In the fertilizer industry, the physical properties of organic fertilizers (mostly made from fermented manure and straw) and compound fertilizers (mostly made from phosphate rock, potassium chloride, and urea) differ significantly. Organic fertilizers are fibrous, highly moist, and prone to sticking together, while compound fertilizers are hard, fiberless, and require high-hardness molding. Ring die pelleting machines, through their “adjustable structure + material adaptability,” can meet the granulation needs of both fertilizer types.
For organic fertilizer granulation, ring die pelleting machines offer two key design advantages: First, they utilize a “low compression ratio” ring die (3:1-5:1) to avoid excessive compression that damages the organic matter and bacterial inoculant activity in the raw material, while ensuring that the granules do not break apart. Second, they feature an “anti-sticking die conditioning system” that precisely controls the amount of water added and a small amount of binder (such as starch residue) to reduce material sticking to the die, thereby improving molding efficiency and discharge speed.
For compound fertilizer granulation, the ring die pelleting machine focuses on “wear resistance and high extrusion capacity”: the ring die is made of wear-resistant alloy material, which can withstand the high-frequency friction of mineral raw materials and has a service life three times longer than that of ordinary materials; the pressure roller is hardened to enhance the extrusion force, and is equipped with a “high compression ratio ring die” (6:1-8:1) to ensure that the hardness of the compound fertilizer particles meets the standard.
Organic fertilizer production lines require flexible design based on the scale of the farming entities. Given the dispersed nature of smallholder farming, small-scale organic fertilizer production lines must offer the advantages of low investment, ease of operation, and portability. For example, modular equipment combinations can be used, with a single line’s daily production capacity limited to 10-50 tons. These lines also support on-site assembly and commissioning, adapting to smallholder farmers’ space and funding needs. Operational processes are streamlined, and one-click control systems lower the technical barriers to entry. Some small-scale lines also feature mobile crushing units, allowing for direct processing of straw in the field.
Large-scale farming (such as 10,000-acre orchards or contiguous farmlands) requires continuous production lines equipped with automated batching, intelligent fermentation monitoring, and large-scale cooling and screening systems to achieve 24/7 uninterrupted production, with daily production capacity reaching hundreds of tons. These lines also require supporting raw material warehousing and a cold chain for finished products to meet the continuous demands of large-scale fertilization.
In addition, to meet the “customized small batch” needs of small farmers, the organic fertilizer production line needs to support rapid switching between multiple recipes, while large-scale production lines focus on “standardized large batches” and ensure that the quality error of each batch of products does not exceed 5% through stable process parameters. This differentiated design enables the organic fertilizer production line to meet the needs of different planting entities.
In the forming process of organic and compound fertilizers, disc granulators and double roller press granulators, with their different shaping logics, have become organic fertilizer granulators adaptable to different raw materials and needs. They not only meet the requirements of diverse fertilizer forms but also make the granulation process more aligned with actual production scenarios.
The core of disc granulators is “rolling agglomeration.” This method is more suitable for organic raw materials with moderate moisture content, such as well-rotted cow manure and straw substrates. The formed granules have a smooth appearance and moderate density, which not only promotes microbial survival (especially suitable for bio-organic fertilizers) but also facilitates subsequent storage and mechanized application, preventing clumping.
Double roller press granulators, on the other hand, follow a “pressure shaping” approach. The advantages of this process are that it requires no binder, has high forming efficiency, and produces granules with high hardness and strong moisture resistance. It is particularly suitable for granulating high-concentration fertilizers or dry raw materials, solving the problems of these materials being difficult to agglomerate and prone to scattering.
For those seeking granule roundness and bioactivity, disc granulators are the preferred choice; for those prioritizing high hardness, dry material forming, and binder-free processes, double roller press granulators are more suitable. These technologies address the pain points of fertilizer forming from different perspectives, providing flexible support for the diverse needs of fertilizer production.
Organic fertilizer fermentation time directly affects fertilizer quality and production efficiency. Typically, a complete fermentation cycle requires 25-45 days, depending on the raw material type, environmental conditions, and fermentation technology used. Under suitable temperature (55-65°C) and humidity (50-60%) conditions, using professional compost turning machines can significantly shorten fermentation time and improve efficiency.
The fermentation process is divided into three stages: temperature rise period (3-5 days), high temperature period (15-25 days), and maturation period (7-15 days). Each stage requires strict control of turning frequency and ventilation conditions to ensure optimal microbial activity.
Organic Fertilizer Machinery Price Analysis
The price of organic fertilizer production equipment varies depending on equipment type, capacity, and automation level. Basic configuration organic fertilizer turners range in price from $8,000-$50,000, while complete production line investments can reach $200,000-$1,000,000.
Equipment Type
Price Range (USD)
Suitable Scale
Small Wheel Turner
8,000-15,000
Below 5,000 tons/year
Chain Plate Turner
25,000-50,000
5,000-20,000 tons/year
Complete Production Line
200,000-1,000,000
Above 20,000 tons/year
Compost Turner Selection and Comparison
Organic fertilizer turners are core equipment in the fermentation process, with main types including:
Wheel Turners: Suitable for large-scale production with strong processing capacity
Chain Plate Turners: Suitable for viscous materials with uniform mixing
Groove Type Turners: Space-saving with high automation level
When selecting compost turning machines, factors such as material characteristics, production scale, site conditions, and investment budget need to be considered. Appropriate turners can not only improve fermentation efficiency but also significantly reduce labor costs and energy consumption.
Organic Fertilizer Production Line Output Optimization
The production line output of modern organic fertilizer factories depends on several factors:
Equipment configuration and automation level
Raw material supply stability
Fermentation cycle control
Production process optimization
Typical production line configurations include: pretreatment system, fermentation system, crushing system, mixing system, granulation system, drying system, screening system, and packaging system. By optimizing coordination between various stages, overall output and quality can be effectively improved.
For an organic fertilizer factory with an annual output of 10,000 tons, it is recommended to configure: 2 groove type turners, 1 crusher, 1 mixer, 1 granulation system, 1 dryer, and a complete automation control system. Such configuration ensures continuous and stable production while maintaining consistent product quality.
Quality Control Key Points
To ensure organic fertilizer quality, focus on:
Accuracy of raw material ratios
Real-time monitoring of fermentation temperature
Scientific control of turning frequency
Moisture and nutrient testing of finished products
Sanitation management of production environment
By establishing a comprehensive quality management system combined with advanced testing equipment, produced organic fertilizer can meet relevant standards and requirements, providing quality product support for sustainable agricultural development.
Advanced Quality Control in Organic Fertilizer Production
Building upon these quality control fundamentals, the entire organic fertilizer production line requires integrated equipment coordination to maintain standards. The organic fertilizer fermentation process relies heavily on proper fermentation composting technology for organic fertilizer, where equipment like the large wheel compost turner and chain compost turner (also known as wheel compost turner) ensures optimal aeration and temperature distribution. These turning machines work in sequence with the organic fertilizer granulator systems, where various organic fertilizer granulation processes transform the fermented material into uniform pellets. The fertilizer granulator stage becomes particularly critical for product consistency, as it must maintain the nutritional integrity achieved during fermentation while creating market-ready products. This seamless integration from composting to granulation represents the pinnacle of modern organic fertilizer manufacturing, ensuring every batch meets the highest quality standards for sustainable agriculture.
In the entire process of turning waste into treasure in bio-organic fertilizer production, every step of the production line is crucial for the preservation and transformation of organic nutrients. The windrow compost turning machine is the “key driver” in the fermentation stage, solving the pain points of large-scale organic material composting with its flexible operation.
The core of a bio-organic fertilizer production line is “harmless composting + nutrient activation,” and the fermentation stage is key to determining the final fertilizer efficiency. After the organic raw materials are mixed in proportion and enter the fermentation zone, the windrow compost turner comes into play. It turns the moist material at the bottom to the surface, while simultaneously turning the aerobic material from the surface to the bottom, achieving uniform mixing of materials and injecting sufficient oxygen into the pile, preventing localized anaerobic conditions that could produce foul odors or harmful substances.
More importantly, the windrow compost turner precisely controls the fermentation temperature. Organic material composting requires a high temperature of 55-65℃ to kill insect eggs and pathogens. The compost turner, through regular turning, effectively dissipates excess heat from the center of the pile, preventing excessive heat from damaging beneficial microorganisms. Simultaneously, it brings the cooler material into contact with the higher-temperature zone, ensuring uniform composting throughout the pile and significantly shortening the fermentation cycle.
Material fully composted by the windrow compost turner is loose in texture and has uniform nutrients, requiring no additional processing before proceeding to the next stage. This avoids equipment blockage caused by clumps of uncomposted material. The final bio-organic fertilizer produced retains rich organic matter and microbial communities while meeting the efficiency requirements of large-scale production.
In the wave of “on-demand fertilization” in modern agriculture, BB fertilizer mixers and NPK fertilizer production lines are not independent entities. Their synergy allows NPK fertilizers to move from “standardization” to “customization,” adapting to the nutrient needs of different crops.
The core value of the BB fertilizer mixer lies in its “uniformity control.” Targeting the physical characteristics of nitrogen, phosphorus, and potassium fertilizers (or additives containing micronutrients), it uses the staggered operation of multi-directional mixing paddles, combined with anti-caking devices, to ensure that raw materials of different particle sizes and specific gravities are thoroughly mixed in a sealed chamber, laying the foundation for “precision fertilization.”
The NPK fertilizer production line, on the other hand, is the complete chain that translates “precise proportioning” into “standardized products.” From raw material screening and automatic metering to the core mixing stage of the BB fertilizer mixer, and then to subsequent granulation, cooling, and packaging, the entire production line is connected through automated processes, avoiding errors and efficiency bottlenecks caused by manual operation.
The synergy between the two also addresses the “single-formula pain point” of traditional NPK fertilizers. Through flexible formula adjustments on the production line, coupled with the precise mixing of the BB fertilizer mixer, it’s possible to quickly switch between specialized NPK formulas for different crops such as wheat, corn, fruits, and vegetables. This meets the needs of large-scale production while reducing fertilizer waste and soil nutrient imbalances.
From “precise mixing” to “closed-loop process,” the linkage between the BB fertilizer mixer and the NPK fertilizer production line ensures that NPK fertilizer production maintains both “quantity” and “quality,” better meeting the modern agricultural demands for “efficiency, precision, and environmental protection.”
Small and medium-sized organic fertilizer companies are characterized by moderate production capacity, diverse raw materials, and large batch sizes. The design features of the flat die pelleting machine perfectly meet these needs, making it a cost-effective choice for these companies.
1.Low Equipment Investment Cost
The flat die pelleting machine has a relatively simple structure and does not require a complex transmission system. The purchase cost of a single unit is only 60%-70% of that of similar granulator equipment with similar production capacity. Furthermore, installation does not require a complex foundation, saving small and medium-sized companies from the high initial investment.
2.Flexible Raw Material Adaptability
Small and medium-sized organic fertilizer companies often purchase local raw materials, which can have large fluctuations in moisture and fiber content. The flat die granulator’s wide adaptability allows it to handle high-fiber straw materials, and the vertical compression of the rollers prevents tangling. For fermented materials with slightly higher moisture content, the flat die surface is easy to clean and prevents sticking.
3.Convenient Production Changeover
Small and medium-sized companies often produce a variety of products in small batches, requiring frequent adjustments to pellet size. It only takes 1-2 people to replace the flat die of the flat die pelleting machine, and it can be completed within 30 minutes. In addition, the cost of flat dies with different apertures is low. The company can reserve multiple sets of flat dies and quickly switch product specifications to meet the needs of different customer orders.
Many small and medium-sized organic fertilizer plants often face the problem of “small batches and a wide variety of products.” Traditional granulators are prone to material waste and time-consuming when changing materials, but new type organic fertilizer granulators offer greater flexibility in this regard.
First, the new type organic fertilizer granulator features a simpler granulation chamber design with fewer dead corners. Before changing recipes, there’s no need to disassemble complex components. Simply empty the chamber of any remaining raw materials and blow compressed air through the feed port for 3-5 minutes. This will completely clear the chamber, preventing the previous material from mixing with the new. For example, switching from straw to mushroom residue can be completed in 10 minutes, saving half an hour compared to traditional machines.
Second, parameter adjustment eliminates the need to start from scratch. The control panel can store 3-5 commonly used recipe parameters. The next time you need a corresponding recipe, simply select the mode and the machine will automatically adjust the speed and pressure, eliminating the need to experiment with parameters step by step. For example, if you’ve made organic fertilizer from chicken manure before, you can simply start the machine directly next time by selecting “Chicken Manure Mode,” making it easy for even beginners to avoid errors.
Finally, there’s “small production capacity, no waste.” Traditional machines tend to idle and consume a lot of power during small batch production. The new type organic fertilizer granulator features a “low-load adaptation” function, allowing it to operate stably even when producing only 3 tons of material at a time. This eliminates the problem of loose or tight pellets caused by low material volume, making it easy for small factories to handle a wide variety of production.
In the organic fertilizer production process, the innovative new type two in one organic fertilizer granulator serves as the core equipment that transforms decomposed organic matter into uniform fertilizer pellets. This advanced machine combines crushing and granulation functions, efficiently processing various organic wastes – including animal manure, agricultural residues, and food waste – into dense, spherical granules with optimal moisture content (typically 25-35%).
The granulation process begins with pre-treated organic materials entering the rotating drum, where specialized agitators and mechanical forces create the necessary friction and pressure for particle formation. The machine’s dual-action design ensures proper particle size distribution (2-4mm) while maintaining the organic matter’s nutrient integrity. This critical stage bridges the gap between raw material preparation and final product refinement in the complete organic fertilizer production line.
1. The Magical Journey from Waste to Fertilizer
Raw Material Preparation: Fermented organic materials are “chewed” by the crusher into fine 40-60 mesh powder, just like sifting flour before baking a cake. Moisture is precisely controlled within the “golden range” of 25%-35%.
Mixing Magic: In the mixing chamber – this “big bowl”, raw materials and no more than 3% binder dance a 5-10 minute “waltz” until every particle is coated with an even “coat”.
Granulation Transformation: Depending on material characteristics, the equipment performs different “magic” – sticky materials use “tooth stirring magic” for agglomeration, while fibrous materials use “roller pressing magic” for forceful forming, ultimately producing perfect 1-6 mm pellets.
Did you know? Unqualified pellets after screening are sent back to “magic school” for retraining, achieving over 95% material utilization rate, truly realizing “every pellet finds its home”.
2. The Unique Skills of new type two in one organic fertilizer granulator
Space Magician
Eliminating conveyor equipment in traditional production lines, it reduces floor space by 30%-50%, like transforming a two-bedroom apartment into a smart one-bedroom.
Efficiency Master
With hourly output of 1-5 tons and 20%-40% efficiency improvement, it’s like upgrading from a regular train to a high-speed rail.
Granulation Artist
The roundness of the particles reaches over 85%, and the strength reaches 10-30N. It is beautiful and practical, and can be called the “Michelin chef” in the fertilizer industry.
Energy-saving Expert
With 15%-25% lower energy consumption and fewer maintenance points, it’s like a hybrid car that’s both fuel-efficient and low-maintenance.
This new type two in one organic fertilizer granulator is sparking a “granulation revolution” in the global organic fertilizer industry, making production smarter, more efficient, and more environmentally friendly. Next time you see those round, uniform organic fertilizer pellets, remember the magical “magician’s hand” behind them.
Under the agricultural trend of “reducing chemical fertilizer use and promoting ecological planting,” organic fertilizer production equipment is quietly rewriting the fate of waste. These unassuming machines use technological power to transform agricultural waste such as straw and livestock manure into “green nutrients” that nourish the soil, becoming invisible heroes of ecological agriculture.
The core logic of organic fertilizer production equipment is simple: to allow organic matter to undergo a “transformation” under scientific conditions. The entire process requires no complicated operations. First, the raw materials such as straw and dead branches are broken down into fine particles by a crushing device. Then, a mixing device mixes them with livestock manure in a specific ratio, adjusting the carbon-to-nitrogen ratio to meet the fermentation requirements. The fermentation stage is crucial. Specialized equipment can precisely control temperature, humidity, and aeration, allowing beneficial microorganisms to efficiently decompose organic matter, shortening the fermentation cycle and thoroughly killing insect eggs and pathogens. Finally, after processing by granulation and drying equipment, the loose fermented material becomes uniformly granulated organic fertilizer that is easy to store and transport.
Compared to traditional composting, these devices solve many pain points. No need for manual turning; automated operation reduces labor intensity. Closed-loop fermentation minimizes odor spread and avoids secondary pollution. More importantly, standardized production ensures more stable nutrient content in organic fertilizer, effectively improving soil compaction.
From field waste to ecological fertilizer, organic fertilizer production equipment bridges the gap in circular agriculture. It not only reduces reliance on chemical fertilizers in agriculture but also makes “turning waste into treasure” a reality, injecting continuous momentum into the development of green agriculture.
fertilizer granulator
