Integrated system for protecting operators, equipment and infrastructure in a pellet and feed plant

QDES.60 - Quick Die Exchange System​

Quick Die Exchange System shortens the pelletizer changeover time to less than one hour. QDES.60 is a system for quick centering and securing the die to the rotary shaft disc. It is carried out using four fixed centering jaws, which determine the position of the die axis relative to the rotary shaft axis and the frontal plane of the rotary shaft disc perpendicular to the rotary shaft axis. The die is released from the jaws by a hydraulic pump in a few seconds, after unscrewing only a dozen or so mounting screws.

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QDES.60 allows the dismantling of a hot die, while maintaining appropriate safety measures, without losing time often associated with the need to at least partially cool it down.

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CALS - Central Automatic Lubrication System (CALS)​

The Central Automatic Lubrication System frees operators from the burdensome duty of ensuring that the granulation unit is properly protected with grease. It is constructed of a progressive valve, a system of high-pressure lines (KO) supplying grease to the roller bearings and the rotating shaft. CALS is controlled by a central controller with a suitably designed program.

High level of automatic operation control

The granulator and all machines are equipped with a full set of sensors that continuously monitor the condition of individual units in the line. Thanks to them, our Automatic Granulator Control System (AIAC) allows for fully automatic and safe operation of the granulator, and AIAC controls the entire factory. We recommend expanding the functionality of the factory with ATEX solutions.

 

Sensors and parameters monitored automatically:

• belt slip sensor,

• roller bearing temperature sensor,

• main rotary shaft bearing temperature sensor,

• central lubrication sensor,

• raw material temperature sensor,

• granulate temperature sensor,

• raw material lack sensor under the rollers,

• main drive motor bearing temperature sensor,

• optionally a roller to die pressure torque sensor,

 

Automation functions

• current overload protection,

• protection against blocking the conditioner by the raw material,

• protection against lack of automatic lubrication,

• protection against overheating of the bearings of the rotating shaft and bearings in the rollers,

• protection against lack of medium in the tank (steam or water cut-off),

• protection against excessive increase in the temperature of the granulate,

• protection against slippage of the driving belts of the rotating shaft,

• fire protection,

• control of the system filling the granulator tank,

• control of the system dosing steam / water and liquid additives,

• optimization of the granulator efficiency,

• control of the operation of the pump lubricating the rollers and the main bearing,

• control of slippage of the main motor belts,

• control of the steam temperature, the temperature of the main bearings of the rotating shaft and rollers.

 

Pellet Mill Control Panel PMCP

Each pellet mill has its own control panel, based on an LCD display, used for local management of work, without the need to go to the often distant control room.

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The Pellet Mill Control Panel displays the current load of the main engines, the % value of the raw material and steam and water feed, roller bearing temperatures, the temperature of the raw material at the discharge from the conditioner, the temperature of the pellets at the discharge from the pelleting chamber and the pressure of the pneumatic system.

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The panel allows to control the left <> right rotation, Start/Stop of the conditioner, Stop of the pellet mill, adjustment of the screw feeder, adjustment of steam/water.

 

Electrical switchboard for the granulator (REG) or Feed Production Unit (REZ1)

The granulator can optionally be supplied with its own electrical switchboard equipped with a controller with our Automatic Granulator Control System (AIAC). The set includes a 10” or 12” LCD control panel. In the version expanded with PC computers (located e.g. in the central control room), there is a standard possibility of current bidirectional viewing of the operating status and remote control.​

 

Soft-Start start-up

All GR granulators equipped with the REG electrical switchboard are started via Soft-Start. Thanks to it, the starting current is low and there is no risk of penalties from the energy supplier related to exceeding the power. Soft-Start extends the life of the drive unit.