Plastics Additive Granulation & Pelletizing

D&A Granulation turns dusty, low-density plastics additive powders into dust-free, free-flowing granules and pellets by dry roll compaction and pellet milling, with no binders or liquids, in an ISO 9001:2015 certified plant in Lakewood, NJ.

Many polymer additives start as fine powders that bridge in hoppers, feed unevenly into the extruder and coat everything around the line. Compounders and masterbatch producers want them in a form that meters accurately and doesn't dust. D&A has processed plastics additives for compounding lines for decades, and four of our seven processing rooms are set up for chemical and additive work, separate from our food and nutritional rooms.

What we do for plastics additives

• Roll compaction (dry granulation) - compacts powder into a dense sheet, then mills and screens it into free-flowing granules in your target size range. See dry granulation.
• Pelletizing - forms pellets from 2.5 to 5.0 mm in diameter on a 100 HP California Pellet Mill. See pelletizing.
• One-packs and no-dust blends - blend two or more additives first, then granulate or pelletize the blend so the compounder handles one ingredient. See blending.
• Screening and repackaging - cut to size on Sweco and Kason screeners, and pack into bags, drums, boxes, gaylords or super sacks.

Problems we solve

• Dust at the hopper, in the plant and in the warehouse.
• Poor flow and bridging that make gravimetric feeders hunt.
• Low bulk density that wastes freight and storage space.
• Segregation in multi-component packages during shipping and handling.
• Heat sensitivity in waxy or low-melting additives, handled with liquid nitrogen injection.

Additives we work with

Typical materials include antioxidants, UV absorbers and light stabilizers, flame retardants and synergists, slip and release agents such as stearamide and erucamide, nucleating and clarifying agents, process aids, color carriers and preservatives for nylon, plastic and rubber compounding.

How a project works

Send us the material name, an SDS, the target form and size range, and the annual volume. We'll tell you whether roll compaction or pelletizing fits, then run a trial before you commit to production. We check particle size distribution against your spec, and every lot is tracked. Your formulation and material stay yours, and we sign NDAs routinely. See how toll processing works and quality and certifications.

Representative materials

Capabilities by category

Frequently asked questions

Can you make a dust-free one-pack from several additives?

Yes. We can blend two or more additives in a ribbon blender and then roll compact or pelletize the blend, so your compounding line handles one free-flowing ingredient instead of several powders.

Should my additive be granulated or pelletized?

Granules from roll compaction suit most powders that need better flow and less dust. Pellets from our pellet mill (2.5 to 5.0 mm diameter) give a denser, more uniform form. A trial run is the quickest way to see which one your material and feeder prefer.

Can you process low-melting additives?

Often, yes. Liquid nitrogen injection keeps temperatures down during compaction and pelletizing, which helps waxy or low-melting materials such as fatty amide slip agents.

What is the minimum batch size?

Around 750 lbs for granulation, pelletizing and blending.