fertilizer production line

The core contribution of cage crushers and double screws compost turning machines

The efficient operation of a bio-organic fertilizer production line relies on the precise coordination of bio-organic fertilizer equipment at each stage. Among these, cage crushers and double screws compost turning machines play indispensable roles in raw material pretreatment and fermentation, directly impacting the quality and production efficiency of the final product.

The cage crusher, as an important pretreatment equipment in bio-organic fertilizer production, primarily functions to refine raw material particles. Raw materials for bio-organic fertilizer production often include straw, poultry and livestock manure, and fallen leaves. These materials have uneven textures and contain large impurities. If directly introduced into the fermentation process, this can lead to insufficient fermentation and uneven nutrient distribution. The cage crusher can refine large materials into uniform particles, laying the foundation for subsequent fermentation and preventing damage to subsequent equipment caused by impurities.

After processing by the cage crusher, the raw materials enter the fermentation stage, where the double screws compost turning machine becomes a core piece of bio-organic fertilizer equipment. Fermentation is a critical step in bio-organic fertilizer production, requiring proper ventilation and uniform temperature to promote microbial activity and achieve complete composting. The double screws compost turning machine, with its unique double-screw structure, ensures stable overall fermentation temperature, significantly improving composting efficiency and shortening the fermentation cycle.

In a complete bio-organic fertilizer production line, the cage crusher and double screws compost turning machine are closely integrated and work collaboratively, forming the core force that ensures a smooth production process and high-quality products. This highlights the important supporting role of high-quality bio-organic fertilizer equipment in the development of the industry.

Understanding the material requirements for rotary drum granulators in fertilizer production

The rotary drum granulator is central to modern fertilizer production, but it demands specific material properties. Knowing these is key to better efficiency and consistent product quality.

1.Physical Requirements

Raw material powder should be 80–200 mesh (180–75 μm). Particles that are too large or too small hurt both granule formation and strength. Good powder flow is also needed for even spreading inside the rotary drum granulator. Moisture content needs to stay between 2% and 5%—too much causes clumping, too little makes stable granules hard to form.

2.Chemical Makeup and Reaction Behavior

Fertilizer materials should dissolve moderately. Fully soluble or insoluble substances both complicate granulation. Materials with some clay minerals or organic matter form more stable granules. Neutral or slightly acidic pH usually gives the best results.

3.Heat Stability and Binding Ability

Since heat (60–80°C) is often used during granulation, materials must handle it without breaking down. They also need just the right stickiness—adjustable with binders like lignosulfonates.

4.Final Granule Quality

Good fertilizer pellets should have: Uniform size (1.5–4 mm), 90% granulation rate, 10 Newton/pellet crush strength, <2% dust content. Their surface should be smooth and dense, with an even internal structure for controlled nutrient release.

In short, knowing what a rotary drum granulator needs from your materials helps fine-tune your process—so you’ll get better pellets, more reliably.

Highly efficient and stable windrow compost turners safeguard the production of high-quality organic fertilizer

In a modern organic fertilizer fermentation plant, one of the most striking scenes is a windrow compost turner steadily moving between raw material piles. This is the starting point for the efficient and coordinated operation of organic fertilizer production equipment.

The significant advantage of the tracked design lies in its superior stability and maneuverability. Whether on soft piles or slightly muddy ground, the wide tracks effectively distribute pressure, preventing the equipment from sinking and ensuring continuous operation. This adaptability to complex environments makes it a reliable and solid foundation in organic fertilizer production lines.

In the family of compost turning equipment, in addition to windrow compost turners, there are also various other types, such as large wheel compost turners. Large wheel compost turning machines, with their unique rotating disc structure, also perform excellently in material mixing and crushing. The choice of equipment usually depends on the production scale, site layout, and raw material characteristics.

After the material has completed fermentation and maturation under the action of the windrow compost turner, the next step is for the organic fertilizer granulator to take over. These loose, powdery fertilizers are transformed into regular, compact granules in the granulator, greatly facilitating subsequent storage, transportation, and application.

From the turning and composting by the windrow compost turner to the shaping and granulation by the organic fertilizer granulator, each piece of equipment is an indispensable part of a modern fertilizer production system.

Organic Fertilizer Granulation Technology: Choosing the Right Solution for You

Introduction

In modern organic fertilizer production, selecting the appropriate granulation technology is crucial. Different granulation processes have their own characteristics in terms of capacity, energy consumption, raw material adaptability, and product quality. Understanding these differences helps production enterprises make informed choices based on their own conditions and market demands. This article introduces three mainstream organic fertilizer granulation technologies to help readers find the most suitable production solution for their needs.

Overview of Three Mainstream Technologies

Currently, the organic fertilizer industry mainly uses three granulation processes: horizontal mixing and extrusion granulation, flat die extrusion granulation, and rotary drum granulation. Each technology has its unique working principle and applicable scenarios, and the selection requires consideration of factors such as raw material characteristics, product requirements, and investment budget.

Horizontal mixing and extrusion granulation technology uses the mechanical action of a spiral mixing shaft to shape materials, making it particularly suitable for organic raw materials with high moisture content. Flat die extrusion granulation uses the cooperation of a die and pressure rollers to extrude materials, requiring strict control over the moisture content of the raw materials. Rotary drum granulation uses the rotation of a drum to agglomerate materials, usually requiring a drying system.

Raw Material Adaptability Comparison

Raw material characteristics are the primary consideration when selecting granulation technology. Horizontal stirred extrusion granulation has the widest adaptability to raw materials, capable of directly processing organic materials with a moisture content of 25%-45%, including livestock and poultry manure, straw, mushroom residue, and various other organic wastes. This tolerance makes it an ideal choice for processing agricultural waste.

Flat die extrusion granulation requires the raw material moisture content to be controlled between 15%-25%, making it more suitable for pre-treated organic materials or some compound fertilizer production. Drum granulation has the strictest requirements for raw material moisture, typically needing to reduce the moisture content to 10%-20%, thus requiring a drying system, increasing energy consumption and equipment investment.

Capacity and Efficiency Analysis

From a capacity perspective, each of the three technologies has its advantages. A medium-sized horizontal stirred extrusion granulation production line has a capacity of 3-8 tons/hour, which can meet the needs of most organic fertilizer production enterprises. Flat die extrusion granulation has a relatively lower capacity, with a medium-sized line of 0.4-2.5 tons/hour, suitable for small-scale or specialty fertilizer production. Rotary drum granulation boasts the highest production capacity, with medium-sized lines reaching 5-12 tons/hour, but its energy consumption is also the highest.

In terms of energy efficiency, horizontal mixing extrusion granulation excels. Since it eliminates the need for drying, its energy consumption per ton of fertilizer is only 20-30 kWh, far lower than the drying required by rotary drum granulation. This energy efficiency advantage is particularly important given the rising energy costs.

Product Quality Characteristics: Products produced by different granulation technologies differ in appearance and properties. Horizontal mixing extrusion granulation produces irregular spherical or cylindrical particles with high strength, easily disintegrating upon contact with water, making it ideal for field application of organic fertilizers. Flat die extrusion granulation produces regular cylindrical particles with a neat appearance. Rotary drum granulation produces standard spherical particles with the best commercial appearance.

For bio-organic fertilizers, the low-temperature characteristics of horizontal mixing extrusion granulation offer a unique advantage. It ensures a survival rate of over 95% for the biological agents in the product, while the high-temperature process in rotary drum granulation leads to the inactivation of most microorganisms.

Investment and Operating Costs

In terms of initial investment, flat die extrusion granulation lines have the lowest cost, with medium-sized lines costing approximately 500,000-800,000 RMB; horizontal stirred extrusion granulation lines are in the middle, costing approximately 800,000-1,200,000 RMB; and rotary drum granulation lines are the most expensive, reaching 1,500,000-2,000,000 RMB. This difference mainly stems from variations in equipment complexity and supporting systems.

Operating costs include energy consumption, maintenance, and labor costs. Horizontal stirred extrusion granulation has the greatest long-term operating cost advantage due to its low energy consumption and simple maintenance. While rotary drum granulation offers high capacity, its high energy consumption and maintenance costs may offset its capacity advantage.

Selection Guidelines

When choosing a granulation technology, the following factors should be considered:

If the main processing involves organic waste with high moisture content, and low energy consumption and bioactivity protection are prioritized, horizontal stirred extrusion granulation is the best choice.

If the raw materials are pretreated, moisture content is well controlled, and the production scale is relatively small, flat die extrusion granulation may be more suitable.

If the highest capacity and best product appearance are desired, and higher energy costs are acceptable, rotary drum granulation is worth considering.

For most organic fertilizer producers, especially those using agricultural waste as raw materials and focusing on the bioactivity of their products, horizontal mixing and extrusion granulation offers the best cost-effectiveness. It not only suits the actual conditions of organic fertilizer production in China but also aligns with the global trend towards sustainable agriculture.

Future Outlook

With continuous technological advancements, these granulation processes are converging and developing. The addition of intelligent control systems makes operation more precise, the use of new materials extends equipment lifespan, and process optimization improves product quality. In particular, horizontal mixing and extrusion granulation technology is continuously innovating, maintaining its original advantages while gradually improving product appearance and expanding its application range.

Regardless of the technology chosen, successful production relies on meticulous management of raw materials, a deep understanding of the process, and strict quality control. With the increasing global emphasis on organic agriculture and sustainable production, choosing the right granulation technology will become one of the key factors for the success of organic fertilizer companies.

Strategic Choice for Sustainable Production

In conclusion, selecting the optimal granulation technology is a strategic decision that balances raw material properties, production goals, and economic viability for any organic fertilizer manufacturing operation. Horizontal stirred extrusion, flat die, and drum granulation each serve distinct niches within the industry.

The choice of fertilizer granulation technology is just one part of a complete organic fertilizer production line. It begins with efficient organic fertilizer fermentation, supported by robust fermentation composting turning technology using equipment like a chain compost turning machine or large wheel compost turning machine. The granulation stage—whether using a new type organic fertilizer granulator, a flat die pelleting machine, or traditional drum granulation—shapes the final product. For a bio organic fertilizer production line, preserving microbial viability during granulation becomes the paramount technical consideration.

Ultimately, a successful operation integrates the right preprocessing, fermentation, and granulation technologies to produce high-quality, market-ready organic fertilizers efficiently and sustainably.

Microbial fertilizer: the active guardian of the soil

Microbial fertilizers, also known as microbial fertilizers, are a type of fertilizer made with specific live beneficial microorganisms as the core functional component, combined with organic matter, carriers, or small amounts of nutrients. They themselves do not contain macro- or micronutrients; their core function is to improve the soil’s micro-ecological environment, activate soil nutrients, and stimulate crop growth through the life activities of microorganisms. When used in conjunction with chemical fertilizers and organic fertilizers, they achieve multiple effects of “promoting growth, resisting disease, and improving quality,” making them a key fertilizer category for developing green agriculture.

Core Mechanism of Action

The efficacy of microbial fertilizers depends entirely on the metabolic activities of beneficial microorganisms, primarily through the following four pathways:

Activating Soil Nutrients and Enhancing Fertilizer Utilization

The soil contains a large amount of “fixed” nutrients that are difficult for crops to directly absorb (such as insoluble phosphorus, potassium, and organic nitrogen). Beneficial microorganisms can secrete organic acids and enzymes to decompose and convert these nutrients into soluble nutrients.

Phosphate-solubilizing bacteria: Secrete organic acids to dissolve calcium phosphate, iron phosphate, etc., in the soil, releasing available phosphorus.

Potassium-solubilizing bacteria: Decompose minerals such as feldspar and mica, releasing potassium ions.

Nitrogen-fixing bacteria: Convert atmospheric nitrogen into ammoniacal nitrogen for crop absorption (e.g., nitrogen fixation through symbiotic relationships between rhizobia and legumes).

Producing growth-promoting substances to stimulate crop growth: Beneficial microorganisms secrete plant growth regulators during metabolism, including auxins, cytokinins, and gibberellins, promoting root development, accelerating stem and leaf growth, and enhancing the crop’s ability to absorb water and nutrients.

Suppressing soil-borne diseases and mitigating continuous cropping obstacles: Beneficial microorganisms can seize living space around crop roots through “occupancy effects” and “antagonistic effects,” inhibiting the reproduction of pathogens; simultaneously, they secrete antibacterial substances (such as antibiotics and chitinase) to directly kill or inhibit soil-borne disease pathogens (such as wilt and root rot pathogens), thereby mitigating the accumulation of soil diseases caused by continuous cropping.

Improving Soil Structure and Optimizing the Micro-ecological Environment

Microbial metabolites (such as polysaccharides and humic acids) promote soil aggregate formation, improve soil aeration and water and fertilizer retention capacity; simultaneously, the proliferation of beneficial microorganisms regulates the balance of the soil microbial community, reduces the number of harmful microorganisms, and improves soil health.

Main Product Types and Applicable Scenarios

Based on the types and functions of the microorganisms they contain, microbial fertilizers can be divided into 5 categories, specifically tailored to the needs of different crops and soils:

Rhizobium Agents

Core Strain: Rhizobium (e.g., soybean rhizobium, peanut rhizobium).

Functional Characteristics: Forms root nodules in symbiosis with the roots of leguminous crops (soybeans, peanuts, peas, etc.), fixing atmospheric nitrogen and meeting 30%-80% of the crop’s nitrogen requirements, significantly reducing nitrogen fertilizer application.

Applicable Scenarios: Seed coating or base fertilizer for leguminous crops. Note the specificity of the strain and crop (e.g., soybean rhizobium cannot be used for peanuts).

Nitrogen-Fixing Bacterial Agents

Core strains: Free-living nitrogen-fixing bacteria and symbiotic nitrogen-fixing bacteria (e.g., *Azotobacter chrysophagus*).

Functional characteristics: Do not require symbiosis with crops; can independently fix nitrogen in the soil while secreting auxins to promote crop growth.

Applicable scenarios: Base fertilizer or top dressing for non-leguminous crops such as wheat, corn, and vegetables; suitable for improving nitrogen supply in poor soils.

Phosphorus- and potassium-solubilizing Bacterial Agents

Core strains: Phosphorus-solubilizing bacteria (e.g., *Bacillus megaterium*) and potassium-solubilizing bacteria (e.g., *Bacillus mucilaginosus*).

Functional characteristics: Decomposes fixed phosphorus and potassium elements in the soil, improving the utilization rate of phosphorus and potassium fertilizers and reducing fertilizer loss.

Applicable scenarios: Base fertilizer for field crops, fruit trees, and vegetables; especially suitable for plots with “soil compaction and nutrient fixation” caused by long-term application of chemical fertilizers.

Compound Microbial Agents

Core strains: A compound of multiple beneficial bacteria, including nitrogen-fixing bacteria, phosphorus-solubilizing bacteria, potassium-solubilizing bacteria, and disease-resistant bacteria.

Features: Combines multiple functions of “nutrient activation + growth promotion + disease resistance,” with a wide range of applications and more comprehensive effects.

Applicable Scenarios: Base fertilizer and top dressing for various crops, and soil improvement in areas with continuous cropping obstacles.

Bio-organic Fertilizer

Core Components: Beneficial microorganisms + well-rotted organic fertilizer (carrier).

Features: Combines the advantages of organic fertilizer (“soil improvement, providing organic matter”) and microbial fertilizer (“nutrient activation, disease resistance, and growth promotion”), providing a gentle and long-lasting fertilizer effect.

Applicable Scenarios: Base fertilizer for facility agriculture, fruit trees, and vegetables; an excellent alternative to traditional chemical fertilizers.

III. Core Advantages

Improved fertilizer utilization rate and reduced fertilizer usage

When used in conjunction with microbial fertilizers, it can increase fertilizer utilization rate by 10%-30%, reducing soil pollution and nutrient loss caused by excessive fertilizer application.

Relieves Continuous Crop Obstacles and Improves Soil Health

For greenhouse vegetables, fruit trees, and other fields with long-term continuous cropping, it effectively inhibits soil-borne diseases, restores the soil micro-ecology, and solves the problem of “repeated cropping leading to reduced yields.”

Green and Environmentally Friendly, Enhancing Agricultural Product Quality

Microbial fertilizers are non-toxic and harmless, leaving no residue in crops. After application, they can improve the taste, sweetness, and safety of agricultural products, meeting the production needs of green and organic foods.

Complementary and Synergistic with Other Fertilizers

Used in conjunction with chemical fertilizers, it can prevent “root burn”; used in conjunction with organic fertilizers, it can accelerate the decomposition of organic fertilizers and enhance their effectiveness.

Precautions for Use

Maintaining microbial activity is key.

Store in a cool, dry, and well-ventilated place, avoiding direct sunlight (ultraviolet rays will kill beneficial bacteria) and high temperature and humidity environments.

Avoid mixing with fungicides, insecticides, and other pesticides. If necessary, allow an interval of 7-10 days.

Prepare and use immediately whenever possible; diluted microbial fertilizer solutions should not be stored for extended periods.

Strictly follow application methods: Seed dressing and root dipping are more effective than broadcasting, allowing microorganisms to be closer to the crop roots. When used as a base fertilizer, it must be thoroughly mixed with the soil to avoid concentrated application that could lead to excessively high local microbial concentrations.

Properly combine with other fertilizers; do not replace chemical fertilizers: Microbial fertilizers cannot replace chemical and organic fertilizers. They must be applied in combination with chemical and organic fertilizers according to the crop’s needs to meet its nutrient requirements throughout its entire growth cycle.

Pay attention to soil compatibility: The activity of beneficial microorganisms is greatly affected by soil pH, temperature, and humidity. They thrive in soils with a pH of 6.0-7.5. Excessively dry or waterlogged soils will inhibit microbial activity.

Conclusion: Integrating Microbial Solutions into Modern Fertilizer Systems

In summary, microbial fertilizers represent a fundamental shift toward biological soil management, enhancing nutrient cycling, soil health, and crop resilience. Their success hinges on maintaining microbial viability and integrating them effectively with conventional nutrient sources.

For manufacturers, microbial inoculants can be incorporated into a complete bio organic fertilizer production line. This begins with producing a high-quality organic base via windrow composting machine technology. The resulting compost can then serve as a carrier for beneficial microbes. For producing compound fertilizers, an npk fertilizer production line using an npk blending machine and granulation equipment like a disc granulator (part of a disc granulation production line), a double roller press granulator, or a roller press granulator production line can be used to create blended or coated products that combine chemical nutrients with microbial agents, following a precise npk fertilizer production process.

Ultimately, the future of sustainable agriculture lies in synergizing biological inputs with precision mineral nutrition, creating fertilizer systems that are both productive and regenerative.

Which Technology Can Convert Waste into Compost?

Transforming organic waste into compost is a sustainable practice that turns waste into a resource that nourishes the soil. The core of this process lies in utilizing microorganisms to decompose organic matter, and the foundational technology that enables this is aerobic composting technology. This technology ensures efficient and environmentally friendly conversion by providing ample oxygen for microbial activity. Depending on the operation method, scale, and requirements, aerobic composting has evolved into several distinct types, each suited to different scenarios ranging from household use to industrial production.

1. Static Windrow Composting: The Basic and Widespread Technique

This is the most classic and simplest form of aerobic composting. The method involves piling mixed organic waste (such as straw, livestock manure, and kitchen waste) into long, narrow windrows (typically 2-3 meters wide and 1.2-1.5 meters high). Oxygen is replenished through natural air convection or occasional manual turning. This approach requires minimal equipment and is perfectly suited for small to medium-sized farms, community gardens, or home gardening. Its main characteristics are flexibility and low cost, but the fermentation cycle is relatively long, taking 60 to 90 days for complete maturation without additional intervention. The cycle can be shortened to 30-45 days by adding commercial microbial inoculants and proper management.

2. Aerated Static Pile Composting: The Efficient No-Turn Solution

This is an intelligent upgrade of static composting. Perforated ventilation pipes are laid beneath the pile and connected to blowers, which actively pump or draw air through the pile to precisely control oxygen supply and temperature. The greatest advantage of this technology is that it eliminates the need for frequent turning while maintaining the pile at the optimal thermophilic temperature range of 55-65°C for an extended period. This ensures more thorough pathogen and weed seed destruction and improves maturation uniformity. It is particularly suitable for processing materials with high moisture content, such as food waste and sludge, and is widely used in small to medium-sized compost processing facilities.

3. In-Vessel (Channel) Turned Composting: The Industrial Standard for Scale

This is currently the mainstream process for commercial compost production, representing the model for large-scale, mechanized operations. Materials are placed in long fermentation channels or bays and are turned regularly and efficiently by dedicated rail-mounted or wheeled compost turners. The turning process mixes the materials, breaks up clumps, and provides thorough aeration. Combined with a ventilation system at the base of the channel, key parameters of the fermentation process (temperature, moisture, oxygen) can be tightly controlled. As a result, the fermentation cycle is significantly shortened to 15-30 days, producing stable, uniform finished products. This technology is ideal for processing large volumes of organic waste like livestock manure (in the tens of thousands of tons) and crop residues.

4. Reactor Composting: Enclosed State-of-the-Art Technology

This is the most advanced and intelligent composting technology. Organic waste is processed inside a fully enclosed reactor (such as a vertical silo or horizontal rotating drum). The entire process is automated and computer-controlled, allowing for precise regulation of aeration, temperature, humidity, and agitation frequency, creating a near-perfect environment for microbial activity. The results are an extremely short fermentation cycle (7-15 days), virtually no odor emissions, and the highest degree of sanitization and maturation. It can efficiently handle high-concentration organic waste like food waste and slaughterhouse by-products. However, the equipment and operational costs are high, making it primarily suitable for large urban organic waste treatment centers or high-standard fertilizer production plants.

5. Vermicomposting: Natural Biological Transformation

This is a unique and gentle biological conversion technology. It utilizes the digestive systems of earthworms (primarily Eisenia fetida) to break down organic waste. Pre-treated materials like kitchen scraps and manure are placed on worm beds. The earthworms consume and digest this material, excreting what is known as “black gold” — worm castings, a top-tier organic fertilizer that is crumbly, rich in humic acids and beneficial microorganisms. This technology consumes almost no energy and produces no secondary pollution. It is especially suitable for households, schools, and small communities to process daily kitchen waste. The resulting product has a mild fertilizer effect and is excellent for gardening and seedling cultivation.

Conclusion: Choosing the Right Aerobic Composting Solution

In summary, while anaerobic methods exist, aerobic fermentation composting technology for organic fertilizer remains the preferred, efficient, and scalable pathway for converting waste into valuable compost. The optimal technology choice hinges on processing goals, waste type, scale, and budget.

For effective implementation, selecting the right compost production machine is crucial. The core of the fermentation composting turning technology lies in reliable turning equipment. Options include the high-volume large wheel compost turner, the flexible chain compost turner, or the efficient trough-type compost turner for controlled trough-type aerobic fermentation composting technology. These machines, along with necessary pre-composting processing equipment, form the essential equipments required for biofertilizer production. Together, they ensure optimal aeration and decomposition, transforming organic waste into high-quality soil amendments.

From a backyard bin to an industrial facility, this scalable suite of aerobic technologies provides a complete solution, enabling organic resources to safely re-enter the ecological cycle and fostering a sustainable, circular relationship with our environment.

Key application points of BB fertilizer mixer and fertilizer granulator

NPK blended fertilizers are widely used in agricultural production due to their flexible nutrient ratios and adaptability to different crop needs. The coordinated operation and standardized procedures of the production line equipment directly determine product quality. Among these, the BB fertilizer mixer and fertilizer granulator play an indispensable role as core equipment.

The BB fertilizer mixer is a crucial link in the NPK blending fertilizer production line, ensuring uniform nutrient mixing. Since NPK blended fertilizers require precise proportions of nitrogen, phosphorus, potassium, and various trace elements, uneven mixing can lead to nutrient imbalances and affect fertilization effectiveness. During operation, it is important to follow the principle of “lighter materials first, then heavier materials; finer materials first, then coarser materials” to prevent material accumulation at the bottom of the equipment. Simultaneously, adjust the mixing speed and time according to the material characteristics to ensure sufficient dispersion and contact of all raw materials, preventing localized nutrient enrichment.

The fertilizer granulator determines the molding quality of the NPK blended fertilizer. After mixing in the BB fertilizer mixer, the materials need to be processed into granules by the fertilizer granulator. This not only facilitates storage and transportation but also reduces nutrient loss during application. During production, the granulator’s speed, pressure, and other parameters need to be adjusted based on the material’s moisture content and particle size.

Furthermore, all stages of the NPK blending fertilizer production line must be closely integrated. From raw material selection and BB fertilizer mixing to fertilizer granulation, every step requires strict parameter control. Only by ensuring stable equipment coordination can high-quality NPK blended fertilizers with uniform nutrients and regular granules be produced, providing strong support for high agricultural yields.

Water-soluble fertilizers: the core of precise and efficient fertigation

Water-soluble fertilizers (WSF) are a type of fast-acting fertilizer with high-purity raw materials that dissolve completely in water. Their core characteristics are no residue and easy absorption. They can be applied through drip irrigation, sprinkler irrigation, and fertigation to achieve integrated water and fertilizer management, precisely matching the nutrient needs of crops at different growth stages. They are a mainstream high-efficiency fertilizer variety for facility agriculture and cash crop cultivation.

I. Core Characteristics and Raw Material Requirements

Completely Water-Soluble: The raw materials for water-soluble fertilizers must be high-purity chemical salts or chelated compounds. After dissolving, they leave no solid residue and will not clog irrigation equipment such as drip tapes and sprinklers.

Macronutrient Raw Materials: Industrial-grade urea, potassium dihydrogen phosphate, potassium nitrate, potassium magnesium sulfate, etc., with a purity typically ≥98%.

Micronutrient Raw Materials: Chelated zinc (EDTA-Zn), chelated iron (EDTA-Fe), boric acid, etc., avoiding binding with ions in the soil and loss of efficacy.

Micronutrient Raw Materials: Flexible Nutrient Ratios

Formulas can be customized according to crop nutrient requirements, for example:

Seedling Stage Fertilizer: High-phosphorus formula to promote root development;

Fruit Expansion Stage Fertilizer: High-potassium formula to enhance fruit sweetness and color;

All-Purpose Fertilizer for the Entire Growth Stage: Balanced nitrogen, phosphorus, and potassium formula to meet the basic growth needs of crops.

II. Main Product Types

Water-soluble fertilizers can be divided into two main categories based on nutrient type and form, suitable for different fertilization scenarios:

 Macronutrient Water-soluble Fertilizers:

 Powder Type: Low water content, convenient for transportation and storage, dissolves quickly, and is the most common type on the market, suitable for fertigation and drip irrigation of various crops;

 Liquid Type: No dissolution required, can be directly diluted for more uniform mixing and faster fertilizer effect, suitable for automated irrigation systems, commonly found in high-end facility agriculture.

 Micronutrient Water-soluble Fertilizers: Primarily composed of micronutrients such as calcium, magnesium, sulfur, iron, zinc, and boron, mostly produced using chelation technology, maintaining activity in soils with different pH values ​​and avoiding soil fixation. Primarily used to correct nutrient deficiency symptoms in crops, such as blossom-end rot in tomatoes (calcium deficiency) and yellow leaf disease in fruit trees (iron deficiency).

III. Core Application Method: Fertilizer and Water Integration The core advantage of water-soluble fertilizers lies in their integration with irrigation systems, achieving simultaneous water and fertilizer supply. There are three common application methods:

 Drip Irrigation Fertilization: Diluted fertilizer solution is injected into drip irrigation pipes, slowly dripping into the soil near the crop roots through emitters, precisely supplying nutrients. This method offers the best water and fertilizer savings, with water utilization rates exceeding 90%, and nutrient utilization rates 30%-50% higher than traditional fertilization.

 Sprinkler Irrigation Fertilization: Fertilizer solution is added to the sprinkler irrigation system and sprayed evenly into the field with irrigation water. Suitable for field crops (such as wheat and corn) and orchards, this method is convenient, labor-saving, and time-saving.

 Fertigation/Leaching: Fertilizer is dissolved and applied between crop rows with irrigation water. Suitable for open-field vegetables, melons, and other crops, this method is lower in cost, but the nutrient utilization rate is slightly lower than drip irrigation.

IV. Core Advantages

 Extremely High Nutrient Absorption Efficiency: Water-soluble fertilizers exist directly in ionic form after dissolving, allowing for rapid absorption and utilization by crop roots. This avoids the lengthy “dissolution-conversion-absorption” process of traditional compound fertilizers, resulting in rapid onset of action and timely relief of crop nutrient deficiency symptoms.

 Water, Fertilizer, and Labor Savings, Reducing Planting Costs: Integrated water and fertilizer technology can reduce irrigation water consumption by over 50% and fertilizer waste by over 30%. Simultaneously, it eliminates the need for manual trenching and topdressing, significantly reducing labor costs, making it particularly suitable for large-scale, mechanized planting.

 Precise Nutrient Regulation, Enhancing Crop Quality: Fertilizer formulas and application concentrations can be flexibly adjusted according to the nutrient requirements of crops at different growth stages. For example, increasing potassium fertilizer during the fruit expansion stage of melons and fruits can significantly improve fruit sugar content and storage and transport resistance; increasing nitrogen fertilizer in leafy vegetables can promote tender and thick leaves.

Precise Nutrient Regulation, Enhancing Crop Quality: Fertilizer formulas and application concentrations can be flexibly adjusted according to the nutrient requirements of crops at different growth stages. Suitable for facility agriculture, with a wide range of applications. Not only suitable for greenhouse vegetables, greenhouse flowers, fruit trees, and other cash crops, but also for topdressing field crops, especially suitable for fertile soils such as saline-alkali soil and sandy soil.

V. Precautions for Use

Strictly control the concentration to avoid fertilizer damage. Water-soluble fertilizers have high nutrient concentrations; insufficient dilution can easily lead to root and leaf burn in crops. Generally, the application concentration for field crops is 0.2%-0.5%, and for facility crops, it is 0.1%-0.3%, with adjustments made according to the crop variety.

Avoid indiscriminate mixing. Different types of water-soluble fertilizers should be tested for compatibility before mixing. For example, phosphate fertilizers should not be mixed with calcium-containing fertilizers, otherwise calcium phosphate precipitates will form, clogging irrigation equipment.

Prepare and use immediately; do not store for extended periods. Fertilizer solutions should be applied as soon as possible after preparation, especially chelated fertilizers containing trace elements. Prolonged storage will cause the chelation structure to break down, resulting in nutrient loss.

Combine soil fertilization with long-lasting effects. Water-soluble fertilizers have a fast effect but a short duration of effect. It is recommended to use them in combination with organic fertilizers and slow-release fertilizers to meet the nutrient needs of crops for long-term growth.

Conclusion: Integrating Precision Application with Efficient Production

In summary, water-soluble fertilizers (WSF) represent the pinnacle of precision nutrient delivery, enabling targeted, efficient crop nutrition through fertigation systems. Their rapid uptake and flexibility perfectly align with the demands of modern, high-value agriculture.

For producers, the efficient manufacturing of the raw nutrient salts used in WSF is equally critical. This is where advanced npk granulation machine technology plays a foundational role. A complete npk fertilizer manufacturing process typically involves precise formulation via an npk blending machine or npk bulk blending machine, followed by shaping the mixture into uniform granules using an npk fertilizer granulator or a complete npk granulation machine line. The choice of npk fertilizer granulator machine equipment directly influences product quality and the overall NPK fertilizer production price, making it a key investment for manufacturers supplying the growing WSF market.

Ultimately, the synergy between high-purity granulated nutrient sources and precise water-soluble application methods creates a powerful toolkit for sustainable intensification, helping farmers achieve higher yields and better quality with optimal resource use.

Flat Die Granulation Production Line: A High-Efficiency Granulation Manufacturing Solution

Flat die pelleting production lines play a vital role in modern industrial production, improving the efficiency of material storage, transportation, and utilization by processing powdered materials into uniform granules. This article introduces the production line’s capacity characteristics, applicable materials, working principle, and selection recommendations to help global readers gain a comprehensive understanding of this technology.

Production Capacity Overview

The hourly output of flat die pelleting production lines varies significantly depending on the model, configuration, and material characteristics. Common small production lines (such as those used in laboratories or small-batch production scenarios) typically have an hourly output between 0.08 and 0.3 tons, with a power configuration of approximately 5.5 to 11 kW. Medium-sized production lines are suitable for small to medium-sized farms or fertilizer plants, with an hourly output of 0.4 to 2.5 tons and a power configuration of 15 to 55 kW. Large production lines are used for large-scale production, with an hourly output of 2.5 to 5 tons and a power configuration of 55 to 75 kW. For extra-large customized production lines, the hourly output can even reach 8 to 20 tons, with power requirements exceeding 90 kW.

Key factors affecting production capacity include material moisture content, particle size, viscosity, hardness, as well as die orifice diameter and roller pressure. Generally, the material moisture content should be controlled between 15% and 25%, the particle size is preferably less than 2 mm, and the die orifice diameter commonly ranges from 3 to 30 mm. Proper control of these parameters helps improve pelleting yield and production efficiency.

Main Application Areas: Flat die pelleting technology is widely used in multiple industries. In the fertilizer industry, it is suitable for the production of organic fertilizers, bio-organic fertilizers, and compound fertilizers. Raw materials include livestock and poultry manure, straw, and humic acid, with a pelleting yield typically exceeding 95%, high particle strength, and low secondary pulverization rate. In the feed industry, this technology is used to produce livestock, poultry, and aquatic pellet feed, retaining nutrients while maintaining a temperature rise below 30 degrees Celsius during processing. In the biomass energy sector, flat die pelleting can compress raw materials such as sawdust and straw into high-density fuel pellets, facilitating storage and combustion. Furthermore, this technology is also suitable for the chemical and mining industries, such as the pelleting of activated carbon, catalyst carriers, and mineral powders, especially suitable for low-viscosity and heat-sensitive materials. Working Principle and Structural Features: The flat die granulator works by using a motor-driven reducer to rotate the flat die. Under centrifugal force, the pressure rollers adhere to the die, forcing the material into the die holes and extruding it into cylindrical granules. Finally, a scraper cuts the granules into uniform lengths. The entire process is carried out at low temperatures (typically below 30 degrees Celsius), making it suitable for processing heat-sensitive materials.

The core components of the production line include pretreatment equipment (such as crushers and mixers), the main unit (including the flat die, pressure rollers, and scraper), and post-processing equipment (such as coolers and screening machines). The flat die is typically made of alloy steel or carburized steel, offering high wear resistance. Particle diameter can be adjusted between 3 and 50 mm, with a granulation rate generally exceeding 95%. Compared to drying granulation technology, flat die pelleting can reduce energy consumption by approximately 40%.

Technical Advantages and Applicable Scenarios

The advantages of flat die pelleting technology include low-temperature processing, which helps retain the bioactivity and nutrients of the material; lower moisture requirements, reducing drying energy consumption; simple equipment structure, low maintenance costs, and convenient die replacement, adaptable to various pellet sizes.

This technology is particularly suitable for the large-scale production of organic and bio-fertilizers, especially composted materials and low-viscosity materials. It provides a low-cost pelleting solution in biomass fuel and feed production. For heat-sensitive or low-viscosity powders in the chemical and mining industries, flat die pelleting is also an efficient pelleting method.

Selection and Operation Recommendations

When selecting a flat die pelleting production line, capacity requirements, material characteristics, and target pellet sizes must be considered. It is recommended to calculate the hourly output based on daily production requirements and reserve 10% to 20% redundancy. For materials with a moisture content exceeding 25%, drying equipment may be required; coarse fibrous materials are suitable for large-roller mills. Common pellet sizes include 3 to 8 mm (for fertilizers) and 6 to 12 mm (for biomass fuels).

During operation, it is recommended to control the raw material particle size to below 2 mm and maintain the moisture content between 18% and 22%. Regularly check the wear of the flat die and pressure rollers, and replace them promptly to maintain a high pelletizing rate. Matching cooling and screening equipment can ensure pellet uniformity and storage stability.

A Brief Comparison with Ring die pelleting

Compared to ring die pelleting, flat die pelleting is more suitable for low to medium production capacity (typically not exceeding 5 tons/hour) and low-viscosity, heat-sensitive, or coarse-fiber materials. Die replacement is simpler, and maintenance costs are lower. Ring die pelleting is suitable for high-volume demands and high-viscosity materials, with a capacity of over 10 tons/hour, but die replacement is more complex. In terms of pellet shape, flat die pelleting primarily produces cylindrical pellets, while ring die pelleting can produce cylindrical or near-spherical pellets.

In summary, flat die pelleting production lines are a flexible, efficient, and energy-saving pellet manufacturing solution suitable for multiple fields such as fertilizers, feed, biomass energy, and chemical and mineral products. By making appropriate selections and operating in a standardized manner, users can achieve their production goals of high quality and low cost.

Conclusion: Integrating Granulation Technologies for Optimal Production

In summary, Flat die pelleting production lines offer a versatile, low-energy granulation solution ideal for small to medium-scale operations, particularly in the organic fertilizer manufacturing process. Their strength lies in processing heat-sensitive and low-viscosity materials at low temperatures, preserving vital nutrients and bioactivity.

For producers aiming for a diversified product portfolio, integrating a flat die line with other advanced fertilizer processing machine technologies creates a robust system. For instance, while a flat die line is excellent for organic granules, a disc granulation production line or roller press granulator production line might be better suited for high-volume npk manufacturing process requirements. Together with equipment like a rotary drum granulator or a drum granulator in a complete npk production line, manufacturers can leverage the full spectrum of npk fertilizer production technology to meet diverse market demands efficiently.

Ultimately, the strategic choice of granulation technology—whether flat die, disc, or roller press—should be driven by material properties, desired capacity, and final product specifications. By selecting the right system, producers can achieve high-quality granule production with optimal cost-efficiency and flexibility.

Wet chicken manure treatment: The most suitable resource utilization solution

Wet chicken manure has a high moisture content of 60%-80% and is rich in nutrients such as nitrogen and phosphorus. Improper disposal can lead to bacterial growth, soil and water pollution, and environmental problems. Among various treatment methods, “fermentation to produce organic fertilizer” is the optimal choice, balancing environmental protection, economic viability, and resource recycling. It effectively solves pollution problems while transforming waste into high-quality agricultural resources.

Common wet chicken manure treatment methods have limitations: direct application to fields can burn roots and seedlings, and does not eliminate pathogens and insect eggs; drying and direct use is energy-intensive and costly; simple composting has a long decomposition cycle and easily produces foul odors. Fermentation to produce organic fertilizer, through scientific processes and specialized equipment, precisely addresses these issues, achieving efficient resource utilization of wet chicken manure.

The optimal treatment process can be divided into three steps: First, pretreatment involves mixing wet chicken manure with auxiliary materials such as straw and sawdust in appropriate proportions to adjust the moisture content to 55%-60%, followed by crushing and screening to remove impurities; second, fermentation and composting involves using a crawler-type compost turning machine for regular turning, ensuring ventilation and oxygen supply to the compost pile, maintaining a high temperature of 55-65℃ for 15-20 days to thoroughly kill pathogens and insect eggs, and allowing the material to fully decompose; third, shaping and processing involves sending the composted material into an organic fertilizer granulator to produce granular organic fertilizer, facilitating storage, transportation, and field application.

This fermentation-based treatment solution can be used to build small-scale or large-scale organic fertilizer production lines with appropriate equipment, adapting to the needs of different farming scales. It not only completely solves the pollution problem of wet chicken manure but also produces high-value organic fertilizer, achieving a closed-loop cycle of “livestock waste – agricultural resources.”