Cat Litter Granulation Production Line
Since the production of micro-particle cat litter has high technical requirements in the actual production process, EMCC engineers can provide on-site leadership services.
Cat litter granulation production line is an automated equipment system specially used to process raw materials into cat litter granules suitable for cats. The production line is mainly composed of raw material processing equipment, mixing equipment, granulator, drying equipment, screening equipment, coating machine, packaging equipment and environmental protection facilities.
The characteristics of cat litter granulation production line include high degree of automation, flexible configuration, good environmental protection and high quality stability. According to different types of cat litter, such as bentonite cat litter, tofu cat litter, silica cat litter and sawdust cat litter, the equipment and process requirements of the production line will also be different.
Cat litter production line types
With the development of economy and improvement of the human living standards, the pet number of cats and dogs kept in households is also increasing. At the same time, the disposal of pet excrement also troubles most households with pets. Therefore, the American scholars researched of the use of cat litter based on the cat’s characteristic that cats will bury their dung with sand or soil. As far, due to the cat litter has the advantages of deodorization, strong adsorption, non-toxic, non-polluting, the cat litter is used for household pet cat, dogs, and other small pets. When your cats use the cat litter, the cat dung or urine are in contact with cat litter to from a spherical shape by the hydroscopic effect of cat litter. What’s more, the cat litter that is not contaminated with feces or urine can continue to be used, and it is extremely easy to clean up the feces and urine of small pets.
Generally speaking, we distinguish cat litter production lines by the type of cat litter, such as tofu cat litter production line, bentonite cat litter production line, sawdust cat litter production line, waste paper cat litter granule production line, silica gel cat litter production line, plant cat litter production line, mixed cat litter production line, clay cat litter production line, etc. All of these production lines are specially customized according to the raw materials and processes of cat litter, and are specifically used to process a certain type of cat litter. Some production lines have similar processes, while others have quite different process designs.
tofu cat litter production line
The tofu cat litter production line is a pellet processing system mainly used for processing tofu cat litter and starch cat litter.
Commonly used raw materials include bean dregs, corn starch, food-grade guar gum, flour, calcium carbonate, citric acid, pea fiber, etc.
Tofu cat litter has low production cost, high sales price and large profit margin. Tofu cat litter is made from tofu dregs or plant materials after processing, shaping and drying.
It is non-toxic and has no side effects and is very environmentally friendly. This characteristic makes tofu cat litter have great market potential today when environmental awareness is increasing, further increasing profit margins.
tofu cat litters
bentonite cat litter production line
The bentonite cat litter production line is mainly used to produce bentonite cat litter. Bentonite cat litter remains the first choice for many cat-raising families because of its affordability, strong water absorption and environmental protection.
The main raw material of bentonite cat litter, bentonite, is cheap, and the production process is mature, which can effectively reduce the production cost. The bentonite cat litter industry has a bright future, with broad market prospects, low investment threshold, high profit margin and relatively low risk.
bentonite cat litters
WOOD cat litter production line
The most common pine cat litter is processed using this type of production line. Wood cat litter is usually made of environmentally friendly materials such as recycled pine, sawdust, wood chips, waste wood, pulp or wheat byproducts, and can be directly discarded or flushed into the toilet after use to reduce environmental pollution.
As consumers’ demand for environmentally friendly and high-quality products increases, wood cat litter is expected to gain more market share due to its environmental friendliness and good user experience.
wood cat litters
Conclusion
EMCC provides customized solutions for cat litter granulation production lines. EMCC’s production line integrates advanced automation technology and intelligent management systems. From raw material processing to final product packaging, every production link is refined. In addition, EMCC also emphasizes environmental protection and energy-saving technology, and adopts dust-free and deodorization technology to meet consumers’ demand for high-quality, environmentally friendly products. Please contact us now for customized service！
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Choose a disc granulator (disc pelletizer) to produce bentonite cat litter
Disc granulator is a widely used equipment in cat litter production, especially for bentonite cat litter production. It plays a core role in bentonite cat litter production line with its high efficiency, stability and simple operation. The following are the specific processes and advantages of using disc granulator production line to produce bentonite cat litter.
Working Principle of DISC Granulator
The disc rotates at a certain inclination angle, and the bentonite powder is subjected to the combined action of gravity, centrifugal force and friction in the disc.The sprayed water evenly covers the surface of the powder, causing the powder to gradually gather into spherical particles.The particles continue to roll and adhere to other powders during the rotation process, gradually growing and eventually forming spherical cat litter particles of uniform size.
In the process of rotation, a small group of particles, formed by the liquid phase and the powder added to the disc from the front conveyor, roll towards the lower side of the disc and continuously adheres to the powder to increase the particle size due to the gravity and centrifugal force generated by the inclined disc in the process of rotation. At the same time, due to the friction between the material and the disc, the particles roll upward with the disc and overflow from the disc edge when they reach the finished granule size.
The main factors affecting the pan granulator are disc diameter, disc inclination, disc edge height, rotation speed, feeding position, scraper position and so on.
Production process
Bentonite cat litter is loved by cat owners for its excellent water absorption and clumping properties. In order to meet the market demand for bentonite cat litter, the design and configuration of the production line are crucial. The bentonite cat litter production line usually includes multiple key equipment and process links to ensure the production of high-quality cat litter particles.
- Raw material preparation: Select high-quality bentonite raw materials, and perform preliminary screening and cleaning to remove impurities to ensure the smooth progress of subsequent processes.
- Crushing and screening: The prepared bentonite raw materials are sent to the crusher for crushing. After obtaining the powder with the appropriate particle size, the screening machine is used for classification to remove unqualified particles.
- Mixing: The sieved bentonite powder is evenly mixed with other additives (such as spices, deodorants, etc.) to ensure that each particle has good functionality and adsorption capacity.
- Granulation: The mixed material is sent to the disc granulator, and the appropriate humidity and stirring speed are controlled to make the material fully roll in the disc to form uniform cat litter particles.
- Drying and screening: The formed particles are dried by a rotary dryer and then screened again to ensure the particle uniformity and suitable particle size of the final product.
- Coating: After drying and cooling, the granules enter the coating process. The coating material is evenly sprayed onto the surface of the granules using a coating machine, and rolled in a drum to evenly distribute the coating material. The coating process can reduce dust, improve water absorption and agglomeration, and enhance the deodorizing effect. Afterwards, the coated granules are dried and cooled again to ensure that the coating material is fully solidified.
- Packaging: After weighing, the qualified cat litter particles are automatically packaged into bags for easy sales and transportation.
Core technical features: achieving efficient, precise and sustainable production
Precise granulation control
The disc granulator is the core equipment of the entire production line. Its design is highly flexible and can be precisely controlled by adjusting a variety of parameters:
- Disc tilt angle: The adjustment of the tilt angle directly affects the residence time and rolling path of the raw materials in the disc. By precisely controlling the angle, the shape of the particles can be ensured to be uniform and irregular particles can be avoided.
- Speed adjustment: The rotation speed of the disc determines the speed of particle formation. Slow rotation is suitable for producing larger particles, while high-speed rotation is conducive to the formation of fine particles, which can flexibly respond to different market needs.
- Water spray control: During the granulation process, the humidity of the raw materials can be precisely controlled by adjusting the water spray amount, thereby improving the cohesion and hardness of the particles. Excessive water spraying will cause the particles to stick together, while too little water spraying will cause the particles to loosen, which is crucial to product quality.
This multi-dimensional control method enables the production line to quickly adjust to the needs of cat litter with different specifications and functions, significantly improving production flexibility and market adaptability.
Efficient coating technology
Coating technology is an important part of improving the performance of cat litter products. The use of advanced equipment and processes can significantly enhance the functionality and added value of particles:
- Dust prevention: By evenly spraying the dust-proof coating, a dense protective film is formed on the surface of the particles, effectively reducing dust generation. This not only improves the user experience, but also reduces air pollution during the cleaning process.
- Functional coating: According to market demand, special functional ingredients can be added to the coating:
- Antibacterial coating: inhibits bacterial growth and ensures pet hygiene and health.
- Deodorant coating: absorbs and neutralizes odors to enhance the deodorization ability of cat litter.
- Enhanced water absorption coating: further enhances the water absorption and agglomeration of particles, making them perform better in use.
- Coating uniformity: using precision spraying devices and roller technology to ensure that each particle can be evenly covered with the coating, enhancing product consistency and reducing waste.
This efficient coating process not only improves the market competitiveness of the product, but also extends the service life of the product, meeting consumers’ demand for high-performance cat litter.
Energy-saving drying system
Optimized airflow design: The rotary drum dryer adopts a co-current or countercurrent heat exchange method to ensure that the hot air and the granular material are fully in contact, thereby achieving more efficient heat transfer.
- Segmented temperature control: The drum of the equipment is divided into several drying sections, and different temperature controls are set for each section to ensure that the particles can obtain the best drying conditions at different stages.
- Uniform heating: There is a lifting plate in the drum, and the material is evenly distributed and rolled under the action of the lifting plate, and is fully in contact with the hot air to avoid local overheating or overhumidification.
- Heat recovery system: Equipped with an exhaust gas recovery device, the discharged hot air is reused for a second time, which greatly reduces energy consumption and improves the thermal efficiency of the equipment.
- Insulation design: The outside of the drum uses high-efficiency insulation materials to reduce heat loss and reduce energy waste during equipment operation.
The rotary drum dryer not only improves the drying efficiency of bentonite particles, but also significantly reduces production costs. Uniform heating, precise humidity control, and environmentally friendly and energy-saving design make this equipment irreplaceable in cat litter production lines and other bentonite application fields.
CONCLUSION
Selecting the right disc pelletizer for a given job can be a challenging undertaking. By considering factors such as on-site testing facilities, material experience, ongoing support, training, and high-quality design and fabrication, however, the process can be made much more simple.
EMCC is the world’s leading provider of disc pelletizers for industries ranging from fertilizers and soil amendments, to specialty chemicals and ores. We offer batch- and pilot-scale testing in our Innovation Center and have a comprehensive parts and service program to support all of your disc pelletizer needs – including training. All EMCC disc pelletizers are designed and manufactured to the highest quality standard for an efficient and reliable result, and can be provided as a stand-alone unit, or as part of a complete pelletizing system. For more information on our disc pelletizers, contact us today!
WE NOT ONLY PROVIDE RELIABLE PRODUCTS, BUT MORE IMPORTANTLY WE PROVIDE RELIABLE PROCESS DESIGN AND EXPERIMENTATION
A combination of environmental protection and comfort: tofu cat litter
Today, as the pet products market is growing, tofu cat litter has quickly become a favorite of cat lovers due to its environmental protection, superior performance and safety. As a plant-based cat litter, it not only meets the functional needs of cats for daily use, but also caters to the modern society’s emphasis on environmental protection. This article will comprehensively analyze the characteristics, granulation process and future development trends of tofu cat litter.
What is tofu cat litter?
Tofu cat litter is a type of cat litter with tofu dregs and bean dregs extracted from soy milk production as the main raw materials. It is made by adding plant fiber, starch, adhesive and deodorant and other ingredients through granulation process. It is characterized by light particles, strong water absorption, excellent agglomeration performance, and environmental friendliness. It can be directly degraded or even flushed into the toilet for treatment.
Main features of tofu cat litter
Environmentally friendly and degradable: As a plant-based product, tofu cat litter can be naturally degraded and does not pollute the environment. Compared with traditional bentonite cat litter, it has lower carbon emissions during production and disposal.
Excellent water absorption and agglomeration: The water absorption of tofu cat litter is 3 to 4 times its weight. Cat urine can be quickly locked to form a solid agglomerate, which is easy to clean.
Good deodorization effect: By adding natural deodorants, tofu cat litter can effectively inhibit the production of ammonia and significantly reduce the odor of the cat litter box.
Low dust and safety: The granulation process ensures the hardness and uniformity of the tofu cat litter particles, with very little dust and will not irritate the cat’s respiratory tract. Ingestion of a small amount of particles will not pose a threat to the health of cats.
Production process of tofu cat litter
The high performance of tofu cat litter is inseparable from the advanced production process. The following are its key steps:
Raw material processing
The bean dregs and other plant fibers are refined through a pulverizer to ensure the uniformity of the particles. Then low-temperature drying is carried out to control the moisture content at 10%~15%, providing the best conditions for subsequent granulation.
Mixing
Bean dregs, plant starch and adhesive are mixed and evenly stirred by a double-screw mixer or horizontal mixer. Natural deodorants are added to enhance product performance.
Granulation and molding
Extrusion granulation: The mixed raw materials are extruded into strips or granules by a screw.
Flat die granulation: The raw materials are pressed into the die hole to form regular columnar particles.
The particle diameter is usually 2~6mm, which is suitable for cats’ usage habits.
EMCC’s Double Roll Granulator
Drying and cooling
The molded particles are removed from excess moisture by a hot air dryer and then enter the cooling system to ensure hardness and shape stability.
Coating treatment
- Film coating: A moisture-proof film is evenly applied to the surface of the particles through a coating machine. This process improves the moisture-proof performance of tofu cat litter and enhances the storage resistance of the particles.
- Further functionalization: Adsorbent materials (such as activated carbon) can be selectively added to enhance the odor control ability of cat litter.
Screening and packaging
Use a vibrating screener to remove unqualified particles and seal the finished products in bags. The packaging needs to be moisture-proof to extend the storage period.
Market performance and development trends
Growth of consumer demand
With the improvement of environmental awareness and the rapid expansion of the pet market, the market share of tofu cat litter has increased year by year. Especially in the European and North American markets, its sales have increased at a rate of more than 10% per year.
Product diversification
Tofu cat litter on the market has expanded from a single natural color to a variety of colors and functional combinations, such as deodorizing type with activated carbon or multifunctional type compounded with bentonite.
Intelligent combination
In the future, tofu cat litter will be more combined with smart cat litter boxes to meet the needs of pet owners for automated cleaning. This will further enhance its convenience and market competitiveness.
Advantages and challenges of tofu cat litter
Advantages
- Health and safety: Suitable for cats of all ages, including kittens and old cats.
- Easy to handle: Can be directly flushed into the toilet or composted.
- User experience: Lightweight and dust-free, the cleaning process is more comfortable.
Challenges
- High production cost: Compared with traditional cat litter, tofu cat litter has higher requirements for raw materials and processes.
- Susceptible to moisture: Moisture-proof should be paid attention to during storage, otherwise it is easy to affect clumping.
- Consumer awareness: Although the market is growing, some consumers are still sensitive to its price.
Conclusion
Tofu cat litter is a pet product that is both environmentally friendly and functional, in line with the current trend of green development. With the continuous advancement of technology and market promotion, its production cost will be further reduced and its functions will be more complete. For every pet owner who cares about the health of cats and pays attention to environmental protection, tofu cat litter is undoubtedly one of the most worthwhile choices.
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Research on the application of activated carbon in cat litter
With the rapid development of the modern pet care industry, cat litter, as a necessity in cats’ daily life, has been increasingly required to be more functional, environmentally friendly and easy to use. Traditional cat litter usually uses bentonite, diatomaceous earth, sawdust and other materials as the main raw materials. However, as consumers’ awareness of pet health and environmental protection increases, more and more studies have begun to focus on how to improve the performance of cat litter by adding functional materials such as activated carbon. As an efficient adsorption material, activated carbon is widely used in cat litter products due to its excellent deodorizing, hygroscopic and antibacterial properties. This paper will combine the paper “Research on the Application of Activated Carbon in Cat Litter” published by Li Fang et al. (2023) in the journal “Chemical Technology and Applications” to analyze the application of activated carbon in cat litter, explore its application effects and challenges, and propose future research directions.
Basic characteristics and application background of activated carbon
Activated carbon is a carbon material with a highly porous structure. Because of its large specific surface area (generally 500-1500 m²/g), it can provide a large number of adsorption sites, so that it can efficiently adsorb various harmful gases, liquids and impurities. The adsorption performance of activated carbon mainly comes from its porous structure and surface functional groups. These characteristics make it widely used in many fields such as environmental protection, air purification, and sewage treatment. In the production of cat litter, activated carbon can not only improve the hygroscopicity of cat litter, but also effectively remove bad gases such as ammonia, reduce odor, and improve the living environment of cats.
The main role of activated carbon in cat litter
Deodorization function
Ammonia, urea and other organic gases in cat excrement are the main sources of odor. Studies have shown that activated carbon has a very strong adsorption capacity and can effectively remove harmful gases such as ammonia and hydrogen sulfide in the air, reduce the concentration of harmful substances in the air, and thus reduce the odor emitted by cat litter. After activated carbon is added to cat litter, it can significantly improve the deodorization effect of cat litter, especially in a humid environment, the moisture absorption and adsorption of activated carbon can significantly reduce the accumulation of odor in cat litter.
Hygroscopic performance
The hygroscopicity of cat litter is one of the important indicators of its performance, which directly affects the cat’s experience and the service life of cat litter. The porous structure of activated carbon enables it to effectively absorb moisture and enhance the hygroscopicity of cat litter. This is especially important for the moisture treatment of cats after daily excretion, which can keep the cat litter dry and prevent bacteria from growing due to excessive moisture.
Antibacterial performance
In addition to the adsorption function, activated carbon also has a certain antibacterial effect. Studies have shown that activated carbon can inhibit the growth and reproduction of bacteria through organic matter and bacteria adsorbed on its surface, and has an antibacterial effect. In cat litter, the addition of activated carbon can effectively reduce the growth of bacteria on the surface of cat litter and reduce the risk of cats coming into contact with harmful bacteria. Li Fang et al.’s research shows that activated carbon can not only absorb moisture and harmful gases in cat litter, but also inhibit pathogens in cat litter through its unique physical and chemical effects.
Improve the life cycle of cat litter
By adding activated carbon, the comprehensive performance of cat litter has been improved, especially in terms of moisture absorption and deodorization. Activated carbon can effectively extend the service life of cat litter and reduce the need to frequently replace cat litter. This can not only reduce the economic investment of cat owners in cat litter, but also reduce the impact of discarded cat litter on the environment.
Challenges of the application of activated carbon in cat litter
Cost issue
As a highly efficient adsorption material, activated carbon is relatively expensive, especially high-quality activated carbon. Therefore, how to control the use of activated carbon while ensuring the deodorization, moisture absorption and other properties of cat litter, thereby reducing production costs, is an important issue currently faced in cat litter production. In the future, the amount of activated carbon added and the formula can be optimized, and combined with other materials for composite application, so as to achieve the effect of reducing costs.
Issues on particle size and distribution of activated carbon
In order to ensure the uniform distribution of activated carbon in cat litter, the particle size and distribution uniformity of activated carbon need to be effectively controlled. Studies have shown that too large particles may lead to poor adsorption of activated carbon, while too small particles may affect the structure of cat litter, reducing its hardness and service life. Therefore, choosing the right activated carbon particle size and mixing it with other raw materials is the key to producing high-quality cat litter.
Environmental protection issues
The production process of activated carbon may produce certain environmental pollution, such as carbon dioxide emissions and energy consumption. In the future, the development of environmentally friendly activated carbon, especially activated carbon produced from natural resources such as agricultural waste and wood, will be an important way to solve this problem. The use of renewable resources to produce activated carbon can not only reduce production costs, but also effectively reduce the impact on the environment.
Regeneration and recycling of activated carbon
Activated carbon will be saturated during use and needs to be regenerated. How to efficiently regenerate activated carbon and extend its service life is another problem currently faced in cat litter production. In the future, it can be considered to combine activated carbon with other renewable materials to develop activated carbon products with higher regeneration performance.
Future development direction of activated carbon in cat litter
Research and application of composite materials
In the future, the application of activated carbon will not only be limited to single addition, but can also be compounded with other natural materials (such as bentonite, sawdust, plant fibers, etc.). Through the design of composite materials, the comprehensive performance of cat litter can be improved, and the effects of deodorization, moisture absorption, and antibacterial can be enhanced, while reducing production costs.
Development of green and environmentally friendly activated carbon
With the improvement of environmental protection requirements, green and environmentally friendly activated carbon will become the focus of future development. Using agricultural waste, wood and other resources to produce activated carbon can not only reduce costs, but also effectively reduce the burden on the environment. Future research can focus on how to optimize the production process of activated carbon and reduce energy consumption and waste emissions in its production process.
Development of functional activated carbon
With the advancement of technology, the research on functional activated carbon has gradually become a hot topic. For example, chemical modification technology is used to combine activated carbon with functional molecules such as antibacterial and antioxidant to enhance its application effect in cat litter. At the same time, the functional modification of activated carbon can not only improve its deodorization and antibacterial properties, but also improve its compatibility with other raw materials.
Conclusion
Activated carbon has become an indispensable additive in modern cat litter due to its excellent adsorption and multifunctional properties. Studies have shown that activated carbon can significantly improve the deodorization, moisture absorption, and antibacterial properties of cat litter and improve the living environment of cats. Although there are certain challenges in the application, such as cost and environmental protection, with the advancement of technology and in-depth research, the application prospects of activated carbon in cat litter are broad. Future research should focus on optimizing the production process of activated carbon, improving its environmental protection and regeneration performance, and further improving the comprehensive performance of cat litter through the design of composite materials, so as to meet the market demand for high-performance cat litter.
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Shanghai Exceed Industry Co., Ltd (China EMCC) is a manufacturing enterprise specializing in high-tech fertilizer machinery. For many years, we have devoted to producing inorganic and organic fertilizers granulator equipments. By consistently creating values for our customers around the world, we have become one of the leading suppliers in global agricultural fertilizers industry. With China EMCC, you may get comprehensive services of consulting, design, equipment, installation, training, emergency assistance, field assistance, spare parts and routine maintenance to save fertilizer plants cost.
