The fermentation process of large-scale organic fertilizer production (processing over 500 tons of raw materials daily) faces the challenges of high processing volume, tight fermentation cycles, and high labor costs. The double screws compost turning machine’s design features perfectly meet these requirements, making it a core piece of equipment for large-scale production.
1.Efficient and Continuous Operation
The double screws compost turning machine continuously moves along the fermentation tank, turning the compost without frequent downtime and adjustments. A single unit can process up to 100-200 tons per hour, meeting the continuous fermentation needs of large-scale production lines and ensuring timely composting.
2.Stable and Uniform Compost Turning Quality
Large-scale production requires high consistency in fertilizer quality. The double screws compost turning machine’s two spirals work in tandem, ensuring uniform mixing of the material, both vertically and horizontally, and ensuring even oxygen exposure. Fertilization temperature fluctuations are controlled within ±3°C, preventing uneven fermentation and causing uneven fertilizer quality.
3.Significantly Reduced Labor Costs
Traditional manual compost turning can only process 5-10 tons of material per person per day. A single double screws compost turning machine can replace 20-30 workers. The machine operates without human intervention (it supports automatic movement and compost turning), eliminating the efficiency fluctuations associated with manual operation.
With the large-scale development of the organic fertilizer industry, production lines are placing increasingly stringent demands on equipment adaptability. With its exceptional integration capabilities, large wheel compost turners have become core equipment for large-scale organic fertilizer production lines.
Within the production line process, they seamlessly connect pre-treatment and processing. During pre-treatment, raw materials such as livestock and poultry manure processed by a solid-liquid separator and pulverized straw from a pulverizer are piled into windrows 5-8 meters wide and 1.5-2 meters high. The large wheel compost turner slowly moves along the windrows, turning and fermenting the material. The fermented material is then conveyed by conveyor to equipment such as granulators, screens, and dryers, forming a complete production chain from pre-treatment to fermentation, enabling continuous production.
For large-scale production lines with an annual output of over 100,000 tons, the equipment rotates through multiple windrows: one receiving fresh raw material, one performing high-temperature fermentation, and one completing cool-down composting. This fixed cycle allows for a daily processing capacity of 800-1,500 tons, meeting the needs of large-scale production.
In addition, its electronic control system flexibly adjusts the turning and travel speeds, adjusting the fermentation progress based on the raw material supply and pelletizing capacity, ensuring a stable production line. Furthermore, compared to tank fermentation, it improves site utilization by over 30%, saving valuable land resources for large-scale production lines.
In organic fertilizer production, the quality of compost turning during the fermentation process directly determines fertilizer maturity and nutrient retention. The double screws compost turning machine, with its unique structural design, is a key device for addressing uneven compost turning and slow fermentation. Its dual helical operation ensures sufficient oxygen and uniform heat dissipation within the fermentation tank, significantly improving fermentation efficiency.
The core working components of the double screws compost turning machine are two sets of parallel spiral blades. As the device moves along the fermentation tank track, the blades rotate clockwise, tossing the bottom material upward while simultaneously dispersing it to the sides. This turning method creates a “rolling up and down, mixing left and right” motion pattern for the material.
During the fermentation process, turning the compost not only provides sufficient oxygen for microorganisms but also quickly dissipates heat generated by the fermentation process, preventing nutrient loss due to localized high temperatures. For different raw materials such as livestock and poultry manure, straw, etc., the spiral speed and double screws compost turning machine movement speed can be adjusted to control the turning depth (up to 1.5-3m) and frequency, ensuring that the materials are fully composted within 7-15 days. Compared with manual turning, the efficiency is increased by more than 10 times.
Double screws compost turning machines operate frequently in organic fertilizer fermentation workshops. Improper operation or untimely maintenance can easily lead to problems such as uneven turning, insufficient power, and equipment jamming, impacting fermentation progress.
1. Dead corners remain after turning, and some areas remain uncomposted
The main cause is excessive clearance between the spiral blades and the sidewalls of the fermentation tank (over 10 cm), or the double screws compost turning machine is moving too fast, preventing material from being turned over the edges. To address this, adjust the position of the spiral blades to reduce the clearance to within 5 cm. Also, reduce the double screws compost turning machine’s speed to ensure that every area is thoroughly turned.
2. Motor overload and tripping, insufficient power
This is often caused by excessive moisture content (over 70%) in the raw materials, resulting in increased friction on the spiral blades due to high viscosity, or by large impurities in the raw materials that may be blocking the blades. To address this, adjust the moisture content of the raw materials to 60%-65% before clearing impurities from the fermentation tank. If the compost tank is frequently overloaded, check the tightness of the motor belt and tighten or replace it.
3. Rapid wear of spiral blades, reducing turning capacity
This is primarily due to the presence of hard impurities (such as sand and gravel) in the raw materials, or the blade material not being suitable for wear resistance. To address this, install a screen to filter out hard particles before the raw materials arrive. Regularly inspect the blades for wear. If the blade thickness has decreased by 1/3 or cracks appear, replace them promptly.
In the modern organic fertilizer production line, efficiency is paramount. While traditional fertilizer granulator systems like the rotary drum granulator are common, they often face challenges like low output, high energy consumption, and inconsistent product quality. This is true whether the machine is used as annpk fertilizer granulator or a standardorganic fertilizer granulator. Our HP series ring die granulator is specifically engineered to overcome these industry pain points. Designed for high-performance granulation, it integrates seamlessly into a production line that may begin with a wheel compost turner, delivering unparalleled efficiency, superior granule quality, and remarkable energy savings to maximize your operational productivity.
After years of dedicated research and improvement by our engineering team, this machine features a unique gear belt drive system that ensures smoother operation while increasing production efficiency by at least 15%, delivering immediate return on your investment.
Outstanding Performance Specifications
Model HP-450:
Capacity range: 1-5 tons/hour
Finished product rate: >95%
Moisture content: <30%
Motor power: 30+2.2kW
Model HP-650:
Capacity range: 5-8 tons/hour
Finished product rate: >95%
Moisture content: <30%
Motor power: 45 (55) +4kW
Why Choose Our Granulator?
Preserves Nutrients: Unique low-temperature processing technology effectively retains nutritional components in raw materials.
Superior Product Quality: Smooth surface and moderate hardness make your products highly competitive in the market.
Easy Operation & Maintenance: User-friendly design reduces training costs and operational difficulties.
Wide Applications: Suitable not only for organic fertilizer production but also for compound fertilizer and feed processing industries.
Imagine this: While your competitors struggle with inefficient equipment, you’re already producing more high-quality fertilizer products from the same raw materials. This is the competitive edge our HP series ring die granulator brings to your business!
Whether you’re a startup or a large-scale fertilizer producer, this high-efficiency, stable, and easy-to-use granulation equipment will become an indispensable asset to your production line. Contact us today to begin your journey toward more efficient production!
Drum fertilizer dryers account for 25%-30% of a fertilizer production line’s total energy consumption. Whether routine operation and maintenance are effective directly impacts a company’s operating costs.
Accurate Maintenance of Thermal Efficiency
Hot air is the core energy source of a drum fertilizer dryer. The pipes connecting the hot air furnace and the drum must be regularly inspected. Damaged pipe insulation can lead to heat loss (up to 10% or more) and require prompt repair or replacement. Clean accumulated slag in the hot air furnace to ensure complete fuel combustion, increase thermal efficiency to over 75%, and reduce fuel waste.
Dynamic Adjustment of Drum Operating Parameters
Adjusting operating parameters based on changes in raw material moisture content can avoid inefficient energy consumption. When the moisture content of the wet material is low, appropriately reduce the hot air temperature and increase the drum fertilizer dryer speed (shortening the dwell time). When the moisture content is high, adjust the opposite direction. This ensures that every unit of energy consumed is used for effective dehydration, avoiding the waste of high energy consumption processing low-moisture materials.
Preventive Replacement of Wear Parts
Worn drum seals (such as the seals at the feed and discharge ports) can cause cold air to infiltrate and hot air to leak, increasing the heating load. Check the seals monthly and replace any signs of aging or deformation. Also, regularly inspect the lift plate. If loose or worn, tighten or replace it promptly. Simple preventive maintenance can significantly reduce future failures and energy costs.
In the fertilizer industry, the drying requirements of organic and compound fertilizers differ significantly. Organic fertilizers require rapid dehydration and fiber clumping prevention, while compound fertilizers require gentle drying to prevent particle breakage.
For drying organic fertilizers, drum fertilizer dryers offer two key design advantages: First, they utilize a “high-speed + multiple lifter” combination. High speed combined with dense lifters effectively lifts fibrous materials, preventing entanglement and clumping. Hot air also directly penetrates the material layer, quickly removing moisture. Second, an anti-stick coating on the inner wall of the drum reduces wet organic fertilizer from sticking to the wall, reducing cleaning frequency and ensuring continuous production.
For drying compound fertilizers, the drum fertilizer dryer emphasizes “gentle temperature control + low speed”: steam heating is used, keeping the temperature between 120-150°C to avoid direct contact with high temperatures that could cause cracking on the particle surface. Furthermore, a reduced drum speed reduces particle friction within the drum, keeping the particle breakage rate below 3%.
Even when processing temperature-sensitive biofertilizers, the drum fertilizer dryer can adapt to these needs through a “low-temperature hot air modification.” This reduces the hot air temperature to 60-80°C, prolonging the material’s residence time. This allows for slow dehydration while maintaining a microbial survival rate above 85%, truly achieving “one device, multiple fertilizers.”
When selecting a rotary drum granulator, companies should pay close attention to its core structure to ensure it precisely matches their production line requirements. A rotary drum granulator primarily consists of a rotating drum, transmission, support system, and spray system. The performance of each component directly impacts the overall performance of the equipment.
The rotating drum, as the core working component, is constructed from rolled steel plate. Lifting plates or spiral blades on the inner wall enhance the tumbling and collision effect of the material. When selecting a granulator, consider whether the steel plate thickness and blade design are compatible with the characteristics of the production material. The transmission provides power, and the power and quality of the motor and reducer affect the equipment’s operational stability and should be selected based on production capacity.
The support system bears the weight and rotation of the drum. The selection of rolling or sliding bearings should be considered based on the equipment load and operating environment. Furthermore, the atomization effect of the spray system determines the accuracy of humidity control, ensuring uniform spraying of water or adhesive. Only by comprehensively considering these structural details can you select a rotary drum granulator that is compatible with your production line and operates efficiently.
For fertilizer companies, choosing the right drum fertilizer dryer not only ensures effective drying but also reduces subsequent energy consumption and maintenance costs.
1. Suitable Heating Method for Fertilizer Type
For organic fertilizer production (including fiber-based fermented materials), the preferred option is “hot air heating.” Direct contact between the hot air and the material results in faster drying and prevents fiber sticking to the wall. For compound fertilizer production (wet granules after granulation), the “steam heating” option offers a milder temperature and reduces granule breakage. For low-temperature drying of biofertilizers (to prevent inactivation of microbial inoculants), the “low-temperature hot air” option is recommended to preserve microbial activity.
2. Matching Drum Specifications to Production Capacity
The drum diameter and length directly determine the processing capacity. When selecting a drum fertilizer dryer, calculate the hourly processing capacity based on the daily production capacity, allowing for a 10%-15% margin to ensure sufficient material residence time.
3. Targeted Selection of Anti-Stick Designs
High-humidity organic fertilizers tend to stick to the inner wall of the drying drum. When selecting a drum fertilizer dryer, confirm whether it features an anti-sticking skimmer or polished inner wall treatment to reduce material residue and avoid frequent downtime for cleaning. When processing highly sticky wet compound fertilizer pellets, a combination of a guide plate and skimmer can be used to guide material flow smoothly.
4. Energy Consumption and Environmental Parameters
Prioritize equipment with high thermal efficiency to reduce fuel waste. Also, consider the suitability of exhaust gas treatment. The hot and humid exhaust gas generated during the drying process requires dust removal and desulfurization equipment to ensure compliance with environmental emission standards in the fertilizer industry.
In today’s pursuit of sustainable development, the NPK compound fertilizerroller press granulation production line is revolutionizing the industry. This advanced npk manufacturing process utilizes a highly efficient fertilizer compactor for fertilizer granules compaction, establishing itself as a superior alternative to traditional methods like the rotary drum granulator. While drum granulation has been widely used, the modern fertilizer compaction machine offers a cleaner, dry extrusion granulation technology that redefines production efficiency. This makes the completenpk fertilizer production line and organic fertilizer manufacturing machine incredibly versatile. The entire fertilizer production machine system, central to any robust npk production line, sets new benchmarks for green manufacturing by significantly reducing energy consumption and emissions, delivering outstanding environmental and economic benefits.
Core Advantages: Perfect Balance of Ecology and Economy
Energy Conservation Pioneer
Utilizing dry granulation at room temperature, the entire production process achieves zero exhaust emissions and no environmental pollution, perfectly meeting modern environmental requirements. Compared to traditional processes, energy consumption is reduced by over 40%, truly achieving green manufacturing.
Significant Economic Benefits
The one-step molding process eliminates the drying step, reduces equipment investment by 30%, and lowers operating costs by 25%. The application of bucket elevators saves 50% of floor space, significantly improving the return on investment.
Optimized Process Layout
The scientifically designed process flow makes the production line layout more compact and efficient. From raw materials to finished products, each link is seamlessly connected, which greatly improves production efficiency while reducing the intensity of manual operation.
Outstanding Features: Versatile Performer Across Industries
Wide Material Adaptability
Processes various materials including compound fertilizers, pharmaceuticals, chemicals, and feed, achieving multiple uses with one machine
Excellent Product Diversity
Capable of producing compound fertilizers with different concentrations and types to meet diverse market demands
Strong Process Stability
Room temperature one-time molding ensures stable product quality with particle uniformity exceeding 95%
Easy Operation & Maintenance
High automation level, user-friendly operation interface, simple and quick daily maintenance
Particularly noteworthy is the innovation of roller press granulation technology in its “compression instead of drying” process concept. By replacing traditional thermal drying with precise mechanical pressure, it not only avoids energy waste but also ensures the integrity of raw material active components. This gentle processing method is particularly suitable for temperature-sensitive materials, opening new pathways for the development of specialty fertilizers.
Wide Applications: Cross-Industry Solutions
The exceptional performance of roller press granulation production lines makes them shine in multiple fields. In the fertilizer industry, it can precisely produce various NPK compound fertilizer formulations; in the pharmaceutical field, it handles temperature-sensitive materials; in feed processing, it maintains nutritional component activity; in the metallurgical industry, it processes materials like mineral powders. This cross-industry adaptability makes it a universal platform for modern industrial production.
The NPK compound fertilizer roller press granulation production line represents not only an outstanding example of technological innovation but also the perfect implementation of sustainable development concepts. With its exceptional environmental performance, significant economic benefits, and wide application range, it is triggering a new technological revolution in the global fertilizer manufacturing sector. From energy conservation to green production, from cost control to quality improvement, this technology provides comprehensive solutions for modern manufacturing and is destined to become an important direction for future fertilizer industry development.
fertilizer granulator
