Zhangjiagang Kaichuang Mechanical GL5-50 Fully Automatic Dry Granulator may encounter the following faults and solutions in production:

1、 Abnormal material handling

1. Interruption or blockage of feeding

Phenomenon: The screw preloading feeding mechanism is stuck, and the material accumulates at the inlet of the material cylinder.

Reason: The material contains impurities or clumps; The synchronous belt of the feeding motor is loose; The gap between the screw and the barrel is improper.

Handling: Shutdown to clean up foreign objects and crush clumped materials; Tighten the synchronous belt; Calibrate the distance between the screw and the barrel to 0.1-0.3mm.

2. Uneven compression

Phenomenon: The thickness of the sheet material output by the pressure roller varies, accompanied by powder leakage from the side sealing plate.

Reason: Unbalanced pressure of the pressure roller; Wear of side sealing plate; The moisture content of the material exceeds the standard (>5%).

Processing: Calibrate the double pressure roller pressure through the hydraulic system; Replace the PTFE seal; Pre dry the raw materials to a moisture content of 3% -4%.

2、 Power system malfunction

1. Main motor overload shutdown

Phenomenon: Motor overheating triggers protection, resulting in an abnormal increase in current.

Reason: The pressure roller bearing is stuck due to lack of oil; Excessive hardness of the material leads to a sharp increase in load.

Solution: Stop the machine to check the lubrication system and replenish high-temperature resistant hydraulic oil; Reduce material hardness or replace high-strength pressure rollers.

2. Abnormal noise from the whole granule mechanism

Phenomenon: The grinding blade shaft produces a metallic friction sound during operation.

Reason: The gap between the whole grain cage and the sieve is too small; Bearing damage; The blade is loose.

Solution: Adjust the distance between the cage and the sieve to 1.5-2mm; replace the bearing; Tighten the bolt of the pulverizer blade.

3、 Particle molding defects

1. Particle adhesion and agglomeration

Phenomenon: The finished particles adhere to each other and form clusters, resulting in poor fluidity.

Reason: The whole grain temperature is too high (>50 ℃); Blade passivation; Insufficient cooling water flow.

Solution: Check if the cooling water channel of the pressure roller is blocked; Grind or replace the cutting blade; Increase the circulation of cooling water.

2. Hollow or broken particles

Phenomenon: The particle structure is loose and fragile.

Reason: Poor vacuum exhaust; Insufficient compression density; The particle size distribution of raw materials is unreasonable.

Solution: Clean the vacuum pipeline; Raise the pressure of the roller to the process standard; Control the fineness of raw materials (with a proportion of ≥ 20% below 0.25mm).

4、 Abnormal temperature control and energy consumption

1. Abnormal increase in energy consumption

Phenomenon: The power consumption per unit output increases by more than 30%.

Reason: Heating element aging; The frictional resistance between the pressure roller and the ring mold increases.

Solution: Replace the electromagnetic heating module; Polish the surface of the pressure roller and apply food grade lubricant.

2. Cooling system failure

Phenomenon: The surface temperature of the pressure roller continues to rise, and the material carbonizes and turns black.

Reason: Blockage of cooling water pipeline; Refrigeration unit malfunction.

Treatment: Use weak acid solution to circulate and clean the waterway; Repair the condenser of the refrigeration compressor.

Regular preventive maintenance (such as replacing hydraulic oil every 500 hours and calibrating pressure sensors) can significantly reduce the failure rate. It is recommended to reserve spare parts for key components such as rollers and screens to ensure continuous production.