From pretreatment to maturity! Standard operating procedures for a windrow compost turner

fertilizer granulator Oct 22, 2025

To maximize the performance of a windrow compost turner, a scientific and standardized operating process must be followed. The entire process of the windrow compost turner revolves around four key steps: raw material pretreatment, windrow accumulation, turning and fermentation, and determination of maturity.

Raw material pretreatment is fundamental. Collected organic materials must first be sorted to remove impurities such as metal and plastic. Livestock and poultry manure should be air-dried to a moisture content below 65%, and straw should be pulverized to 5-10 cm in length. The raw materials should then be mixed at a carbon-to-nitrogen ratio of 25-30:1. The carbon and nitrogen content can be adjusted by adding straw or manure, ultimately achieving a moisture content of 55%-60%. At this point, the material will clump when held and fall apart upon contact, achieving optimal fermentation conditions.
Next, the pre-treated raw materials are stacked into trapezoidal stacks at the fermentation site. These stacks are typically 3-5 meters wide at the base, 1.5-2.5 meters wide at the top, and 1-1.8 meters high. The stack length can be adjusted flexibly based on the site and production volume. A 1.5-2 meter passageway is left between the stacks to facilitate equipment access and ventilation.

Turning and tossing is a key step in fermentation. After starting the windrow compost turner, the depth of the tossing mechanism is adjusted according to the height of the stack, ensuring that the tossing teeth penetrate 10-20 cm into the bottom of the material. The initial fermentation lasts 1-3 days, with the first tossing occurring when the material temperature reaches 50-60°C. The high-temperature period lasts 4-10 days. When the temperature rises to 60-70°C, the stacks are tossed every 1-2 days to kill harmful bacteria. The cooling period lasts 11-20 days. When the temperature drops to 40-50°C, the stacks are tossed every 2-3 days to promote humus formation. The entire fermentation cycle lasts 15-25 days.

Finally, the material is judged by maturity. When the temperature is close to room temperature, the color is dark brown, the texture is loose, and there is no odor or earthy smell, it is considered mature and can be sent to the next stage for processing.

Double roller press granulators empower green fertilizer production

fertilizer granulator Oct 22, 2025

With the advancement of green agriculture, “environmental protection and resource utilization” have become core priorities in fertilizer production. Double roller press granulators (fertilizer compaction machines), with their outstanding environmental performance and resource utilization, have become key equipment for green fertilizer processing.

The double roller press granulator offers significant technological advantages in improving fertilizer quality. The fertilizer granules formed through physical extrusion have uniform density and high hardness, making them less prone to breakage and clumping during transportation and storage. More importantly, after application to the soil, these granular fertilizers release nutrients at a steady rate, extending their effective life and reducing the loss of nutrients such as nitrogen, phosphorus, and potassium through rainwater erosion.

The double roller press granulator’s environmental value is also reflected in its raw material processing and energy consumption control. The double roller press granulator can directly process agricultural waste such as fermented livestock and poultry manure, composted straw, and fruit and vegetable residues, transforming “waste” into high-quality organic fertilizer and achieving resource recycling. The equipment also eliminates the need for high-temperature drying, reducing emissions from coal or gas combustion. Its enclosed conveying design effectively controls dust spillage, improving the production environment.

Furthermore, its operation and maintenance requirements are low. Its simple structure and clear procedures allow workers to master the process after a short training period. Routine maintenance requires only regular inspection of the squeeze rollers for wear and cleaning of the feed channel, significantly reducing operational costs for small and medium-sized fertilizer companies.

NPK Fertilizer: How is Powder Transformed into Harvest Hope?

fertilizer granulator Oct 21, 2025

On the stage of modern agriculture, NPK compound fertilizer has become a “nutrition master” for crop growth with its precise nutrient ratio and efficient fertilizer effect. But have you ever wondered how these uniform, plump fertilizer particles undergo their magnificent transformation from raw powder?

The journey begins with the sophisticated NPK fertilizer production line, where raw materials are precisely blended using an advanced NPK blending machine to create the perfect nutrient balance. This comprehensive NPK fertilizer line integrates both chemical and organic components, sometimes even connecting with an organic fertilizer production line for enhanced soil benefits.

The transformation truly begins in the granulation phase, where specialized granulation equipment takes center stage. The versatile fertilizer granulator, particularly the efficient disc granulator, works its magic in the disc granulation production line. Through a fascinating process of agglomeration, raw powder is transformed into those uniform, plump fertilizer particles that farmers depend on for optimal crop nutrition.

Let’s explore this fascinating journey of NPK compound fertilizer manufacturing, where science and technology collaborate to create the essential nutrients that feed our world.

The Symphony of Precision Production

The production process of NPK compound fertilizer is like a carefully orchestrated symphony, with each step working in harmony to ultimately create a bountiful harvest. The entire process transforms powdered raw materials into uniform granules, making it particularly suitable for producing high-nitrogen products such as organic-inorganic compound fertilizers.

Imagine various basic fertilizer raw materials undergoing meticulous screening and crushing, much like musicians tuning their instruments in preparation for perfect harmony. These materials are then precisely measured and, according to scientific ratio requirements, systematically enter the mixing hopper through conveying and lifting equipment.

The Five-Step Granulation Magic

Fine Preparation

Each basic fertilizer is separately screened, with raw materials crushed and screened again to ensure particle uniformity. Screened materials are fed into corresponding hoppers, laying the foundation for precise proportioning.

Precise Proportioning

Through metering equipment, the feeding ratio of various basic fertilizers is precisely controlled, while recycled materials also enter the feeding hopper together with basic fertilizers through lifting devices, achieving resource recycling.

Moist Granulation

In the rotary drum granulator, the clever use of saturated steam not only raises material temperature but also moderately moistens it. When necessary, small amounts of water or fertilizer solution are added to maintain optimal granulation liquid phase conditions.

Rotational Forming

Utilizing friction generated by drum rotation, squeezing forces between material particles cause them to aggregate into balls. As the drum rotates, particles gradually roll toward the outlet along the inclined direction of the cylinder.

Refined Finished Product

After leaving the granulator, particles undergo drying, screening, cooling and other processes, ultimately being packaged and stored. Unqualified particles are crushed and returned as recycled materials for reprocessing.

Granulator: The Core Engine of Production

As key equipment in NPK fertilizer production, the rotary drum granulator employs wet granulation technology, demonstrating the sophistication of engineering. Its cylinder uses special rubber sheet lining or acid-resistant stainless steel lining to ensure equipment durability.

During granulation, auxiliary materials such as steam, gas ammonia, or added phosphoric acid and nitrogen solutions enable heated compound fertilizer granulation. This design not only improves production efficiency but also ensures product quality stability.

Chain compost turner: efficient composting and resource utilization

fertilizer granulator Oct 21, 2025

The chain compost turner represents a significant advancement in modern composting technology, addressing efficiency bottlenecks in processing large-scale organic waste through its unique design.

Working Principle and Advantages

The chain compost turner represents a significant advancement in organic processing equipment, adopting a continuous conveying composting design that enables uninterrupted fermentation operations. This versatile compost fertilizer machine offers superior operational flexibility compared to traditional trough-type systems, operating without the constraints of fixed fermentation tanks.

As one of the essential equipments required for biofertilizer production, this machine efficiently performs windrow fermentation in open areas, making it particularly suitable for large-scale operations. When integrated with other fertilizer production machine components such as the double roller press granulator and disc granulation production line, it creates a comprehensive system capable of handling the complete npk fertilizer production process.

While the large wheel compost turning machine serves similar purposes for certain applications, the chain compost turner stands out for its efficiency in large-scale organic fertilizer production bases and organic waste treatment centers, providing a robust solution for modern agricultural needs.

This equipment significantly enhances production efficiency while reducing operational costs in organic fertilizer manufacturing facilities.

Main technical advantages include:

• Large processing capacity, single machine daily processing capacity up to 500-2000 cubic meters
• Turning depth up to 1.5-2 meters, ensuring thorough fermentation of deep materials
• High degree of automation, reducing labor costs
• Adaptable to various complex terrains and working environments

Raw Material Processing Capability

Livestock and Poultry Manure

Includes high-density organic materials such as chicken manure, pig manure, cow manure, and sheep manure. The powerful turning of the chain compost turner can break up the compacted state of manure. Through ventilation and temperature increase during the turning process, it effectively kills pathogens, parasite eggs, and weed seeds in the manure, while reducing the emission of harmful gases such as ammonia and eliminating manure odor.

Crop Straw

Such crude fiber materials as corn straw, wheat straw, rice straw, etc. The chain compost turner’s teeth can tear and stir bundled or segmented straw, making it evenly mixed with other organic materials, accelerating the degradation and composting of the straw, and converting it into organic matter and humus in organic fertilizer.

Industrial Organic Waste

These materials include wine lees, vinegar lees, furfural residue, Chinese medicine residue, and slaughterhouse waste. These materials have high moisture content and are easily corrupted. The chain compost turner can reduce the moisture content of the materials through continuous turning, promote the growth of beneficial microorganisms, and achieve harmless treatment and resource utilization of waste residues.

Municipal Organic Waste

Such as kitchen waste, landscaping waste (dead branches and leaves, weeds, etc.). The chain compost turner can centrally process these scattered wastes, converting them into high-quality organic fertilizer raw materials through physical crushing and biological fermentation during the turning process, thereby reducing the amount of urban waste landfilled.

Sludge Treatment

Includes sludge from municipal sewage treatment plants and industrial wastewater treatment plants. After strict testing for heavy metal content and ensuring compliance, the chain compost turner reduces the sludge’s moisture content (from approximately 80% to below 60%) by turning it, stabilizing its properties and eliminating odor and pathogens, making it a safe organic fertilizer raw material.

Double roller press granulators are an efficient and stable choice for fertilizer granulation

fertilizer granulator Oct 21, 2025

In fertilizer production, the granulation process directly impacts fertilizer application convenience, storage stability, and nutrient utilization. Due to its unique technological advantages, double roller press granulators (commonly known as fertilizer compaction machines) are the preferred equipment for many production scenarios. They can transform a variety of fertilizer raw materials into uniform granules without complex pretreatment, offering both adaptability and practicality.

The operating principle revolves around “physical extrusion.” Crushed and mixed fertilizer raw materials are conveyed between two pairs of counter-rotating extrusion rollers at the core of the equipment. Under pressure from the roller surfaces, the raw materials are compressed into continuous flakes. These flakes then enter a crushing unit, breaking them into irregular particles. Screening equipment then selects the finished product that meets the required particle size.

The core advantages of double roller press granulators lie in their flexibility and energy efficiency. Requiring no binders, granulation relies solely on the raw materials’ inherent physical properties, preserving the natural properties of organic fertilizers or the nutrient purity of compound fertilizers. This eliminates the high-temperature drying step required in traditional granulation. Whether processing organic fertilizer, compound fertilizer, or functional bio-fertilizer, stable granulation can be achieved by simply adjusting parameters such as extrusion pressure and roller speed, providing an efficient solution for fertilizer production.

Rotary drum granulators optimize the nutrient content and application experience of organic fertilizer granules

fertilizer granulator Oct 21, 2025

The core value of organic fertilizer lies in nutrient supply and convenient application, and granule shape directly impacts these two properties. Insufficient nutrient retention reduces fertilizer efficiency, while uneven granules increase the difficulty of field application. By optimizing process details, rotary drum granulators can reduce nutrient loss during the granulation process while creating granule shapes that meet field needs.

In terms of nutrient retention, the rotary drum granulator’s low-temperature granulation is particularly advantageous. Relying on physical tumbling to form granules, the granulator eliminates the need for high pressure and maintains an internal temperature below 35°C, maximizing the retention of active ingredients in the raw materials. Its nutrient retention rate is 5%-8% higher than that of traditional equipment.

In terms of granule application experience, granules produced by rotary drum granulators better meet field needs. On the one hand, the equipment can produce uniform granules with a diameter of 2-5mm by adjusting the drum speed and die aperture, making it easier for farmers to apply fertilizers using seed drills and reducing the unevenness of manual spreading. On the other hand, the moderate hardness of the granules (compressive strength of 10-15N) prevents them from breaking down during transportation and slowly disintegrates in the soil, achieving “slow-release fertilizer supply” and avoiding the root burn caused by concentrated nutrient release.

For organic fertilizer companies pursuing “high quality and low price,” the high-nutrient, easy-to-apply granules produced by the rotary drum granulator can significantly enhance their product’s market competitiveness.

Common organic fertilizer production line types and key equipment configurations

fertilizer granulator Oct 21, 2025

In the fertilizer production industry, different types of fertilizer production lines correspond to varying production requirements and process characteristics. Understanding common fertilizer production line types and key equipment configurations is crucial for companies to plan production and improve efficiency.

Currently, mainstream fertilizer production lines include organic fertilizer production lines, NPK fertilizer production lines, and bio-organic fertilizer production lines. Organic fertilizer production lines primarily use agricultural waste and livestock manure as raw materials, producing organic fertilizer through fermentation, crushing, and granulation. NPK fertilizer production lines focus on optimizing the ratio of nitrogen, phosphorus, and potassium to produce compound fertilizers. Bio-organic fertilizer production lines build on traditional organic fertilizer production by incorporating biological strains to enhance the bioactivity of the fertilizer.

While different production lines have different focuses on equipment configuration, they share common core equipment. The crushing stage typically requires a fertilizer crusher to ensure the raw material particle size meets subsequent processing requirements. The granulation stage utilizes fertilizer granulators, such as disc granulators and rotary drum granulators. The mixing stage relies on a fertilizer mixer to ensure uniform mixing of the raw materials. Furthermore, fertilizer conveyors, screening machines, dryers, and coolers are essential equipment, collectively forming the complete fertilizer production process.

When configuring equipment, companies should carefully select equipment specifications and models based on the production line’s capacity, raw material characteristics, and product requirements to ensure optimal compatibility across all stages and improve overall production efficiency.

Flat die granulator: Solving the problem of fiber entanglement in organic fertilizer

fertilizer granulator Oct 21, 2025

Fiber raw materials such as straw, mushroom residue, and rice husks are common components in organic fertilizer production. However, these materials are prone to fiber entanglement with the rollers during pelletizing, leading to equipment stalls and a sharp drop in pelletizing efficiency. The flat die granulator, with its targeted structural design, is an ideal solution for this problem.

The core cause of fiber entanglement is insufficient cleavage of long fibers in the raw material, or a smooth roller surface that causes fibers to entangle as the rollers rotate. The flat die granulator’s design addresses this problem by focusing on two key points: First, the flat die holes feature a “deep straight hole” layout (15-20mm depth). This shortens the vertical force path when the fiber raw material is squeezed into the hole, reducing the fiber’s residence time between the rollers and the flat die.

Second, a pre-crushing pretreatment is recommended, with the fiber raw material pulverized to 0.5-1mm to ensure that long fibers are cut, thus reducing the likelihood of entanglement at the source.

In actual production, if slight entanglement still occurs, the gap between the roller and the flat die can be adjusted to maintain 0.2-0.3mm, or 1%-2% bentonite can be added to the raw materials for further optimization. This solution can increase the smoothness of granulation of fiber raw materials to over 90%, avoiding frequent downtime for cleaning and ensuring stable operation of the organic fertilizer production line.

Drum Cooler: How Does It Gracefully Cool High-Temperature Materials?

fertilizer granulator Oct 20, 2025

In the fiery arena of industrial production, materials processed at high temperatures often undergo a crucial step: cooling. The drum cooler, an industrial “cooling artist,” uniquely provides just the right amount of cooling for hot materials. This equipment can be found in industries ranging from cement to chemicals, from metallurgy to building materials. What makes it so captivating?

The Art of Cooling: Working Principle of Drum Cooler

Imagine materials fresh from high-temperature treatment, carrying intense heat and urgently needing cooling. The drum cooler acts like a skilled temperature regulator, smoothly transitioning materials from high temperatures to suitable levels through exquisite heat exchange processes. When high-temperature materials enter the rotating drum through the feed inlet, a carefully choreographed cooling dance begins.

Within the sophisticated npk fertilizer production line, the cooling drum’s elevator acts as a deft conductor, continuously lifting and dumping material to form a uniform particle curtain. This crucial process in the complete npk fertilizer line ensures optimal product quality after materials have been precisely blended by the npk blending machine and formed through granulation equipment.

Simultaneously, the cooling medium (whether air, water, or refrigerant) comes into close contact with the material, removing excess heat through efficient heat exchange. This rapid, uniform cooling process is essential for stabilizing output from various granulation systems, whether from a disc granulator in a specialized disc granulation production line or other types of fertilizer granulator equipment.

The same precision cooling technology benefits both conventional and organic fertilizer production line operations, ensuring every particle receives perfect thermal treatment regardless of the production method, ultimately guaranteeing consistent fertilizer quality and performance.

Precision Engineering: Every Component Matters

 Core Drum

As the heart of the equipment, the carefully designed cooling devices and lifters inside the drum ensure thorough material agitation while creating maximum heat exchange surface area.

 Transmission System

The precision transmission network composed of motors, reducers, gears, and idlers provides smooth and reliable rotational power for the drum, ensuring continuous cooling processes.

 Temperature Control

Advanced temperature and speed control systems allow operators to precisely adjust cooling intensity to meet specific cooling requirements of different materials.

 Sealing System

Precision sealing design not only prevents cooling medium leakage but also maximizes cooling efficiency while maintaining a clean working environment.

Wide Applications: The Ubiquitous Cooling Expert

• Cement Industry: Cooling clinker to improve cement quality
• Chemical Sector: Processing various chemical raw materials and products
• Metallurgy: Cooling metal ores and metallurgical products
• Building Materials: Handling various construction material raw materials
• Environmental Protection: Treating solid waste materials
• Food Processing: Cooling specific food ingredients

Outstanding Advantages: Why Choose Drum Cooler?

The appeal of drum coolers extends beyond their efficient cooling capacity to include excellent adaptability and operational convenience. Whether handling materials of different particle sizes or meeting varying production demands, they perform with ease. Their straightforward structural design makes maintenance remarkably simple, while flexible cooling medium options allow adaptation to various working conditions.

More importantly, while ensuring cooling effectiveness, drum coolers maintain the physical characteristics of materials unaffected. This precise temperature control capability makes them indispensable key equipment in modern industrial production.

From high temperatures to suitable levels, from intense heat to moderate warmth, drum coolers provide perfect cooling solutions for material processing across various industries with their professional technology and reliable performance. In this era that values both efficiency and quality, they will continue to play vital roles on the industrial cooling stage with their unique charm.

The Modern Evolution of Organic Fertilizer Production

fertilizer granulator Oct 20, 2025

In the wave of sustainable agriculture, organic fertilizer production has transformed from traditional composting methods using equipment like the large wheel compost turner into precisely controlled bioengineering processes. This evolution begins with efficient preprocessing using a wheel compost turner, then progresses through sophisticated granulation systems within a complete organic fertilizer production line.

The transformation is most evident in granulation technology, where various fertilizer granulator options are available. For organic materials, the organic fertilizer granulator and rotary drum granulator excel through gentle drum granulation processes. Meanwhile, for chemical fertilizers, the npk fertilizer granulator plays a crucial role in integrated npk production line setups, often utilizing high-pressure double roller press granulator technology.

Specialized equipment like the double roller granulator and fertilizer roller press machine provide alternative granulation methods, offering flexibility for different material characteristics. This technological evolution not only enhances fertilizer quality but also redefines the value of agricultural waste, creating a sustainable cycle that benefits both agriculture and the environment.

Raw Material Pretreatment: The Foundation of Quality

Modern organic fertilizer production begins with precise raw material formulation. Materials including livestock manure, crop stalks, and food processing by-products undergo strict screening and scientific blending, with carbon-to-nitrogen ratios carefully regulated within the ideal 25-30:1 range. Crushers process materials to optimal particle sizes, creating perfect conditions for subsequent fermentation.

Efficient Fermentation: Precision Control of Microorganisms

Aerobic fermentation stands as the core of the entire process. In modern fermentation tanks, automatically controlled turners regularly aerate the piles, ensuring even oxygen distribution. Temperature sensors continuously monitor pile temperatures, maintaining the golden range of 55-65°C—a temperature that effectively eliminates pathogens while preserving beneficial microorganism activity.

Advanced fermentation technology can complete the maturation process in just 15-20 days, a task that traditionally required several months. By adding specialized microbial agents, fermentation efficiency significantly improves, enabling more thorough organic matter transformation.

Advanced Processing: From Mature Material to Premium Fertilizer

Fully matured materials enter the advanced processing stage. Crushers refine them to uniform particle sizes, after which disc granulators or drum granulators shape them according to target market requirements. During this process, functional microbial strains and trace mineral elements can be precisely added to produce bio-organic fertilizers with specific functions.

Post-Processing and Quality Control

Formed granules undergo low-temperature drying to preserve microbial activity, followed by cooling and screening to ensure uniform product particle size. Each batch undergoes rigorous laboratory testing, including indicators such as organic matter content, effective live bacteria count, and heavy metal content, ensuring compliance with national standards.

Modern organic fertilizer production lines achieve full automation control, with quality monitoring points established at every stage from raw material input to finished product packaging, guaranteeing final product stability and reliability.

Advancing to New Levels of Smart Agriculture

The success of modern organic fertilizer production lies not only in technological innovation but also in philosophical transformation. It converts agricultural waste into “black gold,” achieving resource recycling and providing solid support for sustainable agricultural development. With the deepening application of technologies like intelligent control and the Internet of Things, organic fertilizer production continues advancing toward more precise, efficient, and environmentally friendly directions.