Pelletizing of Powders Can Create New Revenue Streams

April 2017

A combination of cost pressures and environmental regulations have made agitation agglomeration – the process of converting bulk powder materials into spherical pellets – a sound investment for companies that can re-purpose a waste product for use in manufacturing, processing and agricultural applications.

The most effective pelletizing of dusts, fines and powders requires thorough drying that doesn’t alter pellet size, shape or strength. That’s because pellets from which water has been evaporated have a higher degree of structural integrity than those with higher water content. Such pellets are easier to handle and produce less dust.

Typical pelletizing materials and applications include:

  • Limestone as a soil amendment in gardens, lawns and fields
  • Poultry Manure as organically safe fertilizer products
  • Fly Ash from coal-fired power plants as an additive to lightweight cements
  • Recovered Carbon Black (rCB) from tires as a tinting agent, strength additive or UV protectant in automotive, marine and consumer products

The advantages of pelletizing include easier handling, less dust, improved flow characteristics and improved processing performance.

Which System is Best for You?

To determine the ideal pelletizing system for your specific application, it’s advisable to test a material in sample quantities, such as 5- or 10-gallon discs or drums, or 15- to 25-gallon pin mixers. After making the batch, we can help you analyze the results. If the tests are favorable, you can begin pilot scale development using 55-gallon drums.

Binders usually consist of water and two additives. Your sample yield will give you jars of green or dried pellets, depending upon the type of material you’re pelletizing. Pellets that contain binder or slurry can also be produced in larger quantity samples, such as two gallons.

As for special conditions, there are none in the research phase. In the pilot phase, however, milling, pre-treatment, mixing, special feeding, drying, screening and post-treatment in the pilot phase could be considerations. Regardless of what the research and pilot phases reveal, we have the expertise to help you determine whether to move forward, and to assist you with taking the next step.

The Pelletizing Process

Turning dust, fines or powders into pellets is a five-step process.

Deciding How to Proceed

Turning waste material into revenue-producing pellets doesn’t have to be a gamble. With an experienced partner in testing and pilot scale production, you’re guaranteed to undertake pelletizing systematically and prudently.

Let’s work together and determine the best course of action. To start a conversation, contact Bill Harasty at 724.538.3000 or

Mars Mineral • Po Box 719 • Mars, PA 16046 • tel:724-538-3000 • fax:724-538-5078 •

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