We have several decades of granulation and pelleting experience which we use to provide a wide range of client pelleting solutions, typically beginning in our laboratory and then scaling up these pelleting process solutions in our vertically integrated granulation and pelleting facility. We efficiently develop and manufacture our clients' products employing a variety of these process pelleting technologies.
Development and/or production pelleting applications from our experience include:
- Flame Retardants
- Animal Feed Supplements
- Controlled Release Products
- Food Additives
- Detergent Additives
- Plastic Additives
- Water Dispersible Granules
- Organic Fertilizers
We utilize the following key equipment:
Powder Mixing with Optional Liquid Addition:
Our plow mixer with optional use of high intensity choppers is used to obtain a uniform blend. For products that require a wetting agent, liquid is added to form a mass suitable for extrusion.
Low Pressure Basket Extrusion / Medium to High Pressure Pelleting:
Our high pressure Pellet Press is used to compress material into pellets. Various die plates are available to match the application. Our low pressure basket extruders can be utilized as needed for lower pressure and wet granulation applications where quick dispersion or dissolution is required.
Spheronization as needed:
Our spheronizers can be utilized when our clients' products need to be made into spheres for either functional, marketing or aesthetic reasons. We can operate either on a batch spheronization basis for perfect sphere forming for this process step or continuously spheronize when only slightly rounded pellets are necessary.
Pellet Cooling and Drying as needed:
Our vibrating fluid bed processor is used to cool the pellets so that they can be packaged safely. For pelleted products that require drying, up to 300° F air can be used to remove moisture. Drying / Cooling air is filtered before exhausting. The pellets are screened to remove any fines.
Standard product analysis of the pellets such as bulk density, moisture content, and particle size analysis is available. Other analytical techniques can be offered through special arrangements.
Plant Design and Material Limitations:
The pelleting facility has appropriate electrical design, explosion relief and safety considerations to handle Class 1 powders (KST less than 199)
Pelleting Formulation Development and Testing is Available: We carry out formulation development projects for product optimization based on the client goals for active loading level, pellet size, crush strength, dmin/max, release profile, and flow characteristics required. These studies can be either simple refinements or complete development programs. The final goal is to create a client required pelleted product. Typical studies can range from several days to 6 to 8 weeks.