Yongte assists Indian customer in resolving WPC production operation issues

Indian customer meet problem of WPC granulation machine

Today, our Indian client encountered a problem in wood-plastic composite production, and our sales and technical teams immediately responded to help resolve the issue.

The client mentioned the problem in the email:“We are currently facing an issue with the granulator wherein the homogenization is not satisfactory. We observe a powdery form of material coming out of the granulator, whereas the output is expected to be in crumb form. Due to this inconsistency, the bulk density of the granulated material varies significantly, which in turn leads to load fluctuations in the extrusion lines. As a result, the operators are unable to accurately predict or control the material flow into the extruder.”

What is the reason of the problem?

The customer reported operational issues with our SH75 WPC granulation machine. Our technical team analyzed the customer's operation video and identified unreasonable parameter settings as the root cause. For instance, the barrel temperature was set to 200°C, leading to carbonization of the wood flour. Additionally, the feed rate was excessively high while the extrusion speed was too slow—this mismatch resulted in low production output, insufficient plasticization and compounding of materials (causing poor product quality), and significantly increased risk of screw wear or breakage.

Solution to Solve the problem

According to the customer's problem, our engineer suggested the following optimization steps:

1. Adjust the barrel temperature to an appropriate range: For example, set temperatures sequentially as 110°C, 120°C, 135°C, 140°C, 145°C, 150°C, 150°C, 155°C, 155°C,... Gradually adjust temperatures in 5°C increments based on material plasticization status until optimal results are achieved. Note that temperatures exceeding 170°C may cause wood flour carbonization.

2. Optimize extrusion speed: Extrusion speed directly impacts production output and material plasticization. We recommend setting the extrusion speed to 900–1200 RPM to ensure stable production, which typically yields an output of approximately 400–500 kg/hour.

3. Balance the feed rate: An excessively high feed rate leads to insufficient material plasticization and accelerated screw/barrel wear, while an overly low rate reduces output and extrusion pressure. When operating Yongte's SH75 wood pellet mill, operators must continuously monitor the current and adjust the feed rate accordingly. Yongte engineers recommend maintaining a current of around 110A—this ensures proper material plasticization while minimizing machine wear. Specifically: increase the feed rate slightly if the current drops below 110A, and decrease it slightly if the current exceeds 110A.

Finally, the customer’s engineer followed our suggestion, and then made a good production for high capacity and high quality output.