organic fertilizer production line

In the organic fertilizer production line, the granulator plays a crucial role, and its main functions include:

Forming: The fertilizer granulator processes powdered or liquid organic fertilizer raw materials into granules for subsequent drying, screening, packaging, and application.

Improving physical properties: Granular organic fertilizers have better physical properties, such as fluidity, anti caking, and storage stability.

Improving application efficiency: Granular fertilizers can be directly applied to the soil through mechanical fertilization equipment, improving the efficiency and uniformity of fertilization.

Controlled release: The dissolution and nutrient release rate of granular fertilizers are usually slower than that of powdered fertilizers, which helps plants absorb nutrients more evenly.

Easy to store and transport: Granular fertilizers have a small volume, large weight, and are not easily scattered, making them easy to transport and store over long distances.

Improving market value: Granular organic fertilizers have a cleaner appearance, are easier to measure and sell, and enhance the product’s market competitiveness.

Reducing environmental pollution: Through granulation, the loss of fertilizers during storage and transportation can be reduced, reducing environmental pollution.

Adjusting moisture content: During the granulation process, the humidity of the finished product can be controlled by adjusting the moisture content of the raw materials to meet the requirements of subsequent processes.

Adding slow-release materials: During the granulation process, slow-release materials such as sulfur coatings can be added to organic fertilizers to control the rate of nutrient release.

Improving the consistency and uniformity of fertilizers: The granulator ensures consistency in the size and shape of fertilizer particles for each batch, improving the uniformity of fertilizers.

Enhancing the functionality of fertilizers: During the granulation process, other functional substances such as microbial agents, growth regulators, etc. can be added to organic fertilizers to enhance their functionality.

Meeting specific application requirements: Some specific agricultural applications may require granular fertilizers of specific sizes or shapes, and the granulator can be adjusted according to these requirements.

The role of fertilizer granulator in organic fertilizer production line is not limited to changes in physical form, but also includes improvement of fertilizer performance and expansion of fertilizer function. It is an indispensable key equipment in the organic fertilizer production process.

Process flow of organic fertilizer production line for manure treatment in livestock and poultry farms

In livestock and poultry farms, manure treatment is a crucial step, and the production of organic fertilizer is one of the important methods for converting these manure into valuable resources. The process flow is mainly divided into four steps: collection, separation, composting, and fermentation.

The first stage is the collection phase, where livestock and poultry manure is effectively collected and preliminarily separated. It is possible to separate livestock and poultry manure from urine through a centralized collection and separation system to reduce the generation of ammonia and odor, and improve subsequent treatment efficiency.

Then comes the composting stage, where the separated animal manure is sealed and stored, and organic waste is properly organized and stacked, supplemented by ventilation equipment to control temperature, humidity, and oxygen supply, accelerating the decomposition process of organic matter. During this process, it is important to maintain appropriate humidity and ventilation to avoid the generation of odors and harmful gases.

Finally, in the fermentation stage, after the completion of composting, the compost is subjected to secondary composting fermentation to further enhance the stability and efficiency of the fertilizer. This process requires attention to reasonable moisture control and temperature regulation to ensure the full decomposition of organic matter and the killing of harmful microorganisms.

Organic fertilizer provides organic matter to the soil, thereby providing the necessary nutrients for plants and helping to establish a healthy soil system, rather than destroying it. Therefore, organic fertilizers contain huge business opportunities, and with the gradual restrictions and prohibitions on the use of fertilizers by most countries and relevant departments, the production of organic fertilizers will become a huge business opportunity.

Most organic raw materials can be fermented into organic compost. In fact, after crushing and screening, organic fertilizer compost becomes high-quality and saleable powdered organic fertilizer.

Whether building an organic fertilizer production line, an npk fertilizer production line or a bio-organic fertilizer production line, the following suggestions are worth a look.

1. Precautions for administrative handling of factory construction.

First, the feasibility study and demonstration of ecological organic fertilizer enterprises

Prepare a feasibility study report for an organic fertilizer production enterprise and submit it to the local Bureau of Industry and Information Technology (the Industrial Information Committee for project approval)

2, environmental pollution assessment.

Find companies with environmental qualifications to conduct environmental pollution assessments. Submit to the local Development and Reform Commission for formal project approval.

3, apply for an industrial and commercial business license

To set up a company, the business scope must include “organic fertilizer”, “bio-organic fertilizer”, “organic and inorganic compound fertilizer”, “microbial fertilizer” and other formal fertilizer names. After obtaining the business license, it is necessary to complete all the procedures required by the company, including tax registration, company code determination, and company account processing.

4, planning and construction of organic fertilizer factories

Contact the organic fertilizer production equipment enterprise, and with the assistance of the manufacturer, the construction should be carried out reasonably with the permission of the local land planning department. Arrange the relevant equipment reasonably, wait for the acceptance of the provincial and municipal agricultural departments, and prepare for the relevant production registration procedures.

5, buy organic fertilizer production equipment.

Look for a powerful organic fertilizer manufacturer, pay attention to product quality, after-sales service and other factors, and purchase equipment and put it into production. The main equipment of the organic fertilizer granulation production line includes: automatic batching system, disc mixer, double roller granulator, dryer, chain pulverizer, trommel screen, coating machine, packaging scale, cyclone dust collector, conveyor.

6, apply for organic fertilizer trademark

A company that intends to develop for a long time must apply for its own trademark and make its own brand. The normal operation of the enterprise and the application for national registration procedures.

The roller squeezing granulator is an efficient granulation equipment, mainly composed of the following key components:

Pressure roller: The main component of a roll extrusion granulator, usually composed of two relatively rotating pressure rollers, with specific groove designs on the surface of the pressure rollers, used for extrusion molding of materials.

Feeding device: responsible for evenly feeding raw materials between pressure rollers to ensure continuous and stable feeding.

Transmission system: including motor, reducer, coupling, etc., used to drive the rotation of the pressure roller.

Adjustment mechanism: used to adjust the gap between the pressure rollers to control the size and shape of particles.

Cutting device: located behind the pressure roller, used to cut the extruded strip material into particles of the required length. It can be a fixed blade or a rotating blade.

Drying system: Newly formed wet particles need to be reduced in moisture content through the drying system, usually including a dryer and heat source equipment.

Screening and grading device: used to separate particles that meet the standards and unqualified particles that require rework.

Cooling system: The dried particles need to be cooled to ensure their stability during storage and transportation.

Packaging system: including automatic weighing and packaging equipment, used to package finished granular fertilizers.

Control system: Modern roller extrusion granulators are usually equipped with PLC or microcomputer control systems to achieve automatic control of the entire granulation process.

Support and framework: The supporting structure of the entire machine ensures its stability and durability.

Dust removal system: Dust may be generated during the granulation process, and the dust removal system is used to collect dust and reduce environmental pollution.

Lubrication system: Ensure lubrication of pressure rollers and other moving parts, reduce wear, and extend equipment life.

Safety protection devices, such as emergency stop buttons, protective covers, etc., ensure the safety of operators.

The collaborative work of these components of the roller extrusion granulator ensures the efficiency and stability of the granulation process. According to different production needs, the specific configuration of roller extrusion granulators may vary, but the above listed are the basic components common to most roller extrusion granulators.

In general, organic fertilizer mainly includes granular and powder fertilizers, pure organic fertilizers, bio organic fertilizers, and organic-inorganic compound fertilizers. The organic fertilizer production line is a complete set of equipment and processes for fertilizer production, including manure maturation and fermentation, raw material mixing, particle processing, drying, packaging, etc. It includes all equipment for producing organic fertilizer using animal manure as raw material, adding wood chips, mushroom residue, sugarcane bagasse and other accessories for stacking fermentation.

The organic fertilizer production line includes fermentation equipment, granulation equipment, crushing equipment, stirring equipment, screening equipment, cooling equipment, drying equipment, coating equipment, automatic packaging equipment and other process flows.

Introduction to the technology scheme and process for producing organic fertilizer from livestock and poultry manure:

The main method is to ferment and decompose the organic matter mixture, add trace elements such as nitrogen, phosphorus, and potassium according to the formula requirements, crush them, and stir them in a mixer. After thorough stirring, the material is granulated, dried, cooled, and screened, and the finished particles are sent to the finished product silo. The packaged organic fertilizer is made into brown or grayish brown granular form, without mechanical impurities and odor.

1. Disc granulation production line

The disc granulation production line has a high granulation rate, low maintenance rate, smooth operation, sturdy and durable equipment, long service life, and low investment, making it the equipment of choice for many users.

2. Stock conversion and granulation production line

Large production capacity, low maintenance rate, and low energy consumption. We can design organic fertilizer production line equipment with a production capacity of 1-3 million tons according to customer requirements and provide a complete set of organic fertilizer production equipment.

3. Roller granulation production line

Easy to operate, low technical requirements, relatively simple process flow, low investment, strong adaptability to environmental conditions, stable operation, and low noise.

4. BB fertilizer production line

The BB fertilizer production line is designed and manufactured according to the requirements of compound fertilizer factories and fertilizer distributors, with a production capacity of 1-20000 tons. It adopts the process of directly feeding into the lifting tank and discharging from the mixer.

The raw material route of extrusion granulation to produce compound fertilizer is relatively wide, which can be used in npk compound fertilizer production line and npk production line. At present, there are more than 20 kinds of materials that have been successfully used in extrusion granulation: nitrate in nitrogen fertilizer Ammonium, urea, ammonium chloride, calcium nitrate, etc. Phosphate fertilizers include ammonium phosphate, common calcium, heavy calcium, phosphate rock powder, etc. Potash fertilizers include potassium chloride, potassium sulfate, etc., and trace elements such as boron, iron, copper, etc. can be added. Zinc, manganese, etc. Extrusion granulation has no special requirements on the particle size of raw materials. Both 1-4mm granular materials and fine powder materials can be used. Powder materials and powder products with unqualified particle size are better to use. Can reduce costs.

The main equipment included in the double roller granulator production line: automatic batching system, roll extrusion granulator, disc mixer, trommel screening machine, belt conveyor, packaging scale, etc.

Extrusion granulation production process:

1. storage, metering

Mixed fertilizer raw materials such as urea, ammonium phosphate, potassium chloride, etc. are transported to the storage silo by bucket elevator and belt. The number of storage bins, the complexity of metering and mixing techniques, is related to the number of components in the product formulation.

2. extrusion

The mixed fertilizer mixture is extruded by a roller extruder, the principle of which is to shape the material by extrusion. The mixed material is fed into the gap between the two oppositely rotating roller shafts through a vertical screw feeder. During the extrusion process, the pressure of the material gradually increases. When the gap between the two shafts is small, The material is relatively compressed, and then gradually decreases until it reaches 0.

3. Crushing and grading

The slabs formed in the double roller granulator  are further broken up and classified to the desired particle size.

4. Polishing and finishing

Typically, the final product undergoes one or two steps of polishing.

The roller squeezing granulator is a commonly used fertilizer granulation equipment, especially suitable for the granulation production of organic and compound fertilizers. The following is a brief introduction to the working principle and granulation process of the roller extrusion granulator:

operational principle

Extrusion molding: The core part of the roller extrusion granulator is composed of a pair of relatively rotating pressure rollers, which have grooves on the surface. When the material is fed between the two rollers, it is compressed to form a strip shape.

Shear cutting: After the extruded strip material passes through the pressure roller, it is usually cut by a fixed or rotating tool to form the required length of particles.

Adjustment control: By adjusting the gap and speed between the pressure rollers, the size and shape of the particles can be controlled.

Granulation process

Raw material preparation: Firstly, suitable raw materials need to be prepared, such as powder of organic fertilizers or mixtures of compound fertilizers.

Moisturizing and mixing: In order to improve the granulation efficiency, the raw materials usually need to be moistened and mixed with an appropriate amount of water and binder to improve their plasticity.

Conveying and feeding: The mixed materials are uniformly fed into the feeding area of the roller squeezing granulator through conveying equipment.

Squeezing: The material is compressed into strips under the high pressure of the pressure roller, and excess water is squeezed out.

Cutting: The extruded strip material is cut or cut into particles of the desired length.

Drying: Newly formed wet particles contain high moisture and require drying treatment through drying equipment to reduce moisture content, improve particle hardness and stability.

Screening and grading: The dried particles are screened through screening equipment to remove particles that do not meet the requirements and ensure product quality.

Cooling: The screened particles usually require further cooling to ensure their stability during storage and transportation.

Packaging: Finally, the qualified granular fertilizer is automatically weighed and packaged before leaving the factory.

The roller extrusion granulator has been widely used in the field of fertilizer granulation due to its advantages of high efficiency, energy saving, and strong adaptability. By optimizing process parameters and equipment maintenance, the production efficiency and product quality of fertilizer particles can be effectively improved.

Powdered organic fertilizer is commonly used to improve soil and provide the nutritional value components required for crop growth. When they enter the soil, they can also be quickly decomposed and release nutrients quickly. Due to the slower absorption rate of powdered solid organic fertilizers, powdered organic fertilizers have a longer storage time than liquid organic fertilizers. The use of organic fertilizers greatly reduces damage to plants themselves and soil environment.

The process flow of producing organic fertilizer from livestock and poultry manure:

1. Raw material ratio: Various animal feces such as chicken manure, pig manure, cow manure, biogas residue, or fermentable and fertilizer effective raw materials are prepared in a certain proportion;

2. Raw material mixing: Mix the prepared raw materials evenly to improve the overall uniform fertilizer efficiency of the fertilizer particles;

3. Raw material granulation: The evenly mixed raw materials are fed into a fertilizer granulator for granulation;

4. Particle drying: Feed the particles made by the granulator into the fertilizer dryer to dry the moisture inside the particles, increase their strength, and facilitate storage;

5. Particle cooling: The temperature of the dried fertilizer particles is too high, making them prone to clumping. After cooling, they are easy to pack, store, and transport;

6. Particle classification: The cooled particles are classified, and the unqualified particles are crushed and re granulated to screen out the qualified products;

7. Finished product coating: Coating qualified products to increase the brightness and roundness of particles;

8. Finished product packaging: Bag the finished product particles and store them in a ventilated place.

The above are the process steps of the organic fertilizer production line for the treatment of livestock and poultry manure. Of course, the specific operation also involves different processes and equipment choices, which need to be adjusted according to the specific site and actual situation. Because the production capacity requirements of each project, the ground processing site, and the configuration of the entire set of organic fertilizer production equipment are not fixed, there are often many different situations, so the specific price depends on the situation. You need to consider factors such as equipment power, production capacity, automation level, and additional functions. For some special equipment or high-end large-scale production lines, the price may be higher. It is recommended that you conduct market research and communicate with multiple suppliers before making a purchase to ensure that you can obtain the most suitable production line for your needs and budget.

Common organic fertilizer granulators include: double roller granulator, stock granulator, disc granulator, new organic fertilizer granulator, etc. The disc granulator is widely used and can be used for npk fertilizer production line , organic fertilizer production, bio-organic fertilizer production line, etc. Today, let’s understand the working principle of the disc granulator.

The organic fertilizer disc granulator machine is a new type of inclined granulation equipment. The granulation rate of this disc granulator machine  is about 90%. The reducer and motor in the machine are transmitted by a flexible belt, which makes the disc granulator start smoothly, slows down the impact force, and improves the service life of our equipment. The bottom of the granulator disc is reinforced with a variety of radiant steel plates, which are firm and durable and not easy to deform. This thickened and heavier base design is relatively firm, does not require anchor bolts to fix, and is relatively stable. When the disc granulator is running, the granulation is uniform and the spheroidization rate is high. Not only does it run smoothly, but the device is sturdy and durable.

How does the organic fertilizer disc granulator machine work? First, the main motor drives the pulley and belt. The pinion gear is driven by the reducer, and the pinion gear is engaged with the large gear fixed on the ground. The large gear is installed on the main shaft on the frame adjustment disc through a special and reasonable design to support the work of the entire granulation disc. After the material enters the granulation disc, the disc granulation equipment continuously rotates the spray device to make the material evenly bonded to form round spherical particles. The upper part of the disc granulation equipment is designed with an automatic cleaning device, which prevents the material from sticking to the wall and improves the service life of the machine. The motor continuously rotates and the material enters continuously, which can not only realize mass production, but also easily meet the needs of continuous work.

The organic fertilizer tank type flipper is a device used for treating and fermenting organic waste. It improves the ventilation conditions of compost and accelerates the fermentation process through flipping action. The slot type tipping machine is particularly suitable for large-scale composting operations, especially in organic fertilizer production lines. The following are some advantages of the slot type flipper for fermenting raw materials:

1. Improve fermentation efficiency: The trough type flipper increases the ventilation of the compost by flipping it, providing sufficient oxygen for microorganisms and accelerating the decomposition rate of organic matter.

2. Uniform fermentation: The flipping machine can mix fresh materials in the compost with already fermented materials, ensuring a uniform fermentation process throughout the entire compost pile.

3. Reduce odor: Due to the fact that the flipping machine can accelerate the decomposition of organic matter, it reduces the production of ammonia and other odor gases, thereby reducing the odor problem during the composting process.

4. Space saving: The slot type tipping machine usually works in a fixed fermentation tank, which saves space and is easy to manage and control.

5. Reduce manpower: The automated flipping process reduces reliance on manpower, lowers labor intensity and production costs.

6. Improve product quality: Through the uniform flipping of the slot flipping machine, more consistent quality organic fertilizers can be produced.

7. Easy to control: The operation of the slot flipping machine is usually relatively simple, making it easy to control the frequency and depth of flipping, and can be adjusted according to the needs of fermentation.

8. Strong adaptability: The flipping machine can handle various organic waste, such as livestock and poultry manure, crop residues, food processing waste, etc., with strong adaptability.

9. Improving soil structure: Fermented organic fertilizers help improve the physical structure of the soil, increase the organic matter content of the soil, and enhance the soil’s water and fertilizer retention capacity.

10. Environmental protection: The use of slot type tipping machines helps to convert organic waste into valuable fertilizers, reducing waste disposal issues and making it an environmentally friendly treatment method.

11. Improve compost maturity: Through the uniform flipping of the flipper, the organic matter in the compost can be more fully decomposed, producing more mature compost.

12. Reduce pathogens and weed seeds: During the high-temperature fermentation process, the flipper helps maintain the high-temperature state of the compost, thereby killing pathogens and weed seeds, ensuring the safe use of organic fertilizers.

The slot flipper is an important part of the organic fertilizer production line. Through its efficient fermentation treatment, it can produce high-quality organic fertilizers and provide support for agricultural production.