Author: organic fertilizer production line

Under the global trend of green agricultural transformation and solid waste resource utilization, the horizontal mixing extrusion granulation production line has become the mainstream equipment for organic fertilizer and bio-fertilizer production due to its core advantages of no drying, low energy consumption, and wide adaptability. This production line adopts a cold granulation process, eliminating the need for external heat sources and excessive binders. Through mechanical mixing and extrusion, the raw materials are directly agglomerated and shaped, perfectly matching the characteristics of high-moisture, high-viscosity organic fertilizer raw materials, effectively solving the industry pain point of poor adaptability of traditional granulation processes to organic fertilizer raw materials.

Its core adaptability lies in its broad coverage of fertilizer categories. It primarily produces pure organic fertilizer, bio-organic fertilizer, and refined organic fertilizer, and can process various organic composting materials such as livestock and poultry manure, straw, mushroom residue, and kitchen waste. It is especially suitable for bio-organic fertilizer production—the entire process involves low-temperature granulation without damaging the activity of biological bacteria, resulting in a live bacteria survival rate of over 95%. Meanwhile, through process fine-tuning, it can also be compatible with the production of organic-inorganic compound fertilizers, micronutrient fertilizers, and other types, significantly improving equipment utilization and adapting to different fertilization needs for field crops and fruit and vegetable cultivation. It is worth noting that this production line is not suitable for high-concentration compound fertilizers, pure inorganic fertilizers, or other low-viscosity raw materials that require drying; precise matching of production requirements is necessary when selecting the model.

High efficiency, energy saving, and environmental protection are its core competitive advantages for global promotion. The production line eliminates the need for a drying section, consuming only 20-30 kWh per ton of fertilizer, only one-fifth of traditional rotary drum granulation lines, significantly reducing production energy consumption and costs; it can directly process raw materials with a moisture content of 25%-45% without pre-drying, saving investment and energy consumption in drying equipment. In terms of environmental protection, the accompanying pulse dust collector effectively controls dust emissions, meeting environmental standards worldwide, while also promoting the resource utilization of organic solid waste, aligning with green agricultural development policies.

Flexible capacity configuration adapts to different scales of production needs. From 1-3 t/h production lines suitable for small farms, to large-scale lines of 8-15 t/h required by large enterprises, and customized lines of 15-25 t/h for group-scale mass production, the equipment can precisely match the production scale of different regions worldwide. The equipment has a simple structure and low maintenance costs; a medium-sized line requires only 500-800 square meters of plant space, and can be put into operation within 15-20 days after installation and commissioning. This lowers the entry barrier for small and medium-sized organic fertilizer enterprises and provides a high-efficiency mass production solution for large enterprises.

The efficient and stable operation of the horizontal mixing extrusion granulation production line relies on scientific technical principles, reasonable process configuration, and standardized operation management. As the core equipment of the organic fertilizer cold granulation process, its core technology lies in achieving raw material agglomeration and shaping through mechanical force. Simultaneously, its modular process design adapts to different production needs. Mastering its technical points and practical operating procedures is key to ensuring production efficiency and product quality.

The core working principle is simple and efficient. A double-helix stirring shaft inside the horizontal main unit is driven by a motor to rotate at high speed. The raw materials are vigorously stirred and kneaded within the cylinder to form a uniform material agglomeration. Under axial thrust, this agglomerate moves towards the discharge port and is ultimately forced through the screen openings by radial pressure applied by the extrusion scraper and discharge screen, forming cylindrical granules. The particle size can be adjusted via the screen (2~12mm). The entire granulation process is cold-granulation without heating or the addition of additional binders, perfectly adapting to the physical characteristics of organic fertilizer raw materials. This is its core advantage, distinguishing it from other granulation processes.

The production line adopts a modular process design, offering two flow options: a basic flow and a high-end flow. The basic flow covers core steps such as raw material crushing, mixing, granulation, screening, and packaging, meeting production standards at a low cost. The high-end flow adds equipment such as a drum polisher, air cooler, and palletizer, improving granule roundness and storage and transportation stability, adapting to large-scale mass production needs. The core equipment includes a horizontal mixing and extrusion granulation unit (accounting for 60% of the equipment investment), a pre-treatment crusher and mixer, and a post-treatment vibrating screen. Auxiliary equipment can be selected as needed to avoid ineffective investment.

Scientific equipment selection and standardized operation are key to successful production. Equipment selection should be based on production capacity and product positioning. For production lines primarily focused on bio-organic fertilizer or those pursuing low-cost production, this production line should be prioritized. Medium-sized lines can be equipped with polishing machines to improve granule quality, offering the best cost-effectiveness. During operation, raw material control is paramount. The organic fertilizer compost must be crushed to ≤5mm, with a moisture content controlled between 30% and 35%, and the coarse fiber content not exceeding 30%. Equipment operation requires adjusting the mixing shaft speed according to the raw material type and regularly checking screen wear. Simultaneously, environmental protection equipment is necessary to ensure that dust and odor emissions meet standards.

In the future, the production line is being upgraded towards intelligence and integration, realizing automatic parameter adjustment and remote monitoring through a PLC control system, integrating multiple processes to improve production efficiency, and expanding the processing capacity of raw materials such as municipal sludge and kitchen waste, further aligning with the global trend of solid waste resource utilization and green agricultural development.

Diverse Granulation Pathways in Modern Fertilizer Plants

The horizontal mixing extrusion granulation line exemplifies one of several fertilizer granulation processes within a professional fertilizer manufacturing equipment portfolio. This method is ideal for high-moisture organic materials and is central to a dedicated bio organic fertilizer production line, where it preserves microbial viability. For mineral-based production, a different set of technologies is employed. An npk fertilizer production line typically starts with a npk blending machine for powder formulation, followed by granulation. Here, a disc granulation production line using a disc granulator is a common wet agglomeration method, or a double roller press granulator for dry compaction.

Selecting the right fertilizer raw material processing machinery and equipment is fundamental to plant design. An integrated fertilizer manufacturing plant equipment setup may include both organic and NPK lines. For instance, raw materials might first be processed in an organic fertilizer production line fed by a windrow composting machine, while a parallel npk fertilizer line handles inorganic blends. The key is matching the granulation technology—whether extrusion, disc granulation, or roller pressing—to the physical and chemical properties of the feedstock to optimize efficiency, product quality, and energy consumption.

This technological diversity allows manufacturers to build versatile facilities capable of producing a wide range of organic, bio-organic, and compound fertilizers, meeting the specific nutritional and logistical demands of different agricultural markets.

NPK blending, a crucial process in fertilizer production, involves mixing pre-manufactured solid fertilizer particles to create customized nutrient formulations tailored to specific soil and crop needs. Unlike synthetic NPK production that involves chemical reactions, the raw materials for NPK blending are finished granules or prills that undergo no further chemical transformation. These materials are systematically categorized based on the nutrients they provide, supplemented by additives and fillers to optimize performance. Understanding the composition of these raw materials and their quality requirements is essential for producing effective, stable NPK blends.

The core raw materials for NPK blending are classified by their primary nutrient contribution: nitrogen (N), phosphorus (P), and potassium (K). Nitrogen sources form the foundation of many blends, with urea being the most widely used due to its high nitrogen content (46%), making it cost-effective and efficient for boosting foliage growth. Ammonium sulfate is a popular alternative, especially for sulfur-deficient soils, as it provides both nitrogen and sulfur. Ammonium nitrate, though common for its high nutrient density, requires careful handling due to safety considerations. Ammonium chloride serves as another nitrogen source option in pellet form, suitable for specific crop and soil conditions.

Phosphorus sources often double as dual-nutrient ingredients, enhancing the versatility of blends. Diammonium Phosphate (DAP) is a staple, offering both nitrogen and a high concentration of phosphorus, ideal for supporting root development and reproductive growth. Monoammonium Phosphate (MAP) is another widely used dual-nutrient granular material, valued for its stable properties and balanced nutrient ratio. For phosphorus-focused formulations, Triple Superphosphate (TSP) provides a concentrated phosphorus supply, while Single Superphosphate (SSP) offers lower phosphorus levels alongside additional sulfur, addressing multiple nutrient needs simultaneously.

Potassium sources are selected based on cost and crop sensitivity. Muriate of Potash (MOP), or potassium chloride, is the most common and economical option, providing roughly 60% potassium. However, for chloride-sensitive crops such as strawberries, potatoes, and citrus fruits, Sulfate of Potash (SOP) is preferred, as it delivers potassium without the harmful effects of chloride, ensuring crop health and quality.

To address specific soil deficiencies and improve overall plant health, blenders frequently incorporate secondary and micronutrients. Secondary nutrients include magnesium sulfate (kieserite), which supports chlorophyll formation; gypsum (calcium sulfate), which enhances soil structure and provides calcium; and dolomitic limestone, which regulates soil pH while supplying calcium and magnesium. Micronutrients, added in trace amounts, are critical for balanced plant growth, with common options including zinc, iron, manganese, boron, and copper—each playing a unique role in enzyme function and nutrient uptake.

Additives and fillers are essential for fine-tuning NPK blends and improving their physical properties. Fillers such as limestone, dolomite, and bentonite adjust the final product’s weight to meet target NPK ratios and regulate soil pH, ensuring compatibility with different growing environments. Coating agents are applied to prevent moisture absorption and clumping, enhancing the storage stability and handling efficiency of the blend, which is particularly important for bulk transportation and long-term storage.

Critical quality factors ensure the effectiveness of NPK blends, with physical compatibility being paramount. All raw material granules must be roughly the same size (typically 2–4mm) to prevent segregation during transport and application, ensuring uniform nutrient distribution. Moisture content is another key requirement—materials must be dry to avoid unwanted chemical reactions, clumping, or nutrient loss in the mix. These quality standards guarantee that the final blend performs consistently, delivering the intended nutrient benefits to crops.

In summary, NPK blending relies on a diverse range of finished fertilizer particles, secondary nutrients, micronutrients, and additives. The careful selection and combination of these raw materials, based on nutrient needs and physical compatibility, enable the production of customized blends that support sustainable agriculture. By adhering to strict quality requirements and tailoring formulations to specific soil and crop conditions, NPK blending ensures that plants receive balanced nutrition, maximizing yields and promoting long-term soil health.

From Blending to Integrated Granulation Production

The physical blending of pre-granulated materials is executed using specialized equipment like a npk bulk blending machine or a standard npk blending machine. These machines, which are essentially high-capacity fertilizer mixer machine units, homogenize different granular components without chemical change, relying on the uniform size and moisture of the raw materials. This process is distinct from the integrated npk fertilizer manufacturing process that involves chemical granulation. For producing chemically homogeneous NPK granules from raw powders, the industry relies on advanced npk fertilizer production technology, which centers on an npk granulation machine.

This granulation stage is the core of a complete npk fertilizer production line. The npk granulation machine technology can vary, commonly utilizing a rotary drum or pan agglomeration process where a liquid binder is sprayed onto tumbling powder. The entire suite of npk fertilizer granulator machine equipment, including mixers, granulators, dryers, and coolers, transforms raw materials into uniform, durable pellets. While a bulk blending fertilizer machine creates a physical mixture, the sophisticated npk fertilizer machine for chemical granulation creates a single, integrated granule where all nutrients are fused together, often resulting in better physical properties and nutrient synchronization.

Therefore, the choice between using blending equipment or a full granulation line depends on the desired product characteristics, raw material availability, and investment scale. Both are essential npk fertilizer production technology pathways serving different market segments within the compound fertilizer industry.

In numerous industries such as mining, building materials production, chemical processing, and grain storage, vertical material lifting is a crucial link connecting different production stages. As a mechanical device specifically designed for the continuous vertical conveying of bulk materials, the bucket elevator, with its unique bucket-type conveying structure, can efficiently lift bulk or small-piece materials such as coal, ore, cement, and grain from low to high places, becoming a core piece of equipment in industrial production for bridging vertical heights and optimizing material flow. Its continuous and stable lifting capacity solves the problem of conveying materials with high drops, providing reliable vertical conveying guarantees for large-scale production.

The stable and efficient operation of the bucket elevator relies on a scientifically sound structural design, with each core component working in tandem to form a complete lifting system. The buckets (barrels) are the core components that carry the materials, and their shape and size are precisely designed according to the material characteristics—deep buckets are used for granular materials, while shallow buckets or buckets with pointed bottoms are used for powdery materials, ensuring stable loading and thorough unloading. The traction component comes in two types: chain and belt. It connects the buckets and provides lifting power. The chain type is suitable for heavy-duty and high-temperature conditions, while the belt type is suitable for conveying lightweight materials. The drive unit consists of a motor, reducer, and drive sprocket (or drive roller), providing stable driving force to the traction component. The speed is adjusted by the reducer to adapt to different lifting rhythms. The feed inlet is located at the bottom of the equipment, facilitating smooth material entry into the buckets; the discharge outlet is located at the top, ensuring accurate discharge of the lifted material. The support and frame provide stable structural support for the entire equipment, resisting vibration and load during the lifting process and ensuring stable operation. The tensioning device can flexibly adjust the tension of the traction component to prevent slippage or slack during operation; guiding devices such as guide wheels and guide rails guide the buckets to rise and fall smoothly along a fixed trajectory, preventing deviation and collision.

The bucket elevator operates on a simple and efficient principle, achieving continuous conveying through a cyclical process of “loading-lifting-unloading-returning.” During operation, material first enters the waiting hopper through the bottom feed inlet, completing the loading process. Then, the drive unit starts, using a traction component to propel the hopper smoothly upwards along the guide rail or groove, with the material rising synchronously. During this process, the enclosed lifting space effectively prevents material spillage. When the hopper reaches the upper part of the equipment, it automatically tilts under gravity or centrifugal force, emptying the material through the discharge port to a designated location. The empty hopper then returns along the other guide rail to the bottom feed inlet, ready for the next loading cycle. The entire process is continuous and uninterrupted, ensuring both lifting efficiency and orderly material transfer.

The unique structure and working principle give bucket elevators many significant advantages, making them adaptable to the vertical conveying needs of various industries. High lifting height is its core competitive advantage, enabling it to achieve significant vertical lifting heights, perfectly suited for conveying scenarios requiring traversing large height differences, such as high-rise buildings and elevated silos. With outstanding high-efficiency lifting capacity, bucket elevators achieve highly efficient vertical material transfer through continuous bucket circulation, far exceeding the efficiency of traditional vertical conveying equipment and adapting to large-scale production rhythms. They are highly adaptable, handling various bulk or small-piece materials such as coal, ore, cement, and grain. By changing the bucket type and traction components, they can flexibly adapt to different material characteristics and operating conditions. Excellent sealing performance is another major highlight; the enclosed lifting channel effectively reduces material loss and dust emission, making it particularly suitable for dust-sensitive industries such as chemicals and grain processing. The vertical layout makes it compact, occupying only 1/5 to 1/3 of the floor space of horizontal conveying equipment, greatly saving space and making it suitable for production environments with limited space. Furthermore, the equipment structure is relatively simple, core components are easy to inspect and replace, daily maintenance is convenient, and long-term operating costs are low.

From ore lifting in mines to cement transfer in building material plants, from raw material transportation in chemical plants to grain storage in grain warehouses, bucket elevators, with their core advantages of high efficiency, stability, and compactness, provide strong support for vertical material conveying in various industries. Against the backdrop of industrial production transforming towards intensification and efficiency, this core equipment focused on vertical conveying not only optimizes the production process layout and improves production efficiency, but also aligns with the development trend of environmentally friendly production, becoming an important basic equipment for promoting the upgrading of material conveying systems in various industries.

Material Flow and Granulation in Fertilizer Manufacturing

Bucket elevators are a quintessential example of the essential conveying equipment in fertilizer production line. They form a vital link within a complete professional fertilizer manufacturing equipment setup, vertically transferring raw materials like crushed ore, powdered fertilizers, or pre-processed compost between different stages. For instance, in an npk fertilizer production process, a bucket elevator may lift blended powder from a npk bulk blending machine to the feed hopper of a granulator. Similarly, in an organic fertilizer production line, it can convey cured compost from a windrow composting machine (or windrow machine) to the granulation unit.

This reliable vertical transport enables efficient feeding into the core shaping equipment. The material may be directed to a disc granulator (part of a disc granulation production line), where the disc granulator for shaping forms spherical pellets. Alternatively, it could feed a double roller press granulator in a roller press granulator production line for compaction granulation, or even a flat die pelleting machine. These fertilizer raw material processing machinery and equipment units—whether for an npk fertilizer production line or a bio organic fertilizer production line—rely on seamless material handling to ensure continuous, high-volume output.

Therefore, the integration of robust conveying systems like bucket elevators with specialized granulators such as the disc granulator machine is fundamental. It creates a synchronized, automated flow that maximizes the efficiency of the entire fertilizer manufacturing operation, from raw material intake to finished product dispatch.