How Pelletization Adds Toll Processing Value and Efficiency

Pelletization is a common toll processing service, but that doesn’t mean it’s an unremarkable solution. In fact, when used as a strategy to optimize products and processes, pelletizing material could introduce customization options and advanced technologies that add value and efficiency to production.

Let’s explore the fundamentals of pelletization, and how aligning this need with toll processor knowledge, experience, and pelletization capabilities can create an effective partnership that integrates into a breadth of applications.

What is the process of pelletization?

Pelletization is a toll processing method that transforms fine powder or granules into larger pellets that are consistent in size and easier to handle.

The process itself involves four steps that occur within a pelletizing unit:

1. Mixing a homogeneous powder with a liquid binding agent
2. Extrusion or agglomeration that compresses the mixture, forming pellets of desired strength and uniform size
3. Drying the pellets to achieve and maintain the optimal moisture content in the pellets
4. Screening gathers pellets that meet specific size cuts and uniformity by separating them from oversized or undersized product

The benefits of pelletization

While nearly any material can be pelletized, the type of application and material characteristics significantly influence the decision. Those projects that align with pelletization realize four important benefits:

• Minimal material loss with the transformation of powders into useable pellets
• Efficient handling, storage, and transportation due to pellets having better bulk density, flowability, low dust generation, and reduced risk of spillage or contamination
• Enhanced consistency and quality since pelletization can precisely control size, shape, and density of the final product
• Better performance of materials in the final application for reliable overall product effectiveness

A caution about moisture

Equally as important as knowing the benefits of pelletization is being aware of the potential adverse impact of moisture. 

Moisture content can be influenced by the type of raw feed, binder ratios, and/or the drying step in the pelletization process. A binder not optimized for the raw feed formulation or too much or too little moisture post-drying can cause pellets to crumble, affecting material integrity during handling, storage, and transportation.

Further down the line, end-product efficacy could be compromised — a potentially risky proposition, especially when controlled release is fundamental to the application, such as in fertilizers, chemicals, and pharmaceuticals.

Leveraging the value of an experienced toll processor

Navigating the variables of pelletization to arrive at the best solution for your particular application is usually time-consuming and sometimes daunting.

That’s where an experienced toll processor can make all the difference. Their expertise is crucial in guiding decisions, and knowledgeable collaboration ensures the pelletization process, technologies, and process controls are optimized for each use case.

Further, working with a toll processor means gaining efficiency. Pelletizing may need to be a stand-alone process, depending on the material and application requirements. However, more often than not, a toll processor focused on working to the customer’s best advantage will integrate it with other processes such as grinding, blending, and coating.

A toll processor that commits to this level of partnership is valuable. But when a toll processor does all this plus has the foresight to streamline pelletization into a single stream process — that’s a rare opportunity for manufacturers to gain competitive advantage.

The added value and efficiency of a CPS partnership

When it comes to pelletization, Custom Processing Services is the preferred choice in full-service toll processors. Our production lines are equipped with state of the art machinery, configured to make pelletizing an efficient single stream process that saves time and money.

It’s a practicality backed by:

• Proven specialization and experience in pellet processing, resulting in tighter specs and improved throughput
• Extensive understanding of materials that aids in manipulating raw feeds to perform as anticipated and desired for an application
• Advanced automation and robotics technologies to make production more efficient without compromising quality outcomes
• Tailored solutions to meet specific and sometimes unique customer requirements — including customized binder formulations and advanced process controls to enhance process efficiency and product performance

When done in collaboration with a trusted toll processing partner, pelletization is an effective strategy for adding value and efficiency to production and products.

It exemplifies how innovation combined with mastery of techniques can transform raw materials in high-quality products that meet the diverse needs of many industries — much like the particle size technologies explored in our Milling Methods Comparison Guide. Download your copy to get the details.