Tag: Organic Fertilizer Production Equipment

organic fertilizer equipment

Granulation Process and Equipment Advantages of the New Type Organic Fertilizer Granulator

by organic fertilizer production line

The new type organic fertilizer granulator utilizes the mechanical agitation force of high-speed rotation and the resulting air dynamics to continuously mix, granulate, spheroidize, and compact fine powders within the machine, achieving the desired granulation effect.

The resulting granules are spherical with a sphericity ≥0.7, a particle size generally ranging from 0.3 to 3 mm, and a granulation rate ≥80%. Particle size can be adjusted appropriately by adjusting the material mixing ratio and spindle speed. Generally, lower mixing ratios and higher spindle speeds result in smaller particles, and vice versa. This machine is suitable for granulating lightweight, fine powders. The finer the basic particles of the fine powder, the higher the sphericity and the better the particle quality. The particle size before granulation is generally required to be less than 300 mesh.

Typical applications of the new type organic fertilizer granulator include chicken manure, pig manure, cow dung, charcoal, clay, kaolin, and other materials. The new type organic fertilizer granulator boasts uniform granulation and a yield rate exceeding 97%, making it the optimal granulation equipment for organic-inorganic compound fertilizers, organic fertilizers, and bio-organic fertilizers. Due to the coarse fiber properties of the material, rotary granulators have a lower granulation rate, while agitator-type granulators cannot process materials with a nitrogen content exceeding 8% (due to sticking to the wall). This granulator overcomes the shortcomings of both, capable of producing both organic and organic-inorganic compound fertilizers with low energy consumption and high-quality granulation.

The new type organic fertilizer granulator‘s housing is welded from thickened, high-quality carbon steel plates. Ancillary equipment includes pulley assemblies, transmission components, a blower head, and a blower tail. The entire machine is sturdy and durable. The core agitator is precision-cast from a high-chromium alloy and undergoes a special heat treatment, resulting in wear resistance over three times greater than that of ordinary steel. It can withstand the high-frequency friction of fine powders for long periods of time. The main shaft and agitator blades feature a modular design and are fastened with high-strength bolts, enabling easy assembly and simple component replacement, reducing maintenance costs. Adjustable support feet on the bottom of the machine adapt to the flatness of the site, ensuring stable operation and reducing vibration-induced noise and component wear.

organic fertilizer equipment

Cost Analysis of Chicken Manure Fertilizer Processing in an Organic Fertilizer Production Line

by organic fertilizer production line

Chicken manure is indeed a high-quality organic fertilizer raw material, rich in organic matter, nitrogen, phosphorus, potassium, various trace elements, enzymes, and microorganisms. Through standardized aerobic composting processes, it effectively degrades organic matter, kills parasite eggs and pathogens, and renders it harmless and stable. This can then be produced into commercial organic fertilizer through an organic fertilizer production line, creating economic benefits for chicken farms while fundamentally addressing environmental pollution.

However, processing chicken manure into commercial organic fertilizer does involve certain production costs, which can be primarily categorized into the following aspects. First, equipment investment is the core, one-time investment. A complete production line typically includes fermentation and compost turning equipment, a crusher, a mixer, a granulator, a dryer, a cooler, a screener, and an automatic packaging machine. The choice of granulator significantly impacts cost and product form. For example, a rotary drum granulator offers high output, a disc granulator offers a high granulation rate, and a flat die granulator is suitable for organic materials. Different granulator models have varying prices and energy consumption. Secondly, the costs of the pretreatment and fermentation processes cannot be ignored. Fresh chicken manure is sticky and moist, typically with a moisture content exceeding 70%, while the optimal fermentation moisture content needs to be adjusted to 50%-60%. Therefore, a large amount of auxiliary materials (such as straw, sawdust, and mushroom residue) are often required to adjust the moisture and carbon-nitrogen ratios. The procurement, transportation, and crushing of these auxiliary materials all incur ongoing costs.

The initial equipment investment for processing chicken manure in an organic fertilizer production line is relatively high, and ongoing operations also require ongoing investment. The cost level depends largely on the production scale, the degree of automation, the availability and price of raw materials, and the positioning of the final product. For large-scale chicken farms, although the initial investment is high, in the long run, the comprehensive benefits of addressing environmental pressures and creating economic value by turning waste into resources are significant, making the cost acceptable.

organic fertilizer equipment

Factors Affecting the Production of Compound Fertilizers Using a Disc Granulator

by organic fertilizer production line

When producing compound fertilizers using a disc granulator, many factors influence granulation, such as disc diameter, disc speed, disc inclination, nozzle aperture, and moisture content. Generally speaking, disc inclination has a greater impact on the granulation rate, while disc speed has a greater influence on the compressive strength of the granules.

The moisture content of disc granulation significantly influences both the granulation rate and the compressive strength of the granules. When the moisture content of the material is controlled within the range of 16%-20%, the granulation rate and compressive strength of the granules are optimal. Too little moisture results in a low granulation rate; too much moisture causes the material to clump and stick together, resulting in a reduced granulation rate. When the moisture content is too low, the compressive strength of the granules increases with increasing moisture content, which is beneficial for improving the compressive strength of the granules. However, when the moisture content is too high, the excess moisture disrupts the interactions between fertilizer molecules, causing the dried granules to crack and resulting in a decrease in compressive strength. Before using a disc granulator, the optimal moisture content, disc speed, and disc inclination angle should be tested to ensure high fertilizer production line efficiency and high pellet quality. Furthermore, the finer the raw material powder, the better the granulation effect.

Disc granulators are widely used in organic fertilizer production lines and compound fertilizer production lines. Fertilizer production using disc granulators offers low investment, high output, simple process, and intuitive operation, resulting in excellent economic and social benefits.

organic fertilizer equipment

The role of uniform feeder in fertilizer production line

by organic fertilizer production line

In the continuous process of fertilizer production, the uniform feeder is the “nerve center” to ensure the coordinated operation of all links. Whether in compound fertilizer production line or organic fertilizer production line, it can improve the stability of raw material supply by more than 50%, and reduce product quality fluctuations from the source.

The uniform feeder adopts a design combining spiral conveying and frequency conversion speed regulation. The conveying screw is made of wear-resistant alloy material, which can adapt to raw materials with different physical properties such as urea granules, phosphate rock powder, fermented organic fertilizer, etc. The feeding amount can be set with an accuracy of ±2%. It can automatically adjust the conveying speed according to the needs of subsequent crushing, mixing, granulation and other processes to avoid raw material accumulation or feed interruption.

In the compound fertilizer production line, it can accurately convey basic raw materials such as nitrogen, phosphorus, and potassium according to the ratio, so that the nutrient deviation in the mixing link is controlled within 2%, which is much better than 8% of manual feeding. When handling wet organic fertilizer raw materials, its anti-blocking spiral structure combined with the vibration device can effectively avoid material adhesion and blockage, ensuring that the feeding amount per minute is stable at more than 98% of the preset value.

Compared with traditional feeding equipment, the uniform feeder does not require frequent manual adjustment, can reduce 80% of operational intervention, and reduce energy consumption by 30%. The material level sensor equipped with the equipment can monitor the inventory of the silo in real time, automatically start and stop the feeding, and realize unmanned continuous operation.

Whether it is connected to the crushing equipment or the mixer, the uniform feeder can lay a good foundation for the subsequent processes through the stable supply of raw materials. Choosing an appropriate uniform feeder can make the fertilizer production process smoother, the product quality more stable, and demonstrate the core value in large-scale production.

organic fertilizer equipment

Where are flat die granulators used?

by organic fertilizer production line

With its unique extrusion molding principle, flat die granulators have demonstrated strong application potential in a variety of fields, making them an ideal choice for small- and medium-scale production. Their core structure consists of a flat die and a pressure wheel. The rotation of the pressure wheel squeezes the material through the die holes, forming cylindrical pellets. This simple and direct operation gives them wide applicability.

Flat die granulators perform exceptionally well in fertilizer production lines. When processing bio-organic fertilizers, they can directly pelletize wet fermented materials without the need for additional drying pretreatment, preserving the activity of beneficial bacteria while streamlining the production process. For nitrogen, phosphorus, and potassium compound fertilizers, their powerful extrusion capabilities can compress mixed powders into high-strength pellets, effectively eliminating the clumping problem associated with traditional pelleting. They are particularly suitable for producing high-concentration specialty fertilizers.

Flat die granulators are also essential for the feed processing industry. For poultry and livestock feed, they can compress raw materials such as straw powder and soybean meal into pellets, reducing feed losses during transportation. High-temperature extrusion kills parasite eggs in the raw materials, enhancing feed safety. In aquatic feed production, pellet density can be controlled by adjusting die hole size to meet the feeding needs of fish in different water layers.

In the environmental protection field, flat die granulators are a valuable aid in solid waste treatment. They can compress municipal sludge, agricultural and forestry waste, and other materials into fuel pellets, realizing waste resource utilization. These pellets have high combustion efficiency and low pollutant emissions, providing new ideas for the development of new energy sources.

The flat die granulator‘s advantages also lie in its flexible operation. By simply replacing dies with different apertures, a wide range of pellet specifications can be produced to meet the needs of diverse industries. The equipment also occupies a small footprint and is easy to install and maintain, making it suitable for small and medium-sized enterprises. As the concept of green production becomes increasingly popular, the flat die pelletizer, with its high efficiency, energy conservation, and versatility, continues to provide a reliable solution for material forming in various fields.

organic fertilizer equipment

What is the production process of an organic fertilizer production line?

by organic fertilizer production line

In terms of equipment, an organic fertilizer production line requires a fermentation compost turner, fertilizer crusher, fertilizer mixer, fertilizer granulator, fertilizer dryer, fertilizer cooler, fertilizer screening machine, fertilizer packaging machine, fertilizer conveyor, and fertilizer coating machine.

The raw materials used in organic fertilizer production vary widely, including livestock and poultry manure, municipal sewage sludge, and animal and plant residues. These raw materials are rich in organic matter, nitrogen, phosphorus, potassium, and other nutrients, providing essential nutrients for crop growth and are available at low prices.

How an organic fertilizer production line works:

Organic fertilizer processing primarily involves collecting, crushing, and mixing the raw materials. The raw materials are then mixed according to the desired formula, and the moisture content and carbon-nitrogen ratio are adjusted before the fermentation process begins.

Fermentation compost turning machines: Assist in turning the compost during the fermentation process, provide sufficient oxygen, and control the temperature to ensure uniform and thorough fermentation.

Fertilizer mixers: If the size and state of the fermented material are inconsistent, a semi-wet material grinder can be used for fine grinding.

Fertilizer Granulator: The crushed material is processed into uniformly sized organic fertilizer granules by the organic fertilizer granulator.

Fertilizer Cooler: After granulation, the organic fertilizer still contains approximately 30% moisture. To increase its strength, the granules need to be cooled for later storage and transportation.

Fertilizer Screening Machine: After granulation, a small number of unqualified granules, some too large and some too small, will be produced. The fertilizer screening machine is used to separate these granules. Oversized granules are returned to the fertilizer crusher, while undersized granules are returned to the fertilizer granulator for regranulation. Qualified granules are then sent to the automatic packaging machine.

Fertilizer Packaging Machine: The finished organic fertilizer granules are packaged by the automatic packaging machine, completing the entire process.

It should be noted that the above configuration is for a typical organic fertilizer production line and may not be suitable for all situations. In actual production applications, different manufacturers may have different requirements regarding site and raw materials, and adjustments may be required based on actual needs.  

organic fertilizer equipment

What are the main components of an organic fertilizer production line?

by organic fertilizer production line

Those familiar with organic fertilizer production lines can generally identify their components, but for those new to the industry, this may seem a bit vague. Today, Zhengzhou Huaqiang Heavy Industry will share with you the components of an organic fertilizer production line.

The crushing section of an organic fertilizer production line. Given the diversity of user raw materials, our organic fertilizer production line equipment is designed with a crushing section. During the equipment sales process, we found that many users use relatively dry chicken manure or pig manure as raw materials, and some even mix in other raw materials to reduce organic fertilizer production costs. Raw materials with excessively large particle sizes cannot be directly granulated. Therefore, before granulation, the raw materials must be crushed to achieve the desired granulation effect before they can be fed into the organic fertilizer granulator. Of course, for users with sufficiently fine raw materials, this step can be omitted when designing organic fertilizer equipment.
The granulator section of an organic fertilizer production line is the core component of the equipment, making it an essential component. The model of granulator to be selected depends on the user’s production volume. The drying section of the organic fertilizer production line. The granulation process requires that the material humidity be kept below 25%. Therefore, raw materials with an initial humidity above 25% should first enter the drying process, and then enter the granulation process after the dried material reaches the required humidity. Of course, users with sufficient material humidity can omit this step when designing organic fertilizer equipment.
In other parts of the organic fertilizer production line, after the pelletizer completes the processing, it is conveyed by a belt conveyor to a ball shaping machine for shaping, achieving a perfectly spherical shape and forming organic fertilizer granules. For users who require it, we can design a final packaging process to directly package the final product, thus achieving perfect automation of the entire fertilizer granulation process.

organic fertilizer equipment

The unique working principle of the double roller press granulator

by organic fertilizer production line

The reason why the double roller press granulator can occupy an important position in the organic fertilizer granulation equipment is inseparable from its unique working principle, which also allows it to show many advantages.  Its working process is clear and straightforward. First, the pre-treated dry powder raw material is conveyed between two relatively rotating rollers. The surface of this pair of rollers is usually provided with specific lines or grooves. Under the action of strong extrusion force, the raw material is tightly squeezed to form continuous flakes. These flakes then enter the crushing device and are crushed into particles of different sizes. Next, the particles will go through the screening stage, and the fine powder or large particles that do not meet the requirements will be separated and sent back to the granulation system, while the qualified particles will become the final product.

This working principle brings significant advantages. There is no need to add a lot of water, and the subsequent drying step is omitted, which not only saves energy, but also maintains the original nutritional content of the raw materials. The whole process is coherent and efficient, from the entry of raw materials to the output of qualified particles, which can be completed in one go and quickly meet production needs. At the same time, due to the physical extrusion granulation, it has strong adaptability to raw materials, and a variety of organic raw materials can be made into granules in this way.

The double roller press granulator has become an efficient and practical granulation choice in the organic fertilizer production line due to its scientific working principle, helping producers improve efficiency and ensure quality.

organic fertilizer equipment

The secrets of organic fertilizer production line and bio organic fertilizer production line

by organic fertilizer production line

In agricultural production, the quality of fertilizer directly affects the growth and harvest of crops. Today, let’s take a deep look at the differences between organic fertilizer production line and bio organic fertilizer production line to help you make a better choice.

Organic fertilizer production line mainly uses animal and plant residues, such as livestock and poultry manure, crop straw, etc. as raw materials. After collection, pretreatment is first carried out, such as crushing and mixing, to make the raw materials uniform in texture. Then enter the key fermentation and decomposition link, using natural microorganisms to decompose and transform organic raw materials under suitable temperature, humidity and ventilation conditions. This process often takes several months to make organic matter reach a stable state and finally make organic fertilizer.

Bio organic fertilizer production line goes a step further on this basis. After the raw materials are also collected, pretreated and conventionally fermented and decomposed, wait for the material temperature to drop to a suitable range (usually not more than 40℃), and evenly mix in specific microbial agents, such as Bacillus, yeast, etc. These microorganisms play an important role in the follow-up, and can decompose nutrients such as insoluble phosphorus and potassium in the soil and convert them into plant-absorbable forms. However, since microorganisms are sensitive to the environment, the subsequent storage and transportation conditions must be strictly controlled to prevent inactivation.

From the production process point of view, the bio-organic fertilizer production line adds the addition of microbial agents. It seems simple, but it has higher requirements for equipment and environment, and the production process is more complicated.

In terms of product effect, organic fertilizer can improve soil structure, slowly release nutrients, and provide long-term nutrition for plants; bio-organic fertilizer not only has these functions, but also can prevent and inhibit pests and diseases, enhance plant resistance, reduce the use of pesticides, and improve the quality and safety of agricultural products.

Whether you want to invest in organic fertilizer production or focus on bio-organic fertilizer processing, choosing our equipment can escort your production, help you produce high-quality fertilizers, and seize the opportunity in the field of agricultural planting.

organic fertilizer equipment

The Core Value of Granulators in Fertilizer Production Lines

by organic fertilizer production line

Among the numerous pieces of equipment in a fertilizer production line, granulators are a key link in transforming raw materials into finished products, directly determining the fertilizer’s physical form and performance.

The primary function of a granulator is to process evenly mixed raw materials into granules of a specific size. Direct application of crushed and blended powdered raw materials can easily lead to problems such as clumping and flying. Granulators, however, use processes such as extrusion, rolling, or spraying to agglomerate the raw materials into 3-5 mm granules. This form facilitates transportation and storage, reduces waste, and controls the rate of nutrient release into the soil, preventing nutrient loss and improving nutrient utilization. For example, in compound fertilizer production, granulators precisely encapsulate elements such as nitrogen, phosphorus, and potassium, ensuring balanced nutrient release.

Granulators play an irreplaceable role in improving fertilizer quality. High-quality granulation equipment ensures uniform granules with a moderate hardness, neither too hard to break down nor too soft to cause pulverization. Take organic fertilizer as an example. In organic fertilizer production lines, the continuous temperature and pressure during the granulation process further kill pathogens and insect eggs in the raw materials, reducing the risk of crop disease. It also allows the organic matter to more tightly bind with the auxiliary materials, extending the fertilizer’s effectiveness.

Granulators are equally important for improving production efficiency. Modern equipment enables continuous operation, processing several tons of raw materials per hour. Combined with screening machines, they can separate unqualified granules in real time for secondary processing, reducing waste. Compared to traditional manual granulation, mechanical granulation reduces labor intensity and can be controlled through parameter adjustments to maintain stable quality, meeting the needs of large-scale production.

From an ecological perspective, granulators contribute to environmentally friendly fertilization. Granulated fertilizers reduce dust pollution and prevent powder drift. The slow-release granule design reduces the risk of soil compaction and water eutrophication caused by over-fertilization, supporting green agriculture.

Thus, granulators not only shape the fertilizer form but also safeguard its quality, occupying an unshakable core position in the fertilizer production line.

Back To Top