{"id":13682,"date":"2025-10-28T10:00:17","date_gmt":"2025-10-28T06:30:17","guid":{"rendered":"https:\/\/behinpolymerco.com\/a-report-on-single-belt-granulation-systems-ebg\/"},"modified":"2026-06-10T10:50:23","modified_gmt":"2026-06-10T07:20:23","slug":"a-report-on-single-belt-granulation-systems-ebg","status":"publish","type":"post","link":"https:\/\/behinpolymerco.com\/en\/a-report-on-single-belt-granulation-systems-ebg\/","title":{"rendered":"Investigating single belt granulation (EBG) systems and their role in reducing energy consumption"},"content":{"rendered":"

The Single Belt Pelletizing System (EBG), which stands for Einbandgranuliersystem and is equivalent to Single Belt Pelletizing System, is recognized as one of the new technologies in the field of polymer granulation. Developed by the MAAG Group, this system enables the stable processing of moisture-sensitive polymers, highly filled materials (more than 60% filler) and brittle compounds by eliminating traditional water baths and replacing them with a linear conveyor belt. The single belt design of the EBG system allows for precise control of the cooling process while maintaining the integrity of the filaments, and plays an effective role in reducing energy consumption and increasing the stability of polymer compounding processes. <\/p>\n

Major innovations in the design and operation of the EBG system<\/h2>\n

In the single belt granulation (EBG) system, polymer filaments are extruded directly onto a plastic or steel conveyor belt after exiting the die, rather than entering a water bath. This innovative design significantly reduces filament breakage by eliminating water immersion and increases the stability of the granulation process through uniform linear feeding and adjustable belt speeds (from about 8 m\/min). <\/p>\n

Filament cooling in the EBG system is achieved by hot or cold air nozzles as well as water sprays with adjustable intensity, allowing for precise thermal management for a wide range of polymeric materials. For example, starch-based biopolymers<\/strong> are typically cooled by air flow alone, while high-melting-point thermoplastics<\/a><\/strong> such as PEEK and PPS require faster water jet cooling. This design flexibility makes the EBG system an efficient option for processing a variety of thermoplastics with varying<\/strong> thermal properties. <\/p>\n

 <\/p>\n

\"EBG\"<\/p>\n

 <\/p>\n

Synergy of energy and automation in modern granulation<\/h2>\n

In recent years, as energy costs have increased and polymer formulations have become more complex, the industry has turned its attention to equipment that can simultaneously reduce energy consumption and increase the level of automation. Modern granulation systems, including the single-belt granulation (EBG) system, have made it possible to achieve this synergy by utilizing optimized designs, advanced process control and intelligent monitoring systems, and play an important role in increasing productivity, production sustainability and reducing operating costs. <\/p>\n

Reducing energy consumption and optimizing process efficiency<\/strong><\/h3>\n

One of the main challenges in polymer granulation lines is the high energy consumption, especially in systems that use water baths to cool the filaments. In addition to the need for heating and continuous water circulation, these systems require high-energy peripheral equipment such as pumps, heat exchangers and filtration units, which together significantly increase operating costs. <\/p>\n

The single belt granulation (EBG) system minimizes this energy loss by completely eliminating the water bath and replacing it with controlled cooling on the conveyor belt. As a result, the energy consumption associated with heating and water circulation is eliminated, and in many industrial applications, energy consumption reductions of up to 50% have been reported. This advantage is of strategic importance, especially in continuous production lines, large-scale compounding processes and units operating with tight profit margins. <\/p>\n

In addition to mechanical design, melt flow stability in extrusion also plays an important role in reducing energy consumption. In this context, the use of polymer process aids<\/a><\/strong> can help optimize the performance of the EBG system by reducing internal melt friction, preventing flow instability, and reducing extrusion pressure. This not only reduces energy consumption, but also improves equipment life and granule uniformity. <\/p>\n

 <\/p>\n

\"Single<\/p>\n

 <\/p>\n

Intelligent automation and quality control in modern granulation<\/strong><\/h3>\n

In addition to reducing energy consumption, process automation has become one of the main pillars of the development of modern granulation systems. In the EBG system, integration with automatic pelletizers (such as the MAAG PRIMO series) allows real-time process control via PLC systems. In this configuration, parameters such as belt speed, melt temperature, extrusion pressure and filament quality are continuously monitored and, in the event of instability, the necessary adjustments are automatically applied. <\/p>\n

Ancillary equipment such as the hot air knife (HAK) also plays an important role in maintaining process stability. By preventing material build-up on the die plate, this tool prevents output fluctuations and unwanted line stops, and ensures granulation uniformity. Such an approach is in line with global trends in the polymer industry, which focus on reducing human intervention, increasing process repeatability, and improving the quality of the final product. <\/p>\n

As reported in the journal Compounding World, the use of smart sensors in granulation equipment allows for precise monitoring of granule size, extrusion temperature, and pressure, ensuring more consistent quality in production by reducing waste. This is especially important when processing heterogeneous recycled materials and emerging biopolymers, which inherently have more unstable and sensitive process behavior. <\/p>\n

The industrial experience of the Italian company Lati is a practical example of this approach. By replacing old equipment with modern MAAG systems, including filament granulators and then the semi-automatic EBG single-belt system, the company was able to significantly increase granule quality, production line productivity and process reliability. In this system, even in the event of filament breakage, the material is automatically returned to the granulator, a feature that plays an important role in reducing line downtime and increasing production stability (Figure 2). <\/p>\n

Overall, MAAG believes that single-belt filament granulation offers significant advantages over underwater granulation systems in terms of operating cost per kilogram of product, especially in small batch operations, short production runs and processing abrasive compounds.<\/p>\n

 <\/p>\n

Challenges in granulating sensitive and filled polymers<\/h2>\n

Granulation of polymers sensitive to moisture, temperature or mechanical stress has always been one of the most challenging steps in the compounding process. These challenges are exacerbated in the case of highly filled compounds (with more than 60% mineral or fiber fillers), brittle polymers and heterogeneous recycled materials. In traditional water bath-based systems, direct contact of molten filaments with water can lead to thermal shock, instability of the filament structure, increased risk of breakage and ultimately loss of granule quality. <\/p>\n

Furthermore, in many engineering compounds, moisture absorption during the granulation stage can affect the final product properties, an issue that is of particular importance in crosslinkable polymers, biopolymers, and specialty compounds. Hence, the need for a system that allows for precise control of mechanical stress and thermal conditions is an industrial imperative. <\/p>\n

The Single Belt Granulation (EBG) system was developed to meet this exact need. The linear and continuous transport of the filaments on the belt, the elimination of water immersion, and the ability to adjust the speed and cooling conditions, allow the polymer filaments to enter the cutting stage with minimal mechanical stress and maximum stability. <\/p>\n

Next, the performance of the EBG system in one of the important industrial applications, namely the production of PEX compounds, is examined.<\/p>\n

 <\/p>\n

The role of the EBG system in improving granule quality in PEX compounds<\/h2>\n

One area where the benefits of the single belt granulation (EBG) system are demonstrated in a practical and measurable way is in the production of engineering compounds with high quality requirements. In this category of materials, filament diameter uniformity, melt flow stability, and prevention of filament breakage before the cutting stage play a direct role in the final granule quality. <\/p>\n

In particular, in the production of compounds used in PEX systems used in the pipe, plant and high temperature applications, precise control of thermal and mechanical conditions during the granulation stage is of particular importance. By eliminating direct contact of the molten strands with water and providing controlled cooling on the belt, the EBG system allows the production of granules with a uniform structure, minimal internal stresses and higher stability in subsequent process steps. <\/p>\n

Using this approach in the production of PEX<\/strong> compounds<\/strong><\/a> reduces granule surface defects, improves process repeatability, and reduces waste. These benefits ultimately lead to improved mechanical properties of the final product, improved crosslinking behavior, and increased reliability in sensitive applications. <\/p>\n

Additionally, the flexibility of the EBG system in processing elastic polymers and sensitive compounds makes it a suitable choice for production lines with small batches, frequent formulation changes and the need for quick start-up. The ability to automatically return broken strands to the granulator also plays an important role in reducing unwanted line stops and increasing operational efficiency. <\/p>\n

https:\/\/behinpolymerco.com\/wp-content\/uploads\/2025\/03\/Ein-Band-Granulierung-EBG-MAAG-Group-360p-h264.mp4<\/a><\/video><\/div>\n

Conclusion<\/h2>\n

In modern granulation and compounding processes, the simultaneous selection of the right technology <\/strong>and process-compatible polymer materials<\/strong> plays a decisive role in granule quality and production line efficiency. In applications such as the production of PEX compounds<\/strong> and XLPE<\/strong> <\/a>cable compounds, or when using polymer process aids to improve extrusion stability, the use of appropriate technical solutions can lead to reduced energy consumption, increased process repeatability and reduced waste. <\/p>\n

By offering a range of specialized compounds and additives, Behin Polymer is ready to support and provide technical advice tailored to the needs of polymer production lines.<\/p>\n

 <\/p>\n

Resources:<\/p>\n

https:\/\/maag.com\/products\/ebg-belt-conveyor-pelletizing-system<\/p>\n

https:\/\/www.azurr-tech.cz\/en\/products\/maag\/pelletizing-systems\/ebg-belt-conveyor-pelletizing-system<\/p>\n

https:\/\/bruys.nl\/sites\/default\/files\/assets\/files\/downloads\/EBG-1.pdf<\/p>\n

https:\/\/www.cpm.net\/downloads\/Animal%20Feed%20Pelleting.pdf<\/p>\n

https:\/\/content.yudu.com\/web\/1rl19\/0A1rl2p\/CWSept20\/html\/print\/CW%20September%202020%20pdf%20for%20download.pdf<\/p>\n

Content compiler: Mehrnaz Bahadori <\/p>\n

 <\/p>\n","protected":false},"excerpt":{"rendered":"

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