5 Case Studies to Know Before Selecting a Hydraulic Pellet Press for XRF Analyser

Learn from 5 real-world case studies that reveal the challenges and best practices in selecting hydraulic pellet press equipment for accurate XRF analysis.

Introduction: Experience is the Best Guide in Lab Equipment Selection

Selecting a hydraulic pellet press for XRF analysers may seem straightforward—until inconsistencies, cracked pellets, or downtime tell you otherwise.

Whether you’re testing iron ore, cement, ceramics, or metal powders, the right press dramatically impacts data accuracy, throughput, and sample integrity.

In this post, we share five case studies—real-world lab experiences—that reveal what to look for, what to avoid, and how the right hydraulic pellet press can be a game-changer in XRF sample preparation.

✅ Purpose of This Blog

• Share real case-based insights from diverse industries
• Highlight common mistakes and performance challenges
• Help labs choose the right pellet press for their application and sample type

Case Study 1: Iron Ore Testing Lab – The Pressure Consistency Challenge

Sample: Magnetite and Hematite blends
Problem: Pellets cracked frequently during analysis; inconsistent XRF readings

Root Cause:
The lab used a manual press with no pressure hold or control.

Solution:
Switched to a digital hydraulic pellet press with:

• 40-ton capacity
• Holding time control (30 seconds)
• Slow-release valve

Result:
✅ Pellet breakage reduced by 95%
✅ Sample rework time decreased
✅ Consistency in Fe and SiO₂ readings improved across batches

💡 Lesson: Iron ore needs Holding time + slow release for binder activation and integrity.

Case Study 2: Cement QC Lab – Trouble with Die Set Compatibility

Sample: Portland cement with binder
Problem: Pellets stuck inside die; operators used hammers to extract

Root Cause:
Generic die sets not suited for fine cement powder; no ejection cycle

Solution:
Upgraded to a 40 mm hardened steel die set with automatic ejector system

Result:
✅ Operator safety improved
✅ Pellet geometry became uniform
✅ Reduced downtime due to stuck samples

💡 Lesson: Match die design with sample type and operator workflow.

Case Study 3: Ceramic Materials Research – Low Sample Throughput

Sample: Alumina-based ceramic powders
Problem: Manual press took 3+ minutes per pellet; not scalable

Root Cause:
No cycle timing or automation

Solution:
Installed a programmable hydraulic pellet press with:

• Preset pressure + time
• Touchscreen control
• Safety shield for continuous use

Result:
✅ 3x throughput (100+ pellets/day)
✅ Reduced operator fatigue
✅ Improved pellet reproducibility

Case Study 4: Battery Materials Company – Binder Not Activating Properly

Sample: Lithium cobalt oxide
Problem: Pellets crumbled during transfer to XRF cup

Root Cause:
No Holding time = binder not activated under pressure

Solution:
Upgraded to press with programmable Holding pressure control  (60 seconds) and controlled descent

Result:
✅ Crumbling issue resolved
✅ Consistent pellet hardness
✅ Better correlation between XRF

💡 Lesson: Binder needs pressure + time to form a stable matrix.

Case Study 5: Academic Lab – Misalignment Led to Sample Waste

Sample: Soil reference materials
Problem: Pellets were off-center or chipped; some broke during ejection

Root Cause:

Low-quality press with no alignment or support guides

Solution:
Replaced with bench-top lab press featuring:

• Built-in die guide rails
• Transparent enclosure
• Ergonomic layout

Result:
✅ Pellet rejection rate dropped by 95%
✅ Students could safely operate the press
✅ Uniformity improved in collaborative lab projects

Conclusion: Learn from Experience—Don’t Repeat the Same Lab Mistakes

These five case studies demonstrate that sample type, binder, safety, throughput, and pressure control all influence your pellet quality and analytical reliability.

Whether you’re working with iron ore, cement, lithium, or soils, the key takeaway is:
🔧 Select a hydraulic pellet press that fits both your materials and your lab workflow.

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