other materials may contain more impurities or particles with higher hardness, which will cause uneven wear on the roller shell during the flow process.
• RICHI recommends:
  pre-treat the material before pressing. If the material humidity is uneven, you can first mix and dry it to make it uniform. And the material should be screened to remove hard impurities and reduce the adverse effects of impurities on the roller shell.

Differences in the material of the roller shell itself

• Different hardness:
  If the material hardness of the two roller shells is different, the roller shell with lower hardness will naturally wear more easily. For example, one roller shell may be made of ordinary steel, while the other is made of specially treated wear-resistant steel. Under the same working conditions, the roller shell made of ordinary steel will wear significantly faster than the roller shell made of wear-resistant steel.
• Differences in heat treatment processes:
  Even if the roller shells are made of the same material, their performance will be different if different heat treatment processes are used during the production process. For example, roller shells that have been quenched usually have higher hardness and wear resistance, while roller shells that have not been quenched are relatively soft and easy to wear. RICHI rollers are evenly heat treated, and rollers with hardness values ​​of HRC58-62 have higher strength and wear resistance.

Installation and commissioning issues

• Differences in installation accuracy:
  If the accuracy of the two roller shells during installation is different, it will also cause different wear. For example, the installation position of a roller shell may be deviated, so that it does not fit tightly with other parts, and additional friction and vibration will be generated during operation, thereby accelerating wear. Roller shells with higher installation accuracy can work better with other parts and have relatively less wear.
• Improper gap adjustment:
  The gap adjustment between the roller shell and other parts is also very important. If the gap is too large, the material may accumulate in the gap, increasing the wear of the roller shell;
  if the gap is too small, the friction between the roller shell and other parts will increase, which will also cause accelerated wear. Therefore, correctly adjusting the gap between the roller shell and other components is one of the keys to ensure the normal operation of the pellet machine and reduce wear.

The impact of uneven wear of the roller shell

• The quality of pellet forming is reduced.
  Because the pressure of the two roller shells on the material is different, the degree of material extrusion is different, and the size and density of the produced pellets are uneven.
• Affecting the production capacity of the pellet machine.
  Due to the inconsistent working conditions of the two roller shells, the roller shell with severe wear may slip, idle, etc. For example, when the friction of the roller shell is insufficient due to excessive wear, the material cannot be effectively rolled into the pressing area, which slows down the overall production speed of the pellet machine.
• Increase the risk of equipment failure.
  Uneven wear will cause uneven force on the roller bearing, which is easy to cause damage to bearings and other components. Once these key components are damaged, the equipment needs to be shut down for maintenance, which will cause production interruption and seriously affect production efficiency.

If the degree of wear of the pellet mill roller is quite different, then the new roller should be replaced in time, and a roller shell with good quality, high hardness and strong wear resistance should be selected to ensure its service life and stability. Regularly check the wear of the roller shell and do regular maintenance.