A single-roller solution to multiple pelleting challenges. Let’s (mono)roll!

Here at Anderson Feed Technology and Ottevanger Milling Engineers, we spend our days working with feed manufacturers striving to balance capacity and pellet quality against the need to control costs – especially given rising energy prices. Now, we are delighted to announce a pelleting technology that can help you better achieve it.

The revolutionary MonoRoll HE single-roller pellet mill is already delivering a 15% capacity increase in Europe, with improved pellet quality and lower energy consumption. Now, this technology is ready for the North American market…

The conventional two-roller pellet mill has always presented challenges for our industry –
not least because pelleting accounts for approximately 65% of the entire energy used in the compound feed production process. This is largely due to the excessive force on the heavy bearings of the solid main shaft, which in turn creates friction and heavy vibration. However, the multiple rollers also have a tendency to slip when high moisture or steam is added, causing chokepoints and resultant production breakdowns.

The MonoRoll offers a unique solution to this challenge. As the name suggests, it operates using just one roller. This single, larger roller is wider in diameter, which creates an optimum angle with the die. This in turn compresses more product through the pellet mill at a much lower RPM; with no blocking or slipping – even when a thicker dye is used, or if moisture is added.

Increase your efficiency, your way

For feed manufacturers, this unlocks new levels of efficiency. How you use this, is up to you.

• You can increase capacity by a minimum of 15% – as more product is pushed through the die using less kilowatts per ton.
• Alternatively, you can reduce energy consumption by 20% while maintaining capacity due to the smooth action of the single roller, which reduces friction and resultant energy consumption.
• Or you can choose to fine-tune your process to achieve a combination of the two.

Based on extensive testing, the MonoRoll delivers this while maintaining the Pelleting Durability Index (PDI) – to anywhere from 80% to 98% (depending on the feed formulation and other variables).

Furthermore, you can realize further cost savings through reduced maintenance, repair and operator intervention. The single roller not only has less potential for slippage; it also experiences less wear and tear. For instance, the roller bearings and seals exhibit exceptional durability, demonstrating no signs of damage even after prolonged equivalent usage in rigorous testing.

Delivering proven ROI

Having initially explored this innovation in the early 1980s, our European colleagues at the TRIOTT GROUP began serious development of the MonoRoll concept four years ago; working initially with the University of Eindhoven and then with commercial development partners. For the past three years, this technology has been extensively tested and independently validated in Europe, with several feed mill operators using a wide variety of different recipes and processing conditions.

Now the MonoRoll HE is available for the North American market. So, whether you are thinking about replacing your current pellet mill; or are looking to limit CAPEX by refurbishing your current technology, we’d like to leave you with the following closing thought.

The MonoRoll:

• Boosts profitability – depending on operational needs, energy costs, formulation, set-up and local environment the MonoRoll can significantly reduce costs and increase profits.
• Increases capacity by 15% as more product is pushed through the die using less kilowatts per ton.
• Cuts energy use by delivering a 20% increase in energy efficiency versus conventional pellet mills. In a field test, the specialist Dutch feed consultancy Zetadec found that the MonoRoll HE consumes 3 kWh per tonne of feed less energy than a two-roll press.
• Enhances durability – thanks to a single roller, operating at lower RPM, producing reduced noise and vibration levels, thus extending the tool life of both the mold and roller by 2-3 times.
• Minimizes manpower and downtime – there’s less potential for roller slip – which all adds up to less maintenance, repair and operator intervention.

So, if you want a proven way to help future-proof your operational efficiency the MonoRoll serves as an excellent initial step. Contact us to today for an instant ROI calculation. Our team is ready and waiting to help you get (mono)rolling!

Request full calculation here