Pellet machines are essential for producing biomass, wood, and agro-waste pellets used in industries, boilers, and commercial heating systems. However, like any machine, pellet mills can develop problems over time. Understanding these issues early helps reduce downtime, increase output, and improve the overall life of your equipment.
In this article, we explain the most common pellet machine problems, their causes, and simple troubleshooting solutions—designed to help both beginners and experienced manufacturers.
One of the most frequent issues is reduced pellet production.
Causes
• Raw material moisture too high or too low
• Worn-out die or rollers
• Poor-quality raw material
Solution
• Maintain moisture between 8–12%
• Replace worn dies and rollers
• Use clean, properly ground biomass
Overheating can damage the motor and bearing system.
Causes
• Overloading the machine
• Poor ventilation
• Insufficient lubrication
Solution
• Reduce feed rate
• Keep machine area clean and cool
• Lubricate bearings regularly
Pellets may come out loose, powdery, or broken.
Causes
• Wrong raw material size
• Die holes clogged
• Low binding content
Solution
• Ensure powder size is under 3mm
• Clean the die holes
• Add binders if needed (e.g., 2–3% corn starch)
This issue stops production and may indicate a major fault.
Causes
• Voltage fluctuation
• Overload
• Damaged motor
Solution
• Install a voltage stabilizer
• Avoid feeding too much biomass
• Get the motor checked by a technician
Unusual sounds indicate mechanical stress.
Causes
• Loose roller or die
• Worn bearings
• Foreign objects in the chamber
Solution
• Tighten bolts and components
• Replace damaged bearings
• Clean feeding chamber
Excessive vibration reduces machine life.
Causes
• Uneven ground surface
• Misaligned rollers
• Imbalanced feed rate
Solution
• Install the machine on a stable platform
• Align rollers properly
• Maintain consistent feeding
Material may block the feeding chamber.
Causes
• Moisture imbalance
• Sticky or fibrous biomass
• Blocked feeder
Solution
• Correct moisture
• Use a hammer mill for uniform size
• Clean the feeder regularly
Die holes often get clogged, especially with wet or oily materials.
Solution
• Use oil and fine powder mixture to clean
• Heat up the die before starting
• Never leave raw material inside after shutdown
If the machine consumes too much electricity, it affects profit.
Causes
• Overloading
• Poor-quality raw material
• Dull die and rollers
Solution
• Optimize feeding
• Maintain raw material quality
• Replace worn-out parts
10. Pellet Color and Quality Issues
Pellets may turn black or burn.
Causes
• Excessive heat
• Wrong die compression ratio
• Overdry raw material
Solution
• Increase airflow
• Use appropriate die
• Control drying process
Pellet machines are highly efficient when maintained properly. By understanding these 10 common pellet machine problems, manufacturers can avoid breakdowns, reduce operational costs, and ensure smooth production. Regular maintenance, correct raw material preparation, and timely part replacements are the keys to long-lasting pellet machinery.
📞 Interested in setting up a biomass pellet plant in India? Contact Gattuwala Energy for expert consultation, equipment, and government subsidy support.
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