How to Systematically Repair pet food extruder machine-Related Issues?

Step 1: Establish a fault log to accurately pinpoint core issues. Compile statistics on extruder faults over the past month, recording fault type, occurrence time, repair method, and interval, and analyze fault patterns. If 80% of faults are concentrated on blockages and abnormal temperatures, and mostly occur after raw material changes, the core issue is likely improper raw material pretreatment and delayed parameter adjustments. If faults are mainly due to component wear, then equipment maintenance and aging issues need to be addressed.

Step 2: Optimize from the raw material source to reduce fault causes. For continuous faults caused by raw materials, establish a strict raw material pretreatment process: purchased raw materials must first be filtered through a vibrating screen (80 mesh or higher) to remove impurities, and then the moisture content must be measured with a moisture meter. The moisture content of raw materials for dry extruders should be controlled at 10%-15%, and for wet extruders at 18%-25%. Raw materials with unacceptable moisture content must be dried or humidified. Simultaneously, raw material mixing must be uniform to avoid localized high concentrations of certain components that could lead to abnormal extrusion. A "small batch first, large batch later" mixing method can be adopted to ensure consistent composition in each batch.

Step 3: Conduct a comprehensive overhaul of extruder components and replace aging parts. Thoroughly disassemble and inspect the extruder, paying particular attention to vulnerable parts: screw, die head, bearings, and gaskets. If any component wear exceeds specified standards (e.g., screw wear > 0.5mm, die hole enlargement > 10%), it must be replaced with a new one; do not continue using it.

Simultaneously, inspect the electrical system, replacing aging power cords, heating elements, and temperature controllers to ensure stable electrical component performance. For extruders older than 3 years, a comprehensive precision calibration is recommended to adjust the clearance between the screw and the extrusion chamber, restoring the equipment's machining accuracy.

Fourth Step: Standardize operating procedures to avoid human error. Many recurring malfunctions stem from improper operation. A detailed extruder operation manual must be developed, clearly defining pre-start checks (power supply, temperature, raw material preparation), key monitoring points during operation (temperature, pressure, current), and post-shutdown cleaning and maintenance procedures. Provide systematic training to operators, ensuring they pass an examination before commencing work to prevent malfunctions caused by misoperation. For example, before starting the machine, the moisture content and impurity content of the raw materials must be checked. During operation, temperature and pressure data must be recorded every 15 minutes. After shutdown, any remaining raw materials inside the extruder must be thoroughly cleaned.

Step 5: Establish a regular maintenance system to prevent malfunctions. Develop a maintenance plan of "daily cleaning, weekly minor inspections, and monthly major overhauls": clean the feed inlet, die head, and screw daily; check bearing lubrication, belt tension, and sealing weekly; and completely disassemble the equipment monthly, replacing worn parts and calibrating instrument parameters. Simultaneously, establish long-term cooperation with the equipment manufacturer, regularly inviting technicians to conduct on-site equipment inspections to proactively identify potential faults and achieve a "prevention-first, repair-second" equipment management model, addressing continuous failures at their root.

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