Overview
The Double Roller Extrusion Granulator, also known as a Dry Granulation Machine or Roll Press Compactor, is an advanced industrial equipment designed for transforming fine powders into dense, uniform granules without the need for liquid binders. This machine utilizes the principle of Roll Press Compaction, where two synchronized, counter-rotating rollers apply extreme mechanical pressure to the raw material, forcing it through precisely designed molds (roll surfaces). The resulting product is sheet-like material that is then broken down and screened into uniform granules.
This Granulation Equipment is widely recognized for its efficiency in Material Densification, making it a preferred choice in industries such as fertilizer production, chemical processing, and mineral agglomeration. It is a cornerstone of modern Continuous Granulation Processes, offering a clean, economical, and scalable solution for Powder to Granules conversion.
Key Features
The most significant feature is its ability to produce granules without adding moisture or liquid binders. This eliminates the need for subsequent drying steps, saving energy, time, and cost.
- High Pressure Roller Compaction
Equipped with two robust rollers and a powerful hydraulic or spring-pressure system, the machine delivers high compression force, ensuring the production of hard, low-moisture, and highly dense granules.
- Excellent Material Densification
It significantly increases the bulk density of raw materials, improving storage and transportation efficiency, reducing dust, and minimizing material loss.
- Continuous and Automated Operation
Designed for seamless integration into continuous production lines, it offers high throughput with stable and consistent output quality, requiring minimal operator intervention.
- Versatility and Adaptability
The Double Roller Extrusion Granulator can process a wide range of materials, including fertilizers, chemicals, minerals, and various industrial powders. By changing the mold (the pattern on the rollers), the size and shape of the granules can be easily customized.
The closed system minimizes dust pollution during operation. The dry process avoids wastewater generation, making it an eco-friendly Industrial Granulator.
- Low Maintenance and Robust Construction
Built with high-wear-resistant materials for the rollers and other critical components, it ensures long service life and reduced downtime.
Applications
The Double Roller Extrusion Granulator is a versatile machine with extensive applications across multiple industries:
Fertilizer Granulation: Ideal for producing high-quality compound fertilizers, NPK fertilizers, organic-inorganic compound fertilizers, and other blended fertilizers. It effectively granulates materials like ammonium chloride, potassium chloride, and various powder fertilizers.
Chemical Granulation: Used in the chemical industry to granulate pigments, dyes, resins, pesticides, insecticides, and other chemical powders, improving their flowability and reducing dust.
Mineral and Metal Industry: Applied for agglomerating metal powders (like aluminum, magnesium), coal fines, carbon black, and various ores to enhance their handling properties and reduce dust during smelting or processing.
Pharmaceutical and Food Industry: In specific applications where dry granulation is required for powder formulations to improve compression characteristics for tableting or to enhance flow properties.
Other Industries: Also used in the production of ceramics, refractories, and for the recycling of industrial by-products into usable granular forms.
Working Process
The working process of the Double Roller Extrusion Granulator is a continuous mechanical cycle, which can be broken down into the following stages:
- Feeding: The raw powder material is fed uniformly into the granulator's hopper by a feeding screw conveyor. The feeder ensures a consistent and controlled supply of material into the Compaction Zone.
- Compaction Zone: The material enters the narrow gap between the two counter-rotating rollers.
- High-Pressure Extrusion: As the rollers rotate, they exert extremely high pressure (generated by the hydraulic or spring system) on the powder. This pressure forces the material to compact into a solid, continuous sheet or ribbon against the surfaces of the rollers, which are engraved with matched mold cavities.
- Formation of Sheet/Ribbon: The compacted material exits the roller gap as a thin, dense sheet or a ribbon with specific patterns imprinted by the mold cavities.
- Crushing and Sizing: This solid sheet is then directed towards a centrifugal crusher or a granulating mill. Here, it is broken down into smaller, irregular fragments. These fragments are subsequently screened by a vibrating screen to separate the on-size granules from the fines and oversized particles.
- Recycling: The fines and oversized particles are typically recycled back to the feeding system to be reprocessed, ensuring zero waste and maximizing the yield of the final product.
- Final Product Output: The uniformly sized granules are discharged as the final product, ready for packaging or further processing.
In summary, the two-roll extrusion granulator, with its core advantage of efficiently producing high-quality granules without the need for binders, has become an indispensable piece of equipment in modern industry, balancing production efficiency, cost-effectiveness, and environmental sustainability. For even better granule quality, this equipment can be used in conjunction with a spheroidizing machine for spherical shaping and polishing; furthermore, it can be integrated into a complete automated granulation production line, achieving fully automated production from raw materials to finished products.
Product Details
Complete double-roll extrusion granulation production line
About Us
As a leading agricultural equipment supplier with extensive export experience, Gaofen Machinery offers a comprehensive range of products and services tailored to meet diverse customer needs worldwide. Our offerings include:
- Agricultural Equipment Supply: We provide a wide variety of high-efficiency machinery, including organic fertilizer granulators, compound fertilizer granulators, inorganic fertilizer granulators, water-soluble fertilizer granulators, controlled-release fertilizer granulators, fertilizer batching systems, crushers, mixers, dryers, pelletizers, coating machines, particle screening equipment, packaging machines, and complete fertilizer production lines.
- Expert Technical Support: Our specialists deliver professional technical consultation and support—helping clients select the right equipment, optimize production processes, and implement advanced agricultural solutions.
- Installation & Commissioning: We ensure seamless setup and operational readiness with our professional installation and debugging services, guaranteeing that equipment performs to expected standards.
- Comprehensive Training Services: We equip your team with essential operational and maintenance skills through customized training programs—boosting productivity and equipment longevity.
- Reliable After-Sales Service: Our end-to-end after-sales support includes regular maintenance, troubleshooting, and the supply of genuine spare parts to ensure uninterrupted and stable operation.
- Customized Solutions: We design personalized equipment and complete production lines to match specific client requirements—supporting small to large-scale fertilizer production projects across various regions.
Through these integrated services, Gaofen Machinery is committed to delivering high-quality fertilizer production equipment and end-to-end support—empowering businesses to excel in a competitive global market.
Contact us today to explore partnership opportunities and discover how our innovative agricultural machinery and solutions can drive your success.
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