Mega Mill Hammermill for Efficient Mid-Range Particle Size Reduction
Many bulk material processing operations require grinding performance that falls between traditional hammermills and fine grinders. The Prater Mega Mill Hammermill is designed specifically to fill this gap, delivering uniform particle size reduction with improved energy efficiency and minimal heat buildup during processing.
The Mega Mill uses a high-speed rotor with pivoting hammers to break down materials through repeated impact and particle-to-particle collisions inside the grinding chamber. Strategically positioned interrupter plates and precision-balanced rotor assemblies increase grinding efficiency while maintaining stable operation during continuous production.
A distinctive cantilevered rotor design allows easier access to internal components for cleaning, screen changes, and maintenance. Combined with a high screen-to-horsepower ratio and dust-tight construction, the Mega Mill delivers reliable performance for applications such as animal feeds, grains, biomass, fertilizers, spices, and other bulk solids requiring consistent particle reduction.
KEY BENEFITS
The Prater Mega Hammer Mill is designed to fill the gap between our standard hammer mills and our fine grinders. The Mega Mill provides uniform grinding with minimal heat build-up. A unique cantilevered grinding rotor results in smooth, quiet operation that can be maintained 24 hours a day, 7 days a week. Prater’s Mega Mills run more efficiently and with less airflow than conventional hammer mills. Our proprietary fabrication results in reduced downtime, low maintenance, and minimal power requirements. You will obtain a higher quality material and an increase in your bottom line.
The Prater Mega Hammer Mill is ideal for the following materials and products:
Distinctive features of the Prater Mega Hammer Mill include:
Heavy-duty fabrication designed for long life
Unique cantilever rotor design coupled with large hinged doors for ease of maintenance and cleaning
Easy removal of rotor and screens
Dynamically balanced rotor assembly and precision built bearing assembly designed for smooth performance and long life
A dust-tight design ideal for use in a pneumatic-conveyor system
Maximum screen-to HP ratio ensures optimum capacity and uniform grinding with low heat buildup
Multiple hammer styles and shapes for optimized processing of a wide variety of materials and products
Strategically located interrupter plates amplify grinding action and allow for easy screen removal
OPERATIONAL THEORY
The Prater Mega Mill works on the principle of impact to crush particles.. The Prater Mega Mill consists of a high-speed rotor with hammers fixed to support pins at their pivot point and equally spaced around the grinding chamber in a specific pattern. The rotor is supported by precision bearings, allowing the hammers to operate with very close tolerance to one or more screens fixed within the frame. Size reduction is created by the repeated impact from the hammers coupled with collisions as particles are accelerated against one another, the interrupter plates, and the screen surface.
Capacity and particle-size requirements can be regulated as needed by changing the size and number of holes in the screen, the tip speed of the hammers, the number and thickness of hammers, and the clearance between the hammers and the screens.
SYSTEM INTEGRATION
The accompanying diagram illustrates how the Prater Mega Hammer Mill, which is generally integrated with a pneumatic conveying system, can be smoothly integrated into your current operational setup:
WE ARE HERE TO HELP
Let us know how we can serve you. We can customize the fabrication of our mega hammer mill to fit your exact specifications. If there are specific features not found in our standard Mega Mill, we will design and build the ideal Mega Mill for you. If you already own a Prater mill or other product and need maintenance or additional attention, please connect with us for immediate service.
GENERAL DIMENSIONS*
MODEL
A
B
C
D
MOTOR HP
SCREEN AREA SQ. IN.
MM-5
50-1/4
38
35
14
10-30
450
MM-9
64
38
35
14
40-60
900
MM-18
73
63-1/2
53
22
75-125
1850
MM-36
108
63-1/2
53
22
150-300
3650
*Do not use for engineering purposes. Please request a certified drawing for all layout or construction uses.
Frequently Asked Questions
Why is the Mega Mill positioned between standard hammermills and fine grinders? The Mega Mill is designed for applications that require more precise particle size control and efficiency than conventional hammermills but do not require the ultra-fine output of a dedicated fine grinder. This positioning allows processors to achieve consistent grinding while minimizing heat buildup and energy consumption.
How does the cantilever rotor design improve maintenance and cleaning? The Mega Mill uses a cantilevered rotor that can be accessed through large hinged doors, allowing operators to remove screens or service internal components more quickly. This design reduces maintenance time and simplifies cleaning between production runs.
What role do interrupter plates play in Mega Mill grinding performance? Interrupter plates inside the grinding chamber redirect material into the hammer path and increase particle-to-particle collisions. This amplifies the grinding action and helps improve throughput while extending screen life.
How can operators adjust grinding performance on a Mega Mill? Grinding performance can be tuned by adjusting factors such as screen hole size, hammer configuration, hammer tip speed, and hammer-to-screen clearance. These variables allow operators to control capacity and final particle size distribution for different materials.
Why is the Mega Mill commonly integrated into pneumatic conveying systems? The Mega Mill features a dust-tight housing and airflow characteristics that allow it to operate efficiently within pneumatic conveying circuits. This integration helps move processed material through the system while reducing dust generation and heat accumulation.
Here are the following types of material that have been used in our Mega Mill:
