Ecological agriculture’s requirements for “no chemical additives” and “full-cycle composting” of fertilizers are driving targeted adjustments to organic fertilizer production lines.
In ecological farming, the use of chemical regulators is prohibited. Organic fertilizer production lines must optimize the microbial community structure to achieve natural composting of raw materials. For example, complex microbial agents can be used instead of traditional chemical ripening agents to ensure that no exogenous pollutants are introduced during the fermentation process.
At the same time, ecological agriculture emphasizes the “cultivation-livestock cycle.” Organic fertilizer production lines must adapt to a variety of ecological raw materials, such as rice husks and mushroom residues, using precise pulverization and mixing processes to ensure balanced nutrient release.
Furthermore, to meet the demand for “light and simplified fertilization” in ecological farming, end-of-line production lines must enhance granulation and slow-release technologies to adapt fertilizers to various ecological farming scenarios, such as drip irrigation and broadcasting, thus achieving a closed loop of “fertilization-growth-soil maintenance.”
At present, the application rate of products of this type of organic fertilizer production line adapted to ecological agriculture in ecological fruit and vegetable planting has increased by 35% compared with ordinary production lines. After some ecological tea gardens adopted this type of fertilizer, the tea polyphenol content in tea increased by an average of 8%, and the pass rate of pesticide residue detection remained at 100%, further verifying the adaptability of the production line to ecological planting.
In modern fertilizer production, the granule packing machine serves as the precision final step, bringing revolutionary efficiency to the complete manufacturing process. This intelligent equipment perfectly complements advanced npk fertilizer production technology by providing accurate, consistent packaging for granules created through various methods.
Whether handling output from a drum granulator in an organic fertilizer production line, or packaging dense granules from a double roller press granulator, this packaging system maintains product integrity. It seamlessly integrates with both npk fertilizer granulator and organic fertilizer granulator operations, including those utilizing rotary drum granulator technology, ensuring uniform packaging regardless of production method.
By combining advanced technology with user-friendly operation, this packaging equipment redefines industry standards, providing the crucial link between modern granulation processes and market-ready products. Its precision handling preserves the quality of granules throughout the packaging phase, completing the value chain from raw materials to finished goods in both chemical and organic fertilizer manufacturing.
Intelligent Core: Perfect Embodiment of Digital Weighing Technology
Professional Digital Processing System
Equipped with professional-grade all-digital dual-core processing weighing instruments, featuring an intuitive and user-friendly interface that even beginners can quickly master. The system supports multiple range data storage, easily adapting to different product packaging requirements.
Triple Feeding Modes
Innovative high, medium, and low three-stage feeding methods ensure high-speed packaging while achieving high-precision weighing across wide ranges, perfectly balancing efficiency and accuracy.
Smart Calibration System
It has powerful functions such as automatic calibration and real-time data correction, real-time monitoring of weighing accuracy, and immediate alarm when deviations occur, ensuring stable packaging quality.
Sanitary Material Options– Material contact parts available in 304 stainless steel, meeting strict hygiene requirements for food, pharmaceutical, and other industries
Dual Hopper Intelligent Coordination– Two weighing hoppers can work independently, alternately, or simultaneously, significantly improving packaging efficiency
Wide Applicability– Larger weighing range, faster speed, and higher measurement accuracy to accommodate diverse production needs
Multi-material Mixing Capability– Supports simultaneous mixing and packaging of two or more materials, meeting production requirements for complex formula products
Wide Applications: Production Powerhouse Across Industries
The exceptional performance of this granule packing machine makes it shine in multiple fields. In the fertilizer industry, it precisely packages various compound and organic fertilizer granules; in food processing, it handles products like grains, candies, and coffee beans; in the chemical industry, it’s suitable for packaging materials such as plastic pellets and resins. Its flexible configuration and strong adaptability make it an indispensable key equipment in modern production lines.
The most impressive aspect of the granule packing machine is its level of intelligence. The equipment automatically records production data, monitors operational status in real-time, and optimizes packaging processes through data analysis. The powerful computing capability of dual-core processors ensures remarkable weighing accuracy even during high-speed operation. Modular design makes equipment maintenance more convenient, significantly reducing operational costs.
The granule packing machine represents not only technological innovation but also the perfect embodiment of modern intelligent manufacturing concepts. With its exceptional precision, efficient performance, and intelligent operation, it’s playing a vital role in the global packaging sector. From fertilizer plants to food workshops, from chemical factories to pharmaceutical enterprises, this equipment is driving various industries toward greater efficiency and intelligence with its reliable performance and advanced technology.
With increasingly stringent environmental protection policies, environmental retrofitting of organic fertilizer production lines has become an industry imperative, focusing on the treatment of “three wastes” and compliance upgrades.
For waste gas treatment, organic fertilizer production lines must be equipped with sealed fermentation chambers and ammonia collection systems. Biofilter technology is used to control ammonia concentrations generated during the fermentation process to within standards. Some areas also require VOC monitoring equipment to ensure real-time upload of emission data.
For wastewater treatment, production lines must establish a recycling system to sediment and filter wash water and condensate before reusing them for raw material moisture conditioning, achieving zero wastewater discharge.
For solid waste treatment, optimized screening processes are employed to re-crush fermentation residues before mixing them back into fermentation, achieving full solid waste utilization.
Furthermore, the environmental impact assessment process imposes stricter requirements on production line site selection and capacity planning, such as requiring them to be at least 500 meters away from residential areas and designing production capacity to match the regional environmental carrying capacity. Although these transformations increase initial investment (usually the transformation cost of a single production line accounts for about 15%-20% of the total investment), the energy consumption of the organic fertilizer production line can be reduced by 12%-18% after the transformation.
Many people occasionally encounter blockages when using new type organic fertilizer granulators (raw material gets stuck in the granulation chamber, preventing pellets from coming out). However, if you take three steps in advance, this problem is virtually eliminated.
First, avoid any hard lumps in the raw material. Whether it’s manure or straw, lumps may form after fermentation. Before feeding, be sure to use a crusher to break up any lumps. Keep lumps no larger than 1 cm, otherwise they will get stuck in the die holes of the new organic fertilizer granulator. Accumulating these lumps will cause a blockage.
Second, control the moisture content of the raw material. Although new type organic fertilizer granulators are moisture-resistant, raw material that is too moist (over 65%) will stick to the granulation chamber, while too dry (less than 45%) will produce fine powder and clog the screen. Before each feeding, grab a handful of raw material and form a ball that breaks apart easily. This will ensure the raw material flows smoothly through the granulation chamber without blockage.
Third, perform a component inspection every day before starting the machine. Check the pressure roller of the new type organic fertilizer granulator to see if it’s stuck and the scraper at the discharge port to see if it’s blunt. If the roller can’t turn or the scraper is blunt, the pellets won’t come out and the machine will jam. Simply turn the roller manually and check the scraper to see if it’s sharp. If there’s any problem, adjust it immediately to avoid jams.
Organic fertilizer plants now have to meet environmental standards, and dust and noise are prone to complaints. New type organic fertilizer granulators offer more comprehensive dust and noise reduction measures than traditional models, eliminating the need for extensive additional environmental protection equipment. Let’s first discuss dust reduction. Both the feed and discharge ports feature dust-proof designs. The feed port features a soft dust cover that fits over the conveyor belt outlet, preventing dust from escaping as the material falls. The discharge port incorporates a “deflector + atomizing nozzle” system. As the granules emerge, the deflector guides them in a direction, while the atomizing nozzle sprays a small amount of water (just enough to wet the dust without affecting the particles) to suppress any raised fines. This reduces dust concentration in the workshop by over 60%, eliminating the need for separate, large-scale dust removal equipment.
Next, consider noise reduction. The new type organic fertilizer granulator features a soundproofing pad between the motor and the granulation chamber, resulting in a 10-15 decibel reduction in operating noise compared to traditional machines. For example, while traditional machines typically make a tractor-like sound, the new type organic fertilizer granulator’s operation resembles a washing machine spinning, allowing for normal conversation in the workshop without earplugs. Furthermore, its rollers and ring die work together more smoothly, eliminating the sharp noises caused by friction and preventing disturbance to nearby residents.
Organic fertilizer is favored by agricultural production because of its ability to improve soil structure, increase organic matter content and enhance soil fertility. Among them, chicken manure as a high-quality organic fertilizer raw material, its processing has attracted much attention. This article will explore how to efficiently process organic manure from chicken manure through organic fertilizer production lines and ensure its quality and safety.
1. Raw material preparation and pretreatment
Chicken manure requires strict pretreatment before processing to eliminate pathogens and weed seeds in it. This usually involves composting treatment, which breaks down organic matter through the action of microorganisms while releasing heat to achieve bactericidal and deodorizing effects. The pre-treated chicken manure can enter the organic fertilizer production line for further processing.
2. Drying and sterilization of chicken manure
One of the key steps in an organic fertilizer production line is drying. By using professional drying equipment, such as Rotary Dryer Machine, the moisture content of chicken manure can be effectively reduced, its stability can be increased, and the subsequent granulation process can be facilitated. In addition, the high temperature during the drying process can further sterilize, ensuring the safe use of organic fertilizers.
3. Ingredient mix and nutrition balance
In the organic fertilizer production line, chicken manure is usually mixed with other auxiliary materials such as straw, shells, etc., to adjust the carbon nitrogen ratio and ensure the nutrient balance of organic fertilizer. This step is done through the Bulk Blending Fertilizer Production Line, ensuring that the final product can meet the needs of the different crops.
4. Granulation molding
The mixed raw materials will enter the granulator, such as the Fertilizer Granules Compaction Machine, for molding processing. This step forms the raw material into a uniform granular form that is easy to apply and store. Granulation can not only improve the appearance of organic fertilizer, but also improve its dispersion and absorption rate in the soil.
5. Screening and packaging
The organic fertilizer after granulation needs to be screened by Rotary Screening Machine to ensure uniform particle size and meet product quality standards. The qualified product is then packaged to become the final chicken manure organic fertilizer product.
6. Quality control
In the whole process of organic fertilizer production line, quality control is an indispensable link. By regularly testing the number and activity of microorganisms in organic fertilizers, the effectiveness and safety of the product can be assessed. For example, the application of bio-organic fertilizer can increase the capacity of soil microorganisms to utilize carbon sources, improve microbial nutrient conditions, maintain high microbial activity, and increase soil microbial diversity.
Through the above steps, the organic fertilizer production line can efficiently convert chicken manure into high-quality organic fertilizer products. This processing method not only improves the efficiency of resource utilization, but also helps to improve the quality and safety of agricultural products, and also contributes to the sustainable development of agriculture. With the advancement of technology and the growth of market demand, organic fertilizer production lines will continue to play an important role in modern agricultural production.
New type organic fertilizer granulators are more flexible than traditional models. Whether it’s straw, manure, mushroom residue, or distiller’s grains, they can be adapted with minimal adjustments without having to replace equipment.
If using fermented straw for granulation, this raw material is fibrous and somewhat loose, making it difficult to produce compact pellets. Add 5%-8% bentonite (a common binder) to the raw material, mix it thoroughly before feeding it into the new type organic fertilizer granulator, and increase the roller pressure. This will ensure compact pellets without breaking them up and damaging the organic matter in the straw.
For wet, sticky raw materials like chicken manure and pig manure, the biggest concern is clogging the granulator. Instead of adding too much binder, add about 10% dry mushroom residue to reduce moisture. Also, slow the new type organic fertilizer granulator’s feed rate to allow the raw material to fully form in the granulation chamber. The resulting pellets are smooth and less likely to stick to the machine. When it comes to fine raw materials such as mushroom residue and wine lees, they have moderate viscosity and do not require additional adhesives, which saves materials and time.
In the era of green agriculture, theNew Type Two-In-One Organic Fertilizer Granulator has emerged as a revolutionary organic fertilizer production machine, combining mixing and granulation processes to transform organic waste into valuable resources.
Unlike conventional rotary drum granulators, this innovative organic fertilizer manufacturing machine integrates stirring teeth within the drum, enhancing material agitation and creating more uniform granules with higher sphericity and compressive strength.
Compared to traditional fertilizer granules compaction methods, the New Type Stirring Tooth-Drum Granulator operates without binders, producing organic fertilizer through a wet granulation process that preserves nutrient integrity while reducing energy consumption.
This dual-function organic fertilizer production machine represents a significant advancement in sustainable agriculture technology, offering superior efficiency and product quality for modern organic fertilizer manufacturing operations worldwide.
Wide Applications: Green Transformation from Farms to Cities
Large-scale Organic Fertilizer Production
The preferred equipment for large organic fertilizer plants and processing cooperatives, capable of meeting organic fertilizer granulation needs at different scales. The produced granular organic fertilizers are widely used in farmland, orchards, vegetable bases, and flower cultivation.
Organic-Inorganic Compound Fertilizers
In organic-inorganic compound fertilizer production, it handles the pretreatment and granulation of the organic portion, providing key technical support for producing compound fertilizers that combine the advantages of both organic and inorganic fertilizers.
Bio-organic Fertilizer Manufacturing
Better preserves the activity of beneficial microorganisms during the granulation process, ensuring the functionality of bio-organic fertilizers, making it an ideal choice for producing high-quality bio-organic fertilizers.
Diverse Raw Material Processing Capability
· Livestock Manure – Various animal excrements including chicken, pig, and cattle manure
· Municipal Waste – Municipal sludge and other urban organic waste
· Other Organic Materials – Various fermentable organic raw materials
Exquisite Design: Perfect Fusion of Technology and Innovation
Intelligent Mixing System
Utilizes high-strength alloy steel mixing shafts with spiral or paddle-type wear-resistant mixing blades, driven by variable frequency motors with adjustable speeds of 20-60 rpm, ensuring mixing uniformity of over 90%.
Efficient Granulation System
Granulation disc angle hydraulically adjustable (30°-50°), featuring stainless steel base with wear-resistant rubber lining, equipped with various forming mechanisms including stirring tooth type and roller type to meet different material characteristics.
Precision Control System
PLC touchscreen control system monitors parameters such as mixing time, granulation speed, and material moisture in real-time, equipped with sensors for automatic alarms, achieving intelligent production management.
Automated Feeding & Discharge
Hopper equipped with level sensors, variable frequency speed regulation for screw feeders, discharge device with vibration anti-blocking mechanism, ensuring smooth production flow.
Particularly noteworthy is the equipment’s modular design concept, which gives it excellent adaptability. Whether processing viscous livestock manure or loose crop straws, optimal granulation results can be achieved by adjusting process parameters. This flexibility makes the dual-function granulator an ideal choice for various organic fertilizer production enterprises.
Technical Advantages: Redefining Production Efficiency
The most significant advantage of the dual-function granulator lies in its highly integrated design. The mixing and granulation processes that traditionally required multiple pieces of equipment can now be perfectly accomplished with just one machine. This not only significantly reduces equipment footprint but also markedly decreases energy consumption and labor costs. Meanwhile, the enclosed design effectively prevents dust pollution, creating a more environmentally friendly production environment.
The new dual-function organic fertilizer granulator represents not only outstanding technological innovation but also an important force driving sustainable agricultural development. With its wide raw material adaptability, exquisite process design, and exceptional production efficiency, it is playing an irreplaceable role in the global organic fertilizer production sector. From farms to cities, from traditional agriculture to modern circular agriculture, this equipment is contributing significantly to building a greener, more sustainable agricultural production system in its unique way.
Many organic fertilizer plants are concerned about costs. However, when using new type organic fertilizer granulators, paying attention to two small details can significantly save energy and materials.
To save energy, most new type organic fertilizer granulators are equipped with variable-frequency motors. Avoid running them at maximum speed all the time. For example, when initially feeding, use a low speed of 15 rpm. Once the raw materials have stabilized in the granulation chamber, gradually increase the speed to 20-25 rpm. This prevents the motor from exerting sudden force, saving 10%-15% of energy per hour. Additionally, avoid idling the machine. Do not start the machine until the raw materials are ready. The energy wasted in idling for one hour is enough to generate granules for 20 minutes.
To save materials, the key is to reduce waste. New type organic fertilizer granulators have a return device. Instead of discarding the crushed granules, they are directly returned to the granulation chamber through the return port, where they are mixed with new raw materials and granulated again. This can reduce the waste rate from 10% to less than 3%. Also, do not mix impurities such as stones and iron wire into the raw materials. Impurities will wear out machine parts and crush good particles. Use a sieve before feeding each time to avoid a lot of material waste.
In organic fertilizer production, the granulator is a core piece of equipment that determines product quality and production efficiency. The flat die granulator, with its unique design, is the preferred equipment for organic fertilizer production lines. Its advantages are primarily reflected in five key areas.
First, it offers excellent adaptability to raw materials. Organic fertilizer raw materials are complex, with common materials like livestock and poultry manure, straw, and mushroom residue exhibiting widely varying moisture and fiber content. By adjusting the pressure of the rollers and the speed of the die, the flat die granulator can easily process raw materials with a moisture content of 15%-30%. This eliminates the need for over-drying or the addition of large amounts of binders, preserving the beneficial microorganisms in the raw materials while reducing pretreatment costs. This makes it particularly suitable for the diverse raw material production needs of small and medium-sized organic fertilizer plants.
Second, the granulation quality is stable and controllable. The flat die granulator utilizes a “fixed die plate, rotating pressure roller” extrusion granulation method, achieving a pellet forming rate exceeding 95%. Pellet diameter can be flexibly adjusted (typically between 2 and 12 mm) by replacing dies with different apertures, meeting the pellet specification requirements for various applications, such as seedling fertilizer and field fertilizer. The pellets have a moderate hardness and are resistant to breakage, making them easy to package, transport, and spread in the field, effectively enhancing the product’s market competitiveness.
Furthermore, they offer low energy consumption and operating costs. Compared to ring die granulators, flat die pelletizers utilize a lower motor power, reducing power consumption by 20%-30% at the same production capacity. Furthermore, their consumable parts (such as the pressure roller and die) are made of wear-resistant alloy, offering a service life of over 3,000 hours. Replacement frequency is low, and the cost of spare parts is only half that of ring die pelletizers, significantly reducing production line operating expenses over the long term.
Furthermore, they are easy to operate and maintain. The flat die granulator boasts a simple and compact structure, a small footprint, and a quick installation and commissioning cycle. Operators can easily master the machine after minimal training. Routine maintenance requires only the regular addition of lubricating oil and cleaning of residual material from the die holes, eliminating the need for complex technical expertise. This significantly reduces labor costs and is particularly suitable for small and medium-sized manufacturers facing a shortage of skilled personnel.
Overall, the flat die granulator, with its high adaptability, cost-effectiveness, and ease of operation, is an ideal choice for improving efficiency, reducing costs, and ensuring quality in organic fertilizer production lines. It provides strong support for the development of small and medium-sized organic fertilizer manufacturers.
fertilizer granulator
