Meeting increasing process requirements is also a key challenge in pellet production. Manufacturers must meet high quality standards while reducing operating costs and conserving resources. Automation technologies offer solutions: they stabilize processes, reduce energy consumption, and minimize personnel requirements. That is why we at AMANDUS KAHL developed the EAPR and Distamat control systems. These systems optimize the production processes of our pellet mills and actively promote sustainability.
High-performance plants are essential for producing high-quality pellets, but maintaining stable production conditions is the most important factor for ensuring efficient, sustainable operation. Manual monitoring and readjustment are time-consuming and labor-intensive, and frequently lead to interruptions. This is why automation technologies are an ideal solution for pellet producers.
The Electronic Automatic Pellet Mill Regulation (EAPR) controls the pellet mill and the entire production line, contributing to resource-efficient production. Additionally, Distamat technology can be integrated into the pellet mill control system to automatically adjust the roller gap. This maximizes the service life of flat dies and pan grinder rollers while reducing energy consumption and improving pellet quality.
EAPR: automated control for maximum efficiency
The EAPR optimizes the operation of flat die pellet mills by controlling and monitoring the entire production process. Its central components are an on-site control cabinet with a 10" widescreen graphic touch panel (TP) and a programmable logic controller (PLC) with an S7-1500 CPU. Other panel sizes and control systems, such as Rockwell Compact Logix, are also available.
Users set all relevant process parameters and regulate the product supply via the dosing screw. The cooler, conveying screws, and associated auxiliary units can optionally be integrated into the automation solution. After installation, the EAPR takes over control and monitors the processes. Thanks to the optimal coordination of the process sequence and the option of remote maintenance, the system ensures maximum operational reliability and efficiency.
Flexibility and precision in process control
The EAPR offers numerous functions to ensure an optimally functioning production line.
- Load-dependent control: automatic adjustment of operating settings to the product load for consistent product quality.
- Throughput control (t/h): control of the product flow for maximum efficiency.
- Steam or liquid control: precise control of steam supply or liquid addition (e.g., water or molasses).
- Integration of additional liquids in the mixer (optional): option to control steam and up to two additional liquids.
This comprehensive automation solution enables stable, resource-saving, and efficient pellet production—individually adaptable to specific requirements.
Advanced automation options of the EAPR
To further automate the production line, the EAPR can be expanded with additional functions.
- A control unit for the control station enables centralized control and monitoring of all processes from a central control point.
- For seamless integration into existing plants, the EAPR can be connected to existing automation and process control systems (extensive data exchange is possible, e.g., via Profinet).
- Additionally, the EAPR can be expanded to include complete factory automation, including control of coolers, conveying systems, and other elements of the production line.
- A special highlight is the optional integration of the Distamat control system, which ensures a constant roller gap.
Distamat: precision and consistency in pellet production
A constant roller gap – the distance between pan grinder roller and die – is crucial for producing pellets of consistent quality. Distamat technology allows for the continuous adjustment and automatic control of this distance directly via the EAPR touch panel. It offers additional benefits:
- Automatic adjustment: A special measuring process detects deviations and regulates the pressure of the hydraulic system, ensuring that the roller gap remains constant regardless of product quantity or process conditions.
- Component protection: Distamat technology prevents direct contact between the die and rollers when product is lacking, reduces energy consumption, and extends the service life of the rollers, dies, and other wear parts.
- Unblocking program (optional): If the pellet mill becomes overloaded, the rollers are alternately raised and lowered to ensure an automatic restart.
- Simple retrofitting: Distamat technology can easily be integrated into existing control systems to efficiently retrofit older plants.
Conclusion
Whether producing wood pellets as an energy source, plastic pellets for recycling, or pellets from other raw materials, the EAPR with the optional Distamat automatic distance control system increases automation, efficiency, quality, and sustainability in production.
Survey of the benefits:
- Reduced personnel costs through automated control
- Lower energy consumption
- Longer service life of the machines
- Maximum operational reliability thanks to highly automated processes and remote maintenance options
Our technology enables efficient, sustainable, and economical pellet production, optimized for the needs of modern industrial plants.
