Against the backdrop of agricultural green transformation, organic fertilizer, with its “waste-to-treasure” characteristic, has become crucial for protecting soil health and improving agricultural product quality. The creation of this green fertilizer relies on a complete and efficient organic fertilizer production line. From the fermentation and decomposition of organic materials to the application of core fermentation composting and turning technologies, and then to the precise processing of new granulation equipment, each step involves scientific ingenuity, collectively completing the magnificent transformation of agricultural waste into high-quality organic fertilizer.
The core prerequisite of an organic fertilizer production line is organic fertilizer fermentation, a key process in which microorganisms decompose organic materials. Whether it’s livestock manure, straw, or kitchen waste, all require suitable temperature, humidity, and aeration conditions to decompose and transform through the metabolic action of microorganisms, ultimately forming nutrient-rich, mature materials. Fermentation composting turning technology is the core support for ensuring smooth fermentation. Regularly turning the compost pile using specialized equipment replenishes oxygen, meeting the growth needs of aerobic microorganisms and preventing the production of foul odors from anaerobic fermentation. It also regulates the pile temperature, preventing high temperatures from killing beneficial microorganisms, and ensures more uniform material mixing, significantly improving fermentation efficiency and composting quality.
With technological upgrades, organic fertilizer production lines have evolved from traditional single-process systems to intelligent, integrated systems. Bio-organic fertilizer production lines, in particular, have become the mainstream of high-end organic fertilizer production due to their precise cultivation and preservation of beneficial microorganisms. The “finishing touch” of the production line is undoubtedly the core equipment in the granulation process—the organic fertilizer granulator. Traditional granulation equipment suffers from uneven particle size and high energy consumption, but the emergence of new-type organic fertilizer granulators has completely changed this situation.
Among many new granulation devices, the new two-in-one organic fertilizer granulator stands out due to its integrated design. This integrated granulator combines material mixing and granulation functions, simplifying the production process and precisely controlling particle size and hardness. The resulting organic fertilizer granules are uniform and round, facilitating storage, transportation, and field application. Compared to traditional equipment, the new granulator also boasts lower energy consumption and less pollution, aligning with green production principles and finding widespread application in large-scale organic fertilizer production enterprises.
A complete organic fertilizer production line involves interconnected steps, from raw material pretreatment and fermentation turning to granulation, drying, and screening. Fermentation composting technology lays the foundation for material maturation, while the new granulation equipment ensures product quality. Their synergistic effect significantly improves the resource utilization rate of agricultural waste. Today, with continuous technological advancements, organic fertilizer production lines are developing towards greater intelligence, efficiency, and environmental friendliness, not only solving the problem of organic waste pollution but also providing strong support for sustainable agricultural development. Understanding the scientific principles of organic fertilizer production lines allows for a clearer appreciation of the value of organic fertilizer and encourages greater attention to the circular economy in agriculture, injecting new momentum into the development of green agriculture.
In the wave of green agricultural development, organic fertilizer, with its ability to improve soil structure and enhance crop quality, has become a crucial support for sustainable agricultural development. The key step in organic fertilizer production—fermentation composting—relies heavily on the core equipment: the compost turner. From trough-type and wheel-type to chain-type compost turners, different types of equipment adapt to diverse production needs. Combined with scientific fermentation processes, they enable agricultural waste to undergo a remarkable transformation from waste to treasure.
The compost turner is the “soul equipment” in the organic fertilizer fermentation composting process. Its core function is to regulate the temperature, humidity, and aeration within the compost pile by turning it, creating a suitable environment for microorganisms to decompose organic matter. Currently, there are various types of compost turners on the market, suitable for different production scenarios: trough-type compost turners operate using a trough structure, offering deep turning depth and high efficiency, suitable for large-scale, continuous production; large wheel compost turners, with their large-diameter wheels, can move flexibly in open areas, suitable for large-area composting operations, especially for large farms or organic fertilizer plants; chain compost turners achieve turning through chain drive, providing good crushing of the compost pile, allowing for more uniform material mixing, and improving fermentation efficiency; windrow compost turners are specifically designed for windrow composting, offering convenient operation and suitable for small to medium-sized production scales.
The production of high-quality organic fertilizer requires not only suitable compost turners but also scientific fermentation composting technology. Organic fertilizer fermentation is the process of microbial decomposition of organic materials, and fermentation composting turning technologyis crucial to ensuring successful fermentation. In the early stages of fermentation, the compost turner thoroughly mixes organic materials such as straw and livestock manure with microbial agents by turning the compost pile. During the middle stages of fermentation, regular turning lowers the pile temperature, preventing high temperatures from killing beneficial microorganisms, while also replenishing oxygen to prevent the growth of anaerobic bacteria and the generation of foul odors. In the later stages of fermentation, turning promotes uniform decomposition and improves the quality of the organic fertilizer. Throughout the entire organic fertilizer fermentation process, the operating frequency and turning depth of the compost turner need to be dynamically adjusted according to the pile temperature and humidity. Generally, when the pile temperature rises above 55℃ and remains there for 3-5 days, timely turning to cool it down is necessary.
As a core component of the equipment required for biofertilizer production, the compost turner works in conjunction with subsequent equipment such as the disc granulation production line to form a complete organic fertilizer production chain. The material, after fermentation and decomposition by turning, is then processed into granular organic fertilizer by the disc granulator for easy storage, transportation, and application. It is worth noting that the application of fermentation composting technology not only solves the problem of agricultural waste pollution but also achieves resource recycling, aligning with the concept of green agriculture development.
With the improvement of agricultural modernization, the technology of compost turners is constantly iterating, and more intelligent, efficient, and environmentally friendly equipment is continuously emerging, driving the continuous upgrading of fermentation composting technology. Understanding the types of compost turners and fermentation processes can not only help us better understand the scientific principles of organic fertilizer production but also raise awareness of the resource utilization of agricultural waste, injecting more power into promoting the development of green agriculture.
The NPK and potassium chloride combined production line is an integrated solution designed specifically for the “flexible production” needs of fertilizer companies. Through modular equipment configuration and process switching design, it can flexibly produce NPK compound fertilizer (multiple ratios) and potassium chloride granular fertilizer, achieving efficient capacity utilization of “one set of equipment, two products.” It adapts to the diversified market demands of large-scale fertilizer production enterprises, significantly reducing equipment investment and site occupancy costs.
Core Design Logic and Full-Process Configuration of the Production Line
The production line is based on “raw material sharing, process differentiation, and equipment universality.” It integrates key processes such as raw material pretreatment, precise batching, granulation, and post-processing. Through local equipment switching and parameter adjustments, it achieves rapid conversion between the two products. A single production line can achieve a capacity of 10-15 tons (NPK compound fertilizer) or 12-18 tons (potassium chloride granular fertilizer).
I. Raw Material Pretreatment and Sharing Unit: Laying the Foundation for Dual-Product Production
(I) Raw Material Storage and Precise Batching
Multi-Warehouse Storage System: Equipped with 6 raw material warehouses (total volume 150m³), storing urea, monoammonium phosphate, potassium chloride (main raw material), binder, trace elements, and functional additives respectively. The warehouse bodies are made of carbon steel with an anti-corrosion coating (compatible with the corrosiveness of potassium chloride). Vibrators and star-shaped unloaders are installed at the bottom to prevent raw material bridging and blockage.
Intelligent Batching Device: Employs a 6-channel variable frequency screw feeder, paired with a PLC control system. When producing NPK compound fertilizer, the proportions of nitrogen, phosphorus, potassium, and additives are precisely controlled according to the formula (batching error ≤ ±0.8%). When producing potassium chloride granular fertilizer, the amount of potassium chloride is increased separately (≥90%), reducing or closing other raw material channels to achieve rapid switching.
(II) Raw Material Pretreatment and Mixing
Crushing and Screening: Potassium chloride raw material is crushed to ≤2mm using a 400-type vertical crusher (to avoid large clumps affecting granulation). During NPK compound fertilizer production, other inorganic raw materials are simultaneously crushed to ≤3mm. A cyclone dust collector is used in the crushing process, achieving a dust recovery rate of 99%. After crushing, the raw materials are graded using a 1.2×4.0 meter drum screen; unqualified particles are returned for regrinding.
Twin-Shaft Mixer: A 60-type twin-shaft mixer is used. During NPK production, multiple components are thoroughly mixed (mixing uniformity error ≤2%). During potassium chloride production, only potassium chloride and a small amount of binder are mixed (addition amount 2%-5%). The mixer is equipped with a spray humidification device, and the moisture content of the raw materials is adjusted according to the product type (NPK: 25%-30%; potassium chloride: 18%-25%). II. Core Granulation Unit: Dual-Product Adaptability Design
(I) Granulation Machine Selection and Switching
Core Equipment: Two Φ2.0×8.0 meter rotary drum granulators (operating in parallel) are used to accommodate the granulation needs of two products. The inner wall of the drum is lined with wear-resistant ceramic plates (resistant to potassium chloride corrosion), and adjustable lifting plates are used. Process switching is achieved by adjusting the lifting plate angle and the drum speed.
Process Parameter Adjustment:
NPK Compound Fertilizer Production: Drum speed 12-15 r/min, material residence time 8-10 minutes, binder is sprayed through atomization to form 3-5mm rounded granules, granulation rate ≥92%;
Potassium Chloride Granular Fertilizer Production: Drum speed 10-12 r/min, extending the material residence time to 12-15 minutes, reducing the amount of binder, utilizing the crystallization characteristics of potassium chloride to assist in molding, particle size controlled at 2-4mm, granulation rate ≥90%. (II) Optimized Auxiliary Granulation
When producing potassium chloride, a pre-compression device is added to pre-compress the mixed potassium chloride raw materials into dense columns before feeding them into the rotary drum granulator, improving particle strength (to above 2.8 MPa) and avoiding pulverization caused by poor adhesion of potassium chloride.
When producing NPK, the pre-compression device is turned off, and the conventional rotary drum granulation process is used directly to ensure uniform fusion of multi-component raw materials.
III. Post-processing Unit: Branching Design Ensures Product Quality
(I) Drying and Cooling
Drying System: A single Φ2.2×20 meter drum dryer is used. Temperature adjustment achieves dual-product compatibility—NPK compound fertilizer is dried at 80-100℃, reducing the moisture content to below 12%; potassium chloride granular fertilizer is dried at 60-80℃ (to avoid high temperatures affecting crystallization stability), reducing the moisture content to below 8%. The dryer is equipped with temperature and humidity sensors to automatically adjust the hot air supply.
Cooling System: Adopting a “primary cooling + branched screening” design, a single Φ1.8×15m counter-current cooler is used to reduce the temperature of the dried granules to below 35℃. The granules are then branched through a three-way valve and conveyed to dedicated screening equipment.
(II) Grading and Finished Product Processing
NPK Compound Fertilizer: After screening using a Φ1.5×6.0m double-layer drum screen (3-5mm sieve aperture), unqualified granules are returned to the raw material mixing stage.
Potassium Chloride Granular Fertilizer: After screening using a Φ1.2×4.0m single-layer vibrating screen (2-4mm sieve aperture), 0.1% anti-caking agent (such as potassium silicate) is sprayed to improve moisture resistance.
IV. Finished Product Storage and Packaging Unit: High-Efficiency Output Switching
Finished Product Warehouse: Equipped with 3 x 100m³ finished product warehouses (2 for NPK compound fertilizer, 1 for potassium chloride granular fertilizer), all featuring a sealed design with dehumidification and ventilation devices. The potassium chloride warehouse has a dedicated anti-corrosion treatment to prevent corrosion.
Packaging System: Shares 2 dual-station automatic packaging scales, allowing for specification switching by adjusting measurement parameters (NPK supports 25kg/50kg, potassium chloride supports 20kg/50kg). Measurement error ≤ ±0.2kg, packaging speed reaches 120 bags/hour, and a conveyor belt enables rapid transfer of finished products.
V. Environmental Protection and Intelligent Control Unit: Stable Green Production
(I) Environmental Protection
Dust Treatment: Each stage is equipped with a pulse dust collector (total processing air volume 20,000 m³/h). Corrosion-resistant dust collector materials are used during potassium chloride production, with dust emission concentration ≤10 mg/m³.
Wastewater Treatment: Washing wastewater is treated by an oil separator and sedimentation tank before being recycled for raw material humidification, achieving zero wastewater discharge.
(II) Intelligent Control
Integrated PLC central control system, preset with two production modes: NPK and potassium chloride. One-click switching of key parameters such as batching ratio, granulation speed, and drying temperature is supported, along with automatic fault alarms and data recording.
Key equipment (granulator, dryer) is equipped with safety interlock devices to ensure stable operation during production transitions.
Core Advantages and Application Value of the Production Line
Flexible and High-Efficiency Production: One set of equipment enables the production of two mainstream fertilizers, reducing transition time to less than 2 hours, significantly reducing equipment investment and site costs, and allowing for rapid capacity adjustments to adapt to market demand fluctuations. Dual Guarantee of Product Quality: Targeted process design and parameter optimization ensure that NPK compound fertilizer has uniform nutrients and rounded granules, while potassium chloride granular fertilizer has high strength and moisture resistance, both meeting national standards.
Energy Saving, Environmental Protection, and Low Cost: Equipment sharing rate exceeds 70%, reducing energy consumption by 18% compared to two separate production lines; dust recovery and wastewater recycling reduce material waste and environmental pollution.
Enhancing Efficiency and Versatility in Fertilizer Manufacturing
This innovative NPK and potassium chloride combined production line exemplifies a strategic approach to modern fertilizer manufacturing. It maximizes asset utilization and operational flexibility, allowing producers to efficiently respond to changing market demands from a single facility.
The line’s core function as an npk fertilizer production line highlights advanced npk fertilizer production technology. Its intelligent design centers around the npk granulation machine technology. Key components include a high-precision npk bulk blending machine for formula preparation and the npk fertilizer granulator machine (a npk fertilizer granulator) for shaping the mixture into granules. The entire npk fertilizer manufacturing process—from batching to granulation and coating—is integrated and optimized within this single, adaptable npk fertilizer production process, demonstrating how modular design can create a versatile and cost-effective production ecosystem.
Ultimately, this solution empowers fertilizer companies to diversify their product portfolio without duplicating infrastructure, securing a competitive edge through agility and efficiency.
The powder + granular organic fertilizer production line is an integrated solution designed specifically for the diversified production needs of organic fertilizer enterprises. Through its core design of “shared raw materials, differentiated processes, and universal equipment,” it simultaneously achieves large-scale production of both powdered and granular organic fertilizers. One set of equipment meets different application scenarios (powder is suitable for fertigation and drip irrigation; granules are suitable for strip application and broadcasting), significantly improving capacity utilization and market adaptability, and is suitable for green agriculture scenarios such as ecological planting and facility agriculture.
Production Line Configuration and Core Details
I. Raw Material Pretreatment and Sharing Unit: Laying the Foundation for Dual Products
(I) Raw Material Storage and Fermentation Pretreatment
Raw Material Warehouse and Fermentation System: Equipped with 3 large-capacity 100m³ raw material warehouses to store organic raw materials such as livestock and poultry manure, straw, and mushroom residue; equipped with a 500m³ windrow-type fermentation turner (or trough-type turner) to ferment and decompose the raw materials (decomposition degree ≥85%), removing odors and pathogens. The fermentation cycle is 7-15 days. After fermentation, the moisture content of the raw materials is controlled at 35%-45%, laying the foundation for subsequent processing.
Crushing and Impurity Removal: The fermented raw materials are conveyed to a 90-type vertical crusher via a 6-meter belt conveyor, crushed to ≤3mm (granular fertilizer raw materials) or ≤1mm (powdered fertilizer raw materials). During the crushing process, impurities such as stones and plastics are removed by an impurity removal device. The crusher is equipped with a pulse dust collector, achieving a dust collection efficiency of 99% and a material utilization rate of 98%.
(II) Precise Batching and Mixing
Multi-Group Batching System: Equipped with a 4-compartment batching machine, storing fermented organic fertilizer, straw charcoal, trace elements, and functional microbial agents respectively. A variable frequency screw batching scale is used to precisely control the proportions (functional microbial agent addition amount 0.1%-0.5%), with a batching error ≤±1%. When producing powdered fertilizer, soluble additives such as humic acid and amino acids are added to improve the fertilizer’s water solubility; when producing granular fertilizer, 3%-5% binder (such as bentonite or starch) is added to ensure granulation effect.
Twin-shaft mixer: A 60-type twin-shaft mixer is used to thoroughly mix the multi-component raw materials, with a mixing uniformity error ≤2%. The mixer is equipped with a spray humidification/drying device to adjust the raw material moisture content according to the product type (powdered fertilizer: 20%-25%; granular fertilizer: 30%-35%).
II. Process branching unit: Parallel production of powdered and granular fertilizers
(I) Powdered organic fertilizer production line (branching branch 1)
Fine grinding and sieving: The mixed raw materials are further ground to 100-150 mesh using a 13-type ultrafine pulverizer to ensure uniform powder fineness and rapid dissolution. After grinding, the powder is graded using a 1.2×4.0 meter vibrating screen to remove substandard coarse particles, which are then returned to the pulverizer for reprocessing.
Finished Product Storage and Packaging: Qualified powder is conveyed via a sealed screw conveyor into two 50m³ finished product silos (dedicated to powder form). The silos are equipped with dehumidification and ventilation devices to prevent moisture absorption and clumping. The packaging process utilizes a dual-station automatic powder packaging scale with a screw feeder and dust cover design to prevent dust from flying. It supports switching between 20kg and 25kg specifications, with a measurement error ≤ ±0.2kg and a packaging speed of 80 bags/hour.
(II) Granular Organic Fertilizer Production Line (Branch 2) Core Granulation Process: The mixed raw materials are conveyed via an 8-meter belt conveyor to a Φ3.2×1.2-meter disc granulator (or rotary drum granulator). Through centrifugal force and the action of a binder, 3-5mm rounded granules are formed, with a granulation rate ≥90%. The granulator is equipped with a spray humidification device to adjust moisture in real time and ensure granule strength.
Drying and Cooling/Curing: Wet granules are conveyed via a 10-meter belt conveyor into a Φ1.8×15-meter drum dryer, where hot air circulation heating is used to control the drying temperature at 60-80℃ (to prevent inactivation of functional bacteria), reducing the moisture content to below 12%. They then enter a Φ1.5×12-meter counter-current cooler for rapid cooling to room temperature, increasing the granule strength to over 2.0MPa, making them more resistant to storage and transportation and less prone to pulverization.
Grading, Screening, and Packaging: The cooled granules are graded using a Φ1.5×6.0-meter drum screen (3-5mm sieve openings). Unqualified granules are returned to the granulator for reprocessing. Qualified granules are fed into two 80m³ finished product silos (dedicated to granules) and packaged using a dual-station automatic granule packaging scale, supporting 25kg and 50kg sizes at a packaging speed of 100 bags/hour.
III. Environmental Protection and Intelligent Control Unit: Green and Stable Production
(I) Environmental Protection System
Dust Treatment: Four MC-96 pulse dust collectors are installed in the crushing, screening, and packaging stages, with a total air volume of 18,000 m³/h. The dust concentration in the workshop is ≤10 mg/m³, meeting environmental standards.
Exhaust Gas Treatment: Odors generated during fermentation are purified by a biological filter before being discharged, with an ammonia concentration ≤15 mg/m³.
Wastewater Treatment: Production cleaning wastewater is treated by sedimentation and filtration tanks and then recycled for raw material fermentation humidification, achieving zero wastewater discharge.
(II) Intelligent Control System
An integrated PLC central control system is installed, with preset production modes for powder and granules. Process parameters (crushing fineness, ingredient ratio, drying temperature, etc.) can be switched with one click. Real-time monitoring of equipment operation status, raw material moisture content, and finished product output is provided. Automatic fault alarms and data recording (storage period ≥90 days) are supported, reducing manual intervention.
Core Advantages and Adaptability of the Production Line
Flexible Dual-Product Switching: One set of equipment enables simultaneous/switching production of powdered and granular organic fertilizers, with a conversion time of ≤2 hours. This adapts to different customer needs (growers, agricultural input dealers) and application scenarios, enhancing market competitiveness.
Highly Efficient and Stable Production Capacity: Hourly production capacity reaches 5-8 tons (powder) or 6-10 tons (granules), with an annual capacity of 40,000-80,000 tons, suitable for the production needs of small, medium, and large-scale organic fertilizer enterprises. Equipment sharing rate exceeds 70%, saving 30% in investment costs and 25% in floor space compared to two separate production lines.
Superior Product Quality: Powdered fertilizer has uniform fineness and good water solubility, suitable for fertigation and drip irrigation; granular fertilizer is round, dense, and high-strength, suitable for mechanized strip application and broadcasting, with a functional bacteria survival rate of over 90%, ensuring fertilizer efficacy.
Green and Environmentally Friendly: The entire process features a sealed design, dust recovery, and wastewater recycling, meeting national environmental protection requirements. The fermentation process also enables the resource utilization of agricultural waste, contributing to the development of green agriculture.
Suitable and Unsuitable Scenarios
Suitable Scenarios: Large-scale organic fertilizer production enterprises and agricultural waste resource utilization projects that require the supply of both powdered and granular organic fertilizers, suitable for diversified fertilization needs such as ecological planting, fruit and vegetable greenhouses, and grain crops.
Unsuitable Scenarios: Raw materials with a moisture content >50% and that are not fully fermented (easily leading to equipment blockage and product spoilage); pure functional microbial fertilizers (requiring low-temperature processing and additional low-temperature drying equipment).
A Flexible Solution for Diverse Market Needs
This integrated powder + granular organic fertilizer production line provides manufacturers with a highly adaptable and efficient foundation. It enables the flexible production of two major fertilizer forms from a shared raw material base, maximizing equipment utilization and market responsiveness.
While specialized for organic production, this line represents a category of advanced fertilizer production machine technology. Its drum granulation process using a rotary drum granulator is a common and effective fertilizer processing machine method. For operations looking to expand into mineral-based products, the principles of this line are complementary to an npk production line. The granulation stage could be adapted using alternative technologies, such as a roller press granulator production line for dry fertilizer granules compaction, or a disc granulation production line. These technologies are all part of modern npk fertilizer production technology, allowing manufacturers to build upon this organic foundation to create a comprehensive portfolio that serves both organic and conventional agricultural markets.
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