(01594) 825106
+44 (1594) 825106 (int)
+44 (1594) 825106 (int)
With the aid of theses mills you can help ensure that the planet is in a fit state to pass on to future generations. Products used in the mills are generally either sustainable crops or waste products that would otherwise go to a landfill site.
Highlights:
• Plant capacity range 100kg to 1000kg per hour
• Fully automated process
• Operator supervision 2 to 3 hours per day
• Double shift capability
• Pellet sale price £200 per tonne (1000kg) approx.
(depending on market)
• Profit potential per tonne £75 to £100
• Savings on waste disposal costs
Important criteria:
When manufacturing wood pellets there are a number of criteria that must be observed if quality pellets are to be made as follows:
Moisture content: We have found from experience that moisture levels in excess of 16% in the feed stock will result in low grade ragged pellets. It is therefore important to use kiln dried or seasoned timber waste.
Particle size: Sawdust, shavings and wood chip needs to be reduced to a consistent particle size resembling sawdust. This can be achieved by processing the feed stock through a hammer mill or granulator.
Hard and soft woods: It is very important not to mix hard and softwood feedstock as different species affect pellet hardness through a single pellet die. Our pellet mills will handle most hard and soft woods using the same pellet die by manipulation of additives.
Pellet cooling: Pellets exit the mill at temperatures in excess of 80 Deg C with moisture content slightly above 10%. As the pellets cool, moisture is released and this needs to be removed quickly in order to eliminate quality degradation.
Such a plant would include:
Raw materials hopper: This hopper would normally be capable of holding 2 cu M of sawdust, shavings and small wood chip. There will be a variable speed feed auger in the bottom which transfers the feedstock to a hammer mill. Near the base of the hopper is a rotary switch designed to indicate the need for re-filling.
Hammer Mill: The hammer mill receives feedstock from the raw materials bin. Load on the mill is determined by the speed at which the feed auger in the material bin is running. Feedstock is normally processed via a 6mm screen in the hammer mill onto a horizontal fixed speed transfer auger in the base.
Powder binder hopper: A binder hopper is mounted adjacent to the hammer mill. Binder is injected into the base of the hammer mill as required via a variable speed feed auger in the base. Binder is partially mixed with processed feedstock in the hammer mill transfer auger.
Pellet Mill loading auger: A fixed speed pellet mill loading auger is attached to the hammer mill transfer auger. Feedstock and binder is transferred to the top of the Pellet Mill and into a control hopper. Further mixing of feedstock and binder takes place during transfer to the control hopper.
Pellet Mill feedstock control hopper: Mixed feedstock is received in a vertical faced control hopper on top of the pellet mill. A proximity sensor is mounted near the top and bottom of the hopper. These sensors activate and de-activate all previous functions enabling the hopper to be re-filled automatically when feedstock levels are low.
Wood Pellet Mill: A variable speed feed auger is mounted in the base of the control hopper which transfers feedstock to an internal turbulator (mixing chamber). The speed of the feed auger determines load on the pellet mill. Water and vegetable oil can be injected into the turbulator as required and in variable quantities via peristaltic pumps. Fully mixed feedstock is then transferred to the pelleting chamber. A 6 or 8mm pellet die is normally used and pellets extrude through this die by the action of two fluted internal rollers. There is an adjustable knife assembly on the outside of the die which can be set to required pellet length. Hot pellets exit the mill through an outlet chute with an integral fines sieve.
Bucket Elevator: Pellets enter a bucket elevator for transfer to a storage/cooling bin.
Cooling Bin: A storage/cooling bin of capacity up to 3 tons is normally supplied. There is an axial flow fan mounted in the base which switches on when pellets reach a certain level in the bin. There is a rotary switch near the top of the bin which, when activated, signals the need to empty some pellets or shut the plant down. The base of the bin is fitted with a feed control gate. When opened, pellets fall across a sieve for fines removal. The fines fall into a sack for re-cycling. Clean pellets can then be collected for bagging or bulk dumpy bag filling.
Auto Control Panel: The plant is normally supplied with a pre-wired auto control panel. The plant can be operated in manual or auto mode. There is a mimic to indicate operation mode of each function and when operating in auto mode, audible and visual warnings are activated when attention is required. Peristaltic pumps for water and vegetable oil are mounted externally on the panel. All variable speed control knobs are calibrated to facilitate logging of specific additive levels for each species being pelleted.
Liquid vessels: When using vegetable oil and water addition, suitable size liquid containers are supplied on mounting frames plus all pipe work for connection to pumps and pellet mill.
Farm Feed Systems Ltd can offer wood pelleting plants with outputs from 100kg to 1000kg per hour. However, if intended for commercial production, automation is crucial for maximum return on capital investment. A typical automated plant normally requires approximately 2-3 hours operative attention within an 8 hour working cycle.
Experience tells us that the cost of producing 1 ton of wood pellets is approximately £22 - £30. This includes electricity consumption at 10p/kwh, cost of additives and an allowance for consumables such as pellet dies and rollers etc. If the plant can be run on economy night time rates, cost reduces to approximately £12 - £20 per ton.
NOTE! These estimates exclude operator, raw material, capital recover and building overhead costs.
Current capital cost of 250kg per hour plant including installation, wiring, commissioning and operator training = £85,000
Annual production based on 40 hour week x 48 weeks = 480 tons
| Average sale price (ex-factory) per ton of A grade pellets | £200 |
| Manufacturing cost per ton (day shift) | £30 |
| Typical labour cost per ton (@£10 per hour) | £15 |
| Capital cost recovery per ton (5 year write down) | £45 |
| Typical building overhead per ton | £15 |
| Typical total manufacturing cost per ton | £105 |
| Net profit per ton | £95 |
Note: Cost per ton of suitable materials should be deducted from net profit figure
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