Category: organic fertilizer equipment

organic fertilizer equipment

Key Processes and Practices for Granular Fertilizer Production from NPK Raw Materials

by organic fertilizer production line

Converting elemental nitrogen, phosphorus, and potassium raw materials into granular fertilizer requires scientific proportioning, physical shaping, and precise control to achieve balanced nutrients and convenient application. This npk fertilizer production line not only improves fertilizer utilization but also addresses the challenges of bulk raw materials, such as clumping and transportation difficulties.

The first step is raw material pretreatment and proportioning. Nitrogen sources (such as urea and ammonium chloride), phosphorus sources (superphosphate and diammonium phosphate), and potassium sources (potassium chloride and potassium sulfate) must be crushed to a fineness of 80-100 mesh to ensure uniform mixing. The nitrogen, phosphorus, and potassium ratios are precisely adjusted based on the needs of the target crop. For example, the 15-15-15 general formula commonly used for field crops requires strict control of the tolerance of each raw material within ±0.5%. 5%-8% bentonite is added as a binder to enhance granularity.

The core granulation process often utilizes a rotary drum granulation process. The mixed raw materials are fed into a rotary drum granulator, where a 30%-40% solution of warm water or dilute phosphoric acid is sprayed through a spray device to form “mother balls” within the drum. The drum speed is controlled at 20-25 rpm, and the inclination angle is maintained at 3°-5°. This ensures that the mother balls continuously absorb the raw material powder as they rotate, gradually growing into uniform granules with a diameter of 2-4mm. For the production of high-concentration granular fertilizers, an extrusion granulation process is used. A twin-screw extruder presses the material into a cylindrical shape, which is then sheared into granules by a pelletizer. This is suitable for formulas with low moisture content.

After granulation, the granules undergo drying and cooling. The temperature in the drum fertilizer dryer is controlled at 120-150°C to reduce the moisture content of the granules to below 10% to prevent clumping during storage. The granules then enter a drum fertilizer cooler, where low-temperature air is used to cool them to room temperature to prevent condensation during subsequent packaging. Finally, unqualified granules (overly coarse or fine) are separated by a screening machine and returned to the granulator for reprocessing. The finished product is then sprayed with an anti-caking agent in a coating machine to improve storage stability.

Throughout the entire production process, indicators such as granule strength (should be ≥20N) and disintegration (disintegrates in water within 30 minutes) are monitored in real time to ensure product compliance with national standards. This process transforms nitrogen, phosphorus, and potassium raw materials from bulk to granules, facilitating mechanized fertilization while reducing nutrient loss, providing strong support for improving agricultural quality and efficiency.

organic fertilizer equipment

How does a disc granulator granulate?

by organic fertilizer production line

As a key piece of equipment in fertilizer production lines, the disc granulator, with its efficient and stable granulation capabilities, has become a core device for granular material production. Its granulation process follows the scientific logic of “agglomeration – growth – shaping,” achieving precise conversion of raw materials into granules through precise control.

The first step in granulation is raw material pretreatment. Powdered raw materials (such as fertilizer raw materials) are mixed with an appropriate amount of binder (water, starch solution, etc.) to form a wet material with a moisture content of 15%-25%. The mixed wet material is evenly transported by a conveyor belt to the inclined granulation disc. The disc’s tilt angle is typically controlled between 35° and 55°, a value proven through numerous experiments to balance material tumbling efficiency and pellet residence time.

In the core granulation stage, the disc rotates at a constant speed of 10-20 rpm. Under the combined effects of centrifugal force, gravity, and friction, the wet material spirals upward along the inner wall of the disc. During the rotation, the fine powder continuously absorbs surrounding materials, gradually forming small particles with a diameter of 1-3 mm, known as “master particles.” As the disc continues to rotate, the master particles continuously “engulf” the surrounding powder through collision and compression, growing larger like a snowball. The operator monitors the particle size in real time through an observation window. When the particle diameter reaches the target value of 3-8 mm, the disc’s tilt angle and rotational force are used to automatically cause mature particles to overflow from the disc edge, completing the initial granulation process.

The overflowing particles are not immediately finished products; they undergo subsequent optimization steps. The overflowing wet particles first enter a dryer to remove moisture in a hot air environment of 80-120°C. They are then screened by a sieving machine to separate the broken particles from the larger particles that do not meet the particle size requirements. The broken particles are then returned to the raw material system for re-granulation.

The disc speed, tilt angle, and material moisture content are three key parameters throughout the granulation process. Too fast a rotation speed can easily lead to particle breakage, while too slow a rotation speed results in low granulation efficiency. Too large an angle can cause premature overflow, while too small a rotation angle can result in excessive retention time. By precisely controlling these parameters, the disc granulator can achieve a granulation success rate of over 90%, providing an efficient and stable granule forming solution for organic fertilizer production lines.

organic fertilizer equipment

Energy consumption optimization for BB fertilizer mixers: Cost reduction from adjustment to operational details

by organic fertilizer production line

In BB fertilizer production, BB fertilizer mixers account for 20%-30% of total energy consumption. Through equipment adjustment and operational optimization, energy consumption can be reduced by 15%-20% without compromising mixing quality.

For BB fertilizer mixer upgrades, variable-speed motors are preferred over traditional fixed-speed motors. The speed is adjusted according to the mixing stage: in the initial feeding phase (when the raw materials have not yet filled the barrel), a low speed of 15 rpm is used to avoid idling energy waste; in the middle mixing phase (when the raw materials are fully tumbling), the speed is increased to 22-25 rpm for efficient mixing; and in the later stages (when the mixing is nearly uniform), the speed is reduced to 18 rpm to reduce energy consumption from excessive mixing. Furthermore, adjusting the mixer’s blade angle from 45° to 30° (for granular raw materials) reduces blade resistance, reduces motor load by 10%-12%, and reduces energy consumption accordingly.

There are three key aspects to optimizing operational details: First, “full load but not overload”—feeding the equipment at 75% of its rated capacity to avoid wasted idling caused by underfeeding (<60%) or motor overload and energy consumption caused by overfeeding (>90%). Second, “centralized batch production”—concentrating fertilizer production of the same formula within 2-3 hours to reduce energy consumption from frequent equipment starts and stops. Third, “reasonable cleaning cycles”—changing “clean every batch” to “clean every three batches”—reduces the equipment’s idle time during cleaning. Furthermore, an anti-stick coating on the drum wall ensures that residue remains within standards.

In addition, regularly inspect the wear of the BB fertilizer mixer’s blades. If the blade edge is worn by more than 1/4, repair or replace it promptly to avoid extended mixing time due to insufficient blade power.

organic fertilizer equipment

How can we ensure that the effects of BB fertilizer containing functional additives are not lost through a blender?

by organic fertilizer production line

When adding functional ingredients such as slow-release agents, biological agents, and trace elements to BB fertilizer, the BB fertilizer blender requires special adjustments to prevent the additive effects from being lost or unevenly distributed during the blending process.
Biological agents (such as Bacillus subtilis) are sensitive to high temperatures and easily inactivated. Therefore, two key controls must be implemented during blending: first, the blending temperature. By installing a cooling jacket on the BB fertilizer blender barrel, the chamber temperature can be kept below 35°C to prevent frictional heating from the blades, which could reduce the activity of the agent. Second, the mixing order: pre-mix the agent with 10 times the amount of carrier (such as humus powder) to form a “mother powder.” This should then be added after the blender has been running for 5 minutes. This minimizes direct friction between the agent and other ingredients and ensures a viable bacterial count retention rate exceeding 90%.

If adding a slow-release agent, to avoid damaging the coating during mixing, use a “low-shear” impeller (with blunted blade edges), reduce the speed to 15-18 rpm, and control the mixing time to ≤8 minutes. This prevents the slow-release agent particles from excessively colliding and causing the coating to crack, thereby losing its slow-release effect.
For trace elements, they should first be crushed to a size of 100 mesh or larger, pre-diluted with five times the amount of powdered fertilizer (such as monoammonium phosphate powder), and then added to the BB fertilizer blender using a “multi-point feeding” method to ensure even distribution of the trace elements and avoid localized high concentrations that could cause fertilizer damage to the crop.

organic fertilizer equipment

What are the environmental protection measures of organic fertilizer production line?

by organic fertilizer production line

As an important part of agricultural production, its environmental protection measures are of great significance to reduce environmental pollution and improve resource utilization. Here are some effective environmental measures:

  1. Dust control: In the process of mixing, crushing, granulation, etc., dust is collected by sealing equipment and air Collector, and treated by equipment such as Cyclone Dust Collector, bag dust collector or scrubber to reduce dust emission.
  1. Waste Gas treatment: The gas from Gas/Oil Hot Air Stove in the production line needs to be dedusted and desulphurized. Cyclone Dust Collector and water film dedusting technology are adopted to ensure that the exhaust gas meets the emission standards.
  1. Wastewater management: Domestic sewage and production wastewater should be pre-treated through septic tanks, etc., and then appropriate treatment technologies, such as biochemical treatment, physicochemical treatment, etc. should be selected according to the nature of the wastewater to achieve recycling of wastewater or discharge up to standard.
  1. Solid waste treatment: For the solid waste generated in the production process, such as waste packaging bags, dust, etc., should be classified and collected and treated. Recyclable solid waste should be disposed of by the material recovery department, and non-recyclable solid waste should be disposed of safely, such as used as agricultural fertilizer.
  1. Noise control: Through the selection of low noise equipment, plant sound insulation, key parts of the rubber pad and other measures to reduce the noise pollution in the production process.
  1. Odor control: Organic fertilizer may produce odor during the drying process, and the generation and diffusion of odor can be reduced by strengthening ventilation and adopting biological filtration.
  1. Resource recycling: Promote the use of by-products and waste in the Organic Fertilizer Production Line, such as using the hot blast furnace slag generated in the drying process as agricultural fertilizer to realize the recycling of resources.
  1. Enhance environmental awareness: strengthen environmental education and training of employees, improve environmental awareness, and ensure the effective implementation of environmental protection measures.
  1. Environmental monitoring and emergency plan: Regularly monitor the environment around the production line to ensure that pollutant emissions meet standards. At the same time, formulate emergency plans for environmental emergencies and improve the ability to respond to environmental accidents.

 
Through the implementation of the above environmental protection measures, Organic Fertilizer Production Line can not only effectively reduce the impact on the environment, but also improve the efficiency of resource utilization and promote the sustainabl

organic fertilizer equipment

When using windrow compost turning machines in different seasons, pay attention to key details

by organic fertilizer production line

A windrow compost turning machine isn’t a one-size-fits-all model. Adjusting details according to the season will ensure smooth fermentation of your organic fertilizer.

Spring’s high humidity and fluctuating temperatures can easily lead to a musty odor in the compost. When using a compost turner, increase the frequency of turning the compost. Instead of turning every two days, turn every 1.5 days in spring. Loosen the compost to allow moisture to escape, and monitor the temperature. If the temperature is below 50°C, slow the compost turner’s speed to allow for a more thorough turning, allowing microbial activity to raise the temperature.

Summer temperatures are high, and the compost easily overheats (over 70°C kills beneficial bacteria). Reduce the depth of each turning to avoid bringing all the hot material below to the surface. Turn the compost once a day. Sprinkle a thin layer of soil on the surface after each turning to provide shade and reduce temperatures while preventing rapid evaporation.

Autumn is dry, and the pile is prone to dehydration and cracking. Use a windrow compost turning machine with an atomizer, spraying small amounts of water as you turn to maintain a humidity level of 50%-60%. Slow the turning speed to allow the water and raw materials to mix thoroughly and avoid patches of dryness or wetness.

Winter is cold, and the pile struggles to heat up. Reduce turning frequency to once every three days, avoiding frequent turning to disperse heat. When turning, pile the pile higher (1.2-1.5 meters). Try turning the cold material in the center with the windrow compost turning machine, covering the hot material on the outside to help retain heat and ferment.

organic fertilizer equipment

Key factors affecting BB fertilizer mixer mixing uniformity

by organic fertilizer production line

The core quality indicator of BB fertilizer (blended fertilizer) is nutrient uniformity, and the mixing performance of the BB fertilizer mixer directly determines the quality of the final product. This process is influenced by several key factors and requires targeted control.

First, the raw material pretreatment stage. BB fertilizer raw materials are mostly nitrogen, phosphorus, and potassium single granular fertilizers or powdered organic fertilizers. If the raw material particle size varies greatly, stratification due to different densities is likely to occur. Screening is required to control the raw material particle size deviation to within 2mm. At the same time, the raw material moisture content must be maintained at a stable 12%-15%. Too high a moisture content can easily cause the particles to stick together, while too low a moisture content can cause the powdered raw material to generate dust.

Second, the mixing parameter setting is important. The speed of the BB fertilizer mixer should be adjusted according to the raw material type. When mixing granular fertilizer, the speed can be set to 15-20 rpm to avoid particle collision and breakage caused by high speed. When mixing raw materials containing powder, the speed can be increased to 20-25 rpm. The mixing time also needs to be controlled. Typically, 8-12 minutes per mixing cycle is sufficient. Too short a time will result in uneven mixing, while too long a time can easily cause excessive friction and loss of the raw materials.

Finally, the compatibility of the equipment structure is important. The impeller design of the BB fertilizer mixer must balance convection and shearing. If the raw materials contain a small amount of fiber (such as when adding straw powder to organic fertilizer), impellers with scraping functions should be used to prevent the raw materials from adhering to the cylinder walls. The cylinder should avoid right angles and instead use rounded transitions to reduce dead corners where raw materials accumulate, ensuring that every portion of the raw materials is mixed and ensuring uniformity from a structural perspective.

organic fertilizer equipment

How Does Biofertilizer Production Work Step by Step?

by organic fertilizer production line

Have you ever been curious about the fascinating journey of organic waste transforming into valuable biofertilizer? This remarkable metamorphosis occurs through bio organic fertilizer production – a meticulously organized process that relies on specialized equipment at each stage to create high-quality end products.

The complete organic fertilizer production line begins with raw material preparation, where organic waste is composted and treated. The heart of the operation features a fertilizer mixer machine that ensures uniform blending of ingredients, followed by granulation using specialized equipment like a disc granulator or other types of fertilizer granulator that shape the material into consistent, easy-to-handle pellets.

Interestingly, while NPK fertilizer production line configurations often prioritize chemical precision, bio-organic lines focus on preserving natural nutrients and microbial activity throughout the manufacturing process. The journey concludes with automated packaging through a fertilizer packing machine that ensures product integrity from production to field application.

Each piece of equipment plays a crucial role in this sustainable transformation, working in harmony to convert waste into wealth while maintaining the vital organic properties that make biofertilizers so valuable for sustainable agriculture and soil health regeneration.It’s a well – organized process that relies on specific equipments required for biofertilizer production, and each step is key to creating a high – quality end product.
The process starts with raw material pretreatment. First, organic wastes like livestock manure and crop straw are collected. Then, a crusher – a vital fertilizer machine – breaks them down into small particles that are perfect for fermentation. After crushing, a screening machine removes any impurities, making sure the raw materials are clean. Next, the crushed materials are mixed with water and fermentation agents. This mixing step adjusts the humidity and boosts microbial activity, getting everything ready for fermentation. Sometimes, workers also flip the materials to ensure even mixing, which kickstarts the initial microbial work.
Once pretreatment is done, it’s time for fermentation – the core of the process. The pretreated materials are moved to fermentation equipment, such as fermentation tanks or turntables. These fertilizer equipments create the ideal conditions for microbes to thrive. During high – temperature fermentation, the microbes break down the organic matter. To keep things on track, workers or automated systems regularly flip or stir the materials to provide enough oxygen. They also monitor temperature, humidity, and oxygen levels closely. Adjusting these parameters ensures efficient fermentation and produces top – notch fertilizer raw materials.
After fermentation is complete, post-processing begins. First, a dryer removes excess moisture from the fermented material, improving the fertilizer’s stability and making it easier to store. Then, a granulator—another essential fertilizer equipment—transforms the dried material into granules. These granules are convenient for transportation and use. Next, a sieving machine classifies the granules, removing oversized and undersized particles. Finally, a mixer blends qualified granules with additives such as microbial preparations and trace elements to enhance the fertilizer’s nutritional value and biological activity.
The last steps are packaging and storage. An automatic packaging machine – a time – saving fertilizer equipment – packs the finished biofertilizer into bags or boxes. Before sending the products out, strict quality inspections are carried out to make sure they meet national or industry standards. Every step, from start to finish, shows how important each fertilizer machine and equipment is in the biofertilizer production line!

organic fertilizer equipment

The Art of Granulation: How Rotary Drum Granulators Work

by organic fertilizer production line

In modern NPK fertilizer production technology, the rotary drum granulator serves as a cornerstone equipment that miraculously transforms powdered materials into uniform granules through its unique rotating principle. This versatile drum granulator operates by tumbling materials in a rotating cylinder, creating the perfect conditions for agglomeration through centrifugal force and gravitational action.

The application scope of this NPK fertilizer granulator extends beyond synthetic fertilizers, playing an equally vital role in organic fertilizer production line configurations. As a dual-purpose organic fertilizer granulator, it efficiently processes various organic materials including compost, manure, and biomass into consistent, market-ready granules.

The magic happens through a carefully engineered process where the rotating motion creates a cascading effect, allowing fine particles to coalesce into spherical granules. Liquid binders are typically sprayed into the drum to facilitate granule formation, with the tumbling action ensuring even distribution and consistent size development. This transformation from powder to premium granules makes the rotary drum granulator an indispensable component in both synthetic and organic fertilizer manufacturing operations.

Power Transmission: Precision Drive System

The core power of drum granulators comes from their meticulously designed transmission system. The main motor drives the reducer through pulley belts, transmitting power to the drive shaft. The pinion gear on the open shaft meshes precisely with the large gear on the drum body – this gear transmission ensures smooth and reliable power delivery. Notably, the high-precision gears used in modern drum granulators have a service life over twice that of conventional gears.

When the motor starts, the entire system operates like precision clockwork: Motor→Pulley→Reducer→Drive shaft→Gear set→Drum rotation. Each component is carefully calculated and matched to minimize energy loss.

Granulation Process: Material Transformation

After entering the rotating drum from the feed end, materials undergo a remarkable transformation journey:

  • Lifted by internal lifters to a certain height before falling, creating a “waterfall effect”
  • Particles collide and compress in moist conditions, gradually forming nuclei
  • With continuous rotation, nuclei grow into spheres through layering
  • Finished granules finally discharge from the outlet, completing granulation

This continuous process enables 24/7 operation for mass production.

Design Essence: Fusion of Science and Engineering

The brilliance of drum granulators lies in their internal structure design. Specially arranged lifters with optimized angles and distribution ensure ideal material movement trajectories. Meanwhile, precisely calculated drum inclination and rotation speed guarantee sufficient granulation time while maintaining optimal output. This integration of fluid dynamics, mechanical principles and chemical engineering represents the essence of drum granulation technology.

From simple rotation to complex granulation, rotary drum granulators perfectly embody the engineering philosophy of “extraordinary simplicity.” In today’s pursuit of efficient production, they remain irreplaceable core equipment for compound fertilizer granulation.

organic fertilizer equipment

Windrow compost turner: Why is it suitable for organic fertilizer production?

by organic fertilizer production line

In the vast field of organic fertilizer production, the windrow compost turning machine is revolutionizing the game of compost manufacturing with its exceptional performance. This specialized fertilizer equipment is specifically designed for handling organic waste such as livestock manure, crop straw, and organic garbage, playing an indispensable role in the composting and fermentation process.

Compared to traditional wheeled turners, the windrow compost turning machine employs a track walking system that demonstrates unparalleled ground adaptability and stability. This innovative fertilizer machine is particularly suited for operation on uneven, soft, or slippery terrain, ensuring efficient and stable performance even in the most challenging working conditions.

This advanced compost fertilizer machine finds extensive application across various sectors including agriculture, environmental protection, and organic fertilizer production. Its exceptional mobility enables it to complete turning operations successfully even in the most demanding environments, significantly improving the processing efficiency of organic waste.

The windrow compost turning machine not only promotes uniform fermentation of materials effectively but also provides adequate oxygen to the compost through regular turning, accelerating the decomposition process of organic matter. This efficient turning method ensures the consistency and stability of compost quality, laying a solid foundation for producing high-quality organic fertilizer.

In modern organic fertilizer production, this windrow compost turning machine has become an essential piece of equipment. It not only enhances production efficiency but also contributes significantly to sustainable agricultural development with its outstanding performance and reliability, truly realizing the environmental concept of waste resource utilization.

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