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Industrial complete pellet plants

Over 25 years of business, Costruzioni Nazzareno has become a leader in Europe in the design and construction of “turn-key” plants for processing waste from industrial processes.

A plant is a set of machines that, when connected together, create a production cycle.

This cycle differs for each plant as the characteristics (type, particle size, humidity, initial state, etc.) of the product being processed are always different. The plant can be divided into sections, and depending on the customer needs and/or requests we are able to automate and supply the entire system or automate individual sections of the system.

Our flagship has become our wood pellet production plants, the sector in which our brand is now known worldwide. As early as 1999, the company built the first complete plants for pellet production and has become increasingly specialised in this field in recent years, acquiring in-depth experience through the realisation of more than 40 plants worldwide.

How we operate to build the plant

Costruzioni Nazzareno works to build its plants in order to provide the customer with maximum support, carefully assisting the customer from the very initial stages, developing the project according to the following stages.

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Initial contact with the customer, gathering the information necessary to perform a preliminary study.

Plant design and creation of the offer.

Discussion of the offer and consultation with the customer concerning the types of adopted technical solutions and their arrangement within the existing spaces.

Once the order is confirmed, the chosen solution is developed by our technical office and the customer is provided with all the technical documentation necessary to build the plant: complete design, drawings and sizing of building work, drawings and sizing of compressed air, plumbing and electrical systems.

Production of documents to apply for incentives or for applications to specific bodies requested by the customer

Machinery construction.

Plant installation.

Commissioning and testing with production tests.

Training with the transfer of all knowledge to operate the plant to the customer's technicians.

Continuous assistance service during use.

Example of the pellet plant structure


Crushing, rough machining and screening

The particle size of the incoming material is one of the fundamental parameters for deciding on which pellet plant feeding system. In fact it is possible to use two types of material feeding machines:

  • Shredding or chipping machines, fed with belt or chain conveyors, when there are pieces of wood or underbrush waste wood at the infeed

  • Selection and/or sorting machines if there are chips, swarf or sawdust at the infeed (sorting threshold with raw material greater than 25x25x5mm) fed by a hopper with hydraulic or screw extraction.

Specific mechanical or pneumatic conveyor systems take the production flow to the next stages.


Material drying

Another crucial parameter for pellet production is the humidity of the material being processed. The maximum possible humidity to feed the pelleting machine is in fact estimated to be around 12- 13% RH. If the humidity of the material being processed exceeds this parameter, the pellet plant needs a dryer or dehydration unit capable of drying the product.

This machine requires a generator for the production of hot air or, more generally, heat capable of performing the drying process; this can be fed in different ways: with sawdust, wood chips, natural gas and methane, or other systems or fuels on request.

Between the boiler and the dryer it is possible to insert a cogenerator, for the combined production of electric and thermal energy in the form of hot water.

Product preparation

The dried product then goes through dust separation - selection and refining where everything is brought to the maximum particle size (6-7 mm) required for the production of pellets so as to achieve homogeneity - uniformity of the product; from here it will then be conveyed to storage and subsequent final transformation.

Pellet production and bagging

The prepared material is transformed into pellets through a pelleting press. The pelleting line ends with cooling (air/product) and dust separation of the pellets. It includes the installation of an auxiliary general dust extraction system with end filters for handling the air released into the atmosphere and recovery of the dust that is reintroduced into the system. Once the pellets have been cooled and cleaned, they pass through a weighing system before being packaged in special customised bags or in big bags. This bagging system can be managed manually or automatically, like palletisation thereafter.

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