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In the context of the rapid development of modern animal husbandry, feed extruders are widely used in feed processing plants, farms and feed research units as important equipment to improve feed utilization, feed palatability and storage performance. However, due to the complex operating conditions and heavy load of feed extruders, coupled with improper operation and management, it is very easy to cause equipment failure or even premature scrapping. Therefore, how to improve the service life of feed extruders has become the focus of attention of the majority of users. This article will systematically explore effective methods to extend the service life of feed extruders from multiple aspects such as structural understanding, raw material processing, operating specifications, daily maintenance, and fault prevention.

1. Understand the working principle and key components of feed extruders

The first step to improve the service life is to deeply understand the equipment structure and its working principle. The feed extruder mainly expands the raw materials at high temperature and high pressure through the high-speed rotation of the screw in the barrel, and finally extrudes them from the die to form granules or expanded feed. Its core components include:

Feeding system: control the raw material flow rate to ensure uniform feeding.

Screw system: It is the most critical component, which determines the material transportation, mixing, compression and expansion effect.

Heating system: including electric heating or steam heating, adjusting the barrel temperature.

Mold system: different aperture molds can produce different specifications of feed.

Transmission system: ensure the normal operation of the screw and carry the power of the entire equipment.

Control system: intelligent operation panel, set parameters such as temperature, pressure, speed, etc.

Clarifying the functions of the above components will help operators find abnormalities and quickly determine the source of faults in daily use, so as to carry out targeted maintenance and improvements.

2. Select appropriate raw materials and do pretreatment

The selection and pretreatment of raw materials directly affect the load and life of the extruder. The following points should be paid special attention to:

Control moisture content: Too high moisture content of extruded raw materials will lead to difficulty in puffing and blockage, and too low moisture content will easily generate dust and mechanical wear. It is generally recommended to control it at 16%~20%.

Screening raw material impurities: Metal foreign matter, stones, gravel and other impurities entering the machine are very likely to damage the screw, mold and even the whole machine. Impurities should be fully removed by magnetic separators and screening equipment before feeding.

Moderate crushing particle size: Too large particles will not only affect the puffing effect, but also aggravate the wear of the screw and barrel. It is recommended to use powder below 60 mesh.

Even mixing: Feeds of different ingredients need to be fully mixed to prevent local overheating or uneven compression, which will affect the equipment load and output stability.

3. Standardize the operation process and prevent misoperation

Correct operation of the equipment is the key to extending its service life. Improper operation will not only cause instantaneous hard damage, but also cause cumulative losses in long-term operation. Suggestions:

Check before starting: Make sure that all connecting bolts are tightened, the oil level is normal, and there is no oil leakage or loosening.

The preheating process cannot be omitted: The main machine can only be started after the heating system reaches the set temperature, otherwise it will cause the screw to be overloaded and stuck.

Feed at a uniform speed: Avoid feeding a large amount of material at one time, causing overload and damaging the drive motor and screw system. A frequency-controlled feeder should be used to achieve slow and uniform feeding.

Avoid idling and overloading: idling can easily aggravate the dry wear loss between parts, and overloading operation will put the motor and deceleration system in a high stress state for a long time.

Shutdown in an orderly manner: the material should be stopped first, and the main machine should be stopped after the raw material is completely extruded, and finally the heating system should be turned off to avoid the hardening of the residue inside the screw and cause jamming.

4. Regular maintenance and care to prevent problems before they happen

Even the best equipment cannot do without meticulous maintenance. It is recommended that users establish a scientific maintenance ledger and focus on the following aspects:

Lubrication system maintenance: Regularly check the lubricating oil level and cleanliness, replace the lubricating oil according to the equipment manual cycle, and ensure the smooth operation of gears and bearings.

Screw and barrel clearance inspection: The wear between the screw and the barrel will increase under long-term operation, resulting in reduced expansion efficiency and even jamming. Consumable parts should be regularly inspected and replaced in time.

Heating system inspection: If the heater has aging electric heating tubes, inaccurate thermostats, and damaged thermistors, it should be repaired and replaced in time to avoid temperature runaway and burning the equipment.

Cleaning residual feed: After each shutdown, residual materials should be cleaned up in time, especially high-protein and high-fat formulas, which are easy to coke and harden inside the barrel, affecting the next use.

Electrical system maintenance: Regularly check whether the wiring of the motor, line, and control panel is firm to avoid short circuit and burning of the electronic control system.

5. Choose regular brands and original accessories

Purchasing regular brand equipment can not only ensure product quality and after-sales service, but also facilitate subsequent replacement of accessories. Although non-original or inferior accessories are cheap, they have unstable performance, increased wear, and short service life, which increases maintenance costs.

When replacing key components such as screws, barrels, molds, and bearings, be sure to choose original accessories that match the main machine to ensure maximum work efficiency and equipment life.

6. Train professional operators

Technically skilled operators and maintenance personnel are the core guarantee for improving equipment life. Enterprises should organize technical training regularly to make operators familiar with:

Equipment operation logic and parameter settings;

Fault diagnosis and preliminary troubleshooting methods;

Simple repairs and daily maintenance;

Safe operation procedures and emergency shutdown measures.

Avoid the risk of misoperation caused by personnel replacement or temporary workers.

7. Establish a data monitoring and early warning system

With the development of intelligent manufacturing, more and more expansion equipment is equipped with temperature sensors, pressure sensors, current monitoring modules, etc. Enterprises can use these data to achieve:

Real-time monitoring of the screw operation status;

Automatic alarm for abnormal temperature rise and current change;

Analysis of historical data predicts maintenance cycle;

Fault warning to avoid sudden downtime.

Through digital management, equipment maintenance is transformed from "passive response" to "active prevention".

As a high-load, continuously running mechanical equipment, the service life of the feed extruder depends not only on the original manufacturing quality, but also on every detail of the user in actual use. From material selection and ingredient preparation to standardized operation, from regular maintenance to intelligent monitoring, the optimization of each link will significantly improve the equipment operation efficiency and service life, so as to truly realize the efficient, stable and long-life operation of the feed extruder, and create continuous value for feed production enterprises.

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