Category: organic fertilizer equipment

organic fertilizer equipment

Controlling pellet strength in ring die granulators: Key to fertilizer transportation and storage

by organic fertilizer production line

Pellet strength is a core performance indicator for fertilizer products. Ring die granulators require multi-step control to ensure pellets can withstand the pressure of transportation and stacking, minimizing breakage and loss.

First, consider the raw material ratio. If the organic matter content in production is too high (over 60%), binders such as clay and bentonite should be added (control the amount to 3%-5%) to increase the viscosity of the raw materials and lay the foundation for pellet strength.

If the proportion of inorganic fertilizer is high, the moisture content of the raw materials should be controlled between 14% and 16% to avoid pellet brittleness caused by too low a moisture content and easy sticking to the ring die granulator due to too high a moisture content.

Selecting the ring die granulator compression ratio is also crucial. The compression ratio (the ratio of the ring die aperture to the effective thickness) should be adjusted according to the fertilizer type. For organic fertilizers with high fiber content, a low compression ratio of 1:8-1:10 is recommended to prevent pellets from being too hard and easily broken. For compound fertilizers, a high compression ratio of 1:12-1:15 is recommended to enhance pellet density. During production, regular spot checks can be performed using a pellet strength tester. If the strength is insufficient, the steam supply to the conditioner can be temporarily increased (by 10%-15%).

In addition, the gap between the roller and the ring die should be controlled within a range of 0.1-0.3mm. A gap too large will cause the raw material to slip, resulting in insufficient pellet density; a gap too small will increase wear and affect pellet consistency. By synergistically controlling these three factors, the compressive strength of fertilizer pellets can be stabilized at above 20N, meeting transportation and storage requirements.

organic fertilizer equipment

Working principle of the fertilizer granule coating machine: Core design adapted to fertilizer characteristics

by organic fertilizer production line

In fertilizer production, the core function of the coating machine is to address the issues of loose granules and their tendency to absorb moisture and agglomerate. Its workflow is precisely designed based on fertilizer characteristics.

First, during the granule conveying process, the coating machine utilizes an “anti-scattering conveyor belt + vibrating discharge mechanism” to prevent granule accumulation. A flow sensor controls the conveying rate, ensuring that each batch of granules enters the coating area evenly. Even with materials with complex ingredients and uneven particle sizes, such as compound fertilizers, this ensures a uniform distribution of granules of varying sizes, paving the way for subsequent coating.

Next, the film wrapping process occurs. To prevent fertilizers from absorbing moisture, PE or PP film is often used. A film guide mechanism, combined with a particle deflector, tightly wraps the granules from all sides. An adaptive tension system adjusts the film tension based on granule flow to prevent leakage or agglomeration. The heat-sealing and shaping process is particularly critical. The coating machine utilizes hot air circulation to achieve film shrinkage while preventing the loss of fertilizer components due to high temperatures. For example, urea fertilizers are prone to decomposition above 160°C, and precise temperature control maximizes nutrient retention. Zoned temperature control also prevents localized overheating that can lead to pellet clumping, ensuring that pellets remain loose after coating.

Finally, the packaging is cut to pre-set specifications and the bag opening is simultaneously compacted to ensure packaging integrity. This process addresses both fertilizer storage and transportation requirements, ensuring that the packaging is protected from damage and leakage, even during bumpy long-distance transport.

organic fertilizer equipment

How to Improve the Efficiency of a New Two-in-One Organic Fertilizer Granulator

by organic fertilizer production line

The efficiency of a new type two-in-one organic fertilizer granulator directly affects the production capacity of an organic fertilizer production line. Improper operation can easily lead to problems such as slow granulation and low pelletizing yield. Four optimization strategies can improve both efficiency and quality.

First, proper raw material pretreatment is essential. Strict control of raw material particle size and moisture is crucial: crush the fermented organic fertilizer into a 40-60 mesh fine powder to prevent coarse particles from blocking the equipment’s feed inlet and affecting mixing uniformity. The moisture content should be maintained at a stable 25%-35%. Adjust moisture content by drying or adding dry materials; spray water if too low.

Second, precise adjustment of equipment parameters is crucial. During the mixing process, adjust the agitator speed according to the raw material type: when processing high-fiber raw materials (such as straw fertilizer), adjust the speed to 50-60 rpm to increase shear force; when processing highly viscous raw materials (such as chicken manure fertilizer), reduce the speed to 20-30 rpm to prevent material from sticking to the wall. During the pelletizing process, the pelletizing method should be adjusted to suit different raw materials: for high-viscosity raw materials, use agitator pelletizing, adjusting the disc inclination to 40°-45°; for high-fiber raw materials, use roller compaction pelletizing, increasing the die pressure appropriately.After parameter adaptation, the granulation efficiency of the new type two-in-one organic fertilizer granulator can be increased by 20%-25%, and the granule forming rate is stabilized at more than 90%.

Furthermore, daily maintenance is essential. Before starting the machine daily, inspect the agitator blades and pelletizing die for wear. If blade edge wear exceeds 3mm or the die aperture is deformed, replace them promptly to avoid uneven mixing and uneven pellet sizes caused by aging components. Clean residual material inside the equipment weekly, especially the mixing chamber and the inner wall of the pelletizing disc, to prevent material agglomeration that affects subsequent production. Lubricate transmission components such as bearings and gears monthly to reduce mechanical friction and extend equipment operation.

Finally, optimizing production processes can further improve efficiency. The “immediate recycling of screen residue” model allows the screening of substandard fines directly back to the mixing system through a reflux channel, eliminating the need for manual transfer and reducing waiting time for raw materials. If the organic fertilizer production line requires continuous operation, a raw material buffer can be configured to ensure uninterrupted feeding of raw materials, avoiding frequent equipment starts and stops due to material shortages. After process optimization, the equipment’s effective daily production time can be increased by 2-3 hours, increasing overall production capacity by approximately 15%.

organic fertilizer equipment

Analysis of Difficulties in Bio-Organic Fertilizer Production Lines

by organic fertilizer production line

As a crucial pillar of green agriculture, bio-organic fertilizer production lines have standardized processes. However, actual production still faces numerous technical and operational challenges, which directly impact product quality and efficiency.

Raw material pretreatment is the primary hurdle in bio-organic fertilizer production lines. Bio-organic fertilizer raw materials are primarily agricultural waste, such as livestock and poultry manure, straw, and mushroom residue, and their composition is complex and unstable. Moisture content and carbon-nitrogen ratios vary significantly among raw materials, and uneven mixing can lead to low subsequent fermentation efficiency. For example, high moisture content in livestock and poultry manure can easily clump, necessitating the addition of additional ingredients. This not only increases costs but can also disrupt the microbial environment due to improper ingredient ratios. Furthermore, pretreatment is necessary to remove harmful substances such as heavy metals and antibiotics from the raw materials. However, inaccurate testing and screening can result in excessive heavy metal levels in the finished product, failing to meet agricultural safety standards.

Precise control of the fermentation process is a key challenge. Bio-organic fertilizer fermentation relies on microbial decomposition of organic matter, requiring strict control of parameters such as temperature, humidity, and oxygen content. If the temperature rises too slowly during the initial fermentation phase, the composting cycle will be prolonged; excessively high temperatures may kill beneficial microorganisms and lead to nutrient loss. Furthermore, the fermentation process is prone to producing harmful gases such as ammonia and hydrogen sulfide. If the ventilation system is poorly designed, this not only pollutes the environment but also affects the health of workers.

The integration of equipment operation and quality control also presents challenges. In the bio-organic fertilizer production line, the crushing, mixing, and granulation equipment must operate in tandem. Uneven particle size can affect the granulation yield. Improper temperature control in the granulator can easily result in granules that are too hard or too soft, impacting product storage and transportation. Furthermore, relying solely on sampling and testing finished products during quality inspection can hinder timely detection of production process problems, potentially resulting in the rejection of entire batches.

These challenges not only test the technical capabilities of the bio-organic fertilizer production line but also place high demands on the professional expertise of the operators. Only by addressing these challenges in each link can we promote the high-quality development of the bio-organic fertilizer industry and provide strong support for the green transformation of agriculture.

organic fertilizer equipment

Efficient Operation Strategies for the Conveying Segment of an Organic Fertilizer Production Line

by organic fertilizer production line

In an organic fertilizer production line, the conveying segment is the “link” connecting the crushing, fermentation, granulation, and packaging processes. Its efficiency directly impacts the production capacity and stability of the entire line. To avoid material accumulation and conveying jams, scientific planning is required from three aspects: equipment selection, layout design, and operation and maintenance.

Rational conveying equipment selection is crucial. Differentiated selections should be made based on the material characteristics of each process. Belt conveyors are ideal for crushed dry materials (such as straw powder). They offer high conveying capacities (up to 5-20 tons per hour), adjustable speeds, and a smooth, easy-to-clean belt surface, minimizing material residue. Bucket elevators are suitable for granular materials. Vertical conveying saves workshop space, and a sealed hopper prevents granules from spilling, accommodating the required height between the granulator and packaging machine. Furthermore, all conveying equipment must be constructed of corrosion-resistant materials, such as stainless steel or galvanized steel, to accommodate the acidic and alkaline properties of organic fertilizers and extend equipment life.

A scientific layout is essential. Conveyor routes should adhere to the principle of “shortest paths and fewer turns” to minimize resistance and energy consumption. Bucket elevator inlets are equipped with buffer devices to prevent particles from impacting and damaging the hopper. Belt conveyors are tilted no more than 15°; for larger angles, corrugated belts with sidewalls are used. Level sensors are installed at key points to automatically warn when material accumulation exceeds the limit, adjusting the conveyor speed to prevent overload and shutdown.

Proper operation and regular maintenance are key. Operators must strictly follow the “pre-startup inspection – ongoing monitoring – post-shutdown cleaning” process: Before starting up, check the conveyor belt tension and wear of the scraper or hopper. During operation, monitor the material conveying status in real time and make timely adjustments if any deviation or jamming is detected. After shutting down, thoroughly clean any remaining material inside the equipment, especially wet and sticky materials, using a high-pressure water jet to prevent caking and blockage. Regular maintenance includes weekly lubrication of conveyor bearings, monthly inspection of the tightness of the scraper and hopper, and timely replacement of worn parts to ensure efficient operation of the conveying chain and maintain stable production capacity of the organic fertilizer production line.

organic fertilizer equipment

Disc Granulator: The Magic Craftsman of Fertilizer Formation?

by organic fertilizer production line

In the world of fertilizer production, the  disc granulator is the undisputed “core player” in transforming loose raw materials into uniform, easily usable finished products. But don’t assume it can work alone—from raw material pretreatment to finished product packaging, a series of supporting fertilizer equipment work closely together to ensure that every fertilizer grain meets high-quality standards.

As the “heart and soul” of the granulation process, the disc granulator’s “craftsmanship” is truly exquisite. Using its tilted discs, it spins at high speed, magically kneading mixed organic fertilizer or compound fertilizer raw materials into smooth, round granules with a diameter of 2-6 mm.The pelletizing rate is over 95%. Even more impressively, it can flexibly adapt to different raw materials by adjusting the disc’s speed and inclination, ensuring compact, unbreakable pellets while preventing clumping and sticking, ensuring each pellet is both aesthetically pleasing and effective.

However, the disc pelletizer’s outstanding performance relies on the dedicated support of its upstream and downstream equipment. Initially, the raw material mixer is a key partner, blending raw materials like livestock and poultry manure, straw powder, and trace elements into a uniform consistency, providing the disc pelletizer with high-quality ingredients. The  fertilizer dryer, like a “drying master,” dries the wet pellets to a moisture content below 15% to prevent mold.Later, a cooler rapidly cools the high-temperature dried granules to prevent clumping. A screening machine carefully separates unqualified small granules or large lumps for reprocessing. Finally, a  packaging machine accurately weighs and seals the finished fertilizer, allowing it to reach the market smoothly.

Today, with the development of green agriculture, the demand for high-quality fertilizer is increasing. The disc granulator and its supporting equipment work seamlessly together, not only improving fertilizer production efficiency but also ensuring fertilizer quality, providing nutrients to the soil and supporting crop growth.

organic fertilizer equipment

Four Common Problems in NPK Fertilizer Production Lines and Solutions

by organic fertilizer production line

NPK fertilizer production lines involve complex processes and are susceptible to problems due to factors such as raw materials, processes, and equipment. These problems not only affect product quality and production capacity, but can also pose environmental risks and require precise solutions.

Impurities and agglomeration are prominent issues. Stones and metal fragments mixed in with the raw materials can wear the lining of the granulator and clog the screens of the screening machine, causing equipment downtime. Urea and monoammonium phosphate absorb moisture and agglomerate, forming lumps, resulting in uneven mixing and fertilizer nutrient content deviations exceeding 5%. Solutions: Install a magnetic separator and vibration screener machine at the outlet of the raw material silo to separate impurities; equip a pre-crushing system to crush agglomerated materials to 80-100 mesh; and control the humidity in the raw material silo to less than 60% to prevent moisture absorption.

Pelletization and drying are prone to quality problems. Improper moisture content during granulation (less than 15% results in loose granules, while above 18% results in sticking to the pellet wall), as well as imbalanced rotation speed and inclination angle, can lead to uneven granule size and poor roundness (less than 80%). Excessively high drying temperatures (>160°C) can cause nitrogen volatilization (loss rate exceeding 10%), while too low drying temperatures can easily lead to granule agglomeration. Solutions: Install an online moisture meter before granulation to adjust binder dosage in real time; use a frequency converter system to optimize granulator parameters; and equip the drying process with an automatic temperature control system to maintain a stable temperature between 120-150°C.

Dust and wastewater treatment can easily fail to meet standards. Mixing and screening processes generate a lot of dust. If the dust removal equipment’s filter bags become clogged or air volume is insufficient, dust emission concentrations can easily exceed 20mg/m³. Drying condensate and equipment wash water contain nitrogen and phosphorus, which can be directly discharged into water bodies and pollute. Solutions: Clean dust removal filter bags weekly and optimize fan air volume. Establish a wastewater recycling system for treated and reused in granulation to achieve “zero discharge.”

Wear and aging reduce efficiency. Wear and tear of vulnerable components like granulator scrapers and dryer lift plates (e.g., a gap exceeding 15mm between the scraper and the disc) can cause material to stick to the wall and reduce drying efficiency. Oil depletion or aging in the drive system can cause abnormal noise and speed fluctuations. Solutions include establishing a regular inspection system, checking vulnerable parts weekly and replacing them promptly. Lubricate the drive system monthly with specialized lubricant, and perform comprehensive maintenance and calibration quarterly.

organic fertilizer equipment

In the fertilizer granulator series, which granulation method is most suitable for large-scale production?

by organic fertilizer production line

In the field of fertilizer production, granulation technology is a key link to improve the quality and efficiency of fertilizer. In the face of many fertilizer granulator series, choosing the most suitable for large-scale production of granulation methods, you need to consider many factors such as production efficiency, cost, product quality and operation convenience.
 

Fertilizer Granules Compaction Machine: representative of high efficiency

 
Fertilizer Granules Compaction Machine occupies a place in mass production for its high efficiency and good forming effect. The device extrudes material through a pair of rotating rollers to form particles. It is especially suitable for dealing with those materials with poor bonding, such as urea, phosphate fertilizer, etc., and can realize the molding of a large number of fertilizers in a short time. In addition, the Fertilizer Granules Compaction Machine consumes relatively low energy, is easy to maintain, is suitable for continuous and automated production processes, is one of the preferred equipment in large-scale production.

Flat-Die Pellet Machine: has high adaptability

 
A Flat-Die Pellet Machine is used to press the material into particles of the desired shape by pressing the mold. This granulation method is highly adaptable to materials and can handle a variety of different types of fertilizer raw materials, including organic and inorganic fertilizers. Another advantage of the Flat-Die Pellet Machine is that the shape and size of the pellets can be adjusted by changing the mold to meet different market needs. However, Flat-Die Pellet machines are slightly less productive than Fertilizer Granules Compaction machines and may require more mold replacement and maintenance work in mass production.

Rotary Drum Granulator: Uniform particle quality

 
Rotary Drum Granulator turns and rounds materials by rotating the drum and an internal copy plate to form particles. This granulation method is suitable for the production of high-quality organic fertilizers, because the Rotary Drum Granulator can fully mix and form the material at a slower speed, thus ensuring the uniformity and quality of the particles. Rotary Drum Granulator has low energy consumption and wear during the production process and is suitable for long continuous operation, as well as for mass production.

Disc Granulator: Easy to operate

 
Disc Granulator By rotating a disc, the material rolls on the surface of the disc and gradually gathers into particles. This granulation method is simple to operate, easy to control, and suitable for small and medium-sized production. The investment cost of Disc Granulator is relatively low, but its production efficiency and pellet forming effect may not be as good as that of Fertilizer Granules Compaction Machine and Rotary Drum Granulator. Therefore, it may not be optimal in mass production.

conclusion

 
Considering production efficiency, cost, product quality and operation convenience, Fertilizer Granules Compaction Machine and Rotary Drum Granulator have more advantages in mass production. Fertilizer Granules Compaction Machine, with its high efficiency and low energy consumption, is especially suitable for treating materials with poor adhesion, while Rotary Drum Granulator, because of its uniform particle quality and low operating cost, Suitable for the production of high quality organic fertilizer. According to the characteristics and production needs of different fertilizer raw materials, choosing the right granulator is the key to ensure the quality and production efficiency of fertilizer products.

organic fertilizer equipment

Rotary Drum Granulator: The Core of Fertilizer Mass Production?

by organic fertilizer production line

In large-scale fertilizer production workshops, you’ll always see a constantly rotating “huge machine”—the  drum granulator. With its impressive production capacity, it’s become the workhorse of compound and organic fertilizer production. But did you know? A drum granulator alone can’t fulfill production tasks; from raw materials to finished product, it relies on a host of supporting equipment.

As the core of mass production, the power of the drum granulator cannot be underestimated. As its cylindrical drum slowly rotates, the internal lifting plate continuously stirs the raw materials. Combined with the applied binder, the powdered materials gradually agglomerate into uniform granules.Whether it’s compound fertilizers requiring high hardness or organic fertilizers rich in organic matter, it can easily handle them, processing 10-50 tons of raw materials per hour with a consistently high pelletizing rate of over 90%, perfectly meeting the needs of large-scale production.

The drum granulator’s efficient output relies on the close coordination of upstream and downstream equipment. Initially, the crushing equipment breaks down bulky raw materials into a uniform powder for granulation. The  batching system   precisely controls the ratios of nitrogen, phosphorus, potassium, and other elements to ensure the fertilizer’s nutrient content meets standards. Later, the freshly formed wet pellets enter a dryer for rapid dehydration in a high-temperature airflow. A  fertilizer cooler  then cools the hot pellets to room temperature to prevent clumping.Finally, a screening machine selects granules of acceptable size. Unacceptable particles are returned to the granulator for reprocessing before being sealed and packaged by an automatic packaging machine. This complete process is both efficient and precise.

Today, global agricultural demand for high-quality fertilizers continues to grow. A production line consisting of a rotary drum granulator and supporting equipment can ensure both production output and strict quality control, providing strong support for increasing agricultural income.

organic fertilizer equipment

Three Core Application Scenarios for Disc Granulators

by organic fertilizer production line

Due to their high pellet formation rate and highly adjustable parameters, disc granulators have expanded beyond the traditional fertilizer sector to diverse applications such as environmental protection and metallurgy, becoming a “universal device” for material formation across multiple industries. Their differentiated adaptability to various application scenarios is their core competitive advantage.

Agriculture is the primary market for disc granulators, with each specific application focusing on its own specific niche. In organic fertilizer production lines, for fibrous materials such as livestock and poultry manure and straw, the equipment requires rubber-lined discs with anti-sticking walls, an inclination angle of 35°-40°, and a humic acid binder to achieve efficient granulation at a moisture content of 15%-18%. Compound fertilizer applications require even higher corrosion resistance. 304 stainless steel discs, combined with an atomizing spray system, precisely control the adhesion of nitrogen, phosphorus, and potassium mixtures, ensuring pellet roundness that meets high fertilization standards.

In the field of environmental solid waste treatment, disc granulators have become a key component in resource utilization. When processing municipal sludge, the equipment first reduces the sludge’s moisture content to below 20% through a preheating system. Then, using bentonite as a binder, the equipment, operating at a speed of 18-20 rpm, converts the sludge into spherical pellets suitable for incineration or landfill. For the treatment of industrial solid waste such as steel slag and slag, wear-resistant ceramic-lined discs can withstand the impact of high-hardness materials. Combined with a powerful scraper, they ensure uniform mixing of the ore powder and binder, effectively improving solid waste utilization.

Mineral powder granulation in the metallurgical industry places stringent requirements on equipment stability. For high-density materials such as iron ore concentrate and manganese ore fines, disc granulators utilize a thickened steel frame with an adjustable tilt angle of 40°-45°. A high-frequency vibrating distributor ensures uniform feeding and ensures the compressive strength of the ore powder pellets meets the feed requirements for blast furnace smelting. Furthermore, for the granulation of rare earth materials, the equipment must be equipped with a sealed dust cover to prevent leakage of ultrafine powder and ensure a safe production environment.

From agriculture to environmental protection to metallurgy, the disc granulator continues to expand its application boundaries through customized adjustments of materials, parameters, and supporting systems. In the future, with the integration of new materials technology, its application potential in refined fields such as medicine and food additives will be further released.

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