Pellet Mill Daily Checklist: Pre-Start, Running & Shutdown
News 2026-06-12
A pellet machine daily checklist is a record of what the operator checks before start-up, during operation, and at shutdown, but the specific items depend on the machine model, the raw material, and the site safety requirements. Not every machine uses the same list, and a checklist copied from another machine is a starting point, not a procedure.
Its value is not in the number of items on the list. It is in making the checks repeatable, recordable, and reviewable. A check that cannot be repeated the same way each shift, and a record that is never reviewed, does not improve reliability.
Two cautions apply before the checklist below is used. First, it is a general template, not a replacement for the manual for the specific machine. Inspection methods, lubrication intervals, operating limits, adjustment procedures, and safety requirements must be confirmed against the machine manual and the site’s safety procedures. Second, the specific values in this article are deliberately not written as universal standards. A moisture range, a roller gap, a bearing temperature, and a die temperature depend on the material, the die specification, the machine model, and the sensor location. They must come from the manual, the die supplier documentation, and the pelletizing test, not from a general guide. Where a value is needed, request the data for the specific machine from the supplier.
This article focuses on the daily checklist. Machine selection, power consumption, die replacement, and plant start-up are separate topics and are not covered here. It provides three printable checklists, a daily record template, the maintenance points that cause the most downtime when they are skipped, and the questions to settle with the machine manual before the checklists are issued to operators.
Printable Pellet Machine Daily Checklist
Use this checklist as a starting point. Confirm every item, method, and limit against the machine manual for the specific model before issuing it to operators. The tables can be copied into a word processor or spreadsheet and printed as an A4 or A3 sheet for the control panel.
1. Pre-Start Inspection
| Check item | What to verify | Result |
|---|---|---|
| Guards and covers | All required guards are installed and secure | Pass / Fail |
| Emergency stop | Inspect and test according to the procedure in the machine manual and the applicable safety standard. Do not apply a single response-time figure to every machine. | Pass / Fail |
| Work area | No loose tools, debris, or other hazards | Pass / Fail |
| Die and rollers | Inspect for visible damage or abnormal wear, only when safely accessible | Pass / Fail |
| Feed system | Check for blockages or foreign objects using the approved isolation procedure | Pass / Fail |
| Lubrication | Verify lubricant level and maintenance status against the machine manual | Pass / Fail |
| Gearbox | Check oil level and look for leaks where applicable | Pass / Fail |
| Magnet and separator | Inspect and clean according to the equipment procedure | Pass / Fail |
2. Operating Checks
| Check item | What to monitor | Action if abnormal |
|---|---|---|
| Motor load | Compare readings with the approved operating range and the previous shift | Investigate abnormal loading |
| Bearing temperature | Measure with an appropriate instrument where required. Do not touch a bearing on a running machine. | Follow the machine’s temperature limits |
| Noise and vibration | Watch for new grinding, scraping, knocking, or excessive vibration | Stop safely if a hazardous fault is suspected |
| Feed consistency | Check for interruptions, bridging, or uneven feeding | Correct the cause using the approved procedure |
| Pellet quality | Monitor size, appearance, fines, and other product specifications | Check raw material and process settings |
| Material moisture | Measure using the process-specific sampling method | Follow the approved moisture limits |
| Dust and leakage | Inspect accessible areas for abnormal dust release or material leakage | Address the source safely |
3. Shutdown and End-of-Shift Checks
- Stop and isolate the machine according to the shutdown procedure before maintenance or cleaning.
- Remove residual material only using approved methods.
- Inspect accessible components for abnormal wear, damage, or leakage.
- Record operating hours, production volume, downtime, and any unusual events.
- Report unresolved faults to the supervisor or maintenance team.
- Complete required cleaning and shutdown tasks before leaving the equipment unattended.
4. Daily Maintenance Record
| Field | Entry |
|---|---|
| Date and shift | |
| Machine model / ID | |
| Operator | |
| Operating hours | |
| Production volume | |
| Abnormal readings or observations | |
| Corrective action / work order | |
| Outstanding issues | |
| Supervisor review |
Do not adjust rollers, clear blockages, remove guards, or perform maintenance while the machine is running. Follow the site’s energy-isolation and lockout/tagout procedures.
Why the Specific Values Must Come From the Machine Manual
The parameters that appear on a maintenance checklist are the ones that most often get copied from one machine to another and then applied incorrectly. Each one is machine-specific and material-specific.
| Parameter | Why it cannot be written as a universal value | Where the correct value comes from |
|---|---|---|
| Material moisture range | Depends on material type, die specification, and whether conditioning is used | Pelletizing test and the die supplier specification |
| Roller gap | Depends on the die type (ring die or flat die), die size, and roller configuration | Machine manual and die supplier documentation |
| Bearing lubrication interval | Depends on bearing type, load, speed, lubricant, and whether an automatic lubricator is fitted | Machine manual and lubricant supplier documentation |
| Gearbox oil level and change interval | Depends on gearbox model, oil type, and operating conditions | Gearbox supplier documentation |
| Bearing temperature limit | Depends on bearing type, load, and ambient conditions | Machine manual and bearing supplier documentation |
| Die temperature range | Depends on the sensor location, the material, and the process | Machine manual and process specification |
| Emergency stop response | Depends on the machine design and the applicable safety standard. Do not use a single response-time figure. | Machine manual and the applicable safety standard |
| Guard inspection requirement | Depends on the machine and the site hazard assessment | Machine manual and the site hazard assessment |
A checklist that states a single value for each item, without stating the conditions it applies to, usually does not transfer to another machine or another material. It can lead to a wrong decision, and the extent of the error depends on how different the second machine or material is from the first.
The two values that most often cause confusion are moisture and roller gap.
Moisture. A target range and a rejection range are not the same thing. The target range is what the process is set to achieve. The rejection range is what the operator uses to stop accepting material. Both should be stated in the process specification. Neither is a universal value. The rejection range also depends on the material and the process, and it must come from the process specification and the pelletizing test, not from a general guide. A checklist that shows a single range for both will produce either unnecessary rejection or undetected wet material.
Roller gap. A ring die machine and a flat die machine do not use the same gap, and the correct gap for a ring die depends on the die size and the roller configuration. A gap value copied from a different machine can reduce output, increase die wear, or produce no compression at all.
How to Read Motor Load and Temperature Without Universal Limits
Motor load and temperature are on every checklist, but the reading is only useful if it is compared with a reference.
Motor load. The useful reading is the current as a percentage of full load amperage at normal production, and the trend over time. A reading that is within the motor’s rated range but has risen from the previous shift is a warning that the die is loading up or that the feed has changed. The checklist should record the reading and the comparison, not only the value.
Bearing temperature. A bearing temperature reading is useful when it is taken at the same point with the same instrument and compared with the previous readings for that bearing. A single reading without a baseline tells the operator very little. The method of measurement matters as well. A contact thermometer or an installed sensor is reliable. A hand touch is not a measurement. Touching a bearing on a running machine also carries a burn risk and an entanglement risk, and the reading cannot be quantified by touch. Use an installed instrument or a non-contact thermometer, and follow the safety requirements in the machine manual and the site procedure.
Die temperature. A die temperature reading is meaningful only when the sensor location is known and the reading is compared with the manual range for that machine. A reading from a sensor at the die exit and a reading from a sensor in the die chamber are not the same measurement, and their limits are not the same. Where the machine has no die temperature sensor, the check cannot be performed as a reading. The process is monitored through motor load, pellet quality, and the manual’s alternative procedure, and the absence of a sensor should be recorded so that the gap is known.
Common Maintenance Mistakes That Cause Downtime
These are the mistakes that a daily checklist is intended to catch. The list is based on the checks that are most often skipped, not on a statistical claim about failure percentages.
Skipped moisture test. Material that is outside the working range causes die jams, soft pellets, and, in the worst case, a fire risk. The check is skipped when the moisture meter is not at the machine or when the operator assumes the material is dry.
Roller gap not checked. The gap drifts with vibration and wear. Output falls gradually, and the operator may not notice until the gap is far outside the correct range. A daily check with the correct feeler gauge catches the drift before it affects output.
Lubrication missed. A missed lubrication interval is not visible until the bearing fails. The checklist should state the interval and the quantity from the manual, and the record should show when the last lubrication was done.
Magnet not cleaned. A magnet covered with metal fines cannot capture tramp metal. The tramp metal enters the die and damages the die and the rollers. The check is a visual inspection and a cleaning, and it should be recorded.
Unusual noise not reported. A new noise is the earliest warning of a bearing, a coupling, or a roller problem. The checklist should include a noise check, and the operator should know how to report it.
Shutdown not followed. Running the machine empty at shutdown and cleaning the die before a long stop prevents material from hardening in the die. The shutdown checklist should state the procedure from the manual.
How to Keep a Daily Maintenance Log
The log is what turns a checklist into a maintenance record. A checklist that is filled in and never reviewed does not improve reliability.
- Record the reading, not only a pass or fail, for motor load, temperature, and moisture.
- Record the time the reading was taken, because a reading without a time cannot be compared with the next one.
- Record the corrective action, even when the action is “no action required”.
- Review the log weekly. The review should check the reading trends, the abnormal observations, the corrective actions, and the outstanding issues. The review frequency and content should follow the site’s maintenance procedure.
- Use the trend to adjust the inspection interval, not to justify skipping the check.
A digital log on a tablet or a PLC can timestamp the readings and make the trend visible, but the value comes from the review, not from the format.
Frequently Asked Questions
What should a pellet machine daily checklist include?
A daily checklist should cover pre-start inspection, operating checks, and shutdown checks. The items should be confirmed against the machine manual for the specific model, and the values should come from the manual and the process specification, not from a general guide.
How often should material moisture be tested?
The frequency depends on the material supply and the process. Testing each batch is common where the material source varies. The target range and the rejection range should be stated in the process specification and confirmed by a pelletizing test. Neither range is a universal value.
How often should the roller gap be checked?
The gap should be checked at the interval stated in the machine manual. The gap drifts with vibration and wear, and the interval should be short enough to catch the drift before it affects output.
How often should bearings be lubricated?
The lubrication interval depends on the bearing type, the load, the speed, the lubricant, and whether an automatic lubricator is fitted. The interval and the quantity must come from the machine manual and the lubricant supplier documentation.
Can the checklist use fixed values for temperature and motor load?
No. Temperature and motor load limits depend on the machine, the sensor location, and the operating conditions. The checklist should record the reading and compare it with the manual limit and the previous readings for that machine.
Is a daily checklist required by OSHA?
OSHA requires hazard assessment and training. A written checklist supports both, but the specific requirements depend on the site and the applicable regulations. The checklist should be reviewed against the site’s safety programme.
What is the difference between a paper checklist and a digital checklist?
A paper checklist is simple and can be posted at the machine. A digital checklist can timestamp readings and make trends visible. The value of either depends on whether the readings are reviewed and acted on.
What should I prepare before requesting a checklist for my machine?
Provide the machine model, the control panel type, the die specification, the material type, and the current maintenance programme. A checklist that is prepared against these items can be used directly, rather than adapted from a general template.
Get Maintenance Support for Your Pellet Machine
Send your machine model, die specification, material type, current maintenance programme, and the fault or downtime issue you are trying to solve. A checklist and a maintenance interval can then be prepared against your machine and your process, rather than against a general template.
Inspection methods, lubrication intervals, operating limits, adjustment procedures, and safety requirements in this article must be confirmed against the machine manual, the die and lubricant supplier documentation, and the site’s safety procedures. This article does not provide universal values for these items.
