Tag: organic fertilizer making machine

organic fertilizer equipment

Benefits of Using a Flat Die Granulator in an Organic Fertilizer Production Line

by organic fertilizer production line

In organic fertilizer production, the granulator is a core piece of equipment that determines product quality and production efficiency. The flat die granulator, with its unique design, is the preferred equipment for organic fertilizer production lines. Its advantages are primarily reflected in five key areas.

First, it offers excellent adaptability to raw materials. Organic fertilizer raw materials are complex, with common materials like livestock and poultry manure, straw, and mushroom residue exhibiting widely varying moisture and fiber content. By adjusting the pressure of the rollers and the speed of the die, the flat die granulator can easily process raw materials with a moisture content of 15%-30%. This eliminates the need for over-drying or the addition of large amounts of binders, preserving the beneficial microorganisms in the raw materials while reducing pretreatment costs. This makes it particularly suitable for the diverse raw material production needs of small and medium-sized organic fertilizer plants.

Second, the granulation quality is stable and controllable. The flat die granulator utilizes a “fixed die plate, rotating pressure roller” extrusion granulation method, achieving a pellet forming rate exceeding 95%. Pellet diameter can be flexibly adjusted (typically between 2 and 12 mm) by replacing dies with different apertures, meeting the pellet specification requirements for various applications, such as seedling fertilizer and field fertilizer. The pellets have a moderate hardness and are resistant to breakage, making them easy to package, transport, and spread in the field, effectively enhancing the product’s market competitiveness.

Furthermore, they offer low energy consumption and operating costs. Compared to ring die granulators, flat die pelletizers utilize a lower motor power, reducing power consumption by 20%-30% at the same production capacity. Furthermore, their consumable parts (such as the pressure roller and die) are made of wear-resistant alloy, offering a service life of over 3,000 hours. Replacement frequency is low, and the cost of spare parts is only half that of ring die pelletizers, significantly reducing production line operating expenses over the long term.

Furthermore, they are easy to operate and maintain. The flat die granulator boasts a simple and compact structure, a small footprint, and a quick installation and commissioning cycle. Operators can easily master the machine after minimal training. Routine maintenance requires only the regular addition of lubricating oil and cleaning of residual material from the die holes, eliminating the need for complex technical expertise. This significantly reduces labor costs and is particularly suitable for small and medium-sized manufacturers facing a shortage of skilled personnel.

Overall, the flat die granulator, with its high adaptability, cost-effectiveness, and ease of operation, is an ideal choice for improving efficiency, reducing costs, and ensuring quality in organic fertilizer production lines. It provides strong support for the development of small and medium-sized organic fertilizer manufacturers.

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Practical Methods for Improving the Granulation Yield of Flat Die Granulators

by organic fertilizer production line

In organic fertilizer production lines, flat die granulators typically process materials such as livestock and poultry manure and composted straw. These materials contain coarse fiber and experience large moisture fluctuations, which can easily lead to low granulation yields and loose pellets. To improve granulation efficiency, precise optimization in four key areas is necessary, taking into account the characteristics of the organic fertilizer material.

Raw material pretreatment must be tailored to the characteristics of the organic fertilizer. First, the moisture content should be controlled between 25% and 30%, which is the optimal range for organic fertilizer granulation. A moisture content too low can easily result in broken pellets, while a moisture content too high can cause die sticking and clogging. This can be adjusted by airing the material or adding dry straw powder. Secondly, the composted material should be pulverized to ensure that the coarse fiber particle size does not exceed 1/2 the die hole diameter to prevent fibers from wrapping around the die rollers and causing uneven extrusion. Uncomposted lumps should also be removed to prevent clogging. Additionally, 2% to 3% bentonite can be added as a binder to enhance pellet density without affecting the fertilizer’s efficiency.

Equipment adjustments require targeted optimization. Organic fertilizer materials have poor fluidity, so the die roller gap should be adjusted to 0.2-0.4mm, slightly wider than the standard setting, to prevent material from getting stuck. The roller speed should be reduced to 15-20r/min to allow ample time for the coarse fibers to be extruded and formed. For die orifice selection, a tapered die with a diameter of 4-8mm is preferred to reduce material resistance within the die and minimize the likelihood of blockage. Regularly clean the die orifice with a steel brush to remove residual fiber impurities.

Process operations should be tailored to the production scenario. High-temperature preheating is not required before startup. Simply use a small amount of wet material to “prime” the die, forming a thin layer of material on the inner wall of the die orifice to prevent subsequent material from sticking to the wall. Use a spiral feeder with a constant speed to avoid concentrated lumps of material and prevent equipment overload. If fibers are found on the surface of the pellets and they are prone to breakage during production, add binder or adjust the moisture content promptly.

Maintenance should focus on vulnerable areas. Organic fertilizer materials contain corrosive components. The die roller surface should be cleaned weekly, and residual humus should be removed with a wire brush to prevent corrosion. The inner wall of the die hole should be inspected monthly, and burrs caused by coarse fiber wear should be removed with fine sandpaper. The transmission system lubricant should be replaced quarterly, using a corrosion-resistant, specialized oil to prevent component wear caused by humus contamination.

By optimizing these measures for organic fertilizer production lines, the flat die granulator’s pelletizing rate can be increased to over 90%, reducing waste of mature raw materials while ensuring uniform organic fertilizer pellets and ensuring stable and efficient production line operation.

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

The new type two-in-one organic fertilizer granulator’s complete operating process.

by organic fertilizer production line

The new type two-in-one organic fertilizer granulator features an integrated “mixing + granulation” design, simplifying organic fertilizer production. Its operations are centered around four core steps, ensuring pellet quality and efficiently supporting the organic fertilizer production line.

The first step is raw material pretreatment. Fermented organic fertilizer (such as livestock manure and composted straw) must first be crushed to a 40-60 mesh fine powder with a moisture content of 25%-35%. Excessively coarse raw materials will result in uneven granulation, while inappropriate moisture content will affect the final product. Meeting pretreatment standards is essential for stable equipment operation.

The second step is the core mixing process. Pretreated raw materials enter the integrated mixing system. A high-strength alloy steel agitator shaft drives the wear-resistant blades, while a variable frequency motor precisely controls the speed between 20-60 rpm. If binders such as bentonite are required, they are added simultaneously. The blades shear and stir the powder, achieving over 90% mixing uniformity within 5-10 minutes, preventing uneven nutrient distribution in the pellets.

The third step is targeted granulation. The mixed material automatically enters the granulation system, where the equipment changes its forming method based on the raw material’s characteristics. Highly viscous raw materials (such as chicken manure organic fertilizer) use a stirring granulation mechanism, where paddles knead the material into 2-4mm pellets. High-fiber raw materials (such as straw organic fertilizer) use a roller-type granulation mechanism, where die extrusion forms the pellets. The stainless steel disc can be hydraulically adjusted from a 30° to 50° tilt angle, and a wear-resistant rubber lining reduces sticking to the wall. The pellet formation rate exceeds 90%, and the pellets are uniformly shaped.

Finally, the screen residue is recycled and connected. After granulation, the pellets pass through an integrated screening device. Qualified pellets enter the drying stage (dried to a moisture content of less than 10%), while substandard fines are returned to the mixing system through a recirculation channel for processing with new raw materials. This design achieves a raw material utilization rate exceeding 95%, reducing waste and ensuring continuous production.

The entire process eliminates the need for frequent manual handling. The new type two-in-one organic fertilizer granulator can complete the entire process from raw material input to qualified pellet output, significantly improving the efficiency and convenience of organic fertilizer production.

organic fertilizer equipment

Advantages of Rotary Drum Granulators over Disc Granulators

by organic fertilizer production line

When selecting organic fertilizer granulation equipment, both rotary drum and disc granulators are commonly used. However, rotary drum granulators, with their multi-dimensional performance advantages, better meet the efficiency and scale requirements of modern organic fertilizer production lines. The differences between the two are primarily reflected in the following four aspects.

More flexible capacity adaptability meets the needs of large-scale production. Disc granulators are limited by the diameter of their discs, typically with an hourly output of 0.5-5 tons per unit, making them suitable only for small production lines. By adjusting the drum length and diameter, rotary drum granulators can achieve hourly outputs of 1-20 tons per unit. They meet the basic production needs of small and medium-sized enterprises as well as the large-scale production of large factories. They eliminate the need for multiple units in parallel, reducing production line floor space and equipment investment costs.

They offer greater raw material compatibility and reduce pretreatment complexity. Organic fertilizer raw materials have large fluctuations in moisture and composition. Disc granulators must maintain a moisture content of 20%-30%. They also struggle with crude fiber materials, which tend to stick to the disc and produce uneven granules. Rotary drum granulators can process materials with moisture levels of 25%-40%. Leveraging the multi-directional force of the rotating drum, they can smoothly granulate composted straw, livestock manure, and other materials without the need for additional crushing or conditioning, streamlining the process.

The resulting product is more stable and meets standardized requirements. Due to the single direction of centrifugal force, disc granulators produce pellets with a roundness of 70%-80% and large particle size variations. Rotary drum granulators, on the other hand, utilize internal rollers to guide and rotate the pellets, resulting in a fully rolling and shaping process with a roundness exceeding 90% and a precisely controlled particle size of 2-5mm. Furthermore, the granulation process is gentle, does not damage organic matter, and the pellets are of moderate strength. Transportation losses are 15%-20% lower than those from disc granulators.

Operation and maintenance are also simplified, resulting in lower long-term costs. Disc granulators require frequent manual adjustments of inclination and speed, resulting in wear and tear on the disc edges and requiring frequent replacement. Rotary drum granulators, on the other hand, utilize automated control to precisely adjust speed and feed rate, eliminating the need for manual oversight. The drum is constructed of wear-resistant stainless steel, resulting in a 40% lower failure rate and over 30% lower maintenance costs, resulting in superior long-term economics.

In summary, the advantages of the rotary drum granulator in terms of production capacity, raw material compatibility, finished product quality, and cost control make it ideally suited to the diverse needs of organic fertilizer production lines, making it an ideal choice for improving efficiency and competitiveness.

organic fertilizer equipment

The Core Reasons to Choose a Rotary Drum Granulator for Organic Fertilizer Production Lines

by organic fertilizer production line

In the granulation stage of organic fertilizer production lines, rotary drum granulators are the preferred equipment for most companies due to their high adaptability to the characteristics of organic fertilizers. Their unique operating principle and performance advantages effectively address key challenges in the granulation process, ensuring product quality and production efficiency.

In terms of granulation adaptability, rotary drum granulators perfectly match the characteristics of organic fertilizer raw materials. Organic fertilizer raw materials, mostly livestock and poultry manure and composted straw, have complex compositions and contain a large amount of fiber. The rotary drum granulator uses the centrifugal force, extrusion force, and friction generated by the rotating drum to granulate loose raw materials without excessive compression, thus preventing the destruction of organic matter and functional microbial activity in the raw materials due to strong compression. The rotary drum granulator also adapts to fluctuations in raw material moisture content (it can handle raw materials with a moisture content of 25%-40%), reducing the tedious pre-treatment process.

The advantages in granulation efficiency and finished product quality are significant. The drum length and diameter of the rotary drum granulator can be flexibly designed to meet production capacity requirements. A single unit can achieve an output of 1-20 tons/hour, meeting the needs of production lines of varying sizes. Its granulation process is gentle and uniform, resulting in highly rounded granules (over 90% roundness). The particle size can be controlled between 2-5mm by adjusting the drum speed and the baffle, meeting standard requirements for organic fertilizer granules. The granules also possess moderate strength, preventing breakage during transportation while slowly disintegrating in the soil, enhancing nutrient release efficiency.

From a cost and environmental perspective, the rotary drum granulator is also competitive. Its simple structure, minimal transmission components, and low failure rate mean ongoing maintenance costs are approximately 30% lower than those of other granulation equipment (such as disc granulators and extrusion granulators). Furthermore, the granulation process does not require the addition of large amounts of binders; granulation is achieved solely through the raw material’s inherent viscosity. This reduces raw material costs while preventing the impact of foreign matter on the purity of the organic fertilizer, aligning with green production principles.

The comprehensive advantages of the rotary drum granulator in adaptability, efficiency, cost and environmental protection make it an ideal choice for the granulation link of the organic fertilizer production line, providing strong support for enterprises to achieve high-quality and high-efficiency production.

organic fertilizer equipment

New Type Organic Fertilizer Granulator: High-Efficiency Equipment Empowering Multi-Sector Production

by organic fertilizer production line

In response to the need for industrial upgrading, the new type organic fertilizer granulator (models YSL-60 to YSL-150) was developed by the Agricultural Machinery Research Institute. Leveraging its accumulated experience in compound fertilizer processing and its unique mixing and granulation method, it has become a practical device for granule production in various fields.

In terms of core technology, the new type organic fertilizer granulator utilizes high-speed rotating stirring teeth to stir, impact, and tumble the mixed material within the granulation drum. Friction, centrifugal force, and the material’s viscosity aggregate the material into granules, eliminating the need for complex extrusion equipment and making it suitable for high-viscosity or fibrous materials. Performance parameters include a production capacity of 1-8 tons/hour, motor power of 37-90 kW, and granule diameter of 1-5 mm. The YSL-60 produces 1-2 tons per hour, making it suitable for small and medium-sized operations; the YSL-150 produces 5-8 tons per hour, making it suitable for large-scale production.

It has a wide range of applications. In the fertilizer sector, livestock and poultry manure, straw, and other materials can be transformed into organic, bio-organic, and compound microbial fertilizers, eliminating caking issues while preserving bacterial activity and producing medium and trace element fertilizers. In the chemical industry, it can be used to granulate sticky raw materials; in the pharmaceutical industry, it can process traditional Chinese medicine granules; and in the feed industry, it can produce livestock and aquatic feed, achieving a “one machine for multiple uses.”

The core advantages are significant. Granulated particles are round and uniform, with good flowability, and are less prone to clumping during storage and transportation. Operation is simple, requiring only training. The low motor power and operating costs make the equipment affordable, making it suitable for small and medium-sized enterprises. Furthermore, it preserves fertilizer activity, extending its shelf life to 8-12 months, promoting the recycling of organic waste and achieving both economic and environmental benefits.

Daily maintenance requires three key points: regular inspections: daily inspection of the feed mechanism and transmission system; weekly inspection of agitator tooth wear; monthly bolt tightening and motor temperature monitoring; cleaning the granulation drum after production; lubricating transmission components according to specifications, and timely replacement of worn parts to ensure stable equipment operation.

This new type organic fertilizer granulator, with its multiple advantages in technology, performance and application, is providing strong support for production upgrades in agriculture, chemical industry, medicine, feed and other fields.

organic fertilizer equipment

The Secrets of the Double Roller Press Granulator in an Organic Fertilizer Production Line

by organic fertilizer production line

In the granulation process of an organic fertilizer production line, the double roller press granulator, due to its high efficiency and environmentally friendly features, is a core piece of equipment. It uses the principle of physical extrusion to transform loose organic fertilizer raw materials into uniform granules, meeting the needs of fertilizer storage, transportation, and application. Its operation process can be divided into three stages: raw material pretreatment, extrusion molding, and granulation.

Raw material pretreatment is the foundation of granulation. Fermented and crushed organic fertilizer raw materials first enter the batching system, where they are mixed with auxiliary materials in a controlled ratio to achieve a moisture content of 20%-30% and a particle size uniformity of over 80%. The raw materials are then conveyed to the feed inlet of the double-roller extrusion granulator, where they are pushed at a constant speed between two counter-rotating extrusion rollers by a screw feeder. The feeder speed can be adjusted according to the raw material characteristics to ensure a stable feed rate and avoid overloading the equipment due to excessive raw materials or affecting granulation efficiency due to insufficient raw materials.

Extrusion molding is the core step. The surfaces of the two rollers of a double-roller extrusion granulator are equipped with evenly distributed depressions of the same shape. Common shapes include circular and oval. A motor drives the rollers in counter-rotating motion through a reduction gear, generating a strong extrusion force between the rollers, compressing the raw material into the depressions. Under this pressure, the organic particles in the raw material are tightly bound together, forming lumps that conform to the shape of the depressions. This process requires no binder, relying entirely on the raw material’s inherent viscosity and extrusion force to form the product. This reduces costs while ensuring the natural properties of the organic fertilizer. The extrusion force can be adjusted to the desired granule hardness, typically within a range of 15-30 MPa.

The final stage is granulation. After the lumps fall through the gap between the rollers, they enter the crushing and screening system. The crusher breaks down the lumps, and the screen separates the organic fertilizer granules into acceptable particle sizes (generally 2-8 mm). Unacceptable large lumps or fines are returned to the raw material system for recycling, increasing raw material utilization to over 95%.

The double roller press granulator plays a key role in the organic fertilizer production line with its advantages of continuous operation, low energy consumption and high particle strength, and provides equipment support for promoting the development of green agriculture.

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How does a rotary drum granulator work in an organic fertilizer production line?

by organic fertilizer production line

In an organic fertilizer production line, a rotary drum granulator is the core equipment for converting powder into granules. Its operating principles revolve around material agglomeration and granulation. Through a combination of physical and mechanical processes, it transforms fermented organic raw materials into granular products that are easy to store, transport, and apply.

After the equipment is started, fermented and pulverized organic materials (such as decomposed cow dung and straw powder) are introduced into the inclined drum of the rotary drum granulator along with an appropriate amount of binder (usually water or starch solution). The drum rotates at a constant speed of 10-15 revolutions per minute. Lifting plates on the inner wall of the drum continuously scoop up and drop the material, creating continuous agitation and mixing. During this process, the binder moistens the surface of the raw material particles, forming a sticky interface and paving the way for particle agglomeration.

As the drum rotates continuously, the material gradually forms tiny “master particles” under the combined effects of gravity, centrifugal force, and friction. These masterbatch particles continuously roll within the drum, attracting surrounding powdered raw materials like a snowball, gradually increasing in size. Furthermore, the drum’s tilt angle (typically 3-5°) ensures that the material moves slowly toward the discharge end, preventing accumulation within the drum and ensuring that each particle is evenly stressed and grows.

To ensure pellet quality, the drum granulator also uses a temperature control system to regulate the drum temperature (typically between 40-60°C). This prevents excessive moisture content from causing pellet adhesion, while also preventing low moisture content from affecting agglomeration. When the pellets reach the preset size (typically 2-5mm, controlled by adjusting the drum speed and residence time), they are discharged from the discharge end and enter the subsequent drying and cooling processes.

Compared with other granulation equipment, the advantages of the rotary drum granulator are large processing capacity (a single device can produce 50-200 tons of fertilizer per day), high particle strength (compressive strength can reach 15-30N), and strong adaptability to raw materials. Whether it is poultry and livestock manure, straw or mushroom residue, it can be granulated stably. It is an indispensable key equipment in large and medium-sized organic fertilizer production lines.

organic fertilizer equipment

Structural Design and Analysis of a Rotary Drum Granulator

by organic fertilizer production line

As the core granulation equipment in an organic fertilizer production line, the structural design of a rotary drum granulator directly impacts granulation efficiency and product quality. Its overall design is centered around “efficient granulation, stable conveying, and adaptability to the characteristics of organic fertilizers.”

The rotary drum granulator‘s core working component is an inclined rotating drum, welded from steel plates. The inner wall is lined with a wear-resistant lining to prevent abrasion by humic acid and other components in the organic fertilizer raw materials, while also enhancing material friction to aid granulation. The drive system offers both constant and variable speed options.

The constant speed option is suitable for large-scale production with stable raw materials, while the variable speed option (8-15 rpm) can be adjusted to suit different raw materials: reducing the speed to prevent sticking when the liquid content is high, while increasing the speed to promote compact granules when the liquid content is low.The rotary drum granulator drum inclination angle is a critical parameter, typically 3-10 degrees. A too small angle causes the material to remain in the drum for too long, leading to agglomeration or oversized granules. A too large angle results in rapid material flow, insufficient granulation time, and loose granules. A 50-100mm high retaining ring is installed at the feed end to prevent loose powder from flowing back. The height of the retaining ring at the discharge end is adjustable. It can be raised to extend retention time when larger pellets are needed, and lowered or replaced with a spiral discharge ring for faster discharge. The blade angle matches the rotational speed, ensuring a uniform feed to the screen and preventing clogging.

The integrated cylindrical screen is key to finished product screening. Its aperture is customized to meet organic fertilizer requirements (2-5mm). Rotating synchronously with the drum, qualified pellets are discharged while unqualified, large particles are returned for reprocessing, achieving an integrated “granulation-screening” process. The flexible binder injection system allows for pre-injection, suitable for highly absorbent raw materials such as straw. Instantaneous injection allows for precise moisture control to prevent over-wetting. Both methods are equipped with metering pumps to ensure precise dosage (10%-15% of the total raw material) and guarantee pellet formation efficiency.

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