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Correct use of pellet feed processing equipment
In order to ensure that pellet feed processing equipment operates efficiently, extends its service life, minimizes malfunctions, and improves economic returns, the author has compiled a set of practical recommendations for reference. These guidelines cover installation, operation, maintenance, and troubleshooting, aiming to support operators in achieving optimal performance.
1. **Installation and Commissioning of Equipment**
1.1 Before installation, verify the layout and foundation plan to ensure the dimensions match the design specifications. Any discrepancies must be corrected before proceeding with installation.
1.2 Installation personnel should thoroughly understand the technical requirements of each device and follow them strictly during the process.
1.3 During transportation, equipment may suffer damage or deformation. A detailed inspection should be conducted prior to installation to ensure all parts are intact and ready for use.
1.4 Each piece of equipment should be labeled with a number, and an installation flow chart and schedule should be prepared. Install one unit at a time according to the planned sequence.
1.5 The installation order should follow a top-down approach. Once the main unit and frame are in place, connect the pipes and electrical components.
1.6 Ensure all necessary tools and materials are available before starting the installation.
1.7 After installation, check that rotating parts move smoothly without any sticking or unusual noises. All connections should be secure and leak-free.
1.8 Electrical installations must comply with national regulations. Wiring should be clearly marked, and protective covers should be used to prevent rodent damage.
1.9 Conduct individual unit testing under no-load conditions, and perform load tests only after confirming everything is functioning properly.
1.10 Calibrate the electronic batching and packing scales before the load test to ensure accuracy.
1.11 Run the system continuously for 8 hours without faults before handing it over for production.
2. **Operation and Usage**
2.1 On-duty personnel should inspect the equipment before starting. Check for foreign objects, flexible movement of rotating parts, tightness of connections, and signs of leakage.
2.1.1 Ensure gears have sufficient lubrication, belts are properly tensioned, and components like hammers, dies, and rollers are in good condition.
2.2 Control room staff should manage daily production schedules and material storage to ensure smooth operations.
2.3 Operation Sequence: Turn on the main power first, then activate each system switch. Use the alarm signal to notify workers and start the dust removal fan before initiating the production line.
2.3.1 Raw Material System: Start with the dust fan, followed by the crusher, conveyor, sieve, and elevator. Shutdown should follow the reverse sequence.
2.3.2 Secondary Material System follows a similar shutdown procedure.
2.3.3 Batch Mixing System can operate in manual or automatic mode. Manual batching should follow pre-set formulas, while the computer controls weighing and mixing times.
2.3.4 Pelletizing System is controlled via a dedicated control panel.
2.4 Control room staff must monitor the simulation screen and respond promptly to any signals indicating empty or full ingredient bins.
2.5 Operators should enter the correct formula into the computer and manage auxiliary devices as per the production plan.
2.6 When operating the feeding devices, ensure the main motor runs within rated current and avoid clogging.
2.7 Additives such as vitamins and trace elements should be quantitatively fed into the mixer. Input timing should be coordinated with the control room to ensure accurate dosing.
3. **Maintenance and Repair**
3.1 Follow manufacturer guidelines for maintenance. Use ZG-3 calcium-based grease for bearings and HJ-60 oil for reducers. In cold weather, switch to HJ-20 oil.
3.2 Perform minor maintenance every six months and major overhauls annually. Replace lubricants, clean bearings, and fix damaged parts.
3.3 Regularly adjust belt tension to prevent slippage during operation.
3.4 Replace or repair consumables like hammers, screens, and pressure rolls based on performance and product quality.
3.5 If hammers wear out, rotate or replace them while maintaining their original arrangement. New hammers should be weighed and balanced to ensure no more than 5g difference between sets.
3.6 Calibrate the electronic scale after six months of use to maintain accuracy.
3.7 Flush the granulator cavity after each shift to remove residue.
3.8 Keep the control room clean and quiet for efficient monitoring.
4. **Common Faults and Troubleshooting**
4.1 Strong vibrations and noise in the crusher may result from improper hammer alignment, loose bolts, or worn parts. Reinstall hammers according to the diagram or replace damaged components.
4.2 Excessive return of material to the crusher inlet is often due to overfeeding. Stop the machine, clear the chamber, and adjust the feeding rate.
4.3 Unusual noises in the crusher could indicate foreign objects or internal component failure. Shut down immediately and inspect the crushing chamber.
4.4 Coarse particles in the finished product may stem from damaged or improperly installed screens. Clean or replace screens and ensure proper sealing.
4.5 Poor mixing uniformity may be caused by broken belts. Check and tighten the drive belt or replace it if needed.
4.6 Excessive dust in the work area usually results from faulty seals or worn ducts. Inspect and repair all sealing points.
4.7 Motor weakness or overheating could be due to a phase failure or overload. Stop the machine and check the electrical system or reduce the workload.
4.8 Poor discharge from the pellet machine may occur due to blocked inlets, mold holes, or incorrect moisture levels. Clear blockages and adjust steam supply.
4.9 A dim or unlit signal light on the analog screen may indicate a faulty leveler, poor contactor connection, or a broken lamp. Replace or repair as needed.
4.10 A significant drop in productivity could be caused by worn hammers, blocked screens, or low steam pressure. Inspect and adjust accordingly to restore efficiency.