fertilizer production line

Core Value and Application Analysis of Coating Machines

In numerous industries such as food preservation, pharmaceutical protection, electronic protection, daily necessities packaging, and chemical product sealing, surface protection and appearance optimization are key to enhancing product competitiveness. Laminating machines (also known as film packaging machines or film coating machines), as automated equipment for coating product surfaces, have become core equipment for packaging upgrades across various industries due to their high efficiency, wide adaptability, and stable coating quality. By covering the product surface with a thin film, it enhances the product’s moisture-proof, dust-proof, and corrosion-proof properties, while also improving the product’s appearance and packaging protection, providing comprehensive protection for product storage, transportation, and sales.

The stable and efficient operation of laminating machines relies on a scientifically sound structural design, with each core system working in tandem to form a complete laminating operation system. The conveying system is the foundation of material flow, typically employing belt conveyors or chain conveyors, which accurately and smoothly transport products to be coated to the designated laminating station, ensuring the continuity of the operation. The film supply system consists of a film roll, a film guiding mechanism, and a film tension adjustment device. It ensures a continuous and stable supply of film while maintaining a smooth, wrinkle-free surface through tension adjustment, laying the foundation for high-quality lamination. The heating system uses heating tubes and infrared heating lamps to precisely control the temperature, heating the film to a softened state for excellent adhesion. The forming system uses molds or hot air to shape the softened film to fit the product, ensuring a perfect fit. The cooling system intervenes quickly after lamination, using air or water cooling to rapidly set the film, improving lamination adhesion and surface smoothness. The control system uses PLC or microcomputer control to achieve fully automated management of equipment speed, temperature, and workflow, while also featuring fault detection to ensure stable operation. The safety protection system is equipped with emergency stop switches and safety doors, providing comprehensive protection for operators.

The laminating machine’s working principle is clear and efficient, with fully automated control ensuring both lamination quality and efficiency. During operation, the product to be laminated is first precisely delivered to the laminating station via a conveyor system. Simultaneously, the film supply system pulls the film out at a uniform speed, and after being guided by a film guiding mechanism, it is smoothly applied to the product surface. Then, the heating system activates, heating the film to a softened state. The forming system works concurrently, using mold bonding or hot air shaping to ensure the softened film adheres tightly to the product surface. After bonding, the cooling system quickly activates to cool and set the laminated product, ensuring a firm bond between the film and the product, thus completing the entire laminating process. The entire process is automated under the control system, requiring minimal manual intervention, ensuring consistent laminating quality and significantly improving operational efficiency.

The unique structure and working principle give the laminating machine many significant advantages, enabling it to adapt to the complex packaging needs of various industries. High efficiency is its core competitiveness; the equipment can achieve continuous laminating operations, greatly improving production efficiency and adapting to large-scale production rhythms. Its exceptional adaptability is another major highlight. By adjusting the mold or forming parameters, it can adapt to products of different shapes and sizes, achieving high-quality lamination for regular box-shaped, cylindrical, and irregularly shaped products. This high-quality lamination benefits from precise temperature and speed control, ensuring a tight bond between the film and the product, excellent sealing performance, and a smooth, even appearance, effectively enhancing the product’s market competitiveness. The fully automated operation mode significantly reduces manual operation, lowering labor costs and human error. The equipment also features a user-friendly interface with simple and easy-to-understand parameter settings, facilitating operation and maintenance. Furthermore, a comprehensive safety protection system ensures operator safety, and the equipment operates stably with a low failure rate, further improving enterprise production efficiency.

From snack packaging in the food industry and medicine box lamination in the pharmaceutical industry to component protection in the electronics industry and product beautification in the daily necessities industry, laminating machines, with their core advantages of high efficiency, stability, and flexibility, have become essential equipment for packaging upgrades across various industries. Against the backdrop of ever-increasing consumer demands for product quality and appearance, this automated equipment, which combines protection and aesthetics, not only helps companies enhance their product competitiveness but also drives the packaging industry toward efficiency, precision, and automation, providing strong support for the high-quality development of various industries.

Enhancing Fertilizer Products Through Advanced Finishing

While laminating machines serve industries focused on consumer goods, a conceptually similar finishing process is crucial in the fertilizer industry: coating. The protective coating of fertilizer granules is a key final step in modern professional fertilizer manufacturing equipment, enhancing product stability and performance.

This coating process is typically integrated into a complete npk fertilizer production line or organic fertilizer production line. Within the npk fertilizer production process, it occurs after the granulation stage. The process begins with precise formulation using an npk blending machine or npk bulk blending machine. The blend is then shaped into granules using a fertilizer granulator, which could be a disc granulator machine in a disc granulation production line, a double roller press granulator, or part of a roller press granulator production line. For organic operations, the process starts with raw material from a windrow composting machine. After granulation and drying, a coating is applied to the granules to control dust, improve flowability, and provide controlled-release properties, completing the value chain in both standard NPK and specialized bio organic fertilizer production line outputs.Thus, while the machines differ, the principle of applying a protective surface layer is a shared concept across industries, and in fertilizer manufacturing, it is a critical step that adds significant value and functionality to the final product.

Types of organic fertilizer materials and processing characteristics suitable for rotary drum granulators

The rotary drum granulator, with its strong adaptability to various materials and high granulation rate, has become a core piece of equipment in organic fertilizer production lines. It can process organic materials from multiple sources, covering various fields such as livestock farming, agriculture, and industrial processing.

Livestock and poultry manure is the most common suitable material, including chicken manure, pig manure, cow manure, and sheep manure. These materials are rich in basic nutrients such as nitrogen, phosphorus, and potassium. After fermentation and composting, they have a loose texture and a certain viscosity, which meets the granulation requirements of the rotary drum granulator. The rotating agitation of the drum allows the manure material to be fully mixed with auxiliary materials, resulting in granules with moderate strength, effectively solving the problems of seedling burning and environmental pollution caused by the direct application of livestock and poultry manure.

Agricultural straw materials can also be processed by the rotary drum granulator, such as corn stalks, wheat stalks, and rice stalks. Straw is rich in cellulose and organic matter. After crushing and fermentation, it needs to be used in combination with viscous materials such as livestock and poultry manure. The rolling granulation of the drum allows the straw powder to be evenly coated and formed, which not only increases the organic matter content of the organic fertilizer but also realizes the resource utilization of agricultural waste.

In addition, the rotary drum granulator can also process industrial organic waste materials, such as distiller’s grains, vinegar residue, furfural residue, and pharmaceutical waste. These materials are rich in nutrients, but their composition is complex and their moisture content fluctuates greatly. The rotary drum granulator can adapt to the characteristics of different wastes by adjusting the rotation speed and material ratio, converting them into qualified organic fertilizer granules. At the same time, urban and rural organic waste such as kitchen waste and garden fallen leaves, after sorting and fermentation, can also be granulated and recycled through the rotary drum granulator.

From raw materials to granules: The journey to the birth of modern NPK fertilizer

NPK compound fertilizers, widely used in modern agricultural production, undergo a precise and systematic industrial processing procedure. From basic chemical raw materials to uniformly shaped granules, this NPK fertilizer production line integrates chemical synthesis and physical processing technologies, forming a standardized manufacturing system.

Production begins with the precise measurement and synthesis reaction of raw materials. Different proportions of nitrogen, phosphorus, and potassium base materials undergo chemical reactions under controlled conditions to generate a complex containing the target nutrients. This chemical stage establishes the core nutrient content and ratio of the product.

The synthesized slurry then enters the crucial physical molding stage. The rotary drum granulator plays a vital role in this process. By precisely controlling temperature and humidity, these granules achieve a stable physical morphology, preparing them for subsequent processing.

The newly generated granules require complete post-processing. After drying and cooling, the sieving process grades the granules according to their specifications. At this point, lumps with excessively large particle sizes are returned to the previous process, re-crushed in a fertilizer crusher, and then re-granulated. This cycle ensures high raw material utilization and uniform product particle size.

It is worth mentioning that some of the large-particle base fertilizers obtained after drying and screening can be used as raw materials to directly enter another flexible production path—through bulk blending fertilizer machines, they can be quickly and physically mixed with other single-element fertilizers or micronutrients according to actual field needs to produce customized blended fertilizers.

Cage Crusher + Cyclone Dust Collector: A High-Efficiency and Environmentally Friendly Solution for Fertilizer Raw Material Pretreatment

The combination of a cage crusher and a cyclone dust collector is a golden combination for the pretreatment of raw materials in fertilizer production. It achieves both fine crushing of large raw materials and efficient dust collection, purifying the production environment. It is widely applicable to the processing of raw materials for various fertilizers, including organic fertilizers and compound fertilizers, and is especially suitable for large-scale production scenarios requiring strict dust pollution control.

Core Equipment Functions and Synergistic Advantages

Cage Crusher: The Core Equipment for Precise Raw Material Crushing

Working Principle: Utilizing a “double-cage rotor collision + shearing” crushing mode, the inner and outer cage bars are driven by a motor to rotate at high speed (speed up to 1500-2000 r/min). After entering the chamber, the raw material is rapidly crushed through impact, shearing, and mutual collision between the cage bars. The particle size after crushing can be flexibly controlled between 0.5-3 mm.

Suitable Raw Materials: Perfectly processes inorganic fertilizer raw materials such as urea, monoammonium phosphate, and potassium chloride, as well as organic raw materials such as fermented livestock and poultry manure, straw charcoal, and mushroom residue. It can crush large materials with a particle size ≤80mm, with a crushing efficiency of 5-15 tons/hour (adjusted according to machine specifications).

Core Advantages: The cage bars are made of high-chromium wear-resistant alloy material, achieving a hardness of HRC60 or higher after quenching treatment, extending the service life to over 8000 hours; the equipment has a built-in grading screen, which can be replaced with different mesh sizes to ensure uniform output particle size; compact structure and low operating noise (≤75dB), suitable for compact production line layouts.

Cyclone Dust Collector: An Environmentally Friendly Solution for High-Efficiency Dust Purification

Working Principle: Utilizing centrifugal force to separate dust, dust-laden gas enters the dust collector chamber at high speed through the inlet, rotating along the inner wall. Dust particles are thrown against the wall by centrifugal force and slide down the cone wall to be collected in the ash hopper. The purified gas is discharged from the outlet, achieving a dust removal efficiency of 95%-98%.

Suitable Scenarios: Specifically designed for collecting dust generated during the operation of cage pulverizers, especially for dust particles with a diameter of 0.1-10μm in fertilizer production. It can control the dust concentration in the workshop to below 10mg/m³, meeting national environmental protection standards.

Core Advantages: Made of carbon steel or stainless steel, corrosion-resistant and easy to maintain; no need for filter cloths or other easily damaged parts, resulting in low operating costs; large air volume handling capacity (1000-5000m³/h), precisely matched to the dust generation of cage pulverizers, and can be directly connected to a fan for negative pressure dust removal.

III. Collaborative Workflow and Value

After the raw materials are crushed by the cage crusher, the resulting dust-laden gas is drawn into a cyclone dust collector under the negative pressure of a fan.

The dust is efficiently separated and collected, and the purified gas is discharged in compliance with standards. The collected dust is discharged through the ash hopper and can be recycled back to the production line for reuse, increasing material utilization by 3%-5%.

The entire system achieves integrated “crushing + dust removal” operations, ensuring that the raw material fineness meets standards, solving the dust pollution problem, reducing material waste, and lowering production losses.

Selection and Usage Precautions

Selection and Matching Key Points

Capacity Matching: Based on the hourly output of the cage crusher (e.g., 5 tons/hour, 10 tons/hour), select a cyclone dust collector with a corresponding air volume to ensure dust removal efficiency and avoid dust leakage due to insufficient air volume;

Material Compatibility: When handling corrosive raw materials (e.g., ammonium sulfate, monoammonium phosphate), the equipment should be made of stainless steel or have an anti-corrosion coating to extend its service life;

Installation Height: Sufficient installation height (usually ≥3 meters) should be reserved for the cyclone dust collector to ensure that dust settles smoothly into the ash hopper and avoids accumulation and blockage.

Daily Use and Maintenance Regularly check the wear of the cage bars in the cage crusher; replace them promptly if severely worn to avoid affecting crushing efficiency. Clean the screen regularly to prevent material from clogging the screen holes. Clean the dust collected in the cyclone dust collector’s hopper regularly to prevent excessive dust accumulation from affecting the dust removal effect. Check the air inlet and outlet for leaks to prevent a decrease in dust removal efficiency. Maintain the matching fan regularly to ensure stable negative pressure. Adjust the fan speed according to the amount of dust generated to balance dust removal efficiency and energy consumption.

A Foundational Step in the Production Chain

The cage crusher and cyclone dust collector system represents a critical early-stage process within a complete organic fertilizer manufacturing system. It ensures that raw organic materials are properly sized and cleaned before entering the core biological and shaping stages, setting the stage for high-quality final product manufacturing.

This preprocessing step is integral to an efficient organic fertilizer manufacturing operation. The crushed and cleaned material, often derived from compost processed by a chain compost turning machine using advanced fermentation composting turning technology, is ready for the organic fertilizer production granulation stage. Here, manufacturers can choose specialized equipment to shape the material. Options include a dedicated organic fertilizer disc granulation production line featuring an organic fertilizer disc granulation machine for uniform pellets, or a versatile organic fertilizer combined granulation production line that may incorporate a new type organic fertilizer granulator. This systematic integration, from efficient crushing to precise granulation, defines a modern, high-output organic fertilizer production line.Therefore, the value of the crushing and dust removal system extends far beyond its immediate function; it is an essential enabler of consistency, efficiency, and environmental compliance throughout the entire organic fertilizer production process.

Self-propelled compost turner: A bio-organic fertilizer fermentation equipment adapted to complex scenarios

In the fermentation stage of bio-organic fertilizer production lines, the self-propelled compost turning machine is one of the core pieces of bio-organic fertilizer equipment. Compared to fixed composting equipment, its unique mobility and efficient turning capabilities allow it to easily handle complex sites and diverse pile requirements, helping to improve fermentation efficiency and organic fertilizer quality.

Flexible adaptation to complex sites is a core highlight of this bio-organic fertilizer equipment. Whether it’s scattered piles in small and medium-sized bio-organic fertilizer production lines or fermentation areas in rugged outdoor locations, its self-propelled design allows it to move freely without relying on tracks or level ground, significantly reducing site limitations. The working width can be adjusted according to the size of the compost pile, adapting to the fermentation needs of different scales of bio-organic fertilizer production lines.

Efficient turning is key to enabling high-quality fermentation in bio-organic fertilizer production lines. Through a powerful turning mechanism, it can penetrate deep into the compost pile for even turning, breaking up material compaction and ensuring ventilation, providing sufficient oxygen for microorganisms and accelerating organic matter decomposition; at the same time, it quickly dissipates heat, stabilizes the pile temperature, reduces nutrient loss, and improves the effectiveness and stability of the bio-organic fertilizer.

In addition, this bio-organic fertilizer equipment also boasts the advantages of convenient operation, environmental protection, and energy saving. It can provide customized fermentation solutions for bio-organic fertilizer production lines of different scales.

NPK compound fertilizer additives: The key to quality improvement in the production process

In NPK compound fertilizer production, although additives account for a small proportion of the total volume, they directly affect product quality, storage stability, and application effectiveness. Different types of additives need to be precisely matched to each stage of the NPK fertilizer production line. Scientific application can effectively solve problems such as caking, loose granules, and nutrient loss, thereby enhancing product competitiveness.

Anti-caking agents are a core category, mostly added during the raw material mixing stage in the fertilizer mixer machine or after granulation in the granulator. Common types include hydrophobic (mineral oil, silicones) and adsorbent (zeolite powder, diatomaceous earth). The former forms a protective film on the surface of the granules to isolate water and oxygen, while the latter adsorbs free moisture. Both can reduce the risk of caking, especially suitable for NPK fertilizers with high nitrogen and high humidity formulations.

Binding and conditioning agents are suitable for the granulation stage, ensuring molding quality. Binders (starch, lignin sulfonate) increase material viscosity, improving the molding rate of NPK fertilizer granulators and reducing powdering; conditioning agents optimize granule strength and smoothness, adapting to different granulation processes such as rotary drum granulator. The amount of additive needs to be adjusted according to the characteristics of the raw materials to avoid excessively hard granules or slow dissolution.

Nutrient efficiency enhancers need to be added during the mixing stage in the fertilizer mixer machine to improve fertilizer utilization. For example, urease inhibitors delay nitrogen volatilization, phosphorus activators reduce phosphorus fixation, and trace element chelating agents improve nutrient stability. Strict adherence to the formula ratio is necessary to ensure synergy with the main nutrients and avoid affecting fertilizer efficiency.

In summary, the core of additive application is “functional matching to the process stage and precise dosage.” Scientific selection based on raw materials and product requirements is essential to maximize their value and consistently produce high-quality NPK compound fertilizers.

Three core equipment pieces build a robust quality defense line for NPK granular fertilizers

The market competitiveness of NPK granular fertilizers hinges on granule strength, particle size uniformity, and nutrient stability. The progressive synergy of the fertilizer compaction machine, fertilizer screener machine, and NPK fertilizer granulator, from molding and strengthening to screening, builds a robust quality defense line at every stage.

The NPK fertilizer granulator is the first line of quality control. After precisely proportioned nitrogen, phosphorus, and potassium raw materials are fed into the equipment, they are formed into preliminary granules through wet rolling or dry pre-molding. This ensures that the multiple nutrients are evenly distributed within the granules, preventing stratification, and also initially controls the particle size range, laying the foundation for subsequent quality improvement.

The fertilizer compaction machine undertakes the mission of strengthening the granules. The initially formed granules lack sufficient strength and are prone to pulverization in subsequent stages. After precise extrusion, the internal structure of the granules becomes denser, significantly increasing strength and resulting in a more regular shape. Especially in dry granulation scenarios, the combination of these two machines can increase the granule formation rate to over 95%, meeting the needs of storage and transportation.

The fertilizer screener machine is the final quality control officer. The granules, after molding and strengthening, are graded by the multi-layer screens of the screening machine, removing oversized, undersized, and damaged unqualified products. Qualified products enter the packaging stage, while unqualified products are returned to the granulator for reprocessing, forming a closed loop that ensures uniform particle size and reduces raw material waste.

The synergy of these three pieces of equipment achieves controllable quality throughout the entire cycle of NPK granular fertilizer production, from molding to factory delivery. This not only improves the finished product qualification rate but also ensures stable fertilizer efficacy, precisely meeting the core needs of large-scale agriculture for high-quality fertilizers.

How to Handle High-Moisture Materials? Half-Wet Material Crusher

From agriculture to environmental protection, handling high-moisture materials has always been a challenge. Traditional dry crushers often suffer from clogging and low efficiency when processing wet materials, while the half-wet material crusher offers a targeted solution. This specialized equipment is designed specifically for processing materials with a certain level of moisture, revolutionizing the crushing process for wet straw, organic fertilizer, wet waste, and other similar materials in agriculture, food, chemical, and environmental protection industries.

The half-wet material crusher boasts a scientifically designed and robust structure, the cornerstone of its reliable performance. Its core is the crushing chamber, a space specifically designed to accommodate wet materials and house key crushing components. These components, including blades, hammers, and toothed plates, are meticulously designed to withstand the adhesion and abrasion caused by wet materials. The feed inlet facilitates smooth material feeding, while the discharge outlet ensures efficient output of crushed products. The drive system, consisting of a motor and transmission device, provides stable power for the high-speed rotation of the crushing elements. Many models also offer optional screening systems for precise particle size control and are equipped with anti-clogging devices (such as reversing functions or specially structured crushing elements) to prevent material adhesion and clogging during operation.

The working principle of a semi-wet crusher is based on efficient mechanical action. Wet material first enters the crushing chamber through the feed inlet. Once inside, high-speed rotating crushing elements initiate the crushing process through cutting and grinding. Within the crushing chamber, the material undergoes intense collisions and friction with the crushing elements and other material particles, gradually breaking it down into smaller particles. The crushed material is then discharged through the discharge outlet. For models equipped with a screening system, any particles that do not meet the required particle size are intercepted by the screen and returned to the crushing chamber for secondary processing, ensuring uniform particle size. An integrated anti-clogging mechanism plays a crucial role in addressing the inherent adhesion problem of wet materials, ensuring continuous and efficient operation of the equipment.

With its numerous superior characteristics, the half-wet material crusher has become an indispensable tool in the field of wet material processing. Its excellent ability to handle wet materials is its main advantage, effectively avoiding the clogging problems common in traditional dry crushers. The high-speed rotating crushing elements ensure high crushing efficiency, quickly and uniformly crushing materials to the required particle size. This equipment also boasts wide adaptability, capable of processing various wet materials, including agricultural waste such as wet straw, organic fertilizer raw materials, and wet municipal waste. Its user-friendly design simplifies maintenance, facilitating the replacement of worn crushing parts and cleaning of the crushing chamber. Furthermore, particle size can be flexibly adjusted by changing the screen aperture size or modifying the crushing element configuration to meet the diverse application needs of different industries.

In the context of sustainable development, half-wet material crushers play a crucial role in promoting resource recycling. They efficiently process organic waste, transforming wet waste and agricultural residues into valuable resources for organic fertilizer production. By overcoming the technical bottlenecks in wet material crushing, it not only improves production efficiency but also contributes to environmental protection. As various industries increasingly emphasize green and efficient processing, half-wet material crushers will undoubtedly see wider application, driving innovation and progress in material processing across multiple fields.

A Foundational Step in the Organic Value Chain

The half-wet material crusher is a critical preprocessing unit in modern organic waste management. It specializes in the initial size reduction of high-moisture agricultural and green waste, making the material suitable for efficient decomposition in subsequent biological processes.

This crusher is an essential component within the broader equipments required for biofertilizer production. It works upstream of the key biological stage, which relies on advanced fermentation composting turning technology. Equipment like the large wheel compost turner, the chain compost turner, or a self propelled compost production machine is used in this stage as the primary agriculture waste compost fermentation machine to produce mature compost. The uniform, pre-crushed material from the half-wet crusher significantly enhances the efficiency of this fermentation. The resulting high-quality compost can then be processed into a marketable product on a disc granulation production line, completing the transformation from raw waste to a standardized organic fertilizer.Therefore, by solving the initial processing bottleneck for wet materials, the half-wet crusher enables the entire downstream chain, facilitating the efficient conversion of bulky, moist waste into a valuable and manageable resource for sustainable agriculture.

Which Plants Benefit Most from DAP?

Diammonium Phosphate (DAP), a fertilizer rich in phosphorus (46% P₂O₅) and nitrogen (18% N), is widely recognized for its ability to boost root development and early plant growth. When it comes to the question “What plants benefit most from DAP?”, the answer centers on crops that rely heavily on robust root systems, vigorous early growth, and efficient flowering or fruiting. From staple cereals to root vegetables, and from young fruit trees to legumes, DAP proves particularly valuable as a starter fertilizer, laying a solid foundation for plant health and high yields. Understanding which plants gain the most from DAP and why is key to optimizing fertilizer use in agricultural and horticultural practices.

Cereal crops, including wheat, rice, and maize, are among the top beneficiaries of DAP. As the world’s most important staple foods, these crops require strong root establishment in their early growth stages to absorb water and nutrients efficiently. DAP’s high phosphorus content directly supports root development, while its ammonium nitrogen provides the necessary energy for early vegetative growth, ensuring the crops develop strong stalks and healthy foliage. For farmers, applying DAP as a starter fertilizer during sowing helps cereal crops establish quickly, resist early-stage stress, and ultimately improve yield potential—making it an indispensable input for large-scale cereal production.

Root and tuber crops, such as yams, cassava, potatoes, and sweet potatoes, also thrive with DAP application. The edible parts of these crops are underground roots or tubers, so a robust root system is critical for their growth and yield. DAP’s concentrated phosphorus supply stimulates the development of dense, healthy root networks, enabling the crops to better anchor themselves in the soil and absorb nutrients. This not only increases the size and quantity of tubers but also enhances their quality. Unlike some fertilizers that may prioritize leaf growth over root development, DAP’s nutrient ratio is perfectly tailored to the needs of root and tuber crops, making it a top choice for growers of these crops. 

Vegetables like tomatoes, peppers, okra, and cabbage, as well as legumes such as soybeans, cowpeas, and other pulses, also benefit significantly from DAP. For vegetables, phosphorus is essential for flowering and fruiting—DAP ensures abundant blooms and reduces flower drop, leading to higher fruit set and better harvests. For legumes, even though they can fix nitrogen from the air through symbiotic bacteria, they still require phosphorus for strong root development. A healthy root system allows legumes to establish better symbiosis with nitrogen-fixing bacteria, improving overall growth and seed production. Additionally, young fruit trees (e.g., citrus, mango) and oilseeds (e.g., sunflower) rely on DAP during their early stages to establish strong roots and support future fruit or seed production, making DAP a crucial starter fertilizer for these crops.

The reason DAP works so well for these plants lies in its unique nutrient composition and properties. Its high phosphorus content drives root growth, energy transfer, and flowering, while the ammonium nitrogen supports early vegetative growth. As a versatile starter fertilizer, it can be applied during planting to give plants an immediate nutrient boost. Moreover, DAP has a slight alkaline effect, which helps balance acidic soils and improve nutrient uptake—further enhancing its effectiveness for a wide range of crops. In conclusion, DAP benefits most crops that require strong root systems and vigorous early growth, with cereals, root/tuber crops, vegetables, legumes, and young fruit trees being the top beneficiaries. By targeting these crops with DAP, growers can significantly improve plant health and yields.

Manufacturing the Precise Inputs for Targeted Nutrition

The targeted application of DAP for specific crops illustrates the broader need for precision in fertilizer formulation. This precision is achieved on a commercial scale through advanced manufacturing systems capable of producing a vast array of balanced and specialized fertilizers, including those containing DAP as a key component.

This industrial capability is embodied in modern npk fertilizer production technology and the npk fertilizer granulator machine equipment that forms its core. Within a complete npk fertilizer production line, raw materials like DAP are precisely measured and blended with other nutrients using an npk blending machine or npk bulk blending machine. This uniform blend is then shaped into granules using npk granulation machine technology, which may involve a fertilizer roller press machine for dry compaction or other granulation methods. The efficiency of this entire integrated system determines a factory’s total NPK compound fertilizer production capacity, enabling the reliable, large-scale supply of the tailored nutrient products that support specific crop strategies, from DAP-based starters to complex multi-nutrient blends.Thus, the strategic use of fertilizers in the field is underpinned by a sophisticated manufacturing sector that can precisely formulate and produce the specific nutrient combinations required by modern, crop-focused agriculture.

Ten Extrusion Granulation Production Lines Deployed in South China!

In 2025, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. completed the full-process commissioning of a 10-unit extrusion granulation production line tailored for a customer in Guigang, Guangxi, officially entering a new stage of large-scale mass production. This production line focuses on the ultra-large-capacity production needs of compound fertilizers and organic fertilizers, integrating the entire chain of core processes including batching, crushing, mixing, granulation, screening, coating, and packaging. With its robust configuration of 10 granulation main units operating in parallel, highly automated process design, and stable and reliable operation, it has become a benchmark project for fertilizer production equipment in South China, injecting strong momentum into the upgrading of local agricultural industrialization.

Production Line Full-Chain Configuration and Core Equipment Analysis

The entire production line follows a closed-loop process of “precise batching – raw material pretreatment – efficient granulation – fine processing optimization – finished product output.” The equipment layout is compact and orderly, with seamless connections. Each unit works synergistically, ensuring both ultra-large capacity requirements and strict control over product quality stability.

Precision Batching and Raw Material Pretreatment Unit: Strengthening the Production Foundation

Multi-Compartment Collaborative Batching System: The production line starts with a 4-compartment automatic batching system. Each compartment is independently designed to store nitrogen, phosphorus, and potassium as main raw materials, as well as various additives. The total storage capacity meets the requirements of continuous 12-hour full-load production. Precision metering devices are installed at the bottom of the batching compartments. Combined with a PLC intelligent control system, the system automatically adjusts the amount of each raw material fed according to the preset formula, with a batching error of ≤1%, ensuring accurate fertilizer nutrient ratios.

High-Efficiency Crushing and Uniform Mixing: Raw materials are conveyed to a 90-type horizontal semi-wet material crusher via 2.9-meter and 11-meter belt conveyors. This equipment is specifically designed for high-moisture raw materials, employing wear-resistant alloy cutter discs and a graded crushing structure. It can crush large, agglomerated raw materials (particle size ≤80mm) into uniform fine materials ≤2mm, achieving a crushing efficiency of 15 tons/hour, meeting the stringent requirements for raw material fineness in subsequent granulation. The pulverized material is transferred via a Y-shaped tee and a 14-meter belt conveyor to two 2200-type precision mixers (presumably “precision mixers”). These machines feature a dual-shaft counter-rotating design with wear-resistant coatings on the impellers. During mixing, the material forms a strong convection circulation, ensuring thorough mixing of different components with a mixing uniformity error of ≤2%, laying the foundation for high-quality granulation.

Core Granulation Unit: 10 Main Units Create Super Capacity

The mixed material is then diverted via a tee and evenly fed by two 2200-type disc feeders to ten extrusion granulators. The feeders employ variable frequency speed control and automatic material level control technology, allowing real-time adjustment of the feed rate based on the granulator’s operating status, preventing granulation quality fluctuations or equipment overload caused by uneven feeding.

The core highlight of the entire production line is the parallel operation of 10 extrusion granulators. Each machine has an hourly output of 3 tons, and their combined operation achieves a total capacity of 30 tons/hour and a daily capacity of 720 tons, far exceeding the capacity of conventional production lines. The granulators employ a high-strength roller extrusion design, with roller skins made of high-chromium alloy. After quenching treatment, the hardness reaches HRC62 or higher, exhibiting extremely high wear resistance and extending the service life to over 10,000 hours. The equipment is equipped with a hydraulic pressure regulation system, allowing precise control of the extrusion pressure within the range of 6-18 MPa to adapt to the granulation needs of raw materials with different moisture content and compositions. The granulation rate remains consistently above 93%, with uniform particle size controlled at 3-5 mm and particle strength reaching 2.8 MPa. The particles are not easily pulverized, meeting the requirements for long-distance transportation and long-term storage.

Post-processing and Finished Product Output Unit: Enhancing Quality + Efficient Shipping

Screening and Coating Optimization: Granulated granules are transferred to a 15x60m drum screen (presumably a 1.5×6.0m standard size) via 7m and 11m belt conveyors. A double-layer screen design separates large, unqualified granules on the upper layer and selects qualified finished products on the lower layer, achieving a screening efficiency of 35 tons/hour. Unqualified granules are returned to the pre-processing unit via 8m and 5m return conveyors for reprocessing, achieving a material utilization rate of 99%. Qualified granules undergo anti-caking pre-treatment in a 16-type spiral duster, followed by a 1.5×6.0m coating machine. Atomized spraying technology evenly coats the granules with a coating agent, forming a dense protective film that effectively improves the fertilizer’s moisture resistance, stability, and slow-release nutrient effect.

Finished Product Storage and Automated Packaging: Wrapped finished products are conveyed to a finished product warehouse via a 12-meter belt conveyor for temporary storage. The warehouse is equipped with a material level monitoring system to provide real-time inventory status feedback. Finally, quantitative packaging is completed using an automatic packaging scale. The equipment supports rapid switching between multiple specifications such as 25kg, 40kg, and 50kg, with a measurement error ≤ ±0.2kg and a packaging speed of up to 200 bags/hour. Combined with a subsequent transfer system, it achieves rapid warehousing and shipment of finished products.

Core Advantages and Industry Value of the Production Line

Super Capacity Leading the Industry: The innovative configuration of 10 parallel granulation units breaks through the capacity bottleneck of conventional production lines, meeting the quantitative needs of large-scale fertilizer production enterprises and helping customers seize market share.

Intelligent, Efficient, Cost-Effective, and Inefficient: The entire process is integrated with a PLC intelligent control system, achieving automated control of batching, feeding, granulation, and screening, reducing manual intervention and labor intensity. The equipment’s energy consumption is 15% lower than that of conventional production lines with the same capacity, resulting in a significant reduction in overall production costs.

Stable, reliable, and highly adaptable: Core equipment adopts standardized and wear-resistant designs, key components are highly versatile, and maintenance is convenient. The production line can flexibly adapt to the production of various materials such as organic fertilizer, compound fertilizer, and bio-organic fertilizer, and supports product customization with different particle sizes and formulas, demonstrating extremely high adaptability.

The successful commissioning of 10 extrusion granulation production lines in Guigang, Guangxi, not only demonstrates Huaqiang Heavy Industry’s core strength in the R&D and integration of ultra-large capacity granulation equipment, but also provides efficient and stable equipment support for the modernization of agriculture in South China. In the future, Huaqiang Heavy Industry will continue to focus on customer needs, continuously optimize product performance and process solutions, and provide more competitive customized solutions for global fertilizer producers, contributing to the high-quality development of the agricultural industry.

Mastering High-Volume Dry Granulation

This groundbreaking 10-unit production line in Guangxi exemplifies the industrial-scale application of advanced fertilizer granulation technology. Its core innovation lies in the massive parallel deployment of extrusion granulators, a method that falls under the category of dry granulation processes.

The line is a prime example of a roller press granulator production line, where each fertilizer compaction machine (or fertilizer compactor) performs fertilizer granules compaction through high-pressure extrusion. This method of fertilizer compaction is a key fertilizer granulation processes used within the broader npk manufacturing process for specific product types. It stands in contrast to alternative fertilizer processing machine technologies, such as drum granulation using a rotary drum granulator for wet agglomeration. The successful scaling to ten parallel units demonstrates a mastery of this particular fertilizer granulation technology, enabling unprecedented production volumes of dense, low-moisture fertilizer granules.Therefore, this project is not just about capacity; it is a testament to the precision engineering and process control required to reliably scale up dry granulation, providing a model for high-output fertilizer manufacturing that prioritizes product density and energy efficiency.

We warmly welcome people from all walks of life to visit, guide, and discuss business with us, and work together to create a new future for green agricultural development!