DIES & ROLLS

Index

DIES 4

ROLLER-SHELLS 5

machinery and production plants 6

dies & rolls: spare list and technical data 8

Dies: technical specifications 18

Glossary 20

faq 24

Recommendations 26
4 5

La Meccanica srl has been working in the

pelleting industry for over 50 years.

It was founded in 1961 and currently

employs more than 50 staff, with 40 in
production. The production plant covers an
area of approximately 10,000 m2.

DIES All steels undergo quality control. Certificates of analysis can be provided on request.

La Meccanica srl is specialized in the production of dies for all the main brands of pellet mills. To supply the correct die we must know the type of pellet mill and size of the die being used. We can
produce dies with hole patterns to customer specification or manufacture dies to our own hole pattern
50 years of experience in die and roller shell production offers a guarantee of quality and reliability. designs based on our long experience.

We can guarantee:
• high quality special steels to high chromium content steels ROLLER-SHELLS
• extremely precise manufacture
• perforation and mirror polishing of holes All roller-shells are manufactured using high-carbon steels.
• vacuum heat treatment All roller-shells are surface-hardened up to 58-62 HRc.
• minimum die deformation after heat treatment Hardening depth is 6-7 mm for C50 steel.
• test and control before shipment
• rapid delivery times The heat treatment is characterised by uniform hardening and hardening depth to ensure maximum
• all dies are through hardened to 53-54HRc. durability.

Our production plant is fully automated and equipped with cutting edge technology and the dies All our products are finished by skilled staff.
we manufacture are exported to all over the world.
Some salient features of our dies: Roller-shell surface hardening is tested before delivery to ensure premium quality.
• easy production start-up’s
• high productivity
• long life.

Our dies rapidly achieve full production because they have:

• perfect finish of the holes
• vacuum heat treatment eliminating oxidation of the steel.

Long life of our dies is assured by:

• construction in quality steel with high carbon and chromium content
• high hardness after heat treatment.

Moreover:
• delivery times is assured in 4 - 6 weeks
• our dies have an extremely precise and regular perforation: the “honeycomb” layout of the holes
is faultless
• our dies are ground inside in order to eliminate any deformation after treatment (guaranteed
maximum deformation = 0.5 mm).

DIES & ROLLS

6 7

La Meccanica srl:
machinery and production plants

Besides the production of dies and roller shells, La Meccanica srl designs and manufactures machinery La Meccanica srl has a good penetration of over 50 countries, with 28 agents and distributors throughout
and plant projects. Development and manufacturing are in-house to ensure direct quality control in the world.
real time.

Our company primarily operates in the following industries: Service and assistance
• wood pellet
• waste recycling (i.e. RDF, CDR, plastic, paper, etc) The company also provides an assistance service that offers rapid, highly specialized technical call-outs to
• animal feed solve any problem encountered in the pelleting process.
• alfalfa production
• sugar beet
• oil mills
• organic and organ-mineral fertilizers.

A plant project covers every single machine in a pelleting plant: from grinding to mixing, through to the
pelleting process.

Over the years La Meccanica srl has specialized in the construction of pellet mills.

At present over 1500 La Meccanica srl pellet mills have been installed and the company has an
excellent standing all over the world.

14 different models of pellet mills are manufactured, with power ranging from 7.5 kW to 355 kW.
Moreover, the plant projects include:
• complete pellet production plant
• dies for pellet mills
• rollers and spare parts for pellet mills
• three different types of pellet coolers: vertical, counter-flow, horizontal
• crumblers
• hammer mills
• sifters
• expanders
• many others.

DIES & ROLLS

8 9

TW TW TW

WT WT
De - Outer diameter Dies & rolls:
Di - Inner diameter
WT
TW - Total width spare list and technical data
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

BAHOO INDS Bahoo Inds 420.108 A 420 510 158 108

Bahoo Inds 500.156 A 500 600 225 156
BALLARINI Ballarini IB 400 A 402 500 150 105
Ballarini NH 100 A 450 558 180 110
Ballarini NH 100 W A 450 558 220 156
BERGA Berga PC1 A 254 336 72 42
Berga PC2 A 304 381 95 60
Berga PC3 A/B 419 489 127 74
Berga PC M3 A 419 489 152 109
Berga PC4 A 419 510 190 136
Berga PC M4 A 500 600 190 136
Berga PC M5 A/B 630 750 210 147
Berga PC M5 W A/B 630 750 243 182
Berga PC M6 A/B 800 940 240 170
BUHLER Buhler 304.58 A 304 381 95 58
Buhler 304.78 A 304 381 120 78
Buhler 420.108 (DMFJ) (DPCB) A 420 489 152 108
Buhler 420.138 (DFPB) (DFPC) A 420 489 182 138
Buhler 520.138 (DPBA) (DPUC) A 520 610 182 138
Buhler 520.178 (DPBS) A 520 610 222 178
Buhler 660.138 (DPAB) A 660 790 196 138
Buhler 660.178 (DPAA) A 660 790 236 178
Buhler 660.228 (DPAS) A 660 790 286 228
Buhler 660.265 (DPHD) A 660 790 323 265
Buhler 900.178 (DPGC) A 900 1.030 250 178
Buhler 900.228 (DPGB) A 900 1.030 300 228
Buhler 900.300 (DPHE) A 900 1.030 373 300
Finto testo didascalia
CEASA Ceasa 520.166 A/B 520 670 290 165 con breve spiegazione

DIES & ROLLS

10 11

TW TW TW

WT WT
De - Outer diameter
Di - Inner diameter
WT
TW - Total width
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

CEASA Ceasa 220 A/B 572 732 305 181

Ceasa 220 Florida A/B 675 830 320 190
Ceasa 270 California A/B 780 970 375 240
Ceasa 340 A/B 880 1.070 445 300
CHIA TUNG Chia Tung Model 420.150 C 420 535 185 122
Chia Tung Model 520.150 C 520 658 228 150
CPM CPM Master C 304 370 90 60
CPM 21 (Century 2000-75) C 406 558 152 84
CPM 16/25 C 406 558 182 116
CPM A25/212 C 406 558 212 116
CPM Century 2000-125
C 406 559 189 116
(CPM 2016-4)
CPM 3000N (CPM 3020-4) C 508 659 199 115
CPM 3000 W (6000) (3020-6)
C 508 659 237 153
(6020-6) (6122) (4000)
CPM 7000 (CPM A 201)
(CPM 3022-6) (CPM 7122-6) C 572 775 270 157
(CPM 7722-6)
CPM 7000 Compact
C 572 775 295 157
(CPM 7122 Compact)
CPM 7000 W (CPM A201W)
C 572 775 295 180
(CPM 7122-7) (CPM 7722-7)
CPM 7000 W Compact
C 572 775 325 181
(CPM 7122-7 Compact)
CPM 7000 Wide Track C 572 852 342 181
CPM Floting C 642 850 180 133
CPM 7700 (CPM 7726-7) C 672 890 325 182
CPM 7726-9 SW C 672 890 382 239
CPM 7800 (7830-6) (7930-6) C 762 965 266 156
CPM 7800 Compact C 762 965 317 160
CPM 7730-7 Compact C 762 965 340 181
Finto testo didascalia
CPM 7730-8 C 762 965 368 210 con breve spiegazione

DIES & ROLLS

12 13

TW TW TW

WT WT
De - Outer diameter
Di - Inner diameter
WT
TW - Total width
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

CPM CPM 7900 (CPM 8000)

C 762 965 317 210
(CPM 7930-8)
CPM 7900 W (CPM 8000W)
C 762 965 368 210
(CPM 7930-8 W)
CPM 7900 SW (CPM 8000 SW)
C 762 1.010 372 210
(CPM 7930-8 SW)
CPM 7930-4 C 762 1.012 317 100
CPM 7930-9 C 762 965 348 240
CPM 7932-9 C 825 1.025 404 240
CPM 7932-11 C 825 1.025 440 275
CPM 7936 C 917 1.140 522 312
DG DG-1 C 407 527 165 125
GENERAL DESIGN General Design GD 420.130 C 420 534 193 130
GIULIANI Giuliani GH1 A 340 407 130 86
Giuliani GH2 - 440.124 A 440 560 205 125
Giuliani GH2 - Super A 440 560 235 156
Giuliani GH3 - 545.210 C 545 660 295 210
Giuliani GH3 - super C 710 870 310 210
GM GM 804 A01/M A 630 760 194 89
GM 803 A01 - GM 804 A01 A 630 760 194 142
GONDARD Gondard MT 400 A 406 558 182 116
GR GR-2-1-31 B 305 426 143 100
GRANIT Granit 38 C 405 535 200 72
Granit 72 C 407 530 195 112
Granit 90 C 450 600 200 120
Granit 90 W C 450 600 200 135
Granit 132 C 580 760 250 132
HEESEN Heesen V3-30 A 278 380 105 59
Heesen V3-75 A 355 445 135 80
Finto testo didascalia
Heesen V3-150 A 450 558
Finto testo 180
didascalia con 110
breve spiegazione con breve spiegazione

DIES & ROLLS

14 15

TW TW TW

WT WT
De - Outer diameter
Di - Inner diameter
WT
TW - Total width
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

HEESEN Heesen V3-220 A 450 558 220 156

HKJ HKJ-32B Iran A 320 400 161 103
HYFLO HYFLO/MASTER C 304 426 143 98
IEMME IE 36 L C 360 450 180 110
IE 42 GAMMA 420.108 B 420 517 182 108
IE 42 GAMMA 420.110 B 420 517 200 110
IE 42 GAMMA 420.138 B 420 500 226 138
IE DELTA 50 B 500 610 236 144
IE 56 560.170 B 560 700 282 170
IE 67 - CMS IEMME Alfa B 670 790 310 202
JKAP JKAP-11 India A 421 496 154 118
JKAP-10 India A 421 489 158 122
JKAP-18 India A 521 620 184 144
JKAP-08 / JKAP-17 India A 521 610 184 152
JKAP-19 India A 521 616 220 182
KIRAN Kiran Engineering 304.90 A 304 370 120 90
Kiran Engineering 420.120 A 420 490 160 120
KOANGEE Koangee K-200 A 520 610 182 138
LA MECCANICA Lamec 200.35 A 200 256 62 32
Lamec 304 LG A 304 390 116 37
Lamec 304.58 A 304 381 95 58
Lamec 304.78 A 304 381 120 78
Lamec 420.108 A 420 489 152 108
Lamec 420.138 A 420 489 182 138
Lamec 520.138 A 520 610 182 138
Lamec 520.138 C B 520 610 182 138
Lamec 520.170 A 520 610 222 178
Finto testo didascalia
Lamec 630.150 A 630 750 210 147 con breve spiegazione

DIES & ROLLS

16 17

TW TW TW

WT WT
De - Outer diameter
Di - Inner diameter
WT
TW - Total width
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

LA MECCANICA Lamec 630.200 A 630 750 260 197

Lamec 630.240 A 630 750 310 240
Lamec 800.150 C LG B 800 960 255 150
Lamec 800.185 C B 800 960 285 180
Lamec 800.220 A 800 960 285 220
Lamec 800.220 C B 800 960 328 220
Lamec 800.250 C A 800 960 313 250
Lamec 935 A 935 1.065 310 247
Lamec 935 C B 935 1.065 332 247
LARUS Larus 300.48 C 302 435 114 48
LG LG 3 C 305 404 115 84
LG 2/D C 305 405 135 95
LG 5/S C 360 468 150 104
LG 7 A 420 510 194 130
LG 10 A 550 650 260 181
MABRIK Mabrik PV 100 A 354 445 155 103
Mabrik PV 150 A 452 560 180 108
Mabrik PV 220 A 452 560 218 150
Mabrik PV 220 E - PVR 180 A 550 664 218 150
Mabrik PV 220 ET - PVR 180T A 552 664 245 176
Mabrik PV 220 G A 650 780 275 172
Mabrik PV 220 GT A 650 780 303 200
Mabrik PV 270 A 680 804 275 188
Mabrik PDV-300T A 700 800 320 255
Mabrik MDR-270 750.200 A 750 900 310 200
Mabrik PV 270 2T - PVD 300 T A 750 900 340 245
Mabrik PV 340 A 800 950 325 215
Finto testo didascalia
Mabrik PV 360 2T A 850 1.010 370 260 con breve spiegazione

DIES & ROLLS

18 19

TW TW TW

WT WT
De - Outer diameter
Di - Inner diameter
WT
TW - Total width
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

MABRIK Mabrik 360 A 850 1.010 410 300

Mabrik PV 440 A 950 1.120 365 250
Mabrik PV 440 2T A 950 1.120 414 300
MATADOR Matador M5 C 350 466 138 98
(UMT)
Matador M6 C 409 520 164 113
Matador M12 C 490 650 219 157
Matador PMV 515W B 535 635 210 152
Matador PM615 B 600 700 220 160
Matador PM615 XW B 600 701 250 188
Matador M15 C 700 870 218 140
Matador M700B A 700 800 260 190
Matador M700 (M707 SBK)
A 700 800 320 255
(M 720) 700BW
Matador M30 A 850 1.022 240 162
Matador M30 W A 850 1.070 245 162
Matador M900 A 900 1.040 277 190
Matador PMV919 (M 909 A) B 918 1.035 340 258
MAIER Maier 300.59 A 318 395 95 59
MILTECH Miltech 185 C 460 585 203 143
Miltech C235.165 C 800 1.020 300 165
Miltech C235.205 C 800 1.020 340 205
MTV MTV T22 A 220 270 85 50
MTV 300S A 304 385 90 43
MTV 360.110 A 360 458 169 110
MTV 400 A 400 500 114 58
MTV 400.58 S A 400 500 114 58
MTV 400.110 A 400 500 170 110
MTV 400.140 L A 400 500 200 140
Finto testo didascalia
MTV 530 A 530 650 220 150 con breve spiegazione

DIES & ROLLS

20 21

TW TW TW

WT WT
De - Outer diameter
Di - Inner diameter
WT
TW - Total width
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

MTV MTV 530 L B 535 650 250 180

MTV 660 S A 660 800 265 165
MTV 800 A 800 950 280 180
MUNCH Munch RMP 350.100 B 350 415 142 100
Munch RMP 520.1380 B 520 610 182 138
Munch RMP 520.178 B 520 616 222 178
Munch RMP 660.138 B 660 790 196 138
Munch RMP 660.178 B 660 790 236 178
Munch RMP 660.228 B 660 790 286 228
Munch RMP 680.230 B 680 820 286 230
Munch RMP 700.230 B 690 829 284 227
Munch RMP 800.265 B 800 960 366 265
MUYANG MUZL 600 B 550 670 235 170
NORVIDAM Mix Compress MC 640 (M12) A 640 730 210 156
PALADIN Paladin 350 A 452 560 180 108
Paladin 600 B - 130 A 550 670 210 130
Paladin 600 B - 150 A 550 670 230 150
Paladin 600 B - 170 A 550 670 235 170
Paladin 1200B A 650 790 230 140
Paladin 600D/HR-141
B 650 790 230 141
(1200D-141)(1200B)
Paladin 1200D-175
B 650 790 264 175
(Paladin 1200 W)
Paladin 1200D-175
B 650 790 245 175
(Paladin 1200 EW)
Paladin 1600-175
B 850 1.050 295 175
(Paladin 1200B/HR)
Paladin 1600-210 (2000-210) B 850 1.050 310 210
Paladin 2000 B 883 1.040 350 250
Paladin 2000W B 883 1.040 400 300
Finto testo didascalia
PROMILL Promill 1450 B 450 610 224 140 con breve spiegazione

DIES & ROLLS

22 23

TW TW TW

WT WT
De - Outer diameter
Di - Inner diameter
WT
TW - Total width
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

PROMILL Promill 1580 B 580 700 235 148

Promill 1676 B 676 828 286 204
Promill 1800.206 Evolution B 800 996 297 206
Promill 1800.250 Evolution B 800 996 346 250
Promill 2300 B 1.000 1.203 435 250
PTN PTN HB 150 A 453 558 180 115
PTN Progress 580-2 A 580 690 215 146
PTN 650 A 650 665 250 175
PTN Progress 850.210 A 850 1.050 310 210
PTN Progress 900 A 900 1.045 363 275
SALMATEC Salmatec Maxima 500 A 500 620 205 130
Salmatec Maxima 580 A 580 680 222 143
Salmatec Maxima 620 A 620 760 222 146
Salmatec Maxima 700.170 A 700 840 246 170
Salmatec Maxima 700.225 A 700 840 301 225
Salmatec SPM 840.180 B 840 1.000 240 180
Salmatec SPM 840.240 B 840 1.000 370 240
Salmatec Maxima 840/3 B 841 1.019 309 118
SEMT WHEEL SEMT wheel 600 445.145 A 445 600 230 147
SEMT wheel 1000 810.245 A 810 890 350 225
SIZER ORBIT Sizer Orbit 254.42 A 254 342 73 42
SKJOLD SKJOLD DS4 A 360 434 138 50
SOGEM Sogem T90 C 355 480 150 94
Sogem 430 (T120) C 430 590 215 133
Sogem 500 (T180) C 500 660 250 159
Sogem 585 (T240) C 585 755 260 160
Sogem 680.175 A 680 883 249 175
Finto testo didascalia
Sogem 865 A 865 1.038 310 212 con breve spiegazione

DIES & ROLLS

24 25

TW TW TW

WT WT
De - Outer diameter
Di - Inner diameter
WT
TW - Total width
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

SPROUT (UMT) Sprout Waldron 500 junior

A 304 381 95 58
SW 500 B
Sprout Waldron 501 H A 420 489 152 108
Sprout Waldron Super Ace A 420 489 152 110
Sprout Waldron 21.108/158 A 532 625 158 108
Sprout Waldron SW21 A 533 622 160 108
Sprout Waldron SW21-250
A 533 650 203 152
(SW 21W) (PMV 515)
Sprout Waldron SW26.250 A 660 750 167 107
Sprout Waldron SW26W
A 660 750 210 153
(Sprout Bauer 26-300)
Sprout Waldron SW32"WX A 812 929 319 255
Sprout Waldron PMV919W A 918 1.038 280 193
Sprout Matador PMV 919 XW A 918 1.035 340 280
STOLZ Stolz 52.14 B 520 610 182 138
Stolz 52.18 B 520 610 222 178
Stolz 66.14 B 660 790 196 138
Stolz 66.18 B 660 790 236 178
Stolz 66.23 B 660 790 286 228
Stolz LYD 66.23 C C 660 930 331 230
SWISS COMBI Swiss Combi 22 K A 750 910 165 111
TRIUMPH Triumph TMP 520.200 C 520 680 300 200
Triumph TMP 672.228 C 672 893 372 228
VAN AARSEN Van Aarsen R180 A 498 580 235 165
Van Aarsen R150 A 500 580 210 140
Van Aarsen 500 Compact B 500 652 290 190
Van Aarsen C 600-200 (R 270) B 600 750 300 200
Van Aarsen C 600-225 B 600 750 325 225
Van Aarsen 750.215 Compact B 750 900 313 215
Finto testo didascalia
Van Aarsen 750.250 Compact B 750 900 350 250 con breve spiegazione

DIES & ROLLS

26 27

TW TW TW

WT WT
De - Outer diameter
Di - Inner diameter
WT
TW - Total width
WT - Working track

A - Die fixed by bolts B - Die fixed by bolts C - Die fixed by collar

cylindrical version tape version

INNER OUTER TOTAL WORKING

MILL
MODEL T DIAMETER DIAMETER WIDTH TRACK
MANUFACTURER
(Di) (De) (TW) (WT)

VAN AARSEN Van Aarsen 900.275 B 900 1.050 375 275

VINCENT Vincent TD 100 A 390 504 176 93
WALTER Walter Leo B 450 561 206 142
Walter Toro B 550 663 232 160
Walter Mamut B 670 810 300 180
Walter Jumbo B 670 810 300 200
Walter Mamut B 780 920 380 276
YEMMAK Yemmak 420.106 A 420 520 176 106
Yemmak 420.108 A 420 489 165 108
Yemmak 420.138 A 420 520 207 138
Yemmak 520.138 A 520 620 203 138
Yemmak 520.175 A 520 628 243 175
Yemmak 660.178 A 660 802 262 178
Yemmak 660.228 A 660 802 312 228
Yemmak 900.228 B 900 1.040 316 228
YMS YMS 420.110 C 420 520 177 110
ZEPI ZEPI 680.211/323 C 680 860 323 211
ZEPI 700.240/352 C 680 898 352 240
ZEPI 826.100/350 C 826 1.106 350 100

Finto testo didascalia

con breve spiegazione

DIES & ROLLS

28 29

Dies: technical specifications

Our company has been manufacturing
dies and roll shells for over 45 years.

The experience we have gained over the years ensures: Die lifespan
• high-quality raw materials including high chrome steels
• state of the art plant and machinery implementing cutting edge technology The lifespan of a die depends on many factors:
• gun drilling and mirror-polishing of holes • the composition of the raw material (formulation)
• vacuum hardening - heat treatment • the characteristics of the raw materials used in the feed
• negligible die distortion during heat treatment • the fat content
• rigorous quality control prior to delivery • the particle size of the mash
• rapid delivery times. • the moisture content before pelleting
• the heat conditioning of the mash
Our dies are manufactured in the following steels: • the pellet mill controls (i.e. automatic or manual)
• X46Cr13 (i.e. “stainless” steel or “chrome-steel”) • many others.
• 20MnCr5 (i.e. “alloy” steel)
• 18NiCrMo5 (i.e. similar to 20MnCr5 but with a higher alloy content). • Composition
High fibre formulations such as rabbit feed are harder to pellet and therefore the die will have a much
The specific properties of these materials have different applications. shorter lifespan. As a comparison, for instance, if the lifespan of a die is 1 when used to make rabbit
feed, it would be 4 for cattle feed and 5 when used on poultry feed.
Properties of the alloy components:
• nickel has a strengthening effect • Raw material characteristics
• manganese improves the resistance to wear and shock loads Raw materials containing silica or sand wear dies more rapidly.
• chrome improves mechanical properties like strength and hardness, while also providing corrosion
and oxidisation resistance • Fat content
• molybdenum reduces brittleness. Formulas containing 1.5-2% fat run smoother and are less abrasive since the fat acts as a lubricant.

The X46Cr13 steel dies are vacuum/through hardened. The heat treatment achieves 53-55 HRc hardness • Particle size of the mash
on the surface and in the core. The high chrome content makes it corrosion resistant. Mashes with large particle sizes are more abrasive.
Although it costs more than a normal alloy, X46Cr13 is by far the most common material used throughout
the feed milling industry. • Moisture content and heat conditioning of the mash
A poorly conditioned mash is drier and harder to pellet.
Dies made in 20MnCr5 and 18NiCrMo5 steel, on the other hand, are case hardened to obtain
60-62 HRc hardness for approximately 0.8-1.2 mm. Under the case hardened layer the steel remains • Press control
malleable and therefore less brittle. The dies made of this steel are more resistant for pelleting extremely The operator should regularly check for wear on deflectors and scrapers and also on the roll adjustment
difficult fibre-rich products such as beet pulp, alfalfa, straw and hay. to avoid uneven wear on the die leading to inefficient pelleting. Conditioner paddles must not be worn
to ensure efficient pre-conditioning. Steam traps and filters ensure that no condensate passes through to
the conditioner.

DIES & ROLLS

30 31

Glossary

Effective thickness Compression index

The die thickness, which aids pellet compression, is actually in other words, the working thickness of The ratio between the actual compression thickness (i.e. effective pelleting length) and the hole diameter. This
the die. The effective thickness of the straight hole die (i.e. die without relief) is its overall thickness. The index varies according to the type of feed. This means that when the pellet diameter has been selected, to
effective thickness of a relieved die is its overall thickness less the relief. obtain an estimate of the compression thickness, multiply the index by the diameter.

Outside relief
The die is often made thicker than necessary for feed compression, to give the die greater strength. The holes
are then drilled from the outside diameter of the die with a larger diameter leaving the original hole at the
outside surface hole diameter
of the die required pelleting length.

outside surface hole diameter

of the die

total
thickness relief

effective total
thickness thickness
(working
length)
inside surface
of the die

inside surface
countersink of the die

countersink

STRAIGHT ON HOLES OUTSIDE RELIEF

DIES & ROLLS

32
Glossary
Variable relief
The outer rows of holes in a die will pellet less efficiently than the central rows. This is because the feed
tends to escape towards the outer edges. To reduce this problem (which causes uneven die wear) the
relief on the outer rows is deeper to encourage an even pellet extrusion over the whole die.
DIE WITH RELIEF ON THE EXTERNAL RAWS
DIE WITH REVERSE TAPER RELIEF
Reverse taper relief
For ‘spongy’ materials such as alfalfa or fish feed, a reverse taper relief can be used. The holes are
gradually tapered out as the pellets leave the compression area. The effect of this feature is that, when
wear on the die enlarges the hole diameter, thereby decreasing the compression index, it is partly
recovered by the length of the compression thickness increasing as the diameter increases.
DIES & ROLLS
33
Countersink
The inlet of the holes in the die have a countersink, guiding material into the holes. Countersinks can have
different shapes:
The countersink is normally 55-60°. The countersink characteristics are also important because, when a
countersink is too deep it could give the die a pre-compression effect, risking clogging and blockages
especially in the first working hours.
Taper inlet
When a die is not compressing sufficiently (i.e. low compression index) it tends to produce crumbly pellets.
The pressure can be increased by introducing a tapered inlet on the hole and by increasing the taper depth
and angle the pressure is increased. In many cases dies with a large diameter (i.e. > 6-7 mm) are made
with a large taper depth (15-25 mm depth) to avoid having to use a large die thickness, while still ensuring
a strong compression action.
Well inlet
The well inlet configuration is the most extreme form of pre-compacting in the die hole. The well is a cylindrical
hole drilled from the inside of the die. It can reach a maximum of 30% of the total hole length and can be
up to twice the diameter of the pellet.
Well inlets are used in the following situations:
a) when extra compression is required because of a high oil content (i.e. lubrication)
b) when extra compression is required to create a mechanical shear action to form hard pellets (i.e. dry
heat production).
Shallow wells are often used for very bulky raw materials, which are difficult to feed into the original small
hole diameter.
34 35

FAQ

How can the die characteristics be determined? Disadvantages:

• increased steam requirement
This is where experience becomes an important factor. The selection of a die specification is often the • possible cooling problems due to higher conditioning temperatures
result of a compromise between the different needs of the many formulas produced in a production plant • need for greater operator input and experience to ensure pellet quality
and from the specific properties of the actual plant. The most common mistake is to assume that the die • pellets have a mat appearance
is the cause of all problems. Pellet quality can depend on many factors that have nothing to do with the • lower pellet density /durability.
die, the most common being poor steam-conditioning of the formulas. To overcome these problems, dies
with a high compression index (i.e. large thickness) are used.
This is an analysis of the advantages and disadvantages. rollover

Thick dies What is “rollover”?

Advantages: Rollover is the condition of the die face when the hole inlets start to peen closed.
• pellet quality is not dependent on operator experience
• increased pellet durability. If the rolls come into contact with the working surface of the die and damage it, laminating its surface and
deforming the entrance of the holes. This peening action has disastrous effects on both pellet quality and
Disadvantages: the die throughput.
• lower capacity / productivity
• frequent clogging When does “rollover” arise?
• higher production costs
• increased wear on dies and roller shells 1. when the rolls are too close to the die
• lower conditioning temperature 2. when the wear ring (or clamping ring) has excessive play
• lower moisture content of feed 3. when the main bearings of the die holder assembly
• higher temperature caused by friction have excessive play.
• die track liable to damage.
What problems can “rollover” cause?
Thin dies
1. inadequate production with the motor at full-load
Advantages: 2. excess mill vibration
• higher capacity 3. early breakdowns.
• lower clogging risks
• option of adding more moisture
• option of conditioning the mash at a higher temperature
• better suited to a wider range of formulations
• cost savings in the reduction of die and roller shell wear
• reduced stress on machinery
• cost savings because of lower power consumption.

DIES & ROLLS

36

Recommendations

Basic rules for the correct use of dies

1) Make sure that the rollers are correctly adjusted: the roller to die distance must be 0.2-0.3 mm. A
bad roller setting can cause contact between rollers and die. This may cause “rollover” on the die
holes - deformation and partial blockage of the holes.

2) A new die requires a running-in period. Start new dies progressively, at least for the first 20-40
minutes, so they warm up slowly. If problems are encountered during start up, operate the die for
20-40 minutes with a mix of bran, oil (2%) and abrasive powder (2%). When production is finished,
only stop the die after running it on oats or maize.

3) When changing dies, carefully inspect the condition of the die seating surfaces and the fixing
systems (i.e. collar, clamp or wear ring). N.B.: if the die is not properly fixed it can break.

4) If die “rollover” is found on the hole face, check that the wear ring (or clamping ring) of the die
holder assembly has not gained excessive play. If this is the case, the rollers might may come into
contact with the working surface of the die and damage it, laminating its surface and deforming the
hole entrances (see rollover).

5) The die clamping rings should be checked every time a new die is mounted on the machine,
especially for dies with large flanges. Experience shows that the majority of broken dies are caused
by worn out or defective clamping rings. Dies running with a defective clamping ring can create
strong vibrations, broken dies and a reduced die lifespan.

Inspecting the die:

1. make sure that the material is evenly distributed across the whole working area
2. make sure that all holes work to uniformly (opening clogged/closed holes if necessary)
3. make sure that the hole inlets are not damaged by contact with the rollers or as a result of tramp
metal. Restore the countersink of the holes if necessary.

DIES & ROLLS

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