With the continuous development of animal husbandry and aquaculture, feed processing equipment plays a vital role in the breeding chain. As a device that can improve the palatability, digestibility and nutritional utilization of feed, feed extruders are favored by the majority of farms and feed processing companies. However, like all mechanical equipment, feed extruders may also have various faults during use. Timely detection of problems and taking effective treatment measures can not only reduce maintenance costs, but also extend the service life of equipment and improve production efficiency.
This article will systematically introduce the common faults, cause analysis and response plans of feed extruders in daily operation, helping users to achieve safe, efficient and stable extrusion production.
Reasons:
The moisture content of the raw materials is too high or too low;
Large impurities or foreign matter are mixed in the raw materials;
The feeding system is blocked or faulty;
The frequency or angle of the vibration feeder is not adjusted properly.
Treatment method:
Check the dryness and humidity of the raw materials and maintain them within the standard moisture range recommended by the manufacturer;
Use a purifier or screening equipment to remove large foreign particles in the raw materials;
Clean the feeding system regularly to ensure smooth flow;
Check and adjust the parameters of the feeding equipment to ensure uniform and continuous feeding.
Reason:
The raw material particles are too fine or too wet;
The die orifice is too small, the mold is worn or blocked;
The temperature inside the equipment is abnormal, resulting in gelatinization of the raw materials;
The adhesion inside the extrusion chamber is not cleaned in time.
Treatment method:
Adjust the raw material formula ratio and add dry materials appropriately;
Stop the machine to clean the mold and replace it with a new mold;
Check whether the heating system is working properly and set the temperature control reasonably;
Clean the inside of the extrusion chamber regularly to prevent material accumulation.
Reason:
Uneven raw material particle size or unreasonable oil and fat ratio;
Unstable heating temperature;
Deformation of the discharge hole caused by die wear;
Unstable extrusion pressure.
Treatment method:
Improve formula design and optimize material mixing;
Check temperature control system and heating device to maintain stable temperature;
Replace severely worn molds;
Adjust spindle speed and optimize pressure output.
Reason:
The foot is not firmly fixed;
The spindle or bearing is worn or loose;
The internal parts are improperly installed or loose;
The motor rotor is unbalanced.
Treatment method:
Re-fix the anchor bolts;
Replace or add lubricating oil, replace bearings;
Check connecting parts and tighten loose screws;
If the motor problem is obvious, it is recommended to send it to the factory for correction or replacement.
Reason:
Overload operation for a long time;
Failure of cooling system;
Poor lubrication or aging of oil;
Excessive resistance in the extrusion cavity.
Treatment method:
Control the length of each production to avoid long-term continuous operation;
Check the water cooling or air cooling system to ensure normal operation;
Regularly replace lubricating oil;
Check whether the discharge is unobstructed and eliminate the factors of excessive extrusion resistance.
Reason:
Long-term use without replacement;
Excessive sand content in the raw materials;
Poor quality of mold materials;
Failure to clean the mold on time.
Solution:
replace the die regularly to ensure output quality;
Pre-treat the raw materials to reduce impurities;
Select molds made of highly wear-resistant materials;
Set a periodic cleaning and maintenance plan.
Reason:
Aging of electrical circuits;
Damage to PLC or sensors;
Failure of software programs;
System errors caused by improper operation.
Solution:
Check all electrical connectors and circuits, and replace them in time if problems are found;
Replace failed sensors or overhaul PLC modules;
Restart the control system or update the software program;
Operators should receive standardized training to avoid misoperation.
Reason:
Lubrication oil pipe rupture or loose interface;
Oil seal damage;
Lubrication system pump does not work;
Lubrication oil has not been replaced for a long time.
Treatment method:
Replace damaged oil pipes and seals;
Check the lubrication pump to confirm its working status;
Check the oil level and oil quality regularly, and replace new oil on time;
Establish equipment lubrication ledgers for systematic management.
In addition to timely handling of existing failures, it is more important to prevent equipment failures through standardized operations and daily maintenance.
The suggestions are as follows:
Establish an equipment maintenance plan: set up daily inspection, weekly inspection, and monthly inspection systems.
Strengthen operator training: ensure that operators understand the principles of the equipment and emergency treatment methods.
Use high-quality raw materials: avoid inferior or impure raw materials from entering the extrusion system.
Arrange production time reasonably: avoid equipment overload and set reasonable working hours.
Regularly replace wear parts: molds, bearings, seals, etc. are replaced regularly to prevent sudden failures.
Configure spare parts: conventional wear parts keep spare parts in stock to ensure emergency maintenance needs.
As an indispensable and important equipment in modern breeding industry, the stability of feed extruders is directly related to production efficiency and feed quality. By mastering common fault types, understanding the causes and taking scientific treatment and maintenance measures, users can greatly improve the reliability and service life of equipment operation. For companies pursuing efficient and intelligent feed processing, regular inspections, technical personnel training and good communication with equipment suppliers are also essential.
If you encounter any problems in the use of feed extruders, please feel free to contact us. We will provide professional technical support and solutions to help you easily cope with various production challenges.
If you need custom feed extruders or obtain more maintenance information, please leave a message or call us. We are happy to provide you with a one-stop solution.
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