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Differences between a Granulator and other crushing equipment, and their combined usage plans
| Comparison Dimension | Granulator (Pelletizer) | Traditional Crushing Equipment |
| Working Principle | Uses heating, plasticizing, screw extrusion, mold forming, and cutting to convert material from a semi‑molten state into pellets. | Relies mainly on mechanical impact, shear, or compression to directly break solid raw material into fragments or powder. |
| Material State | Suitable for plastics, rubber, biomass and other materials that require heating and plasticizing. | Suitable for dry, brittle or medium‑hard solid materials (ore, scrap metal, wood, etc.). |
| Product Form | Uniformly sized, regularly shaped pellets (cylindrical, spherical, etc.). | Irregular fragment shape, usually chips or fine powder. |
| Energy Consumption & Process Steps | Requires heating, cooling, cutting and other multiple stages; overall energy consumption is relatively higher. | Simpler structure, mainly a crushing stage; relatively lower energy consumption. |
| Typical Applications | Plastic recycling, feed production, chemical industry pellets, biomass fuel pellets. | Construction materials, mining, scrap metal recycling, paper shredding, etc. |
Combined usage plans
1. Pre-crushing followed by granulation
For large or hard waste plastics and metal scraps, a pre-crusher (crusher) is used to coarsely crush them to a size of 30-80mm.
The coarsely crushed material enters the Granulator for heating, extrusion, and pelletizing to obtain uniform granules. This process significantly reduces the Granulator's load and improves both production capacity and granule quality.
2. Post-processing and grading
After the Granulator discharges, a vibrating screen or cyclone separator is often used for granule grading to remove fine powder and impurities.
For products requiring finer powder, a fine crusher can be connected after the Granulator for secondary crushing, achieving multi-stage refinement from granules to powder.
3. Fully Automated Process
Through a PLC or DCS system, pre-crushing, granulation, cooling, and grading units are connected in series to achieve continuous production.
Real-time monitoring of key parameters such as temperature, pressure, and rotational speed, combined with the aforementioned preventative maintenance plan, maximizes equipment uptime.
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