We plan, design, and build machines, complete plants, and turnkey production facilities for processing, conditioning, refining and pelleting of many different products for a wide variety of industries.
AMANDUS KAHL today looks back on more than 140 years of machine and plant construction. In 1920, the first pellet mill designed as a worm extruder was produced. Our know-how in this field continues to develop, so that today we have gained international renown thanks to our flat die pellet mills. Worldwide subsidiaries and worldwide service show our steady and well-founded growth.
Pelleting - also referred to as granulation - is suitable for compacting product mixtures or individual components.
There are no limits to the materials that can be compacted: from biomass such as wood or straw to pelleting of household waste and other recycling materials to the granulation of chemical and pharmaceutical raw materials.
These substances and materials are pelleted using pellet mills. AMANDUS KAHL designs and manufactures pellet mills in different sizes and for different throughput capacities. Get informed here or contact us directly - together we will find the right solution for your project.
Particularly fine-particle or dusty products are often a challenge when it comes to storage. Both the porosity and the volume require special measures – also during transport. Our KAHL pellet mills help you to save operating, transport and above all storage costs. Products with different structures, bulk densities, binding strength and particle sizes are no problem for the flat die pellet machines. It is also irrelevant whether the products are powdery, fibrous, lumpy or pasty. The following products are mainly pelleted: Compound feed, raw materials and mineral mixes as well as by-products in flour and oil mills or malthouses. Also straw, wood, biomass and dried sludge (see sewage sludge).
Applications and AdvantagesOur expanders, extruders and hydrothermal reactors ensure conditioning of the product.
The KAHL annular gap expander is used in the production of feedstuff and it allows you to add fat, molasses, vinasse and fishsolubles to the product to be expanded.
Our extruder OEE NG (New Generation) is used for the production of fish feed, shrimp feed and petfood.
Hydrothermal reactors are used for the gentle pre-treatment and modification of raw materials such as legumes, cereals, soya and rape.
The annular gap expander consists of a thick-walled mixing tube with replaceable liners and cantilevered shaft which is provided with proportioning, mixing and kneading elements.
The hydraulically adjustable cone at the outlet together with the outlet ring form the patented annular gap. By adjusting the cone during operation, pressure, kneading intensity, product heating and energy consumption can be controlled and programmed continuously and without delay.
Applications and AdvantagesTwo steps with one machine: The crown expander not only expands a product, but shapes it at the same time. This allows shaped products to be produced for all animal species.
The expander technology is one of the best and most comprehensive conditioning methods for compound feed and individual components. The KAHL crown expander OEK facilitates the processing of feed mixtures.
Applications and Advantages:With our extruder OEE 25 NG (New Generation) we provide the extruder market with fresh impetus. The highest level of engineering and professional further development of our existing extruder make operation even easier than before.
After more than 20 years of experience with extrusion systems, AMANDUS KAHL has developed the extruder OEE 25 NG to meet the increasing demands of the fast growing fish and animal feed markets. The new extruder features AMANDUS KAHL stop bolt technology for ideal mixing and venting in the first cylinder section. Special process sections for compaction, cooking and kneading provide a high degree of flexibility and a wide range of setting options for processing feed. Exchangeable screw elements ensure perfect adaptation to different recipes and quality parameters.
Applications and Advantages of the ExtruderThe KAHL extruder OEE 8 offers the optimum solution for the production of food extrudates such as muesli flakes or snacks made of different cereals.
For the production of instant food, AMANDUS KAHL supplies various machines for processing the desired product. While the KAHL flat die pellet mill can be used to produce pellets from food concentrates, snacks and muesli flakes can be produced with the KAHL extruder OEE 8.
Applications and AdvantagesOur hydrothermal reactors from KAHL offer gentle and uniform product treatment due to separately adjustable temperature, moisture, retention time, mechanical treatment and pressure.
AMANDUS KAHL has many years of experience in the design of complete production lines in which different pre- and post-treatments can be combined with hydrothermal treatment depending on the requirements.
Applications and AdvantagesDifferent individual components and product mixtures often require different pre-treatment. AMANDUS KAHL offers four machines for the field of crushing: the KAHL hammer mill, the KAHL crushing roller mill, the KAHL pan grinder mill, and the KAHL crumbler.
Our hammer mill is appropriate for crushing individual feed components and feed mixtures. However, it can also be used for crushing cereals and biomass such as straw and wood.
The KAHL crushing roller mill crushes feed mixtures, but also oilseeds and legumes. Unlike in the hammer mill which crushes the grain by impact, specific crushing takes place in this machine.
The pan grinder mills work according to the pan grinder principle and are used in wood processing. By means of the pan grinder rollers and the die, the product to be crushed is ground to a defined size.
Our KAHL crumbler is used when coarse products such as pellets have to be crushed.
Our crushing roller mill is used for crushing natural food and feed mixtures. The two counter-rotating rollers crush the respective product so that small particles are produced with low fines content.
The structure of the animal feed is important for a successful animal nutrition. Our crushing roller mill is used to obtain a homogeneous and high quality feed structure. Its rollers break the feed into small and uniform particles so that a coarse granulate is produced instead of a mealy product.
Applications and AdvantagesWood chips, sawdust or wood shavings as well as other lumpy biomass e.g. biogas substrate can easily be ground with our KAHL pan grinder mill.
The raw materials differ in their surface, consistency, but also in their moisture content. Wood often has a higher moisture content than other biomasses, which can cause problems during grinding. However, pan grinder mills are adapted to precisely such biomasses and are therefore ideally suited for the grinding of wood products. The success is due in part to the crushing and grinding effect of the pan grinder rollers. The capacity ranges between a few hundred kilograms and over 40 t/h. The KAHL pan grinder mill achieves all this with minimum energy consumption in combination with silent operation, low space requirement and without aspiration system, cyclone, filter and exhaust air plant.
Our KAHL hammer mills are used for the grinding of feed components and mixtures, but also for all types of grain, straw, wood and similar products.
In the feed industry, a distinction is made between the grinding of feed mixtures and individual feed components. The reason for this are the different surfaces and consistencies that can be found in the individual components of a feed mixture, while the individual feed components are largely homogeneous. For KAHL hammer mills, grinding of neither product is a challenge. This type of mill is also frequently used in grain processing. There are many reasons for this:
The hammer mill is characterised by simple operation and handling. The machine works according to the principle of crushing by multiple impact, so that the most effective crushing takes place by the direct impact of the hammer mill beater on the product. The circumferential speed of the beater tip is approx. 360 km/h. Accordingly, screen perforations, beater designs, beater arrangements and speeds can be adapted to the structure and fineness of the end product. The final size of the grain is determined by the setting of the screen hole diameter and the mill speed. The product only leaves the hammer mill when it is smaller than the screen hole diameter - in approx. 95% of cases the products are smaller than half the screen hole diameter.
The KAHL crumbler is characterised by smooth operation and low wear. The advantages of the crumbles clearly lie in the optimum feed conversion by the animal. KAHL crumblers are used for crushing pellets or coarse-grained products in the animal feed industry - more precisely in the compound feed industry. The finished product is broken or crumbled. Crumbling is carried out by corrugated rollers and different rotating speeds. This results in only a small amount of fines, which can be returned to the press after screening. In addition, the particle size range can be influenced by changing the spring preload.
More than 1000 KAHL belt units are in operation worldwide and work in different sectors. Before you decide on a belt drier, you have the opportunity to perform a belt drier simulation for your project in our pilot plant. Both cooling and drying are carried out according to the cross and counter current principle, depending on the number of belts. Due to the modular design of the belt units, they can be optimally combined to meet the required plant size. They are designed to suit both small and large units according to the modular principle.
Applications and AdvantagesOur KAHL fabric belt drier ensures optimum drying of the product as well as filtration of the exhaust air. The fabric belt drier is used in particular for drying wood.
As the name suggests, the KAHL fabric belt drier is characterised by a tightly woven plastic fabric belt, which does not only dry the product but also filters the exhaust air to ensure that the legal limit value for dust fibres in the exhaust air is below the threshold value. Measurements by independent institutions have proven that the value is below the limit value - the average value was even far below half the permitted value. Discontinuous automatic cleaning of the belt avoids clogging of the belt openings with wood particles.
Applications and AdvantagesAMANDUS KAHL offer continuous mixers and mixing conditioners for the production of homogeneous mixtures from individual components.
KAHL continuous mixers are used for all mixing tasks where liquids have to be continuously added to solids. This ensures a homogeneous ratio between solids and the added liquids.
Our KAHL mixing conditioner, on the other hand, is particularly suitable for the production of feedstuff. Apart from the addition of water, steam and other liquids, the machine ensures the simultaneous thermal treatment of the product.
With our horizontal and fast-rotating agitator-blade mixers, mealy, granular, fibrous and/or flaky carrier substances can be mixed with liquids.
Our continuous mixer allows simultaneous addition of several bulk product flows, liquids and steam. Using the whirling principle, you can produce a lump-free mixture. The throughput time and the type of whirl formation can be influenced by adjusting the agitator blades. Thus the mixing effect can be adapted to the product. In addition, we manufacture the continuous mixer in four different sizes with a motor power from 7.5 to 110 kW, which provides a high variability in throughput time.
Our retention conditioner enables you to condition feed mixtures or individual components with the addition of steam and small quantities of liquid such as oil. In addition, our conditioner type "VK" ensures a determined retention time upstream of an extrusion process.
Conditioning of fish feed, for example, is necessary to reach the best quality in terms of nutritional and physical properties. At the same time, the treatment serves as preparation for the subsequent (extrusion) process.
Applications and AdvantagesBy adding steam, water, and other additives, feed mixtures or individual components can be conditioned efficiently with the KAHL conditioner "K". Conditioning of feed is necessary to ensure the best quality in terms of nutritional properties. At the same time, conditioning serves as preparation for, for example, the subsequent pelleting process.
Applications and AdvantagesExact proportioning of the material to be treated is one of the most important preparatory steps for subsequent processing. AMANDUS KAHL designs and manufactures two proportioning machines for this process step, which ensure optimum proportioning of the product.
Our KAHL screw conveyor is suitable for transport and proportioning of all kinds of bulk products.
Our continuous cellular wheel weighers are used when powdery, mealy, fibrous or structured products have to be exactly proportioned.
A simple design and low maintenance requirements - this is what distinguishes our KAHL proportioning and conveying screw and ensures a high level of operational reliability.
The proportioning and conveying screw is suitable for conveying bulk products of any kind in horizontal or ascending direction. Apart from our standard lengths of 1500, 2000, 2500 and 3000 mm, we also supply special lengths on request.
The worm shaft consists of a tubular shaft with welded-on solid thread (sheet steel). In addition, it runs on anti-friction bearings with stuffing box packing. If larger lengths are required, maintenance-free intermediate bearings are used. The tubular shaft parts are connected by means of bolts. The inlets and outlets can be arranged according to requirement. The proportioning and conveying screw is driven by offset geared motors - however, if space is limited, other drive types are also possible.
Our continuous cellular wheel weighers are designed for measuring and recording mealy, powdery, fibrous and structured products.
The AMANDUS KAHL continuous cellular wheel weighers offer precise measurement of bulk materials with a wide range of surfaces. Our load cells continuously measure the weight of the filled cellular wheel and thus an instantaneous weight of the varying product flow. Mealy, powdery, fibrous or structured products can be measured and/or weighed with an accuracy of ± 2%.
In order to make the operation of our machines as user-friendly and simple as possible, AMANDUS KAHL has developed various control systems. They include the electrical control system of our expander (ESEP), the automatic control of our flat die pellet mill (EAPR) and the adjustment of a constant roller gap during pelleting (DISTAMAT). ESEP ensures full automation of the complete expander line and a constant product quality.
The EAPR system ensures fully automatic operation of your pellet production. In addition, our DISTAMAT system provides a constant distance between the pan grinder rollers and the flat die.
Automation is in the focus of KAHL systems. We have developed the EAPR and DISTAMAT for the automatic control of our KAHL flat die pellet mill.
The EAPR from KAHL consists of a local control cabinet with graphic touch panel (TP) and a PLC with Step 7 CPU as central components. It thus controls and regulates all relevant process parameters. As an option, the DISTAMAT can be used for continuous adjustment and regulation of the roller gap, as good pellet quality requires a constant roller gap. Our EAPR and DISTAMAT systems therefore ensure optimum press operation combined with low manpower requirements.
Applications and Advantages:Depending on the setpoint deviations, the pressure of the hydraulic system of the pellet mill is controlled in such a way that the roller gap is kept constant. In this way, our DISTAMAT allows a continuous preselection of the roller gap. Apart from that, the direct contact of die and pan grinder rollers which usually results from a product shortage is avoided. Thus service lives of pan grinder rollers and die are considerably increased. By means of alternating lifting and lowering of the pan grinder rollers, the optional unblocking programme causes an automatic unblocking in case of an overfilling of the pellet mill.
Applications and Advantages:Our ESEP is an automation concept that makes optimum use of the potential of the annular gap expander and far exceeds simple machine control. The ESEP was developed for the simple control of our annular gap expander and now contains more than twelve years of process and automation knowledge. It consists of two essential components - the switch cabinet with Siemens PLC S7 and the PC-based visualization and operating station. The actual control and regulation of the process takes place at the switch cabinet. Therefore, the cabinet should be close to the machine. The visualization and operating station represents the interface to the operator and is implemented using Windows and Intouch (Wonderware).
Applications and Advantages:The KAHL Rotospray enables you to refine your end products using liquid additives: Add more ingredients to your product or refine its appearance.
Our KAHL Rotospray is a micro-spraying system for the application of liquid additives to the end product. The rotation nozzle allows ultra-fine spraying of liquids on solids: 1 millilitre of liquid is diffused into 10,000,000 droplets. The special distribution of the solid matter flow ensures spraying of the product from all sides.
Applications and AdvantagesIncrease the quality and/or the energy content of your feed and introduce liquids deep into the pores of shrimp and fish feed, pellets, extrudates, poultry feed and pet food. Vacuum coating is a standard process in fish feed production. Depending on the feed type, 4 to 40 % oil are subsequently applied to the extruded fish feed.
As this process results in excellent product quality, the vacuum coater is also used in the production of dog and cat food. The process is also increasingly being used in the field of compound feed production, particularly poultry feed. The subsequent addition of fat significantly increases the energy content of the feed, allowing high-fat compound feed components to be minimized in the formulae. This reduces the costs for the raw materials. Low-fat feed pellets often have significantly better qualities (e.g. abrasion resistance).
For processing powdery substances and for shaping liquids, the fluidised bed technology provides optimum solutions to reach efficient production processes. Contrary to continuous fluidised bed plants, batch-wises processes take place consecutively. They are reproducible at any time and ensure a high product quality. The batch technology is an alternative, when fast throughput times do not matter and fixed batch sizes are to be processed or when a frequent product change is planned. AMANDUS KAHL fluidised bed plants are versatile and flexible. They can process a variety of products and refine powders, granules or pellets or shape liquids to particles.
Examples for the application of the batch fluidized bed technologyThe continuous fluidised bed technology offers ideal possibilities for a targeted modification or customised optimisation of the product properties of bulk goods. In continuous fluidised bed plants, the processes are fully automatic. They are reproducible at any time and ensure a high product quality. Unlike batch plants, the product passes through several zones in one apparatus, in which run various processes such as agglomeration, granulation and drying take place simultaneously.
Examples for the use of continuous fluidized bed technologyWe offer high-performance laboratory plants for continuous and batch-wise processing in different versions. Our laboratory apparatuses help you to improve your processes, to define parameters, to test recipes and to optimise product handling before starting mass production. Carry out feasibility studies, develop special substances and innovative products – a safe scale-up of the results provides your R & D department with all options for conducting a low cost, successful project management and supports you in every phase of production.
Conti FB Pilot are extremely flexible pilot plants in different sizes, with which all continuous fluidized bed processes and almost any product can be tested:
As experts in mechanical and thermal process engineering, our special plant design belongs to the leading-edge cluster technology in international markets.
For the development of innovative products, we work with the most modern testing procedures in our highly specialised pilot plant. We offer the engineering by dedicated process engineers with detailed application knowledge, cooperative reliability and the high quality of a German machine manufacturer.
Our competence exceeds the design and construction of fluidised bed plants. We also design special plants and provide specific solutions. These include mixing granulators of laboratory and production scale (high shear mixer) as well as belt dryers for special hygienic purposes and high temperatures. Our manufacturing program also includes special conditioning and drying units, for example spiral belt dryers, in which the product is heated under certain conditions for a certain time.
Sustainability and recycling are becoming increasingly important issues. "What happens to the waste produced?" AMANDUS KAHL plants provide the answers to these questions.
AMANDUS KAHL offers plants for pelleting municipal and domestic waste and sewage sludge. Furthermore, we plan, manufacture and build waste tyre recycling plants. Domestic waste and sewage sludge are characterised by a high storage volume and a low bulk density. Pelleting the materials is a convenient solution to both problems. Pellets from domestic waste and sewage sludge are ideally suited as an alternative fuel and conserve other resources. Several processing steps are required prior to pelleting domestic waste or sewage sludge. From the very first minute, KAHL will assist you in planning your project.