Unfortunately, Process yields (the % of the spheroids produced in any batch that are within the size range required) will never be 100%.
However, it is possible to achieve yields of greater than 98% if the formulation, process parameters and the equipment used are optimised.
Formulation and process parameters are outside the control of Caleva, but the quality of the equipment used is our direct responsibility and concern.
The design and manufacture of the disc pattern in a spheronizer is crucial for keeping usable yield high. A 1% or 2% lower yield in each batch could cause a significant loss of income over the lifetime of a product.
To obtain the highest possible yield, the equipment used should be manufactured within tolerances that are as tight as possible.
An example of how equipment can vary between manufacturers is shown in the pictures below.
The first disc is not manufactured by Caleva, but the second disc is.
Uneven, poor quality disc cut pattern not from Caleva ...
- Detail of the disc pattern cut from a disc from a lower cost manufacturer.
- Uneven pattern suggests an uneven spheronization action on the extrudate leading to higher variability in the spheroids.
- Less usable yield throughout the lifetime of the product.
Even, high quality disc cut pattern from Caleva ...
- Detail of the disc pattern cut from Caleva
- A completely even pattern suggests an even spheronization action on the extrudate leading to lower variability in the spheroids.
- More usable yield throughout the lifetime of the product.
How might this effect you?
Consider the total cost over the full life cycle of a product. Imagine you’re using a spheronizer to produce a product worth £4 per kilo (a low value product) over a 10-year period.
Your spheronizer produces:
- 50 kg per hour
- For 8 hours a day
- 5 days a week
- 40 weeks per year
If your spheronizer has a reduced usable yield of only 5%, it would mean a loss of £160,000.
Caleva's pelleting equipment could be increasing your throughput, and lowering your cost.
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