Consumption ecology. Manor: Everyone can make pellets with their own hands. It is enough to get acquainted with the technology, as well as have the necessary equipment, and the home master will be able not only to supply his house with cheap efficient fuel, but also to create promising business selling pellets.

Everyone can make pellets with their own hands. It is enough to get acquainted with the technology, as well as have the necessary equipment, and the home master will be able not only to supply his house with cheap efficient fuel, but also to create a promising business selling pellets.

Pros and cons of granulated fuel

Today, pellets are understood not only as finished products from small sawdust, but also granulated waste from the woodworking and agricultural industries in general. Everything that can burn and that previously in most cases was simply thrown away or inefficiently disposed of is used for the production of pellets.

Granular fuel is divided into three classes:

  • premium - made from small sawdust of soft wood species cleaned of impurities and waste;
  • industrial - made from sawdust and other small woodworking waste;
  • industrial - almost everything that remains in the waste is used for manufacturing Agriculture, logging, wood processing and even poultry farming.

The first class has a low ash content (about 0.5% of the total mass of pellets), but it is more expensive. The second class, as well as the third, is more affordable, but the amount of residues of combustion products is higher. The third class is used mainly for heating boiler rooms, low cost and sufficient calorific value makes this type very profitable.

The disadvantages of pellets include the fact that they require special conditions storage, dryness and reliable fire protection. They have many more advantages. This and low price relative to other types of fuel (primarily - natural gas), and high heat transfer, and ease of production, and ease of storage and transportation.

But the main plus is that the home master will be able to set up the production of pellets with his own hands without special costs and special skills.

Equipment and materials

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In order to establish the production of granular fuel at home, you will not need much equipment. And the material can be both waste from carpentry workshops, as well as small branches and brushwood that can be collected. The owners of large farms use even chicken manure for the manufacture of pellets, but the calorific value of such pellets is lower than that of wood pellets.

So, in the mandatory set of equipment for the production of pellets, the following mechanisms and devices are needed:

  • crusher;
  • Dryer;
  • grinder;
  • granulating press.

In addition, additional equipment may be required, for example, if it is necessary to moisten overdried materials. It could be steam plant, saturating the raw material with moisture to the required consistency (10-12%), or a system using ordinary water.

A grinder will be needed to obtain a fine mass for pressing out granules. It, like a crusher, can be made by hand, but most business executives prefer to use ready-made installations. But you can make a granulating press with your own hands based on the volumes that you need to get. His drawings are simple and clear.

The granulator consists of an electric drive, a gearbox, a mass drum, a shaping matrix and rollers. They (except for the electric motor) can be made by any master with experience in turning and milling machines.

In the production of fuel, two types of matrices are used - flat or drum (cylindrical). In the granulator of the first type, the raw material is poured from above, the rollers are rolled over it, squeezing out the mass. The second type is relevant for large productions, rollers are located inside the drums, into which the chopped wood and other raw materials are fed.

Some owners, for greater efficiency, supply the granulator with a conveyor belt, which provides automatic supply of the source material, and the same conveyor for the removal of finished pellets so that they do not fill up the press and do not interfere with its normal operation.

Note that home-made installations have low productivity in comparison with factory models. And now we will pay attention to the production of granular fuel and consider in detail the whole process from beginning to end.

Making granules


Pellet fuel has a lot of advantages, the main thing is ease of manufacture. The first stage is the procurement of raw materials. To do this, you can use, as mentioned above, woodworking waste, branches and small brushwood remaining in forest plantations after cutting down trees, husks from seeds and grain, peat.

The feedstock is crushed in a crusher, resulting in a fine fraction with a diameter of about 2-4 mm.

Given that the material has not previously been heat treated, its moisture content may be higher than required. The standard indicator is 12% moisture from the total mass of raw materials. For this, the second stage is performed - drying the raw materials to the required condition. For this, industrial equipment such as drying drums or pneumatic dryers is used.

After that, they proceed to the third stage, the secondary grinding of the prepared raw materials. By passing it through a grinder, the so-called wood flour is obtained. At this stage, the moisture content of the mass should be checked. Why is it so important? Too dry flour will not be pressed properly, as a result, fuel pellets will crumble into dust immediately after exiting the press.

Finally, the last thing to do with your own hands is to fill the prepared mass into a granulating press and start the process. The gearbox transmits rotational motion to the rollers, which extrude the raw material through the shaping matrix.

Under pressure, pellet fuel adheres due to lignin released from wood, a substance contained in stiff plant cells. It plays the role of natural glue, fixing the shape of the granules and preventing them from crumbling.

A few words about storage

At the exit from the press, the granules are heated to 90°C. Therefore, they should be cooled and dried "until fully cooked." Drying is carried out naturally, that is, without the use of additional heating.

For this diligent hosts the resulting pellets are packed in bags weighing from 10 to 20 kg each. They are convenient to store, and if the granulated fuel is made for sale, it is also convenient to release to customers.published

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The production of pellets has become popular quite recently - since the prices for conventional heat transfer fluids have risen sharply. This alternative type of fuel gives a little less heat, but it allows you to save significantly, because it costs less than coal or firewood. It turns out that you can save even more on heating costs if you produce it yourself. This is not difficult to do, but you will need special equipment - everything in order in this article.

What are pellets and what are their advantages

Pellets are pressed granules of crushed raw materials. Straw, sawdust, sunflower husks, rice or buckwheat can be used as raw materials. All these components give different efficiency, but they are quite inexpensive, because, in fact, they are waste from the woodworking or agricultural industry.

It is impossible to heat ordinary boilers with pellets; for these purposes, it is necessary to purchase special pellet stoves. But practice shows that pressed waste also burns well in solid fuel boilers.

Important! With good heating equipment and high-quality fuel, pellet boilers have to be serviced only once a month. All work consists in adding fuel to the bunker and cleaning the boiler pan from accumulated ash.

Three types of pellets are distinguished by quality:

  1. White - first-class pellets made from clean sawdust without foreign inclusions and bark. It is a pleasure to heat with such pellets, because they practically do not leave ash (only 0.5% of the mass of the burned pellets) and give a large number of heat.
  2. Gray pellets may contain a small percentage of needles, bark or foreign matter, but their ash content should not exceed 1.5%.
  3. Dark pellets are used only in industrial boilers. They differ not only in ash content (up to 5%), but also in size. As a raw material for these pellets, straw or husks are most often used.

For heating private households, white or gray pellets are used. Such granules have a diameter of up to 8 mm and emit about 4.7 kWh of heat.

It is impossible to use industrial pellets for conventional boilers, since these granules leave a lot of ash after combustion, and also contain a fine fraction (dust) that will easily clog the nozzles and burners of the pellet boiler.

The advantages of pellets over other types of fuel are obvious:

  • pellets are absolutely environmentally friendly, as they consist of only one component - sawdust of natural origin;
  • a low percentage of ash content makes it possible to rarely service boilers, heating is almost completely automated;
  • compact pellets are convenient to store and easy to transport;
  • the cost of the material is significantly lower than the price of coal or firewood;
  • good heat transfer during the combustion of sawdust;
  • You can make pellets from sawdust at home, thereby saving even more money.

How to make pellets from sawdust, straw or husks with your own hands

First of all, it is necessary to make a careful calculation of the feasibility of this event. If the raw material for pellets is free or the owner got it for next to nothing, then the implementation of the idea will be profitable.

For the production of pellets, two components are needed: raw materials and equipment. Sawdust, husks or straw are also not suitable for everyone, they must first be prepared:

  1. Only soft wood will make it possible to produce high-quality pellets. Sawdust of hardwoods will have to be mixed with softer ones, otherwise the granules will not form - the pellets will crumble into powder, and when burned they will give a large amount of ash.
  2. The moisture content of the sawdust is far from last role in the production of pellets - it should be at the level of 12%. Wetter sawdust will have to be pre-dried (straw and husks, as a rule, are initially well dried), and overdried raw materials must be moistened, otherwise the granule will not form.
  3. Sawdust of a large fraction must be crushed, since sawdust or straw, previously cut into small pieces, is fed into the granulator.

Based on these requirements, it is easy to determine the number of pieces of equipment in the production line for the manufacture of pellets with your own hands:

  • crusher for primary crushing of branches, wood chips and bark;
  • drying or drying chamber;
  • another crusher for finer and better grinding of sawdust;
  • humidifier for sawdust;
  • granulator;
  • pellet cooler.

Each of these devices needs to be told in more detail, but the most great attention the working tool - a granulator or a press for extrusion of granules deserves.

Sawdust pretreatment

Before pressing, raw materials for pellets must go through several stages of preparation:

  • primary grinding, during which branches are cut, bark, knots and other hard and large fragments that can be caught in sawdust break. For these purposes, it is necessary to use a crusher capable of crushing sawdust to a size of 1.25 cm³. You can avoid this stage if you use high-quality furniture or joinery sawdust, straw or husks.
  • It is necessary to dry sawdust in special chambers with a high temperature. The moisture content of the material after this stage should not exceed 8-12%.
  • In small hammer-type crushers, dried sawdust is crushed to a fraction of 1.5 mm. Straw is cut with special scissors.
  • In order for the powder from sawdust or hay to crumple, it must be moistened again. Softwood sawdust is sprinkled with water, while oak or beech sawdust must be treated with hot steam.

Attention! It is much easier to make pellets from straw than from sawdust. The straw does not need to be dried, it is crushed with scissors, not crushers, and, due to its softness, the straw is much easier to push through the holes of the granulator. Less equipment, less power spent on granulation - the result is lower costs for the production of pellets.

Raw material pressing

The granulator is the most important and most expensive piece of equipment for the production of fuel pellets. This device can be bought, but craftsmen with access to lathe and a welding machine, they can make a pellet press with their own hands.

There are several types of pellet mills:


Advice! Home sawdust granulators, as a rule, do not have high power, so they work quite slowly. In order not to stand all the time near the bunker and not to fill up the raw materials, it is possible to make a screw conveyor, along which the sawdust will move to the granulator bunker at a certain speed.

final stage

In the process of pressing, sawdust is heated to 70-90 degrees, in this form the granules are very brittle, they can easily crumble and deteriorate. Therefore, the pellets must be cooled immediately after leaving the granulator. To do this, they are placed on flat pallets and blown with cool air or left to cool in natural conditions.

After cooling, the granules become hard, they are no longer so easy to break. Now the pellets need to be sieved to separate the unformed parts, dust and fine wood powder - all this causes excess ash to appear on the walls of the boiler.

Sieved sawdust pellets can be put into plastic bags and stored until the next heating season.

Important! In the room where sawdust pellets are stored, fire safety standards must be strictly observed, since the material is highly flammable.

Feasibility of pellet production

Independent production of pellets can be justified only in a few cases:

  1. When the host has free pellet raw materials.
  2. If it is possible to manufacture equipment for the production line on your own, rather than buying expensive parts.
  3. If the productivity of the line is such that it will be possible to produce pellets for sale, that is, production volumes will be higher than their own needs.

The rest of the options will not be beneficial for the owner of a private house, in such cases it will be cheaper to buy ready-made pellets for your boiler. But, if there is an opportunity to install equipment for free and get sawdust, you should definitely use it!


Alternative energy sources are in increasing demand. Wood pellets are no exception. They are produced from environmentally friendly raw materials - sawdust, and sometimes contain some impurities (sunflower husks, straw, etc.). The higher the percentage of impurities, the lower the quality of the pellets.

What is the production process for pellets?

Initially pre-weighed sawdust is crushed into small fractions. As a rule, they have high humidity. Therefore, the raw materials are sent to dryers, where the humidity drops to about 10%. After drying, the material is subjected to thorough grinding by hammer mills.

In screw mixers, impurities are added, as well as raw materials are moistened, in order to ensure easy and high-quality formation of pellets in the next stage. With the help of special matrices, the mixture is formed into finished pellets, after which the material is packed.

Equipment for the production of pellets from sawdust

Equipment for the production of wood biofuels is divided depending on the power and productivity.

It can be like a pellet production line, including separators for separating various fractions of sawdust, a drying chamber in the form of a conveyor, a granulator itself and a drum cooler; as well as stationary press-granulators, which produce pellets from pre-prepared raw materials.

At the same time, a pellet production line can have a capacity of more than 2 tons / hour, while a mini-granulator produces only about 200 kg / hour. When purchasing a stationary granulator, you can choose the fuel on which its engine runs (diesel, gasoline or a granulator driven by a tractor power take-off shaft).

Lines for the production of high performance pellets

- A line for the production of pellets using a press granulator OGM-0.8. The line is fully automated and easy to install. The result is pellets with a diameter of 8 mm. Specifications: capacity 500 kg/h, press engine power 45 kWh, press die rotation frequency 250 min-1.

Drum granulator OGM-0.8.

The process of biofuel production is as follows: initially, sawdust with the help of a scraper conveyor enters the dryer drum, where excess moisture is removed and the raw material is dried. At the same time, the heat generator maintains optimum temperature in the drum.

From the drum, sawdust enters through a pipeline with a stone trap (to catch foreign bodies) into a cyclone accumulator, from where the raw material is gradually sent to a hammer grinder, the function of which is to grind sawdust to the required fraction.

Then the raw material feed screw feeds the crushed sawdust to the humidification line, after which the most important process takes place - granulation. In this case, the raw material is heated to a temperature of 180 ̊С, and pressed under pressure.

Since the granules have a high temperature, they are not strong enough. To give the appropriate density and strength, their temperature is lowered in the cooling line using a VVD No. 2 fan. Then the feed screw directs the finished pellets to the packaging area, where they are packaged into briquettes of various sizes and weights.

Line for the production of pellets using a press granulator OGM-1.5

The complex differs from the previous one only in its power and productivity. As a rule, any pellet production cycle consists of the above stages and is not complete without the use of drying equipment, crushing crushers, a moistening, pressing and cooling section for pellets.

Specifications: productivity - 0.8-1 tons / hour, power 160 kWh, granulator engine power 75 kW / h, press matrix rotation frequency - 140 min-1.

The installed capacity of the line is 520 kW, the complex is serviced by 2-3 employees. It is allowed to use raw materials with a moisture content of up to 60%, a diameter of up to 20 cm and a length of up to 75 cm. Sawdust along the loading conveyor enters the drum chipper, while stones and foreign objects are caught from the raw materials. Then moisture is removed in the drum dryer, and sawdust is sent to the drum for dry prepared raw materials.

A press with a power of ≈ 190 kW is installed on the granulation line, which, under pressure at high temperature manufactures granules. The counterflow cooler lowers the temperature of the pellets, which are then packed into big bags. The room in which the equipment is installed must have an area of ​​more than 1000 m2 and a height of >8 m.

Equipment for the production of pellets of small and medium capacity

Press PG-200 is a mini-line for the production of pellets. At the same time, its productivity is significantly lower - 200 kg / h, and power - 30 kW / h. It consists of a granulator with a matrix with a diameter of 200 mm, a mixer-moisturizer and a granule cooler. The output also produces pellets with a diameter of 8 mm.

However, this installation does not include a tumble dryer. Therefore, for the production of biofuel using this equipment, it is necessary to use pre-dried and crushed sawdust.

Granulator Kompakt PP300

This type of equipment is perfect for installation at sawmills and small enterprises that are engaged in wood processing. The productivity of the Swedish press is about 200-300 kg/h. The machine is equipped with one die (cylindrical type, diameter 410 mm) that produces granules with a diameter of 8 mm.

Sawdust with a moisture content of not more than 15% and a size of about 3 mm is suitable as a raw material. If moisture content and size exceed these values, sawdust must be pre-dried and crushed in crushers.

The Kompakt PP300 is equipped with an electric oven that operates in automatic mode, a 7.5 kW mill-crusher and a cooling tower. In general, this mechanism is an excellent alternative to complex pellet production lines.

Press Amandus Kahl

The granulator has the following advantages: it produces pellets from raw materials of different sizes, fluctuations in the moisture content of sawdust are allowed, and the press operates almost silently. Amandus Kahl is a reliable, durable equipment, presented in various configurations and sizes.

The diameter of flat dies can reach 1250 mm, and the power can reach up to 400 kW. Low-power models are used for non-serial production of pellets, while more powerful models can be installed on automated lines. The principle of operation of the granulator is that sawdust is pressed through the holes in the matrix with the help of runners, and then the knives cut the tourniquet into granules.

Both pellet production lines and stationary granulators make it possible to produce high quality products. When burned, pellets give only 1.5-5% ash content, unlike wood, in which this characteristic reaches 15%.

For heating, it is economically profitable to use pellets, the production of which with the help of the equipment described above becomes affordable and profitable.

If you want your business to be related to a material such as wood, then it will be extremely useful for you to read

homemade press

The photo shows a device, or rather, its “blank”, for the manufacture of compressed fuel at home. Anyone can do this.

The press is quite simple in design. You don't need to invent anything from scratch. You just need to have a machine, you can not work, for the production of oil and some additional parts. Consider what the pressing machine consists of, where and what is located, what parts are best to use.

The working engine is a regular low-power one. In our case, its power is not enough to compress sawdust. We change it to a three-phase, with a power of 400 watts.

1. The belt from the engine to the flywheel is toothed. But it is allowed to put and flat. True, in this case, the briquette may turn out to be “underpressed”. A flat belt will slip under increased load.

3-4. Starters - designed to ensure the operation of the machine in reverse mode. The starters are controlled by limit switches installed above the control unit in the upper part. You can see them in the photo below.

1. Direct travel limit switch.

2. Reverse switch.

The ends are adjusted so that the substrate and sawdust are pressed into a briquette with optimal force. If desired, they make it possible to adjust the stroke of the working piston. The consistency of the original material of the future fuel is different, the press force may also be needed differently.

There is a minimum of electrical wires, their wiring is simple, requires minimal knowledge of electrical engineering. You don't have to be a great specialist.

The briquette is pressed in a special tray. A worm gear is used to transfer the engine power to the piston. The option is the most optimal when hard sawdust is the main component of briquette fuel.

This is on the inside. Now about the hinged parts.

A container is installed on top of the machine, where sawdust or other material is placed for “cooking” briquette fuel.

On the one hand, on the piston side, the container has slots for fastening 1 and 2. They hold the tray in place, do not allow it to “walk” around, while sawdust with filler is pressed and a fuel briquette is formed.

A piston made of PTFE is installed on the pressing machine.

The material can be taken differently, but the fluoroplastic has good strength characteristics: it does not crumble, does not break, there are no cracks. This is important when hard sawdust or other similar material is used to produce fuel. A groove is made on the piston, with which it is attached to the rod in the container.

Since the machine on which the briquette is pressed is made, or rather, converted from a machine for the production of oil, there is a hole 1 in its front part (bottom photo). We don't need it. You can close it with a plate made of any hard material.

How to make pellets with your own hands at home will be described in detail in the article below, you can also watch a video that shows the work process in detail.

Pellet production at home

The process of producing pellets at home is quite complicated, but quite feasible, with special equipment.

Equipment for the production of pellets at home:

1. Wood chipper or crusher - provided that the raw material is from wood, sawdust or husks. Is not required component, since it is possible to purchase ready-made crushed raw materials.

2. Drum or aerodynamic dryer, for the manufacture of which a metal barrel is perfect.

3. Secondary crusher, which grinds raw materials into sawdust.

4. Granulator with a flat or cylindrical matrix.

In the case of using high quality fuel, the heat transfer rate significantly exceeds that of traditional solid fuel.

The high fire safety of pellets is due to the absence of decay or decay processes. The use of high-quality granulated fuel and high-tech boilers reduce heating costs.

Many thanks for the information sites: stroychik.ru, strport.ru, home.sd1.su

Constantly rising environmental requirements, low price and energy efficiency make pellets an increasingly popular type of fuel. When burning a ton of pellets, the same amount of heat is released as 680 liters of fuel oil, 1500 kg of firewood, 485 cubic meters of gas. They are made by hand from wood processing waste (sawdust) on special equipment.

Types of pellets

Pellets are also called sawdust granules. There are many varieties containing pure sawdust, with the addition of bark, straw, seed or nut peelings, low-grade wood.

It is important to understand that the presence of impurities lowers the quality of the pellets by increasing the percentage of ash. The best fuel pellets are made by hand from sawdust without impurities!

First grade. The granules contain less than 1.5% ash. The granule diameter is from 6 to 8 mm. The heating capacity of a kilogram of pellets is 4.7 kilowatts per hour. They are suitable as fuel and also for cat litter.

Industrial grade. With an ash content of 1.5 - 5%, pellets are sold as a filler for trays. Only industrial-type boilers can be melted with their own hands. Their size can reach 12 mm, the heat output is 4 kilowatts per hour. Ash content above 5% is not allowed.

It takes about 6 cubic meters of raw materials to produce 1 ton of granules.

Pellet making process

The production of wood pellets consists of several stages.

  1. Grinding of raw materials to a large fraction in crushers. The output is particles with a maximum diameter of 2.5 mm. Before drying, it is necessary to protect them from mixing with stones or earth. Scraper equipment mass is fed to the dryer.
  2. Drying it to a moisture level of 7-12% in belt or drum dryers. The optimum output humidity is 10%.
  3. Grinding of a semi-finished product to a fine fraction in hammer mills. The final particle diameter is 1.5 mm.
  4. Wetting or water treatment of the mass with steam or water with constant mixing in screw installations and preparation for processing by a press. You can compress into the required shape a mass, brought to the required humidity with your own hands. Moisture is supplied to the mixing drum by a dispenser. Hot steam is applied to hardwood raw materials, old or of poor quality.
  5. Pressing on a matrix of a cylindrical or flat shape. Are used various designs presses up to 500 kilowatts.
  6. Cooling of granules. From the press come granules with a temperature of up to 90 degrees, here they are cooled and lose the remaining moisture.
  7. Screening and packaging. Most often, fuel pellets are kept in large containers and transported in bulk. Product highest quality it is recommended to pack with your own hands in large-volume bags in order to avoid deterioration of properties. Such granules are sold in packages of 20 kilograms.

Auxiliary stages of production: cleaning of raw materials from stones and metal debris, transportation, storage and dosing.

All waste obtained during screening goes to recycling. Therefore, the production of wood pellets with their own hands is waste-free.

Machines and lines for the production of pellets

Do-it-yourself fuel pellets can be made on mini-granulators or production lines. Mini granulators are equipped with diesel engine or electric motor. The first one can be moved, which is very convenient for making pellets right at the sawmill. The second is very large and is installed permanently. The maximum productivity of the mini-granulator is 250 kg of finished products per hour.

The main equipment for pellet production:

  • chipper-cutter;
  • dryer for raw materials;
  • press - granulator;
  • cooler;
  • conveyor.

Choppers

They can be disc or drum type. Drum grinders are used in large-scale industries, their second name is chip cutters. They can work with trunks up to 30 cm thick. The log is fed along the conveyor into a drum with several knives. During rotation, the log is cut, chips are fed to the conveyor. Chip size 5 - 30 mm.

Disc shredders are suitable for working with branches of different diameters and wood waste. They can be in the form of a trailer or a stationary device. Knives in such a chipper are mounted on a disk and cut off pieces of wood.

Dryers

In the production of fuel pellets, aerodynamic or drum dryers are used. Aerodynamic work with particles up to 3 mm in diameter. Used in large industries, the kit includes a heat generator.

Drum dryers dry coarse raw materials:

  • sawdust;
  • wood chip;
  • peat;
  • manure;
  • reeds;
  • herbal mass.

The dryer consists of a drum, an oven, a temperature controller, a fan, an air curtain and a control box. The operating temperature in drum-type equipment can reach 800 degrees Celsius.

Granulators

All granulation equipment is divided by performance. Presses with an hourly efficiency of less than 300 kg are usually equipped with a flat die and a motor up to 30 kilowatts. The press engine can be diesel or electric.

Presses with an efficiency of more than 300 kg per hour are equipped with cylindrical dies, their maximum productivity is 3.5 thousand kilograms of granules per hour. Such powerful presses work only on electric motors.

Coolers

The final stage of making pellets with your own hands is cooling. The production uses counterflow and louver coolers, different in performance. In louvered equipment, a stream of air is blown onto the granules through slots in the side walls. As soon as the cooling tank is full, a sensor is triggered and the sorting drive that moves the conveyor stops. The performance of louvered coolers is up to 2 tons per hour.

Counterflow coolers are more powerful - up to 20 tons per hour. They are a cooling hopper, an unloading mechanism, an electric lock and funnels. Air enters the bunker from below through an unloading funnel. Filling of the bunker is controlled by sensors.

Packing machines and conveyors

Finished granules are poured into bags of a certain capacity, which are sealed or sewn up. The process takes place automatically under the supervision of the operator.

Raw materials and finished products moves around the workshop by belt or screw conveyors. Screws produce less dust, but work slower than belt ones.

Details about the effectiveness of the use of pellets and their production in the video: