Author: organic fertilizer production line

This innovative carbon-based fertilizer disc + drum granulation production line integrates two processes: “disc pre-granulation + drum finishing.” Specifically designed for the granulation needs of carbon-based raw materials (straw charcoal, bamboo charcoal, biochar, etc.), it solves the granulation pain points of lightweight and poor binding properties of carbon-based raw materials through a closed-loop process of “pre-forming + densification.” This enables large-scale, high-quality production of carbon-based fertilizer, suitable for green development scenarios such as ecological agriculture and organic farming.

Production Line Configuration and Core Details

Raw Material Pre-treatment Unit: Laying the Foundation for Granulation

(I) Raw Material Storage and Precision Batching

Multi-Compartment Storage System: Equipped with 5 raw material compartments (total volume 120m³), storing biochar, organic fertilizer fermentation material, nitrogen, phosphorus, and potassium inorganic fertilizer, binders (such as bentonite and starch), and trace elements respectively. The compartments are made of carbon steel with an anti-corrosion coating, and vibrators and star-shaped unloaders are installed at the bottom to prevent bridging and clogging of carbon-based raw materials.

Precision Batching Device: Employs a frequency-controlled screw feeder, with 5 batching systems operating synchronously, achieving a batching error of ≤±1%. The proportion of biochar can be flexibly adjusted (30%-60%), the ratio of inorganic to organic fertilizer is customized according to crop needs, and the binder addition is controlled at 3%-8% to ensure pellet formation rate.

(II) Raw Material Mixing and Moisture Adjustment

Twin-Shaft Mixer: A 50-type twin-shaft mixer is used. The impellers employ an anti-rotation design, driving strong convection and shearing of the materials to thoroughly mix the charcoal-based raw materials with other components, achieving a mixing uniformity error of ≤2%. The mixer is equipped with a spray humidification device to precisely adjust the raw material moisture content to 28%-35% (suitable humidity for the charcoal-based raw materials), preventing clumping due to excessive moisture or insufficient adhesion due to insufficient moisture.

Pulverization Pretreatment: If large lumps (particle size > 10mm) of biochar exist, they are first crushed to ≤3mm using a 400-type vertical pulverizer to ensure uniform raw material fineness and improve subsequent granulation results. The pulverizer is equipped with a cyclone dust collector to collect and reuse the crushed dust, achieving a material utilization rate of 99%. II. Core Dual Granulation Unit: Carbon-Based Particle Densification Forming

(I) Disc Pre-granulation: Key to Lightweight Material Pre-forming

Core Equipment Selection: Two Φ3.2×1.2 meter disc granulators (3-5 tons per hour per unit), with an adjustable inclination angle of 45°-55° and a rotation speed controlled at 20-30 r/min. The discs are lined with wear-resistant rubber plates to prevent wear from the carbon-based raw materials and enhance material adhesion.

Pre-granulation Process Details: The mixed raw materials are fed into the disc granulator. Through the centrifugal force and friction generated by the rotating disc, spherical wet particles with a diameter of 5-8 mm are formed (granulation rate ≥85%). A scraper is installed at the edge of the disc to promptly clean material adhering to the wall, and a spray device replenishes moisture in real time to ensure that the pre-formed particles are round and uniform, laying the foundation for drum finishing.

(II) Rotary Drum Granulation: Particle Densification Upgrade

Core Equipment Configuration: One Φ2.2×10 meter rotary drum granulator (6-10 tons per hour) is used, precisely matched with the capacity of the disc granulator. The inner wall of the drum is lined with wear-resistant ceramic plates, combined with a spiral layout of lifting plates, driving the material through a “tumbling-rolling-collision” motion to achieve particle densification.

Refinement Process Highlights: A spray device is installed inside the drum to replenish a small amount of binder solution, further rolling the pre-formed granules into dense granules of 3-6mm, increasing the particle strength from 1.2MPa to over 2.5MPa, solving the problem of easy pulverization of carbon-based granules. The drum speed is adjustable from 10-18 r/min, and the material residence time is 8-12 minutes to ensure dense and uniform particles.

III. Post-processing Unit: Quality Optimization and High-Efficiency Output

(I) Drying and Cooling Curing

Low-Temperature Dryer: Equipped with a Φ1.8×18 m drum dryer, using hot air circulation heating, the drying temperature is controlled at 70-90℃ (to avoid high temperature damage to carbon-based nutrients), reducing the particle moisture content from 30% to below 12%. The dryer has a built-in staggered lifting plate layout, ensuring uniform heating of the carbon-based particles, with a drying uniformity error ≤2%.

Dual-Stage Cooler: Employing a “first-stage counter-current cooling + second-stage co-current cooling” process, the particle temperature is first reduced from 70-80℃ to below 40℃ by a Φ1.6×15 m counter-current cooler, and then cooled to room temperature ±3℃ by a Φ1.2×12 m co-current cooler, further improving particle strength and moisture resistance. The cooler is equipped with a pulse dust collector to collect dust for recycling.

(II) Grading and Finished Product Processing

Grading and Screening Machine: A Φ1.5×6.0 meter drum screen with a double-layer screen design (upper layer aperture 6mm, lower layer aperture 3mm) is used to screen out qualified particles (3-6mm). Unqualified particles are returned to the disc granulator for reprocessing via a return conveyor belt, achieving a material utilization rate of 98%.

Anti-caking Treatment: When the screened finished particles are conveyed via conveyor belt, 0.1%-0.2% of an anti-caking agent (such as talc powder) is sprayed on them to ensure even mixing and prevent clumping during storage.

(III) Finished Product Storage and Packaging

Finished Product Silos: Two 100m³ sealed finished product silos are provided, equipped with dehumidification and ventilation devices to maintain a relative humidity of ≤60% to prevent the carbon-based fertilizer from absorbing moisture. A quantitative discharge device is installed at the bottom of the silo to achieve continuous and stable discharge.

Automated Packaging: Utilizing a dual-station automatic packaging scale, supporting rapid switching between 25kg and 50kg specifications, with a measurement error ≤ ±0.2kg and a packaging speed of 100 bags/hour. The packaging machine is equipped with a dust cover to reduce dust emissions, and the fully automated operation minimizes manual intervention.

Environmental Protection and Intelligent Control Unit: Stable Green Production

(I) Environmental Treatment System

Dust Treatment: Each dust-generating stage of the production line (crushing, screening, packaging) is equipped with a pulse dust collector, with a total processing air volume of 18000m³/h. Dust emission concentration ≤10mg/m³, meeting national environmental protection standards.

Wastewater Treatment: A small amount of cleaning wastewater during production is treated in a sedimentation tank and then recycled for raw material humidification, achieving zero wastewater discharge.

(II) Intelligent Control System

Integrated PLC central control system, real-time monitoring of key parameters such as ingredient ratio, moisture content, granulation speed, and drying temperature, supporting automatic fault alarms and data recording (storage period ≥90 days). The system supports manual and automatic mode switching and can dynamically adjust process parameters according to raw material characteristics to ensure stable production.

Core Advantages and Application Value of the Production Line

Breakthrough in Granulation Pain Points: The combined disc and drum granulation processes solve the problems of poor adhesion and low granulation rate of carbon-based raw materials. Granulation formation rate is consistently above 90%, with a strength exceeding 2.5 MPa, making it resistant to storage and transportation and less prone to pulverization.

Flexible Capacity: Hourly capacity covers 6-10 tons, with an annual capacity of 50,000-80,000 tons (based on 300 days of operation per year and 8 hours per day), adapting to the production needs of enterprises of different sizes.

Superior Product Quality: Carbon-based raw materials and nutrients are uniformly integrated, resulting in rounded granules with good flowability, facilitating mechanized fertilization. The slow-release characteristics of carbon-based components can improve fertilizer utilization by more than 30% and reduce nutrient loss.

Green, Environmentally Friendly, and Energy-Saving: High dust recovery and utilization rate; energy consumption is reduced by 12% compared to conventional single-process granulation production lines, meeting the requirements of green agricultural production.

A Specialized Link in a Broader Manufacturing Ecosystem

This carbon-based fertilizer granulation line represents a significant advancement in processing challenging, lightweight organic materials into high-quality, market-ready fertilizers. Its innovative dual-granulation approach sets a new standard for product quality and production efficiency in the niche of carbon-enriched soil amendments.

This specialized line is a prime example of professional fertilizer manufacturing equipment designed for a specific purpose. It exists within a larger ecosystem of fertilizer production technologies. For instance, the disc granulator used here is a key component in a disc granulation production line and can also serve as a disc granulator for shaping in other contexts. While this line produces organic-carbon blends, its principles complement other systems. A complete organic fertilizer production line might begin with a windrow composting machine to produce the base compost. For mineral-based production, an npk fertilizer production line would utilize an npk blending machine and different granulation technologies like a roller press granulator production line or a double roller press granulator as part of the npk fertilizer production process. Each type of fertilizer granulator serves a unique role in the diverse portfolio of modern fertilizer manufacturing.

Thus, this carbon-based line is not an isolated solution but an integral part of a comprehensive toolkit that allows manufacturers to meet the growing global demand for both specialized organic inputs and conventional high-analysis fertilizers.

The NPK and potassium chloride combined production line is an integrated solution designed specifically for the “flexible production” needs of fertilizer companies. Through modular equipment configuration and process switching design, it can flexibly produce NPK compound fertilizer (multiple ratios) and potassium chloride granular fertilizer, achieving efficient capacity utilization of “one set of equipment, two products.” It adapts to the diversified market demands of large-scale fertilizer production enterprises, significantly reducing equipment investment and site occupancy costs.

Core Design Logic and Full-Process Configuration of the Production Line

The production line is based on “raw material sharing, process differentiation, and equipment universality.” It integrates key processes such as raw material pretreatment, precise batching, granulation, and post-processing. Through local equipment switching and parameter adjustments, it achieves rapid conversion between the two products. A single production line can achieve a capacity of 10-15 tons (NPK compound fertilizer) or 12-18 tons (potassium chloride granular fertilizer).

I. Raw Material Pretreatment and Sharing Unit: Laying the Foundation for Dual-Product Production

(I) Raw Material Storage and Precise Batching

Multi-Warehouse Storage System: Equipped with 6 raw material warehouses (total volume 150m³), storing urea, monoammonium phosphate, potassium chloride (main raw material), binder, trace elements, and functional additives respectively. The warehouse bodies are made of carbon steel with an anti-corrosion coating (compatible with the corrosiveness of potassium chloride). Vibrators and star-shaped unloaders are installed at the bottom to prevent raw material bridging and blockage.

Intelligent Batching Device: Employs a 6-channel variable frequency screw feeder, paired with a PLC control system. When producing NPK compound fertilizer, the proportions of nitrogen, phosphorus, potassium, and additives are precisely controlled according to the formula (batching error ≤ ±0.8%). When producing potassium chloride granular fertilizer, the amount of potassium chloride is increased separately (≥90%), reducing or closing other raw material channels to achieve rapid switching.

(II) Raw Material Pretreatment and Mixing

Crushing and Screening: Potassium chloride raw material is crushed to ≤2mm using a 400-type vertical crusher (to avoid large clumps affecting granulation). During NPK compound fertilizer production, other inorganic raw materials are simultaneously crushed to ≤3mm. A cyclone dust collector is used in the crushing process, achieving a dust recovery rate of 99%. After crushing, the raw materials are graded using a 1.2×4.0 meter drum screen; unqualified particles are returned for regrinding.

Twin-Shaft Mixer: A 60-type twin-shaft mixer is used. During NPK production, multiple components are thoroughly mixed (mixing uniformity error ≤2%). During potassium chloride production, only potassium chloride and a small amount of binder are mixed (addition amount 2%-5%). The mixer is equipped with a spray humidification device, and the moisture content of the raw materials is adjusted according to the product type (NPK: 25%-30%; potassium chloride: 18%-25%). II. Core Granulation Unit: Dual-Product Adaptability Design

(I) Granulation Machine Selection and Switching

Core Equipment: Two Φ2.0×8.0 meter rotary drum granulators (operating in parallel) are used to accommodate the granulation needs of two products. The inner wall of the drum is lined with wear-resistant ceramic plates (resistant to potassium chloride corrosion), and adjustable lifting plates are used. Process switching is achieved by adjusting the lifting plate angle and the drum speed.

Process Parameter Adjustment:

NPK Compound Fertilizer Production: Drum speed 12-15 r/min, material residence time 8-10 minutes, binder is sprayed through atomization to form 3-5mm rounded granules, granulation rate ≥92%;

Potassium Chloride Granular Fertilizer Production: Drum speed 10-12 r/min, extending the material residence time to 12-15 minutes, reducing the amount of binder, utilizing the crystallization characteristics of potassium chloride to assist in molding, particle size controlled at 2-4mm, granulation rate ≥90%. (II) Optimized Auxiliary Granulation

When producing potassium chloride, a pre-compression device is added to pre-compress the mixed potassium chloride raw materials into dense columns before feeding them into the rotary drum granulator, improving particle strength (to above 2.8 MPa) and avoiding pulverization caused by poor adhesion of potassium chloride.

When producing NPK, the pre-compression device is turned off, and the conventional rotary drum granulation process is used directly to ensure uniform fusion of multi-component raw materials.

III. Post-processing Unit: Branching Design Ensures Product Quality

(I) Drying and Cooling

Drying System: A single Φ2.2×20 meter drum dryer is used. Temperature adjustment achieves dual-product compatibility—NPK compound fertilizer is dried at 80-100℃, reducing the moisture content to below 12%; potassium chloride granular fertilizer is dried at 60-80℃ (to avoid high temperatures affecting crystallization stability), reducing the moisture content to below 8%. The dryer is equipped with temperature and humidity sensors to automatically adjust the hot air supply.

Cooling System: Adopting a “primary cooling + branched screening” design, a single Φ1.8×15m counter-current cooler is used to reduce the temperature of the dried granules to below 35℃. The granules are then branched through a three-way valve and conveyed to dedicated screening equipment.

(II) Grading and Finished Product Processing

NPK Compound Fertilizer: After screening using a Φ1.5×6.0m double-layer drum screen (3-5mm sieve aperture), unqualified granules are returned to the raw material mixing stage.

Potassium Chloride Granular Fertilizer: After screening using a Φ1.2×4.0m single-layer vibrating screen (2-4mm sieve aperture), 0.1% anti-caking agent (such as potassium silicate) is sprayed to improve moisture resistance.

IV. Finished Product Storage and Packaging Unit: High-Efficiency Output Switching

Finished Product Warehouse: Equipped with 3 x 100m³ finished product warehouses (2 for NPK compound fertilizer, 1 for potassium chloride granular fertilizer), all featuring a sealed design with dehumidification and ventilation devices. The potassium chloride warehouse has a dedicated anti-corrosion treatment to prevent corrosion.

Packaging System: Shares 2 dual-station automatic packaging scales, allowing for specification switching by adjusting measurement parameters (NPK supports 25kg/50kg, potassium chloride supports 20kg/50kg). Measurement error ≤ ±0.2kg, packaging speed reaches 120 bags/hour, and a conveyor belt enables rapid transfer of finished products.

V. Environmental Protection and Intelligent Control Unit: Stable Green Production

(I) Environmental Protection

Dust Treatment: Each stage is equipped with a pulse dust collector (total processing air volume 20,000 m³/h). Corrosion-resistant dust collector materials are used during potassium chloride production, with dust emission concentration ≤10 mg/m³.

Wastewater Treatment: Washing wastewater is treated by an oil separator and sedimentation tank before being recycled for raw material humidification, achieving zero wastewater discharge.

(II) Intelligent Control

Integrated PLC central control system, preset with two production modes: NPK and potassium chloride. One-click switching of key parameters such as batching ratio, granulation speed, and drying temperature is supported, along with automatic fault alarms and data recording.

Key equipment (granulator, dryer) is equipped with safety interlock devices to ensure stable operation during production transitions.

Core Advantages and Application Value of the Production Line

Flexible and High-Efficiency Production: One set of equipment enables the production of two mainstream fertilizers, reducing transition time to less than 2 hours, significantly reducing equipment investment and site costs, and allowing for rapid capacity adjustments to adapt to market demand fluctuations. Dual Guarantee of Product Quality: Targeted process design and parameter optimization ensure that NPK compound fertilizer has uniform nutrients and rounded granules, while potassium chloride granular fertilizer has high strength and moisture resistance, both meeting national standards.

Energy Saving, Environmental Protection, and Low Cost: Equipment sharing rate exceeds 70%, reducing energy consumption by 18% compared to two separate production lines; dust recovery and wastewater recycling reduce material waste and environmental pollution.

Enhancing Efficiency and Versatility in Fertilizer Manufacturing

This innovative NPK and potassium chloride combined production line exemplifies a strategic approach to modern fertilizer manufacturing. It maximizes asset utilization and operational flexibility, allowing producers to efficiently respond to changing market demands from a single facility.

The line’s core function as an npk fertilizer production line highlights advanced npk fertilizer production technology. Its intelligent design centers around the npk granulation machine technology. Key components include a high-precision npk bulk blending machine for formula preparation and the npk fertilizer granulator machine (a npk fertilizer granulator) for shaping the mixture into granules. The entire npk fertilizer manufacturing process—from batching to granulation and coating—is integrated and optimized within this single, adaptable npk fertilizer production process, demonstrating how modular design can create a versatile and cost-effective production ecosystem.

Ultimately, this solution empowers fertilizer companies to diversify their product portfolio without duplicating infrastructure, securing a competitive edge through agility and efficiency.

Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. has successfully completed the installation and commissioning of a customized extrusion granulation production line for its Zambian clients, officially entering the stage of large-scale production. This production line focuses on the localized production needs of compound fertilizers and organic fertilizers, integrating the entire chain of processes including raw material pretreatment, precise mixing, efficient granulation, grading and screening, and finished product packaging. With its robust configuration of three granulation main units operating in tandem, stable design adapted to African conditions, and efficient and environmentally friendly operation, it has become a benchmark project for Chinese agricultural equipment in supporting the development of green agriculture in Africa, providing Zambian fertilizer producers with a one-stop mass production solution.

Production Line Configuration and Core Equipment Analysis

The entire production line follows a closed-loop logic of “refined raw material processing – uniform mixing – batch granulation – quality control – finished product output.” The equipment layout is scientific, the connections are tight, and the functions of each unit are complementary, ensuring both production efficiency and full adaptation to the characteristics of local raw materials and production conditions in Zambia.

Raw Material Pretreatment Unit: Laying a Solid Foundation for Granulation Quality

Raw Material Feeding and Crushing: The production line starts with a large-capacity feed hopper, adapting to the rapid feeding needs of bulk raw materials. The feed inlet is equipped with a spill-proof buffer device and an impurity filter grid, effectively reducing raw material loss and equipment failure risks. Raw materials are conveyed via an 11-meter belt conveyor to an 80-type vertical semi-wet crusher. This equipment is specifically designed for high-humidity agricultural waste and mineral raw materials in Africa, employing a “high-speed impact + shearing grinding” composite process. The cutter head is made of high-chromium wear-resistant alloy, achieving a hardness of HRC60 or higher after heat treatment. It can crush large, agglomerated raw materials (particle size ≤80mm) into uniform fine materials ≤3mm, with a crushing efficiency of 4 tons/hour, meeting the stringent fineness requirements of subsequent granulation. The crusher features a sealed casing design, coupled with a negative pressure dust removal interface, effectively controlling dust leakage and improving the production environment.

Grading, Screening, and Transfer: The crushed raw materials are transferred via a 9-meter belt conveyor to the first 2.0×4.0-meter drum screen, which uses a single-layer high-precision screen design to separate substandard coarse particles. These particles are then returned to the crusher for reprocessing via a subsequent return system, achieving a material utilization rate of 98%. Qualified fine materials are transferred systematically via 6-meter, 5-meter, and 8-meter belt conveyors. These conveyors use wear-resistant, non-slip conveyor belts with anti-slip textures, adapted to Zambia’s hot and dry climate, preventing slippage and spillage during transfer, ensuring stable and reliable transfer efficiency.

Raw Material Mixing and Feeding Unit: Precise Control Ensures Uniform Granulation

High-Efficiency Mixing Process: The transferred raw materials enter a 40-type twin-shaft mixer. This equipment uses an anti-rotating blade design with a wear-resistant coating on the blade surface. During mixing, the materials undergo strong convection, shearing, and tumbling motions, ensuring thorough mixing of the main nitrogen, phosphorus, and potassium raw materials with trace element additives, achieving a mixing uniformity error of ≤2%. The mixer is equipped with a variable frequency speed control system, which can flexibly adjust the mixing speed (15-30 r/min) according to the moisture content and ratio of the raw materials. It also supports automatic material level monitoring and automatic unloading to prevent material overflow or insufficient mixing, ensuring continuous production.

Stable feeding control: The mixed material is conveyed to a 2200-type disc feeder via 9-meter and 6-meter belt conveyors. This feeder uses variable frequency speed control and material level sensor linkage control technology to precisely control the feed rate (adjustment range 1-3 tons/hour), ensuring uniform feeding to the three granulation units and avoiding granulation quality fluctuations or equipment overload caused by uneven feeding. The feeder disc surface features an anti-slip design, adaptable to raw materials with different flowability, ensuring stable operation without material jamming, and guaranteeing efficient subsequent granulation.

Core Granulation Unit: Three Main Units Working Together for Production Capacity Advantage

The core highlight of the production line is the collaborative operation of three granulators, including two conventional extrusion granulators and one twin-shaft extrusion granulator, forming a “multi-machine complementary, high-efficiency mass production” production mode. The conventional extrusion granulators employ a high-strength roller extrusion design, with roller skins made of high-chromium alloy, achieving a hardness of HRC62 or higher after quenching treatment, exhibiting extremely high wear resistance and extending service life to over 8000 hours. The twin-shaft extrusion granulator is optimized for highly viscous raw materials, employing a twin-shaft synchronous extrusion structure to enhance material plasticization and molding effects, adapting to a wider range of raw material characteristics.

All three granulators are equipped with a hydraulic pressure regulation system, allowing precise control of the extrusion pressure within the range of 6-18MPa. The granulation rate remains consistently above 92%, with uniform particle size controlled at 3-5mm and a compressive strength of 2.5MPa, preventing pulverization and fully meeting the needs of field application and long-distance transportation in Zambia. The three machines operate in tandem, with each machine producing 2 tons per hour, resulting in a total capacity of 6 tons per hour and a daily capacity of 144 tons, fully meeting the local demand for large-scale fertilizer production. The granulator is installed on a dedicated granulator platform (4.5 x 3.2 x 3 meters), designed to meet equipment maintenance and operational safety requirements while optimizing plant space utilization.

Grading and Finished Product Output Unit: Strict Quality Control and Efficient Delivery

Secondary Screening and Recycled Material Utilization: Granulated particles are transferred via a 10-meter belt conveyor to a second 2.0 x 4.0-meter drum screen. This screen features a double-layer design; the upper screen separates large, unqualified particles, while the lower screen selects qualified finished products. The screening efficiency reaches 7 tons per hour, with a 98% pass rate for qualified particles. Unqualified particles are returned to the raw material pretreatment stage via a 7-meter return conveyor, re-entering the production process, achieving resource recycling and effectively reducing production costs. The screening machine is equipped with an automatic screen cleaning device, which can clean the material adhering to the screen surface in real time, preventing screen blockage and ensuring stable screening efficiency.

Finished product storage and automated packaging: Qualified granules are conveyed to the finished product silo via a 10-meter belt conveyor. The silo adopts a sealed design and is equipped with ventilation and moisture-proof devices to effectively prevent fertilizer from absorbing moisture and clumping, ensuring product storage stability. The silo capacity can meet the finished product storage needs of continuous 5 hours of full-load production. The packaging process is equipped with an automatic packaging scale, supporting rapid switching between multiple packaging specifications such as 25kg and 50kg. It adopts the gravity metering principle, combined with a high-precision sensor, with a metering error ≤ ±0.2kg and a packaging speed of up to 80 bags/hour, realizing rapid quantitative packaging of finished products. Combined with the subsequent transfer system, it efficiently completes the warehousing and shipping of finished products.

Core Advantages and Regional Adaptability of the Production Line

High Adaptability, Unaffected by Complex Operating Conditions: Core equipment utilizes high-temperature, wear-resistant, and corrosion-resistant materials, adapting to Zambia’s hot and dry climate. Crusheres, mixers, and other equipment have optimized parameters for local raw material characteristics, capable of processing various raw materials such as livestock manure, mineral powder, and straw, demonstrating exceptional adaptability.

Stable and Reliable, Low Maintenance Costs: Key components employ standardized designs, and easily replaceable wear parts are readily available locally. The equipment boasts a low failure rate and an overall operating rate exceeding 95%. Furthermore, the company provides comprehensive technical guidance and spare parts supply services, significantly reducing customers’ subsequent maintenance costs.

High Efficiency and Environmental Protection, Meeting Local Standards: The entire production line utilizes energy-saving motors and optimized process design, reducing energy consumption by 12% compared to conventional production lines of the same capacity. Sealed equipment design and dust collection devices effectively control dust pollution during production, meeting Zambia’s local environmental protection requirements.

A Keystone Project for Modern Fertilizer Production in Africa

This successful Zambian project highlights Huaqiang Heavy Industry’s capability to deliver complete, localized professional fertilizer manufacturing equipment solutions. The installed extrusion granulation line serves as a versatile core for producing compound fertilizers, fitting seamlessly into the broader spectrum of global fertilizer production technologies.

Specifically, this line represents a robust npk fertilizer production line capable of executing the complete npk fertilizer production process. While it utilizes extrusion granulators, the same client needs could be met with other granulation technologies within Huaqiang’s portfolio. For instance, a disc granulation production line using a disc granulator (or disc granulator for shaping) is ideal for different material properties, while a roller press granulator production line offers another efficient dry compaction option. For operations requiring organic inputs, this NPK line can be integrated with feedstock from an organic fertilizer production line that might begin with a windrow composting machine. Furthermore, an npk blending machine is a fundamental component for precise formulation in any blended fertilizer operation, showcasing the interconnected nature of these fertilizer granulator and processing systems.

The successful commissioning of the extrusion granulation production line in Zambia not only demonstrates Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd.’s comprehensive strength in the R&D of high-end granulation equipment and the implementation of overseas projects, but also provides efficient and stable equipment support for the modernization of agriculture in Africa. In the future, Huaqiang Heavy Industry will continue to focus on the production needs of different regions, optimize product performance and service solutions, and provide more competitive customized solutions for global customers, enabling “Made in China” to benefit the agricultural industries of more countries and regions.

Recently, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. completed the installation and commissioning of a customized BB fertilizer coating production line for its client, officially commencing large-scale production. This production line focuses on the core needs of precise proportioning and enhanced efficiency through coating of BB fertilizer (blended fertilizer). It integrates key processes such as batching, melting, coating, storage, and packaging. With its compact layout, efficient equipment coordination, and stable coating effect, it provides fertilizer production enterprises with a high-quality customized BB fertilizer solution, helping to improve fertilizer utilization and crop yield.

Core Configuration and Full-Process Analysis of the Production Line

The entire BB fertilizer coating production line is built around the core logic of “precise batching – coating solution preparation – uniform coating – finished product output.” The equipment selection is professional, the process is seamless, and the functions of each unit are precisely matched, fully ensuring the accuracy of the BB fertilizer formulation and the quality of the coating.

Precision Batching Unit: Laying a Solid Foundation for Nutrient Balance

The production line is centered around a 5-compartment automated batching unit. Each of the 5 independent compartments stores nitrogen, phosphorus, and potassium as primary raw materials, as well as two different types of trace element additives. The compartments are designed with partitioned isolation to effectively prevent cross-contamination and ensure formula purity. A high-precision metering screw conveyor is installed at the bottom of each batch of batches. Combined with a PLC intelligent control system, it automatically adjusts the feed rate of each raw material according to the preset formula, with a metering error of ≤0.5%. This ensures that the nutrient ratio of each batch of product is accurately met, adapting to the fertilization needs of different crops and different growth stages.

After batching, the mixed raw materials are smoothly transferred to a 9-meter bucket elevator via a 9-meter belt conveyor. This elevator uses a plate chain drive design, has a strong load-bearing capacity, and operates stably. It can vertically transport materials to the subsequent coating stage, with a conveying efficiency of 8 tons/hour. The equipment also has excellent sealing, effectively reducing dust and material loss during the transport process.

Core Coating Unit: Achieving Efficient and Uniform Coating

Coating Solution Preparation System: Equipped with a dedicated coating solution melting and stirring tank. This equipment adopts a double-jacketed heating design, which can precisely control the temperature inside the tank (50-80℃), ensuring that the coating agent (such as anti-caking agent, slow-release agent) melts rapidly and mixes uniformly. The stirring speed can be adjusted by a frequency converter (20-40r/min) to avoid sedimentation and stratification of the coating solution, ensuring consistent coating effect. The tank is equipped with liquid level monitoring and automatic replenishment functions to maintain the coating solution level in real time and ensure continuous operation of the production line.

Core Coating Equipment: Employs a Φ1.8×7.0 meter drum-type coating machine. This equipment is the key equipment for BB fertilizer coating treatment. The inner wall of the drum is lined with special wear-resistant plates, combined with a spiral layout of lifting plates, which can drive the material to fully tumble and scatter within the drum, ensuring that each fertilizer particle is evenly contacted with the coating solution. The coating machine is equipped with an atomizing spraying system that evenly sprays the molten coating liquid onto the material surface in the form of micron-sized droplets. The spraying amount can be precisely controlled according to the material flow rate, ensuring uniform coating thickness (0.05-0.1mm) and a coating rate of over 98%. During equipment operation, the drum speed and material residence time can be flexibly adjusted to adapt to BB fertilizer raw materials of different particle sizes and characteristics, achieving customized coating effects.

Finished Product Storage and Packaging Unit: High-Efficiency Output Ensures Quality

After coating, the BB fertilizer granules are transferred to the finished product silo via a 6-meter bucket elevator. The silo features a sealed design and is equipped with dehumidification and ventilation devices to effectively prevent the fertilizer from absorbing moisture and clumping, ensuring product storage stability. Material level sensors are installed inside the silo to provide real-time feedback on inventory status, facilitating companies to rationally plan production and shipment schedules.

The packaging process is equipped with a dual-station automatic packaging scale, supporting rapid switching between various packaging specifications such as 25kg and 50kg. Utilizing gravity-based metering principles and high-precision sensors, the metering error is ≤±0.1kg. A single station can package up to 100 bags/hour, while parallel operation with two stations can achieve a packaging capacity of 200 bags/hour, perfectly matching the production line’s wrapping output efficiency. The packaging machine integrates automatic sewing and conveying functions. After metering, bagging, and sewing, materials are directly transported to the finished product stacking area via conveyor belt. The entire process is automated, reducing manual intervention, labor intensity, and material loss.

Core Advantages and Application Value of the Production Line

Compact and Efficient Layout: The entire production line adopts a modular and compact design, requiring only 300 square meters of space, saving 30% of space compared to traditional wrapping production lines. The reasonable spacing between equipment facilitates later maintenance and repair.

Superior Coating Quality: The precise coordination of the roller coating machine and the atomizing spraying system ensures a uniform and dense coating layer, effectively improving the BB fertilizer’s resistance to moisture absorption, anti-caking, and slow-release nutrient effect, increasing fertilizer utilization by 15%-20% compared to ordinary BB fertilizers.

Intelligent and Convenient Operation: The entire production line integrates a PLC control system with a Chinese touchscreen interface, allowing real-time monitoring of key parameters such as ingredient ratios, coating solution temperature, and equipment operating status. It supports automatic fault alarms and data recording, facilitating refined management for enterprises. The equipment operation process is simple, and users can become proficient after a short training period.

Integrated Solutions for Complete Fertilizer Production

This BB fertilizer coating line represents a specialized segment of modern fertilizer manufacturing. It demonstrates Huaqiang Heavy Industry’s capability in providing targeted solutions that enhance product value through precise blending and coating.

For clients requiring a more comprehensive production system, this line can be integrated as a finishing module within a complete npk fertilizer production line. The coated BB fertilizer produced here is a key product type within the broader npk fertilizer manufacturing process. The initial stage of this process often relies on core blending and granulation technologies. An npk bulk blending machine (or bulk blending fertilizer machine) is essential for creating the uniform raw material mix. For producing compound granules, advanced npk granulation machine technology is employed, utilizing equipment such as an npk fertilizer granulator machine to perform the fertilizer granulation that transforms powder into robust, market-ready NPK fertilizer granules.

We warmly welcome people from all walks of life to visit, guide, and discuss business with Huaqiang Heavy Industry to create a new future for green agricultural development!