January 2023 – fertilizer production line

Production cost and benefit analysis of equipment production line with an annual output of 5000 tons of organic fertilizer

fertilizer granulator Jan 30, 2023

Nowadays, organic fertilizer has been loved by cash crop growers all over the country, and plays an indispensable role. Bioorganic fertilizer contains a large amount of organic matter, which is an important source of organic matter in soil. It can improve soil, improve soil fertility, turn lean soil into fertile soil, and turn bad soil into good soil. Because soil organic matter forms humus through the action of microorganism and physical chemistry, it can promote the formation of soil water-stable aggregate structure, make cohesive soil loose and easy to cultivate, and sandy soil become structured.

Taking livestock and poultry manure as an example, the annual output of 5000 tons of granular organic fertilizer equipment investment, production cost and benefit analysis.

Input cost of organic fertilizer production line:

Plant: at least 500 square meters, including fermentation tank area, raw material manure stacking area, fermented organic fertilizer processing and packaging area, finished organic fertilizer stacking area, etc. The plant does not need good materials, but its height is at least 5 meters, and the construction cost per square meter is about 350 yuan.
Fermentation of livestock and poultry excrement: build a relatively large excrement treatment station in a large-scale (one machine with multiple tanks) centralized breeding area. The daily treatment of livestock and poultry excrement is more than 12 tons, with a 3M span trough tipper, and the unit price is 26000 yuan/set; Build a 300-500 square meter transparent greenhouse, with several fermentation tanks built in the greenhouse (the cost depends on the local actual situation due to different materials).
Tipper: fixed rail type tipper: the price of the tipper is about 15-200 yuan, and the cost of the line, rail and installation is about 30000 yuan. Two fermentation tanks share one tipper (including exchange equipment); If a walking tipping machine is used, the price of each machine is 6-150000 yuan, but it can be directly stacked on the ground for fermentation without building a fermentation tank.
Forklift: This is a necessary equipment to improve efficiency. Small-sized forklifts are generally priced at 6-150000 yuan. You can buy second-hand ones, generally around 30000 yuan; At present, there are also walkable tipping machines+forklifts in one, with a price of 55-1200 (different specifications).
Organic fertilizer crusher: the fermented organic fertilizer is crushed to more than 40 meshes, and the finer the crushed organic fertilizer is, the more beautiful the later granulation is. The specifications with the price of 4500-200000 yuan are determined according to different output.
Conveyor: configure belt conveyor, bucket elevator or screw conveyor according to the actual needs of customers. According to the length of transmission, a production line generally needs two conveyor belts of about 10 meters, and the price of each belt is between 15000 and 25000 yuan.
The packaging machine is mainly composed of material inlet, feeding mechanism (gate), weighing bucket, bag clamping mechanism, frame, suction port, pneumatic system, sensor, control box, conveying and sewing mechanism, etc.
Multi-element organic fertilizer formula batching machine (equipment price is between 11000 and 18000 yuan): adjust the content of nitrogen, phosphorus, potassium, humus and organic matter of powdered organic fertilizer according to different crop requirements.
Formula mixer (equipment price is between 21000 yuan and 38000 yuan): fully mix and evenly mix the prepared formula elements.
Organic fertilizer granulator: the prepared fertilizer elements are used to agglomerate the powder into particles under the mechanical action by centrifugal granulation.
Dryer (equipment price is 28-1800 yuan): dry the prepared particles for storage.
Cooler (the equipment price is about 3.5 yuan): quickly cool the dried fertilizer particles and facilitate bagging.
Screening machine (equipment price is about 5-2000 yuan): classify the size of fertilizer particles, and bag them in batches according to the size of the particles.
Fertilizer granule coating machine (equipment price is about 20000 yuan): Apply a layer of non-caking agent on the surface of the finished granules to make the fertilizer granules not stick.

Calculation of production cost of organic fertilizer (organic fertilizer per ton of product):

Daily consumption of fresh livestock and poultry manure: daily output of 12 tons × 2.7 m3/t × 15 yuan/square meter=486 yuan (excluding freight), the subtotal is 40.6 yuan per ton.
The annual production of 5000 tons of organic fertilizer requires 100 tons of dry straw powder. (For summer use, purchased from outside) 170 yuan per ton, totaling 17000 yuan, with a subtotal of 3.4 yuan per ton.
The dosage of bacteria is 1/15000, 2.16 kg per day × 100 yuan=216 yuan, subtotal 18 yuan per ton.
The subtotal of freight is 20 yuan per ton. (transported from the breeding farm to the packaging workshop)
The depreciation cost of facilities and equipment is calculated as per five years (equipment and facilities, calculated as per 200000 yuan, is about 40000 yuan per year, with a subtotal of 8 yuan per ton).
Total wages. There are 5 workers, and the daily wage of each person is 100 yuan. The total daily wage is 500 yuan/12 tons=41.6 yuan/t, and the subtotal of each ton is 41.6 yuan.
Daily power consumption: 80 kWh × 10 hours/day × 0.6 yuan/degree=480 yuan, with a subtotal of 48 yuan per ton.

The total production cost per ton of granular pure organic fertilizer (with nutrient content of more than 9% and organic matter of about 75%) is about 180.0 yuan/ton.

Analysis of organic fertilizer sales income

The production cost per ton of pure organic fertilizer produced by fermentation mode is about 180.0 yuan/ton. It is adjusted according to the national organic fertilizer standard, plus the warehousing cost of packaging bags, etc. of 50 yuan/t. It is sold at the current market price of 600 yuan per ton. The gross profit per ton is 270 yuan/ton. The net profit is calculated at 50 yuan, excluding the intermediary and transportation fees. The annual sales of 5000 tons * 270 yuan/ton can earn 1.35 million yuan.

The above data are for reference only, mainly because the prices of facilities and equipment produced by different factories are different, and the costs of plant construction and labor costs are different in different places. In addition, the above is the investment required for one production of organic fertilizer. If multiple organic fertilizer production lines are built, they can be calculated by superposition, but some equipment and facilities can be shared. Therefore, the more production lines, the lower the average investment.

NPK fertilizer production line

Fertilizer equipment Mixer mixes different raw materials to process fertilizer

fertilizer granulator Jan 30, 2023

There are many kinds of raw materials for organic fertilizer processing. We will use organic fertilizer mixing machine when processing. The different materials mixed by the mixer and the nutrient are even, so they can be suitable for the granulation of the organic fertilizer granulator machine.

So what are the characteristics of blenders and what are the common types? What are the specific functions? The following is a brief introduction to the twin shaft mixer and horizontal mixer.

The double shaft mixer uses the synchronous rotation of two symmetrical spiral shafts to transport dry ash and other powdery materials while adding water for mixing. It is suitable for organic fertilizer and NPK production line. The dry ash powder material is evenly humidified to achieve the purpose that the humidified material does not emit dry ash and does not exude water drops, so as to facilitate the loading and transportation of the humidified ash or transfer to other conveying equipment.

The horizontal mixer is a batch mixer, which is a small mixing equipment that can mix a variety of materials and is suitable for the production of organic fertilizer, NPK fertilizer, compound fertilizer, formula fertilizer, and water-soluble fertilizer. The horizontal mixer has high mixing degree, less residual amount, and the material is fully mixed, thereby improving the mixing uniformity; the novel rotor structure makes the gap between the rotor and the casing adjustable to close to zero, which effectively reduces the residual material The machine’s special rotor design can also crush larger materials, the overall structure is more reasonable, the appearance is beautiful, and the operation and maintenance are convenient.

Which of the two-axis mixer or the horizontal mixer is affordable? Are there any requirements for the moisture content of the mixing raw materials? As a professional fertilizer production line manufacturer, the fertilizer mixer models are very complete to meet the needs of users with different yields.

compost turner machine

rail-type dumper for fermenting organic fertilizer Economical and practical

fertilizer granulator Jan 30, 2023

Economical and practical compost turning machine

1. The track type compost turner is composed of mixing and shifting. It can realize the functions of air permeability, crushing and loosening when working. It is a common equipment for organic fertilizer production.

2. Under the action of the shift machine, the compost turner machine can change the composting production from single tank to multi tank fermentation, and can change the tank at will in multiple tanks, realizing the use of one machine with multiple tanks.

3. Compost turning machine composts evenly without agglomeration, the fermentation temperature rises quickly, and the dehydration and drying effect is good. Greatly reduce labor intensity, reduce production labor and save costs.

Working Principle

The NPK production line is simple, and the production of organic fertilizer requires fermentation and turning. The stacker is placed on the fermentation tank and can walk back and forth along the track on the tank. The trolley is placed on the work frame, and the stacking components and hydraulic system are installed on the trolley. When turning and throwing, the work frame moves forward at a certain speed from the initial end of the fermentation tank, and the trolley is stationary relative to the work frame. The stirring parts in the lower part of the turner machine turn over the fermented material continuously to make the material contact with air.

compost turner machine

Small organic fertilizer production line for treatment of livestock manure

fertilizer granulator Jan 30, 2023

Small-scale organic fertilizer production line is mainly used for livestock manure organic fertilizer processing production line project. It is characterized by low overall investment price, low cost and low technical requirements, which is suitable for large-scale planting and breeding enterprises and small fertilizer plants.

Finally, according to the desired form of organic fertilizer, it can be divided into powder organic fertilizer and granular organic fertilizer. Different forms of fertilizer require different production line equipment. Because the configuration, specification and required equipment of organic fertilizer production line are different, the price will also affect the quotation.

The production of powdery organic fertilizer is based on the fine crushing treatment after the fermentation of organic fertilizer. The required equipment: fermentation tipper, forklift silo, semi-wet material crusher, drum screening machine, automatic packaging scale. The price of the smallest powdered organic fertilizer production equipment is about 100000 yuan.

At present, the production process of granular organic fertilizer is the most complex, and it is also based on the continuous fermentation process and the wages of powdered organic fertilizer. Therefore, the equipment required is also relatively comprehensive, including fermentation tipper, forklift silo, semi-wet material crusher, horizontal mixer, stirrer granulator, rotary dryer, rotary cooler, drum screening machine, coating machine, and automatic packaging machine. Dynamic batching scale is also required in case of special process requirements. The price of the complete set of equipment with the minimum specification is about 200000 yuan.

In terms of production scale alone, the small-scale organic fertilizer processing plant takes the annual output of 5000 tons to 10000 tons as the standard, which is also the most selected production line scale for investors who are new to the industry. The complete set of equipment is composed of many kinds of equipment. Their type selection, specification and quantity directly affect the final price of the production line. That is to say, the price of the production line with the same output is not the same, even very different. Under the same output, the powdery production line is much cheaper than the granular production line, but the corresponding powdery finished organic fertilizer is not as expensive and profitable as the granular organic fertilizer. Finally, it is suggested that you should pay attention to two points: first, raw material procurement; The second is marketing. These two aspects are very important. In short, the same sentence: entrepreneurship is risky, and investment needs to be cautious.

NPK fertilizer production line

How long does it take for organic fertilizer fermentation equipment to process compost

fertilizer granulator Jan 30, 2023

According to different raw materials, organic composting fermentation equipment can be divided into high temperature composting and ordinary composting. High temperature composting takes plant materials with high fiber content as the main raw materials, and generates a lot of heat through composting and fermentation under aerated conditions. The temperature of composting is very high (50-60 degrees Celsius). Therefore, it matures quickly, composts quickly and has high nutrient content. The following NPK production line manufacturers introduce how long it takes for organic fertilizer fermentation equipment to process.

Fermentation composting and turning of organic manure

Most organic fertilizer products are fermented for 15-20 days. During the fermentation, the compost turning machine is used to treat the materials, which can only reach the harmless standard. The fermentation process of high-quality organic compost generally takes 45-60 days. This is because in the early heating and high temperature stage of composting, harmful microorganisms such as plant pathogens, insect eggs and weed seeds will be killed, but the main role of microorganisms in this process is metabolism and reproduction, and only a small amount of metabolites are produced, which are unstable and easy to be absorbed by plants.

In the later period of cooling, microorganisms decompose organic matter and produce a large amount of metabolites that are beneficial to plant growth and absorption, which takes 45-60 days. Through this process, composting can achieve three goals: harmlessness; humification; and a large number of microbial metabolites, such as antibiotics and proteins.

In the high temperature fermentation process, it can kill pathogenic bacteria, insect eggs and weed seeds. Ordinary compost is usually mixed with more soil, the fermentation temperature is low, the decomposition process is slow, and the composting time is long. During the composting process, the chemical composition of nutrient differentiation changes, the carbon to nitrogen ratio decreases, the mineral nutrients directly absorbed by plants increase, and humus is formed. The decomposed compost is suitable for processing high-quality organic fertilizer with a fertilizer granulator.

NPK fertilizer production line

High efficiency and high quality controlled release fertilizer has a broad market space

fertilizer granulator Jan 30, 2023

1. High quality controlled release fertilizer is a special fertilizer for vegetables and fruits.

Vegetables, fruits and other products are high-value agricultural products, in the international market price competitiveness is strong, so vegetables, fruit crops in the special fertilizer demand is larger.

2. Industrial organic fertilizer.

Long term partial application of chemical fertilizer can easily lead to the decline of soil organic matter and the decline of crop quality, such as melon is not sweet, rice is not fragrant, vegetables are tasteless, etc. One of the key measures to improve the quality of agricultural products is to apply more organic fertilizer. The organic fertilizer processed by compost turning machine has high fertilizer efficiency, and has gradually replaced other fertilizers and become the main force of fertilizer industry.

It is expected that the organic and inorganic compound fertilizers in the future will be mainly organic fertilizers (containing more than 70% organic matter). A small amount of inorganic fertilizers will be transported to the places where organic fertilizer resources are concentrated, and granulation will be carried out by rotary drum granulator to adjust the proportion of nitrogen, phosphorus and potassium in organic fertilizer or increase the quick acting nitrogen in organic fertilizer.

3. Efficient controlled release of fertilizer.

In the future, chemical fertilizer will not only develop in the direction of high concentration and high quality, but also in the direction of high utilization rate, energy saving, and multi-functional compound. The main development direction of high-efficiency fertilizers is the production of slow-release and controlled-release fertilizers and fertilizers and foliar fertilizers mixed with nitrification inhibitors or urease inhibitors. The processing of the high-efficiency NPK production line is mainly granulation, which requires roller granulator, drum granulator, organic fertilizer granulator, flat die pellet mill and other equipment.

The dissolution rate and nutrient release rate of high-efficiency and high-quality release fertilizer can be controlled, which can maximize the utilization rate of fertilizer. Due to the extensive use of controlled release fertilizer in developed countries, the utilization rate of chemical fertilizer is more than 60%. Therefore, there is a broad market space for high-efficiency and high-quality controlled release fertilizer.

NPK fertilizer production line

How much will it cost to set up an organic fertilizer production line in the countryside to process fertilizer?

fertilizer granulator Jan 30, 2023

China is a large agricultural country, with an effective land planting area of more than 3.1 billion mu, and a large demand for fertilizer. With the rapid development of social economy, people’s awareness and requirements for organic and green food are gradually increasing, and the development of organic agriculture and ecological agriculture is also gradually increasing. The application of chemical fertilizer in agricultural production has led to soil hardening and degradation of agricultural product quality, resulting in low crop yield. Therefore, the State encourages the use of organic fertilizer and has issued relevant subsidies and preferential policies, which has promoted the development of the organic fertilizer industry, and also brought good development opportunities and good market prospects to the organic fertilizer industry.

The factories that set up an organic fertilizer equipment production line to process fertilizer in the countryside are generally privately built, so a small organic fertilizer equipment production line with an annual output of about 10000 tons is sufficient to meet the sales demand. The primary focus of the organic fertilizer processing is the purchase of raw materials, and the most simple and small production line of organic fertilizer is raw and auxiliary materials:

Organic main raw materials: livestock manure, domestic sludge, domestic garbage and other solid wastes account for about 50-80% of the formula;
Inorganic main raw materials: urea, ammonium phosphate, superphosphate, calcium carbonate, potassium chloride, potassium sulfate, etc. account for about 10 to 30% of the formula;
Medium and trace element additives account for about 10% of the formula;
The bio-organic compound fertilizer also needs to add biological bacteria powder: 5 ‰ – 10%;
Other raw materials that may be used as required: peat, oil residue, fly ash, etc;
Auxiliary energy: water, electricity and coal.

Purchase organic fertilizer processing raw materials, chicken manure, pig manure, sheep manure, cow manure. These raw materials are not expensive, and the purchase price can be cheaper.

The investment of small organic fertilizer production line is between 80000 yuan and 120000 yuan. The main equipment of the small-scale organic fertilizer equipment production line includes fermentation tipping machine, pulverizer, granulator, screening machine, automatic weighing and packaging machine, etc. This series of small organic fertilizer production line has not only high cost performance, but also high efficiency, good energy saving and simple operation for workers. Equipment for small organic fertilizer production line:

Fermentation tipping machine: ferment the materials in the fermentation process to turn over (flip);
Pulverizer: pulverization of raw materials such as high humidity materials in the production process;
Granulator: granulate the mixed materials; Convenient for sorting and packaging;
Organic fertilizer screening machine: screen and classify the finished fertilizer;
Automatic weighing and packaging machine: quantitative bagging and packaging of finished products.

NPK fertilizer production line

NPK fertilizer production line uses drum granulator to adjust pH value

fertilizer granulator Jan 30, 2023

In the process of compound fertilizer granulation by rotary drum granulator, the pH of material is a main factor of fertilizer granulation, and also has an important impact on fertilizer efficiency and NPK production line.

PH is an important indicator of whether the material system is suitable. In the granulation system of ammonium phosphate, the pH value of material should be controlled between 6.0 and 6.5. When the material is slightly acidic, the solubility of the material is large, and the reaction is violent. It is easy for particles to bond into balls and produce large particles. If it is slightly alkaline, the ammonia loss is large, the reactivity of the material is poor, and the material divergence is not easy to form granules. During the operation of the rotary drum granulator, the pH value can be adjusted by adding ammonium bicarbonate and calcium magnesium phosphate fertilizer. If the conditions permit, a small amount of gas ammonia and granulation steam can be added into the material layer to neutralize map, and the reaction heat can increase the granulation temperature at the same time.

NPK fertilizer production line

Difference between organic fertilizer equipment and npk fertilizer granulator equipment

fertilizer granulator Jan 30, 2023

When selecting organic fertilizer equipment, we should pay attention to the annual output, organic raw materials, compost fermentation mode, and the degree of mechanization of the compost turning machine. These are the key factors for organic fertilizer processing. In short, organic fertilizer production is a relatively complex process, but the risk is relatively small. If all aspects are mature, it can bring huge profits to the enterprise. The following describes the difference between organic fertilizer equipment and inorganic fertilizer equipment.

Organic fertilizer production equipment and inorganic fertilizer equipment are different, organic fertilizer equipment is mainly divided into two parts, fermentation part and production granulation part. There is also a big difference between the production of granulation part and inorganic fertilizer part, because organic raw materials and inorganic raw materials are different, the production of inorganic raw materials can be processed according to the formula of raw materials, mainly chemical reactions. If the compound fertilizer formula is appropriate and the operation is skilled, the pelletizing rate of rotary drum granulator is very high, and the production is relatively easy.

Even if the fermentation of organic fertilizer raw materials is better, granulation is relatively difficult, because the characteristics of organic raw materials are that the raw materials are light, rough, and the bonding rate is relatively low, and various organic raw materials have different characteristics. Therefore, the selection of organic fertilizer granulator machine should be particularly careful, otherwise it will not only affect the output, but also make the appearance of the product is not beautiful.

The internal quality of organic fertilizer mainly depends on the fermentation part and the formula of the product. The key factors in the fermentation part include: microorganism, C / N ratio, C / P ratio, water content, pH value and aeration control. If one of the factors is not well controlled, the fermentation will be affected. Either the fermentation is not carried out, or the fermentation is incomplete or the fermentation time is long. Therefore, fertilizer plants usually use compost turning machine to cut the yeast to ensure smooth fermentation.

NPK fertilizer production line

The process of making biological fertilizer by organic fertilizer production line

fertilizer granulator Jan 30, 2023

The process of making biological fertilizer by organic fertilizer production line

The ground noodle pile, the ground dumper, or the fermentation tank to put materials, and the trough dumper.
Evenly sprinkle the organic fertilizer starter, and turn over the pile for fermentation to reach the temperature rise, deodorization, maturity, and killing miscellaneous bacteria grass seeds.
Fermentation lasts for 7-12 days, and the number of turns varies according to the temperature in different places.
Completely ferment and decompose, and leave the pond (ground type is directly collected by forklift).

5 Use a grading screen to screen the coarse and fine (the screened powdered fertilizer can be sold directly).

6 Crush the screened large pieces with a pulverizer and return to the grading screen.

For raw material mixing, the quantity of each raw material shall be added in strict accordance with the requirements of technical personnel, and various raw materials shall be added in the electronic belt scale or batching machine.

8 Crushed raw materials enter the aggregate belt conveyor, and then granulate with a granulator.

It is fed into the livestock and poultry organic fertilizer dryer, which adopts the method of cylinder edge transmission, flange connection and direct heat transfer, and is applicable to the drying of compound fertilizer after granulation.
Enter the cooler for cooling. The rotary cooler is mainly used for cooling the dried compound fertilizer products. It can directly cool the hot granular fertilizer to close to normal temperature.

11 After screening again, the separated large particles are broken by the large particle crusher and enter the return belt together with the separated fine powder, and then return to the granulator for granulation.

12 Lift the finished product into the material box on the packaging machine through the belt conveyor, and discharge it into the scale body according to the set weight for automatic weighing operation, and finally package and sell the finished product.

Each production line has its own characteristics. What kind of organic fertilizer is suitable for production depends on what kind of organic fertilizer equipment is needed. For example, the production line of disc and rotary stirrer must be equipped with a drying cooler, which uses hot air to dry the organic fertilizer, and then uses a cold air extraction system to cool the organic fertilizer, so that the hardness of the particles produced will be better. Users can customize appropriate configurations according to their needs. The organic fertilizer production line also has different equipment configurations according to different raw materials, and can also make appropriate plans according to the investment budget. The price of the organic fertilizer production line with different output is also different. The investment in building a large-scale organic fertilizer production line is not small, but the return on profits is also considerable. The operating effect is good for two years, and it can almost return the cost.