fertilizer production line

Key Role of Compost Turner in Fertilizer Production Line

fertilizer granulator Oct 29, 2025

Production Process Connection

In the fertilizer production line, the compost turner serves as the core equipment in the raw material fermentation process. Raw materials that have undergone pretreatment (crushing, mixing, and carbon-nitrogen ratio adjustment) are transported to the fermentation area and stacked into windrows for turning and fermentation by the crawler-type compost turner. The composted materials are then conveyed to subsequent processes (crushing, granulation, drying, etc.) through conveyors, forming a continuous “pretreatment-fermentation-deep processing” workflow. This efficient turning operation provides high-quality raw material assurance for subsequent processing stages.

Large-scale Continuous Fermentation

For large-scale fertilizer production lines (with an annual output of over 50,000 tons), the compost turner can simultaneously serve multiple groups of windrows, achieving continuous production through a “multi-zone rotation” model: Zone one for new material loading, zone two for high-temperature fermentation, and zone three for cooling and maturation. The equipment operates on a fixed cycle with an average daily processing capacity of 800-1,500 tons, meeting the needs of large-scale production. This operation mode significantly improves site utilization and equipment efficiency.

Production Rhythm Matching

The travel speed and turning frequency of the compost turner can be steplessly adjusted through the electronic control system, allowing flexible adjustment of the fermentation schedule according to the raw material supply rate and backend processing capacity. For example, when granulator capacity increases, the turning frequency can be correspondingly increased to accelerate material maturation, ensuring the fermentation process remains synchronized with the overall production line rhythm. This flexible adjustment capability ensures stable operation of the production line.

Diversified Production Models

The compost turner can independently complete open-air windrow fermentation operations or combine with fermentation silos, conveyors and other equipment to form semi-closed production lines. For scenarios requiring mobile operations (such as livestock farms and temporary waste disposal sites), the compost turner can be flexibly moved with raw material production sites without fixed installation, greatly enhancing the production line’s mobility. This flexibility enables it to adapt to different production environments and operational requirements.

Process Optimization Value

In contemporary fertilizer manufacturing, the strategic deployment of specialized equipment forms the backbone of efficient production systems. The compost fertilizer machine, particularly the large wheel compost turner and chain compost turner, plays a pivotal role in initial processing stages, significantly enhancing fermentation efficiency while ensuring consistent product quality through precise aeration and temperature control. These robust machines serve as crucial connectors between preliminary and subsequent stages within the comprehensive organic fertilizer production line.

The transition from composting to granulation represents a critical phase in the equipments required for biofertilizer production. Advanced granulation technologies, including the versatile rotary granulator for organic materials and the precision-oriented disc granulation production line for uniform particle formation, demonstrate the sophistication of modern fertilizer production machine systems. The drum granulation process further expands this capability, particularly within npk fertilizer production line configurations, while the double roller press granulator offers alternative compaction-based granulation methods.

Complete production ecosystems, whether configured for bio organic fertilizer production line operations or dedicated npk production line setups, integrate these components into seamless manufacturing processes. The large wheel compost turning machine ensures optimal composting conditions, while downstream equipment like the drum organic fertilizer dryer maintains product integrity through controlled moisture reduction. Each fertilizer granulator unit contributes to creating specialized formulations, demonstrating how interconnected technologies support the standardized, large-scale advancement of sustainable fertilizer production worldwide.

Turning Pig Manure into Treasure: Bio-organic Fertilizer Innovation

fertilizer granulator Oct 29, 2025

Environmental Challenges in Livestock Development

With the global scale development of animal husbandry, the treatment of large amounts of pig manure has become a serious environmental issue. Traditional composting methods suffer from long cycles, significant nutrient loss, and improper carbon-to-nitrogen ratios, resulting in low efficiency and atmospheric pollution.

Innovative Solution

The new bio-organic fertilizer technology effectively addresses the shortcomings of traditional composting by adding efficient microbial agents and optimizing formulations. This technology uses scientific microbial combinations to significantly improve composting efficiency and quality.

Core Technical Formula

· Fermented pig manure: 65-85 parts by weight

· Conventional additives: 5-10 parts

· Compound microbial agent: 3-5 parts

· Binder: 1-10 parts

Optimal formula: 80 parts fermented pig manure, 8 parts conventional additives, 4 parts compound microbes, 8 parts binder

Microbial Ratio Innovation

The compound microbes consist of yeast and rhizobium in a ratio of 3:1 to 1:1, with the optimal ratio being 2:1. The preferred yeast is Candida, while rhizobium includes peanut rhizobium or pea rhizobium, with strain concentrations of 10⁴cfu/mg.

Outstanding Product Characteristics

· Moisture content: <30%

· Organic matter content: >30%

· NPK nutrients: 25-30g/kg

· pH value: 7.5-8.0

· Parasitic egg mortality: >95%

· Colony count: <100 CFU/kg

Global Environmental Significance

This technology not only solves the problem of livestock manure pollution but also provides high-quality fertilizer for organic agriculture. Through microbial action, waste is transformed into valuable resources, achieving sustainable development in circular agriculture, which is of great significance for global environmental protection and food security.

Conclusion

In conclusion, this innovative bio-organic fertilizer technology represents a paradigm shift in sustainable agriculture by transforming environmental challenges into valuable opportunities. The integration of specialized equipment such as the rotary drum granulator and new type two in one organic fertilizer granulator ensures efficient fertilizer granules compaction while maintaining nutrient integrity. The complete fertilizer production machine ecosystem—including the fertilizer compaction machine, chain compost turning machine, and roller press granulator production line—forms a seamless production chain that optimizes the equipments required for biofertilizer production. The drum granulator and rotary granulator work synergistically with microbial agents to create uniform granules with enhanced soil amendment properties. This holistic approach, combining advanced fertilizer compactor technology with biological innovation, not only resolves livestock pollution but establishes a circular economy model where waste becomes wealth. Ultimately, this system demonstrates how technological integration can simultaneously address environmental protection, agricultural productivity, and resource sustainability on a global scale.

Windrow compost turning machines offer a standardized, complete process for recycling chicken manure

fertilizer granulator Oct 29, 2025

Chicken manure, a common waste product in the livestock industry, is rich in nitrogen, phosphorus, potassium, and organic matter. However, its direct use without treatment can easily cause soil contamination and crop burn. The windrow compost turning machine uses a scientific processing process to transform chicken manure into high-quality organic fertilizer, effectively recycling pollutants.

The first step is raw material pretreatment. Fresh chicken manure has a moisture content of approximately 60%-70% and a low carbon-nitrogen ratio. Straw, sawdust, and other auxiliary materials are added proportionally to adjust the carbon-nitrogen ratio to 25-30:1, and the humidity is controlled at 55%-65% to create a suitable environment for aerobic microbial fermentation. After mixing, a loose pile is formed.

The second step is pile construction and initial fermentation. The mixed material is piled into a long, 3-5 meter wide and 1-1.5 meter high pile. The windrow compost turning machine, with its crawler tracks, can operate directly on the soft pile, avoiding sinking. After the equipment is started, the turning gears penetrate deep into the pile, thoroughly mixing the bottom and top layers. Air is introduced simultaneously, promoting the growth of aerobic microorganisms and rapidly raising the pile temperature to above 55°C.

The third step is continuous turning and temperature control. During the fermentation period, the compost turner operates at a set frequency: once daily in the early stages and every other day in the later stages. This turning process not only replenishes oxygen and removes fermentation waste gases, but also stabilizes the pile temperature at 55-65°C. This temperature effectively kills harmful substances such as E. coli and roundworm eggs in the chicken manure, while also accelerating the decomposition and conversion of organic matter.

The entire processing cycle takes approximately 25-35 days. After being processed by the windrow compost turner, the chicken manure is transformed from sticky, foul-smelling waste into a loose, odorless, and mature material. It can then be crushed and screened to produce organic fertilizer.

Windrow compost turning machine: Efficient equipment for converting livestock manure into organic fertilizer

fertilizer granulator Oct 29, 2025

In the resource utilization of livestock and poultry waste, windrow compost turning machines, with their flexible and efficient operation, have become a core piece of equipment for converting livestock manure into organic fertilizer. Through mechanized turning and plowing, they accelerate manure composting and fermentation, transforming livestock pollutants into high-quality organic fertilizer, addressing environmental challenges while also promoting resource recycling.

The core advantage of windrow compost turning machines lies in their adaptability. Their crawler-type design allows for free movement in muddy composting areas. The large ground contact area and low pressure prevent them from sinking into the manure pile, making them suitable for various sizes of fermentation workshops or open-air sites. Equipped with a hydraulically driven turning gear shaft, the equipment can reach a turning depth of 0.8-1.5 meters, thoroughly mixing the bottom layer of manure with the surface material, breaking up compacted materials and ensuring uniform fermentation.

In the livestock manure processing process, windrow compost turners play a key role in promoting fermentation. First, livestock manure is mixed with supplementary materials such as straw and sawdust in appropriate proportions, adjusting the carbon-nitrogen ratio to 25-30:1 and the humidity to 55%-65% to create optimal conditions for microbial fermentation.

Subsequently, a compost turning machine regularly turns the pile, introducing sufficient oxygen to support aerobic microbial activity and rapidly dissipating the heat generated by fermentation, keeping the pile temperature between 55-65°C. This temperature range effectively kills pathogens, insect eggs, and weed seeds in the manure, preparing the compost for subsequent operation in the fertilizer granulator.

This equipment boasts high efficiency and a high degree of automation. By setting the turning frequency and path, continuous operation is achieved, reducing labor input.

Flat die granulators: Common failures and solutions

fertilizer granulator Oct 29, 2025

Poor pellet formation is a common problem with flat die granulators. Improper material moisture is the primary cause. Excessively high moisture content can cause the material to stick together, making it difficult to form; while excessively low moisture content can lead to a lack of cohesiveness and loose pellets. Die wear can also cause forming problems, resulting in irregular die holes and poor pellet quality. Insufficient roller pressure can also prevent the material from being fully extruded. Solutions include strictly controlling material moisture content to maintain it within the appropriate range; regularly inspecting and replacing severely worn dies; and adjusting roller pressure to ensure uniform and adequate pressure.

Abnormal equipment noise is often caused by multiple factors. Bearing damage is a common cause, producing abnormal noise during operation. Loose components, such as loose screws and connectors, are also important, as they can generate vibration and noise during operation. Gear wear can also increase noise, as worn gears mesh poorly. If these problems occur, promptly inspect the bearings, tighten loose components, and replace damaged gears as necessary to reduce noise and ensure proper operation.

Routine maintenance is crucial to minimizing flat die granulator failures. Regularly check the wear of equipment components, such as rollers, dies, and bearings, and replace wearing parts promptly. Keep the flat die granulator clean to prevent residual material from corroding the equipment. Lubricate the equipment regularly to reduce friction between components. These routine maintenance measures can effectively reduce the incidence of equipment failures, extend equipment life, and improve production efficiency.

Efficient production in the organic fertilizer industry

fertilizer granulator Oct 29, 2025

The organic fertilizer industry is experiencing rapid growth. With the growing adoption of green agricultural development, market demand for organic fertilizer continues to grow, driving both innovations in raw material processing and the upgrading of production technologies.

Granulation is a key step in the organic fertilizer production process, directly impacting the product’s granule shape and application efficiency. Flat die granulators play a crucial role in this process. These machines extrude fermented and decomposed organic materials into uniform, solid granules, facilitating transportation and storage while also facilitating mechanized fertilization.

The advantages of flat die granulators lie in their adaptability, ability to process a wide range of organic materials, and relatively relaxed requirements for raw material moisture content. This relatively simple structure and easy operation and maintenance make them widely used by small and medium-sized organic fertilizer manufacturers. Flat die granulators offer a high granulation rate and moderate granule strength, helping to reduce dust issues during use.

Currently, the organic fertilizer industry is moving towards scale and standardization. Technological advances in production equipment, particularly the continuous optimization of the granulation process, have provided strong support for improving product quality and production efficiency. With the iteration of technology, organic fertilizer production in the future will be more efficient and energy-saving, contributing more to sustainable agriculture.

Rotary Drum Granulation: Core of Efficient Fertilizer Production

fertilizer granulator Oct 28, 2025

Process Overview

The rotary drum granulation production line is essential equipment in modern fertilizer industry, widely used in large-scale production of various fertilizers including NPK compound fertilizers, bio-fertilizers, and controlled-release fertilizers. This technology achieves efficient and energy-saving continuous production through innovative steam granulation processes.

Core Working Principle

New blended raw materials are fed into the drum granulator uniformly according to the balling rate, while saturated steam is introduced into the material layer as required. This unique steam granulation process enables materials to complete granulation at lower moisture content, which not only raises material temperature but also humidifies the material, effectively reducing the drying load.

Technical Features and Advantages

Steam Granulation Technology

By introducing steam into the material layer, the temperature of granulated materials is increased, dissolving salts in the materials. This achieves high liquid volume under low moisture content to meet the liquid phase required for material granulation, while reducing water evaporation in the drying process.

Ammoniation Reaction Function

Ammonia can be applied to the material layer in the drum as required to promote chemical reactions in the materials, optimizing fertilizer formulation and nutrient release characteristics.

Automatic Cleaning Design

The inner wall of the rotary drum granulator is lined with multiple soft rubber plates or polypropylene plates, with air holes in corresponding positions of the cylinder. When the lining rotates from the bottom to the top of the cylinder, it sags due to its own weight, causing materials adhering to the lining to fall off by gravity, achieving automatic cleaning and anti-caking functions.

Wide Raw Material Adaptability

This process has strong adaptability to raw materials, allowing combination of low solubility materials (such as calcium chloride, ammonium sulfate, potassium chloride, etc.) and high solubility materials (such as urea, ammonium nitrate, ammonium phosphate, etc.) according to requirements, while also enabling the addition of organic matter and medium-trace elements.

Global Application Value

Rotary drum steam granulation technology has revolutionized the NPK fertilizer manufacturing process, establishing itself as a cornerstone in global fertilizer production. This advanced NPK fertilizer production line integrates multiple specialized equipment including the NPK blending machine, fertilizer mixer machine, and NPK fertilizer granulator machine to create a seamless manufacturing system.

The core of this technology lies in the sophisticated NPK granulation machine and complementary equipment such as the disc granulator machine, which work in harmony to transform raw materials into high-quality fertilizers. The complete NPK production process begins with precise formulation using either a modern NPK blending machine or bulk blending fertilizer machine, followed by the crucial fertilizer granulation phase where the NPK fertilizer granulator and disc granulator create uniform, durable granules.

This integrated approach to manufacturing of NPK fertilizer offers exceptional flexibility, allowing producers to efficiently switch between different compound formulations using the same NPK fertilizer machine infrastructure. The technology’s robust design, particularly the NPK bulk blending machine components, ensures consistent performance across various production requirements, making the entire NPK manufacturing operation more economical and environmentally sustainable.

Through optimized fertilizer granulation techniques and advanced NPK fertilizer production line configurations, this technology continues to set new benchmarks in production efficiency and product quality, contributing significantly to sustainable agricultural practices worldwide.

Disc Granulator: Why Is It Preferred?

fertilizer granulator Oct 28, 2025

 In modern fertilizer production, the disc granulator stands as a master craftsman, becoming the preferred equipment for numerous enterprises within the NPK manufacturing process. While the rotary drum granulator offers an alternative approach, the disc granulator’s unique design philosophy and exceptional performance for creating uniform fertilizer granules make it indispensable. For materials requiring fertilizer compaction, the fertilizer compactor and roller press granulator production line provide specialized solutions for fertilizer granules compaction. A reputable fertilizer machine manufacturer typically integrates both technologies into a comprehensive NPK fertilizer production line, ensuring optimal equipment selection for each production stage. This sophisticated fertilizer production machine ecosystem, whether utilizing a drum granulator or specialized fertilizer compaction machine, contains profound engineering wisdom that transforms powder materials into valuable agricultural nutrients through precise mechanical design and controlled agglomeration processes.

Precision Structure: Every Component Is Indispensable

Core Granulation Disc

As the heart of the equipment, the granulation disc is welded from high-quality steel plates with wear-resistant lining on the inner wall, ensuring long-term stable operation. With diameters ranging from 1-5 meters, depths of 0.3-1.5 meters, and adjustable inclination angles between 30°-60°, it meets diverse production requirements.

Precision Transmission System

The transmission device, composed of motor, reducer, and pulley, ensures the granulation disc rotates steadily at 5-30 rpm. This precise power system is key to ensuring uniform particle quality.

Intelligent Control System

Equipped with advanced feeding devices and water spray systems, it achieves uniform material feeding through screw feeders or belt feeders, combined with precise water spraying to ensure optimal material moisture content.

Outstanding Advantages: Redefining Granulation Standards

Excellent Pelletizing Effect

Particle sphericity exceeds 80%, smooth surface, high uniformity, and excellent strength

Easy and Flexible Operation

Simple and intuitive structure, precise control through speed and angle adjustment

Wide Adaptability

Processes various materials, from powders to viscous materials with perfect results

Energy Efficient Operation

Lower energy consumption compared to other equipment, more competitive operating costs

Particularly noteworthy is the remarkable flexibility disc granulators demonstrate when processing different materials. Whether dealing with fine powders or somewhat viscous raw materials, they can achieve optimal granulation results through precise adjustment of process parameters. This powerful adaptability ensures excellent performance in varying production environments.

Production Efficiency: Driving Force of Continuous Innovation

Disc granulators employ continuous production methods with hourly outputs ranging from several tons to dozens of tons, fully meeting production needs of different scales. Their efficient operation and stable product quality make them indispensable key equipment in modern fertilizer production lines. Meanwhile, the modular design concept makes equipment maintenance more convenient, significantly improving overall operational efficiency.

The disc granulator represents not only an outstanding example of mechanical engineering technology but also the perfect embodiment of modern production process wisdom. From precise component design to intelligent operating systems, from excellent pelletizing effects to efficient operational performance, every detail demonstrates the sophistication and innovation of engineering technology. As global fertilizer production continues to pursue efficiency, energy conservation, and environmental protection, disc granulators are consistently providing strong technical support for global agricultural production with their exceptional performance and reliable quality.

A brief discussion on the key role of extrusion in the organic fertilizer industry

fertilizer granulator Oct 28, 2025

In organic fertilizer production lines, there’s a seemingly simple yet crucial process: extrusion granulation. It transforms loose, uneven powdered organic raw materials into uniform, solid granules. This isn’t just a change in form; it’s a crucial step in improving the quality and modernizing the development of organic fertilizer.

Although rich in nutrients, unprocessed powdered organic fertilizer faces numerous challenges in practical application. First, its low density and bulk increase storage and transportation costs. Second, during application, powdered fertilizer is easily dispersed by the wind, resulting in fertilizer loss and environmental pollution. Extrusion technology specifically addresses these issues.

The extrusion process applies tremendous pressure to a fertilizer granulator, forcing the fine fertilizer powder through a specialized die, where it is squeezed into uniform, high-density, and strong granules.

The widespread adoption of extrusion granulation technology marks a significant shift in the organic fertilizer industry from extensive to refined, and from traditional to modern. This enables the standardization and commercialization of organic fertilizer products, shedding their image as “earth-based fertilizer” and making them more readily accepted and trusted by large-scale farms and specialized agricultural practitioners.

In short, these tiny fertilizer pellets embody not only rich organic matter but also the wisdom of modern processing technology. Extrusion molding, as a core component, continues to provide solid technical support for improving quality, increasing efficiency, and promoting green development in the organic fertilizer industry.

Small pellets, big impact: The evolution of organic fertilizer through granulation

fertilizer granulator Oct 28, 2025

In organic fertilizer production, granulation is more than just a cosmetic enhancement. Its primary purpose lies in practicality. Powdered organic fertilizers have a low density and are bulky, taking up a lot of space during storage and transportation. They are also prone to generating dust, leading to nutrient loss and environmental pollution. Granulation compacts the material, significantly reducing its volume, making long-distance transportation and economical storage possible.

More importantly, granulation profoundly impacts the ease and efficiency of fertilization. Uniform granules facilitate mechanized spreading, adapting to the operational needs of modern large-scale farms. Furthermore, their compact structure regulates the release rate of nutrients into the soil, preventing rapid decomposition and providing a more stable and long-lasting nutritional supply for crops.

So, how are various agricultural and forestry wastes transformed into uniform granules? Currently, mainstream granulation processes, such as disc granulators and double roller press granulators, each have their own advantages.

The advancement of granulation technology, from dusty powder fertilizer to uniform, uniform granules, is a significant step toward the modernization and standardization of traditional organic fertilizers. It has transformed organic fertilizer from a traditional “homegrown” method into a standardized commodity that can be integrated into modern agricultural production systems. These tiny granules embody the industry’s unwavering pursuit of efficiency, environmental protection, and practicality.