The advantages of roller extrusion granulator in creating high-strength organic fertilizer granules

fertilizer granulator May 10, 2025

The roller extrusion granulator creates high-strength organic fertilizer particles in a unique way during the organic fertilizer granulation process, meeting specific market demands.

The working process of the roller extrusion granulator is to feed the pre treated mixed organic fertilizer material into the interior of the granulator. The granulator applies tremendous pressure to the material through a powerful pressure device, forcing it to pass through specific shaped mold holes. At the moment when the material is extruded from the mold, a columnar shape is formed, and then the cutting device precisely cuts it into particles of appropriate length.

The biggest feature of this granulation method is the high density and strength of the organic fertilizer particles produced. This is due to the high-pressure extrusion process, which greatly compresses the distance between material molecules and makes the internal structure of particles more compact. High strength particles perform well during storage and transportation, and are less prone to breakage and pulverization, effectively ensuring the quality and nutrient content of fertilizers. Whether it is long-term storage or long-distance transportation bumps, it can maintain the integrity of particles and provide users with stable and reliable products.

Another major advantage of the roller extrusion granulator is its ability to precisely control the shape and size of particles. By simply changing different molds, various shapes and specifications of organic fertilizer particles can be produced, such as cylindrical, spherical, sheet-like, etc., fully meeting the diverse needs of different users and markets. For example, some special agricultural planting scenarios or horticultural cultivation may have specific requirements for the shape and size of fertilizer particles, which can be easily handled by extrusion granulators.

In addition, the roller extrusion granulator has high production efficiency and can work continuously and stably, producing a large amount of organic fertilizer particles per hour. It also has strong adaptability to raw materials, whether it is organic materials with high viscosity or raw materials with high fiber content, they can be smoothly processed into granules. In the organic fertilizer production line, the extrusion granulator provides a solid guarantee for the production of high-quality and diversified organic fertilizers with its high efficiency, precision, and durability, promoting the continuous development of the organic fertilizer industry.

Crop straw is a renewable resource in the field of organic fertilizer granulation

fertilizer granulator May 10, 2025

Crop straw is a common waste in agricultural production, but in the field of organic fertilizer granulation, it has become a valuable renewable resource.

Wheat straw is rich in organic substances such as cellulose, hemicellulose, and lignin. After being crushed, these straw fragments become a good base material for organic fertilizer granulation. Through microbial fermentation, the organic matter in straw gradually decomposes and transforms, releasing nutrients such as nitrogen, phosphorus, and potassium. In this process, adding appropriate amounts of other nutrients and biological agents, and then using an organic fertilizer granulator for processing, can produce organic fertilizers rich in various nutrients and with soil improvement functions.

Corn stover is also a high-quality raw material choice. Corn straw has a relatively high carbon and nitrogen content. During the fermentation process, microorganisms utilize the carbon source in the straw for growth and reproduction, while fixing the nitrogen in the surrounding environment, thereby increasing the nitrogen content in the fertilizer. After fermentation and maturation, corn stover is pressed into granules by an organic fertilizer granulator, which is not only convenient for storage and transportation, but also can slowly release nutrients after being applied to the soil, providing long-term fertility support for crops.

Rice straw also has unique advantages. It contains a certain amount of silicon element, which has a positive effect on improving the lodging resistance and disease resistance of crops. Pre treat rice straw to fully soften and decompose it, then mix and ferment it with other organic materials, and use an organic fertilizer granulator to process it into granular fertilizer. After being applied to farmland, this fertilizer can increase the silicon content of the soil, improve the physical properties of the soil, and promote the healthy growth of crops.

In addition to common grain crop straw, some economic crop straw such as cotton straw, rapeseed straw, etc. can also be used for organic fertilizer granulation. These straw also contain abundant organic matter and minerals, and after reasonable treatment, they can become raw materials for producing high-quality organic fertilizers.

As a raw material for organic fertilizer granulation, crop straw not only realizes the resource utilization of agricultural waste, reduces environmental pollution, but also provides a sustainable source of fertilizer for agricultural production. By processing with organic fertilizer granulators, these straw can be converted into efficient organic fertilizers, which helps promote the development of green agriculture.

The core equipment of fertilizer production line from raw materials to finished products

fertilizer granulator May 10, 2025

The equipment configuration of fertilizer production line directly affects product quality and production efficiency. Whether producing organic fertilizers, compound fertilizers, or biological fertilizers, a series of professional equipment are required for collaborative operation. This article will systematically introduce the key equipment and its functions in fertilizer production lines, helping you understand the core equipment of modern fertilizer production.

1、 Raw material pretreatment equipment

Flipping machine

Function: Used for aerobic fermentation of organic materials, promoting oxygen exchange and water evaporation through flipping.

Type:

Slot type stacker: suitable for fixed fermentation tanks, with a processing capacity of 10-30 tons/hour.

Crawler type compost turning machine: suitable for outdoor composting, with a turning depth of up to 2 meters.

Advantages: High degree of automation, which can effectively shorten the fermentation cycle (from 60 days to 20-30 days).

crusher

Function: Crush raw materials (such as animal manure and straw) to a suitable particle size (usually 3-5mm).

Common equipment:

Semi wet material crusher: processes raw materials with a moisture content of ≤ 30% to avoid clogging.

Chain crusher: suitable for coarse crushing of compound fertilizer raw materials (such as phosphate).

2、 Mixing and batching equipment

Mixing machine

Dual axis blade mixer: mixing uniformity ≥ 95%, can add microbial agents or trace elements, with a production capacity of 5-20 tons/hour.

Vertical mixer: suitable for small-scale production, small footprint, low energy consumption.

Automatic batching system

Electronic belt scale: dynamic batching accuracy ± 0.5%, combined with PLC control to achieve precise nitrogen phosphorus potassium ratio.

Micro addition device: used for quantitative addition of functional microbial agents in biological fertilizers.

3、 Granulation molding equipment

Disc Pelletizer

Features: Low investment, simple operation, suitable for small and medium-sized production lines, adjustable particle diameter of 2-8mm.

Applicable materials: Organic fertilizers, compound fertilizers, and other raw materials with good viscosity.

Rotary Drum Granulator

Features: Continuous production, high production capacity (up to 50 tons/hour), high particle roundness.

Application: High tower granulation of compound fertilizers or production of urea based fertilizers.

Flat die extrusion granulator

Features: No need for drying, direct cold pressing molding, suitable for the production of bio organic fertilizers.

Advantage: Low temperature process protects microbial activity.

4、 Drying and cooling equipment

Rotary Dryer

Function: Reduce the moisture content of particles from 25% -30% to ≤ 15%.

Heat source selection: coal, natural gas or biomass fuel, modern equipment thermal efficiency can reach 80%.

Cooling and screening integrated machine

Workflow: Particles are classified through a vibrating screen (4-6 mesh) and forced to cool to room temperature by a fan.

Function: To prevent clumping of finished products and improve storage stability.

5、 Packaging and auxiliary equipment

Automatic Packaging Machine

Type:

Valve pocket packaging machine: accuracy ± 0.2%, speed 800-1200 bags/hour.

Ton bag packaging machine: used for large capacity (500-1000kg) bulk fertilizers.

Dust removal system

Cyclone dust removal+water film dust removal: Ensure that the dust concentration in the production workshop is ≤ 10mg/m ³, which meets environmental protection requirements.

intelligence control system

Function: Real time monitoring of temperature, humidity, production and other data to achieve remote fault diagnosis.

6、 Equipment selection suggestions

According to the selection of raw materials:

Mainly for livestock and poultry manure: priority should be given to configuring a stacker+chain crusher.

Straw raw materials: Additional pre-treatment with a grass cutting machine is required.

Select based on production capacity:

Small scale production line (annual output of 10000 tons): with an investment of approximately 800000 to 1.5 million yuan, centered around a disc granulator.

Large scale production line (with an annual output of 100000 tons): requires a drum granulator and automated packaging system, with an investment of over 5 million yuan.

Energy saving design:

The use of waste heat recovery devices can reduce drying energy consumption by 30%.

The modern fertilizer production line has achieved a high degree of mechanization and intelligence. Reasonable equipment configuration can not only improve product quality, but also reduce energy consumption and labor costs. It is recommended that enterprises conduct raw material testing and process demonstration before investment, and choose equipment solutions that match their own needs. In the future, with the popularization of IoT technology, fertilizer production will further move towards “unmanned workshops”.

Characteristics of disc granulator in the process of organic fertilizer granulation

fertilizer granulator May 10, 2025

The disc granulator is a classic equipment in the field of organic fertilizer granulation, and its unique granulation characteristics make it highly favored.

The working principle of a disc granulator is based on the movement of materials on a rotating disc. When the disk begins to rotate, the material gradually gathers at the edge of the disk under the combined action of centrifugal force, frictional force, and gravity. As the disk continues to rotate, the material keeps rolling, and the newly added material continues to adhere to the existing small particles, gradually growing and forming like a snowball.

This granulation method produces organic fertilizer particles with a rounded shape and relatively uniform size. Round particles have obvious advantages in the fertilization process, as they can pass through the fertilization equipment more smoothly and reduce the possibility of clogging. And it is more evenly distributed in the soil, which is conducive to the balanced absorption of nutrients by crop roots.

The structure of the disc granulator is relatively simple, which not only reduces the manufacturing cost of the equipment, but also makes operation and maintenance convenient. For many small and medium-sized organic fertilizer production enterprises, lower investment costs and easy to master operating techniques greatly reduce the production threshold. Operators can easily adjust parameters such as the rotation speed of the disc, the speed of material addition, and humidity, thereby accurately controlling the size and strength of fertilizer particles. For example, increasing the disk speed appropriately can make the material move more vigorously on the disk, which helps to form smaller particles; Increasing the humidity of the material enhances the viscosity between particles, resulting in higher particle strength of the produced fertilizer.

In addition, the disc granulator has strong adaptability to raw materials. Whether it is animal manure, crop straw or other organic materials, as long as they are properly pretreated, they can be smoothly granulated in a disc granulator. This makes enterprises more flexible in raw material selection and able to fully utilize local resource advantages for organic fertilizer production.

The disc granulator occupies an important position in the field of organic fertilizer granulation due to its classic granulation method, good particle characteristics, simple structure, and wide adaptability to raw materials, providing reliable guarantee for the production of high-quality and uniform organic fertilizers.

Livestock manure is a high-quality raw material for organic fertilizer granulation

fertilizer granulator May 10, 2025

Livestock manure, as an important raw material for organic fertilizer granulation machine processing, has rich nutrients and unique advantages, and occupies an important position in the field of organic fertilizer production.

Pig manure is one of the common raw materials for livestock and poultry manure. Pig manure contains high levels of organic matter and abundant elements such as nitrogen, phosphorus, potassium, as well as various trace elements and amino acids. It has a fine texture and strong fertility retention. After fermentation treatment, it is very suitable as a raw material for organic fertilizer granulation. Through the processing of organic fertilizer granulators, pig manure can be transformed into organic fertilizers with uniform particles that are easy to store and use, providing long-lasting fertility to the soil, improving soil structure, and increasing crop yield and quality.

Cow manure is also a high-quality organic fertilizer raw material. Cow manure contains abundant cellulose, although its nutrient content is relatively low compared to pig manure, it can produce a large amount of humus after composting and fermentation. These humus substances help improve soil aeration and water retention, making the soil more fertile and soft. Using an organic fertilizer granulator to turn fermented cow manure into granular fertilizer not only facilitates fertilization operations but also reduces nutrient loss, allowing crops to better absorb nutrients.

Chicken manure is highly regarded for its high nutrient content. The content of nitrogen, phosphorus, and potassium in chicken manure is higher than that in other livestock and poultry manure, and it also contains abundant trace elements and vitamins. However, chicken manure has a high uric acid content and must undergo sufficient fermentation and maturation before use to eliminate harmful substances. After processing, chicken manure is processed into granules by an organic fertilizer granulator, which can effectively preserve nutrients, extend the fertilizer efficiency period, and provide sufficient nutritional support for crop growth.

Sheep manure is also an ideal raw material for organic fertilizer granulation. Sheep manure has a loose texture, good breathability, and is rich in organic matter and minerals. Its fertilizer effect is long-lasting, mild and does not burn seedlings, suitable for various crops and soil types. After being processed into granular fertilizer by an organic fertilizer granulator, sheep manure can be widely used in orchards, vegetable fields, flower planting and other fields, creating a good soil environment for plant growth.

Animal manure, as a raw material for organic fertilizer granulation, has a wide range of sources and abundant nutrients. Through proper processing and the use of organic fertilizer granulators, waste can be turned into treasure and high-quality organic fertilizers can be produced, contributing to the sustainable development of agriculture.

Equipment configuration for processing fertilizers on NPK fertilizer production line

fertilizer granulator May 6, 2025

The reasonable equipment configuration of NPK fertilizer production line is the key to ensuring efficient production and high-quality products. A complete production line covers multiple stages, each requiring specific equipment to work collaboratively.

In the raw material pretreatment stage, the crusher is the primary equipment. For high hardness raw materials such as phosphate ore and potassium ore, jaw crushers can initially crush large materials into smaller particles with strong extrusion force, reducing the burden for subsequent processing. For some organic materials with slightly soft texture but high fiber content, the hammer crusher can finely grind them by high-speed rotating hammer blades, ensuring uniform particle size of the raw materials and facilitating subsequent mixing.

The mixing process is crucial for the quality of fertilizers. The dual axis blade mixer is the core equipment in this process, with two shafts equipped with special blades rotating towards each other to fully flip and mix materials in three-dimensional space. This mixing method can evenly blend nitrogen, phosphorus, potassium raw materials and various additives in a short period of time, ensuring precise distribution of fertilizer nutrients.

Granulation is a crucial step in the NPK fertilizer production line. The disc granulator is widely used. Through the rotating disc, materials gradually aggregate into granules under the combined action of centrifugal force, friction force, and gravity. Its advantages are round particles, relatively uniform size, and good appearance quality. If producing fertilizers with high requirements for particle strength, an extrusion granulator is more suitable. It uses strong pressure to shape the material through a mold, producing particles with high density and compressive strength.

After the fertilizer particles are formed, they need to be dried to reduce moisture content and enhance stability. The rotary dryer utilizes the principle of heat exchange to quickly evaporate moisture through the full contact between high-temperature hot air and particles. The temperature of hot air and the residence time of materials can be precisely controlled to avoid damage to fertilizer nutrients due to overheating.

The cooling process follows closely after drying, and the air-cooled cooling machine can quickly reduce the particle temperature, improve the physical properties of the particles, and prevent deformation or adhesion of the particles during subsequent storage and transportation.

The screening equipment is used to screen out fertilizer particles with qualified particle size. The vibrating screen separates particles that are too large or too small through screens of different apertures. Oversized particles are returned to the crusher for re crushing, while undersized particles can participate in the granulation process again to ensure that the product particle size meets the standard.

Finally, the automatic packaging machine achieves precise packaging of fertilizers. It can quickly and accurately complete packaging tasks based on preset weight, improve production efficiency, and ensure uniform packaging specifications for easy storage and sales of products.

The NPK fertilizer production line achieves efficient production from raw materials to finished products through the scientific configuration of these equipment, and provides high-quality NPK fertilizers for agriculture, helping to increase production and income.

Drying and cooling equipment used after granulation in fertilizer production lines

fertilizer granulator May 6, 2025

In the fertilizer production line, drying and cooling equipment are important links to ensure the quality and performance of fertilizers, and they play a crucial role in the final quality of fertilizer particles.

In terms of drying equipment, rotary dryers are widely used. The mixed and granulated fertilizer particles enter the rotary dryer, where the high-temperature hot air in the dryer comes into full contact with the material. Hot air is blown in from one end, and the material slowly moves in the rotating cylinder. During this process, moisture is continuously evaporated and carried away. By adjusting the temperature and speed of the hot air, as well as the residence time of the material in the cylinder, the drying degree can be precisely controlled to ensure that the fertilizer particles reach the appropriate moisture content. Rotary dryer has the advantages of large processing capacity and stable drying effect, which can meet the drying needs of large-scale fertilizer production.

Another common drying device is an airflow dryer. It uses high-speed flowing hot air to suspend and transport fertilizer particles, achieving rapid drying in this process. The drying speed of the airflow dryer is extremely fast, which can reduce the moisture content in the particles to the specified level in a short period of time. Moreover, due to the short residence time of materials in the dryer, the damage to fertilizer nutrients is minimal, making it particularly suitable for temperature sensitive fertilizer varieties.

After the fertilizer particles are dried, they need to be cooled to improve their physical properties and stability. Air cooled cooling machine is one of the commonly used cooling equipment. It uses forced ventilation to allow cold air to come into full contact with hot fertilizer particles, resulting in a rapid decrease in particle temperature. The air-cooled cooling machine has a simple structure, easy operation, and good cooling effect, which can effectively prevent particles from deforming or sticking due to high temperature during subsequent storage and transportation.

Water cooled chillers use water as the cooling medium. The specific heat capacity of water is relatively large, which can absorb more heat, therefore the cooling efficiency of water-cooled chillers is higher. It takes away heat through a circulating water system, rapidly cooling the fertilizer particles. However, water-cooled chillers have a relatively complex structure and require a matching water circulation system, resulting in relatively high maintenance costs.

Drying and cooling equipment complement each other in fertilizer production lines. Drying equipment removes excess moisture from fertilizer particles, enhancing the stability and storage period of fertilizers; The cooling equipment further optimizes the physical properties of the particles to ensure that the fertilizer maintains good quality at all stages. They jointly ensure the quality of fertilizer products and provide a solid backing for fertilizers to enter the market.

The unique contribution of rotary drum granulator in fertilizer production line

fertilizer granulator May 6, 2025

The rotary drum granulator has a unique working mode and significant contribution in fertilizer production lines. It utilizes the rotational motion of a drum to achieve fertilizer granulation.

When the mixed fertilizer materials enter the rotary drum fertilizer granulator, with the uniform rotation of the drum, the materials continuously roll and collide inside the drum. During this process, the moisture in the material acts as a binder, promoting the gradual aggregation and growth of particles. Meanwhile, by spraying an appropriate amount of adhesive solution into the drum, the viscosity between materials can be further enhanced and the granulation speed can be accelerated.

The rotary drum granulator has significant advantages. Firstly, its production efficiency is extremely high. The continuous rotation of the drum enables the granulation process to proceed uninterrupted, processing a large amount of materials per hour, making it suitable for large-scale fertilizer production enterprises. Secondly, the granulator has a wide range of adaptability to raw materials. Whether it is various chemical fertilizer raw materials, organic fertilizer raw materials, or even some mixed raw materials containing impurities, they can be effectively pelletized in a rotary drum granulator.

Furthermore, by adjusting parameters such as the rotation speed of the drum, the filling rate of materials, and the spraying amount of binders, the size and strength of fertilizer particles can be flexibly controlled. For example, appropriately reducing the rotational speed of the drum will prolong the residence time of the material in the drum, which is conducive to the formation of larger particles; Increasing the amount of adhesive sprayed can improve the strength of the particles.

In the fertilizer production line, the rotary drum granulator has become an important equipment for producing various types of fertilizers with its efficient production capacity, wide adaptability to raw materials, and flexible parameter control ability, playing a key role in meeting the large demand for fertilizers in the market.

The granulation characteristics of fertilizers processed by NPK fertilizer production line

fertilizer granulator May 6, 2025

In the NPK fertilizer production line, the granulation process is crucial as it not only endows the fertilizer with a specific physical form, but also has a profound impact on its performance, storage, and transportation. Different granulation methods have their own characteristics and jointly serve the goal of producing high-quality NPK fertilizers.

Disc granulation is a common method with unique advantages. In the process of disc granulation, the material gradually aggregates into granules under the combined action of centrifugal force, frictional force, and gravity of the rotating disc. Its notable feature is that the particle shape is rounded and the size is relatively uniform. This enables fertilizers to be more evenly distributed in the soil during the application process, which is beneficial for the balanced absorption of nutrients by crops. Moreover, the structure of the disc granulation equipment is relatively simple, easy to operate and maintain, and the investment cost is relatively low, making it suitable for medium and small-scale NPK fertilizer production enterprises. However, the particle strength produced by the disc granulator is relatively limited, which may not be suitable for some application scenarios that require high particle strength.

Extrusion granulation exhibits different characteristics. This method uses strong pressure to extrude materials into molds, producing particles with high density and strength. This feature makes the NPK fertilizer produced by extrusion granulation less prone to breakage and pulverization during storage and transportation, enabling better maintenance of particle shape and nutrient content. Especially suitable for fertilizer supply under long-distance transportation or harsh storage conditions. In addition, extrusion granulation can precisely control the shape and size of particles, meeting the special needs of different users for fertilizer particle specifications. However, extrusion granulation equipment is relatively complex, with high investment costs and certain requirements for the physical properties of raw materials. The energy consumption during the production process is also relatively high.

Drum granulation is also a commonly used granulation method in NPK fertilizer production. It uses the rotation of the drum to make materials roll and collide inside, achieving agglomeration into particles. The characteristic of the rotary drum granulator is its high production efficiency, which enables continuous and stable large-scale production. At the same time, by adjusting parameters such as the speed of the drum and the humidity of the material, the size and strength of the particles can be flexibly controlled. Moreover, rotary drum granulation has strong adaptability to raw materials and can handle various materials with different properties.

The granulation process of NPK fertilizer production line endows fertilizers with diverse physical properties through the characteristics of different granulation methods. Production enterprises can choose appropriate granulation methods based on their own production scale, product positioning, market demand, and other factors to produce high-quality NPK fertilizers that meet the actual needs of agricultural production.

Packaging and conveying equipment required for granulation in fertilizer production line

fertilizer granulator May 6, 2025

At the end of the fertilizer production line, packaging and conveying equipment undertake the important mission of safely and efficiently delivering finished fertilizers to users.

Packaging equipment is the final process before fertilizers enter the market. The automatic quantitative packaging scale is one of the core equipment, which can accurately measure the weight of fertilizers and accurately pack them into packaging bags according to the preset packaging specifications. This device is equipped with high-precision weighing sensors and advanced control systems, which can quickly and stably complete quantitative packaging tasks, effectively improve packaging efficiency and accuracy, and reduce manual errors.

Sealing machine is also an essential equipment in the packaging process. It tightly seals the packaging bag containing fertilizer through heat sealing or other sealing methods to prevent fertilizer leakage during storage and transportation. Different types of sealing machines are suitable for packaging bags made of different materials, such as plastic film bags, woven bags, etc., to ensure the sealing and firmness of the packaging.

The labeling machine attaches product information labels to fertilizer packaging bags, including important information such as fertilizer name, ingredients, usage method, production date, etc. The labeling machine can quickly and accurately stick the label on the designated position of the packaging bag, making the product information clear, standardized, and easy for consumers to identify and use.

The conveying equipment is responsible for transferring and transporting fertilizers in the production workshop. Belt conveyor is the most common conveying equipment, which uses rubber or plastic conveyor belts as carriers and drives the drum to rotate through a motor to achieve smooth conveying of fertilizers. Belt conveyors have the advantages of large conveying capacity, smooth operation, and low noise. They can be flexibly arranged according to the layout of the production workshop to connect various production links.

The bucket elevator is used for vertical conveying of fertilizers. It drives the hopper to rise through a chain or tape, lifting fertilizer from low to high, achieving material transportation between different floors or heights. The bucket elevator has a small footprint, high conveying efficiency, and can effectively save production space.

Spiral conveyor is suitable for conveying powdered or small granular fertilizers. It pushes materials forward along the pipeline through the rotation of spiral blades. Spiral conveyor has good sealing performance, which can avoid material leakage and flying, especially suitable for conveying fertilizer raw materials or finished products that are prone to dust.

The packaging and conveying equipment are closely coordinated. The packaging equipment ensures the quality and standardization of fertilizer packaging, while the conveying equipment ensures the smooth transfer of fertilizers in the production and circulation process. They together form an important component of the fertilizer production line, providing strong guarantees for the smooth entry of fertilizer products into the market.