organic fertilizer manufacturing process – organic fertilizer production line

Organic fertilizer production lines improve efficiency through continuous operation, but improper integration of various stages can easily lead to problems, impacting production stability and product quality.

The raw material pretreatment stage is prone to conveyor blockage. If raw materials such as straw and manure are not crushed to a particle size of 5-10mm or have a moisture content exceeding 65%, they can easily form lumps in belt conveyors and screw feeders, causing production line downtime. Screener machines should be added to the pretreatment stage to control the particle size. At the same time, the moisture content should be adjusted to 55%-60% through drying or the addition of dry materials to ensure smooth material conveyance.

Uneven compost turning and insufficient oxygen supply are common problems in fermentation systems. If the chain compost turning machine rotates too fast or has an inappropriate stroke setting, the compost will not be turned thoroughly, resulting in local temperatures below 55°C and failure to achieve the desired compost maturity. Insufficient fan pressure can cause oxygen deprivation in the compost, producing harmful gases such as hydrogen sulfide. To address this, adjust the compost turner speed according to the pile height (2-3 rpm is recommended). Regularly check the fan filter to ensure a ventilation rate of 0.3-0.5 m³/min per cubic meter of pile.

The drying process is prone to moisture control imbalances. If the feed rate to the drum fertilizer dryer fluctuates, or if the hot air temperature fluctuates by more than ±5°C, the finished product moisture content will fluctuate (the acceptable standard is 15%-20%), impacting subsequent granulation. Install an automatic feed regulating valve to stabilize the feed rate, employ a temperature control system to precisely control the hot air temperature at 80-100°C, and install a moisture detector at the discharge end for real-time monitoring.

Inaccurate metering and loose sealing are common problems in the packaging process. Aging load cells in quantitative packaging machines can lead to bag weight errors exceeding ±2%. Low temperatures or insufficient pressure in heat sealers can cause cracking in the bag seals and moisture absorption and caking of the finished product. The load cell must be calibrated monthly, the heat sealing temperature must be adjusted to 150-180°C, and the pressure must be controlled at 0.3-0.5 MPa to ensure packaging quality.

Addressing issues in all aspects of the organic fertilizer production line requires strengthening equipment maintenance and process control to achieve continuous and stable production and guarantee the quality of organic fertilizer.

Organic fertilizer production is an ecological cycle of “turning waste into treasure.” Organic fertilizer production lines transform agricultural waste into nutrients that nourish the soil, and the entire process is guided by a green and environmentally friendly philosophy.

The first step in production is the collection and mixing of raw materials. Common raw materials include plant residues such as crop straw, rice husks, and peanut shells, as well as livestock manure such as chicken, cow, and sheep manure. These raw materials must be strategically combined to achieve a carbon-to-nitrogen ratio of approximately 30:1, for example, a straw-to-manure ratio of approximately 3:1. A small amount of wood ash is added to adjust the pH and create a suitable environment for microbial activity.

Next, the fermentation and composting stage begins, the core of organic fertilizer production. The mixed raw materials are transferred to a fermentation silo where they are regularly stirred by a turning device to maintain a temperature of 55-65°C. This temperature not only kills pathogens, insect eggs, and weed seeds, but also stimulates microbial activity. After 20-30 days of composting, the raw materials will gradually darken and soften, emitting a faint earthy odor, indicating that the organic matter has been fully decomposed.

The composted material needs to be refined. First, it is crushed into a fine powder by a crusher to remove impurities and large particles. Then it enters the granulation stage, where a granulator is used to make the powder into granules with a diameter of 2-5 mm for easy storage and application. Finally, it is screened by a screening device to separate the qualified granules, and the unqualified crushed materials are returned for reprocessing.

The finished product also undergoes quality inspection, testing for organic matter content, pH, and heavy metal content to ensure compliance with national standards. Qualified organic fertilizer granules are uniform, have a moderate moisture content (approximately 20%), and slowly release trace elements such as nitrogen, phosphorus, potassium, and calcium and magnesium.

The entire production process utilizes agricultural waste as a resource, addressing environmental pollution while replenishing natural nutrients to the soil. This “take from the field, return to the field” model is the key to the sustainable development of organic agriculture.

Tag: organic fertilizer manufacturing process

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