What is the optimal maintenance cycle and key component replacement recommendations for granulators?

Granulator Maintenance and Key Component Replacement Recommendations

As the core equipment for processing powdered or semi-molten raw materials into uniform granules, the reliable operation of the granulator directly affects production capacity and product quality. Based on industry standards and the practical production experience of Jiangsu Saide Machinery Co., Ltd., the following maintenance cycle and key component replacement points are proposed:

1. Daily Inspection (Daily/Shift)

Feeding System: Check for blockages or foreign objects in the hopper and screw inlet; clean residue to prevent scaling.

Lubrication System: Observe oil level and temperature, and ensure unobstructed oil passages in the gearbox and bearings.

Safety Devices: Check the emergency stop button, protective cover, and interlocking devices for integrity.

2. Regular Maintenance (Weekly/Monthly)

Screw and Barrel: Clean residual material from the screw surface weekly; check the wear of the screw and barrel monthly, and perform precision measurements if necessary.

Die Head and Pelletizing Blades: Disassemble and inspect the die head channels monthly to remove accumulated material; check blade sharpness and replace when wear exceeds 10% to ensure uniform particle size.

Electrical and Control Systems: Verify the readings of temperature, pressure, and speed sensors monthly to ensure parameter stability.

3. Overhaul and Replacement of Key Components (Every 6-12 Months)

Gear Reducer: Hardened gears will experience tooth surface wear after long-term high-load operation. It is recommended to replace the seals and check the gear meshing clearance every 12 months.

Bearings: Depending on operating time and load, bearings need to be replaced when the inner and outer rings are worn or the lubricating oil deteriorates. A full inspection is typically performed every 6-9 months.

Pelletizing Blades: High-hardness alloy blades are prone to micro-cracks during high-speed cutting. It is recommended to replace them every 8 months to prevent increased particle debris.

4. Principles for Determining Maintenance Cycles

Based on production capacity and raw material characteristics: High-viscosity or high-temperature raw materials will accelerate component wear, requiring a correspondingly shorter replacement cycle.

Based on equipment monitoring data: Online monitoring indicators such as temperature, vibration, and power provide early warnings of anomalies and facilitate preventative maintenance.