Industrial
pelletizing
at the source.
A factory-built, containerized modular pelletizing line for straw and selected agro-biomass, configured to your feedstock, target pellet specification and site conditions.
One line — from feedstock to finished product.
PelletCore is the process system that converts locally available biomass into a defined pellet product. Material preparation, size reduction, automatic moisture conditioning, pelletizing, counterflow cooling and finished-product handling — integrated within a factory-built containerized architecture.
Factory-assembled and tested as one complete line.
The line is fully assembled, connected and integrated at the factory. Comprehensive functional testing covers conveyors, buffer hoppers, pneumatic transport, automation, sensors, interlocks, safety systems, and spark detection and extinguishing.
One architecture. Engineered for your feedstock and site.
During engineering, representative samples of the customer’s actual feedstock are tested in a specialized laboratory, simulating the key preparation, size-reduction and pelletizing stages. In parallel, we carry out a comprehensive engineering survey of the site — infrastructure, utilities, logistics and installation conditions — and provide recommendations for site preparation and optimization. This work defines the required particle size, moisture-conditioning regime, pellet-mill die specification and initial automation settings.
Scalability is built into the architecture.
The modular architecture allows throughput to be scaled through the number and configuration of modules. For each project, the line scope and format are defined around the required output, feedstock characteristics and site conditions.
PelletCore is the pelletizing core of your operation.
A turnkey modular pelletizing line — from feedstock to finished product. Process equipment, engineering, automation and control logic are integrated into one complete system. The line scope and format are defined by the feedstock, required output, target product and site.
Your project defines the line. PelletCore makes it a system.
- ●Shaftless screw feeder
- ●Automatic moisture-conditioning and stabilization system — meters water and maintains the defined material-conditioning regime before pelletizing.
- ●Pellet mill — 160 kW — the central process stage, 1.5–2.0 t/h.
- ●Counterflow cooler — cools pellets to a temperature suitable for storage and packing.
- ○Feedstock preparation — intake, primary size reduction and fine grinding to suit the material.
- ○Drying — added where required by the feedstock.
- ○Storage — buffer capacity at the line inlet or outlet.
- ○Dosing and mixing — additives and formulations where specified.
- ○Packaging — 15 kg bags, 1,000 kg big bags and extended options.
- ○Throughput expansion — 3 t/h+ project direction.
From bale to bag. Fourteen units. One material path.
The base configuration comprises two factory-assembled 45FT modules forming one continuous line: four process phases and fourteen units along a single material path, from feedstock intake to packed product. Line scope and format are defined by the feedstock, required output, target product and site; full unit-by-unit detail is provided below.
P1
P2
P3
P4
Intake & preparation
In the base configuration, baled feedstock enters on an inclined infeed conveyor and is opened by the bale shredder. For loose feedstock, the intake and feeding system is defined by the project. Pneumatic transport moves the shredded material, while aspiration provides dust extraction throughout preparation and transfer; the hammer mill reduces the material to the target particle size.
Moisture conditioning & pelletizing
The ground material is accumulated in a buffer hopper and metered by a shaftless screw feeder into the automatic moisture-conditioning and stabilization system. The conditioned material is then pelletized in the 160 kW pellet mill at a base output of 1.5–2.0 t/h.
Cooling & transfer
Hot pellets are air-cooled in the counterflow cooler to a temperature suitable for storage and packing, then transferred to the second module for finished-product handling.
Storage & packaging
Cooled pellets are accumulated in the finished-pellet hopper, weighed and fed to packaging — into 15 kg bags or 1,000 kg big bags, according to project requirements.
Technical breakdown — all fourteen units
Module 1 · Preparation & pelletizing · 45FT
- 01Inclined bale infeed conveyorReceives baled feedstock; the infeed system for loose material is project-defined.
- 02Bale shredderPrimary size reduction of baled material.
- 03Pneumatic transport and aspirationTransfers shredded material; aspiration provides dust extraction.
- 04Hammer millFine grinding to the target particle size.
- 05Buffer hopperBuffer storage of ground material.
- 06Shaftless screw feederMetered feeding into the moisture-conditioning system.
- 07Automatic moisture-conditioning and stabilization systemAutomatically conditions and stabilizes material moisture before pelletizing.
- 08Pellet mill — 160 kWPelletizing. Base output 1.5–2.0 t/h.
- 09Counterflow coolerCounterflow air cooling to a pellet temperature suitable for storage and packing.
- 10Flexible screw conveyorTransfers cooled pellets to Module 2.
Module 2 · Storage & packaging · 45FT
- 11Finished-pellet hopperBuffer storage of finished pellets.
- 12Flexible screw conveyor to packagingFeeds pellets to the packaging unit.
- 1315 kg baggingMetered filling of 15 kg bags.
- 141,000 kg big bag fillingBulk packaging for commercial supply or downstream processing.
Two containers today. A system designed to scale.
The base two-module system uses factory-built container modules for preparation, pelletizing, cooling and finished-product handling. Depending on the project, PelletCore can be configured as a single process module, a base two-module line or an expanded arrangement — subject to engineering definition.
From intake to cooling — within one module.
The core process sequence in the base 45FT module configuration.
Controlled finished-product handling.
Receiving, buffer storage, weighing and filling into retail bags or bulk big bags.
Modularity goes beyond the container.
- Drying
- Extended storage
- Additive dosing and mixing
- Extended packaging
Scalable beyond 2 t/h
The containerized arrangement is the standard delivery format. Module scope and throughput are scaled to the project specification.
The two-module base — in numbers.
Base output depends on the feedstock and agreed operating parameters.
Base two-module configuration.
Standard process and finished-product handling modules.
Typical duration, subject to full site readiness.
Design basis for annual operation.
Typical pellet diameter; the final specification is project-defined.
Reference values for the base two-module configuration. Final parameters are defined for each project based on material assessment, site conditions and the agreed technical specification. Expanded-capacity direction: 3 t/h+.
It all starts with your material.
Feedstock type, moisture content and delivery form determine material preparation and the preliminary line configuration. The final solution is defined after assessment of the feedstock and project conditions.
Material → assessment → configuration → target product. Suitability and achievable specification are determined individually for each project.
One system. A defined product for each application.
Bedding pellets
Selected dry biomass is processed into a pelletized bedding product for equestrian and livestock applications. The configuration follows the material condition and the required pellet characteristics.
Dry biomass → line → bedding productFuel pellets
Where the available biomass and intended energy application support this route, the line is configured to produce fuel pellets to a defined specification — a denser, easier-to-handle fuel for a specific boiler or heating system.
Assessed feedstock → line → fuel productPelletCore is not built around one universal product specification. The final specification is defined by the project, feedstock and intended application, taking into account the standards applicable to each product route.
From feedstock assessment to stable operation.
- 01
Assessment
Feedstock, target product and site conditions.
- 02
Technical specification
Output, configuration, interfaces and scope boundaries.
- 03
Engineering
Process flow, equipment arrangement and module layout.
- 04
Main equipment fabrication
Equipment manufacturing and component preparation.
- 05
Assembly & factory testing
Mechanical and control-system integration followed by functional testing.
- 06
Delivery
Prepared modules are delivered to the project site.
- 07
Installation & connection
Positioning, mechanical installation and electrical connection.
- 08
Commissioning & ramp-up
System checks, process-parameter setting, trial production and staged ramp-up to the agreed output.
A real module at the customer’s site.
The module manufactured and assembled through the preceding stages is shown installed at the customer’s site.
Start with the material.
We will engineer the rest.
Five input parameters create a preliminary project brief. It structures the consultation but does not replace feedstock assessment or an engineering survey of the site.
Complete the form below or send your enquiry to info@pelletcore.com.
What material do you plan to pelletize?
Initial feedstock moisture content
Required when feedstock moisture is above 12%.