How to Process Compound Fertilizer Using a Rotary Drum Granulator

fertilizer granulator Aug 21, 2025

With the development of agriculture and technological advancements, market demand has become increasingly diversified. Rotary drum granulators have also attracted significant attention for their high efficiency, ease of operation, and excellent granulation results, making them a standout among other fertilizer granulators.

In the fertilizer production process, fertilizer granulators are crucial for determining fertilizer yield and quality. The quality of this equipment directly impacts the user’s economic benefits. During the rotary drum granulator production process, increasing the material temperature is necessary to improve the solubility of the granules. To reduce heat energy consumption during the drying process, the performance of the granulator must be effectively maintained.

To reduce production costs throughout the fertilizer production process, low energy consumption and high efficiency must be achieved at every stage of the granulation process. A high granulation rate in a rotary drum granulator ensures consistent production. To ensure this high granulation rate, the smoothness of the granulator’s inner wall must be enhanced. A smooth inner wall reduces friction, allowing the material to roll back and forth and quickly form granules. Our rotary drum granulator differs from traditional granulators. As the granulator’s lining rotates upward with the drum, it sags due to its own weight, allowing any material adhering to the lining to fall due to gravity, thus automatically removing lumps. Furthermore, this reduces the amount of water added during the granulation process, thereby alleviating the drying load during fertilizer processing.

In fertilizer production, large-scale rotary drum granulators can be equipped with two drum fertilizer screeners. The first is used to remove fines and small particles. The second drum fertilizer screener has two screen sections. One section, with a small mesh, selects particles that meet the requirements. These particles are then conveyed by a conveyor to the packaging machine. The other section, with a mesh, removes oversized particles, which are directly sent to a chain crusher for crushing before returning to the granulator.

2-in-1 Granulator: The Transformer of Organic Fertilizer Production

fertilizer granulator Aug 21, 2025

In the field of bio organic fertilizer production, the innovative 2-in-1 granulator works like a master magician, perfectly integrating mixing and granulation processes. This “Transformer”-like equipment is redefining efficiency in the organic fertilizer production line through ingenious design innovations. By combining two essential functions into a single machine, it significantly streamlines the complete organic fertilizer line, reducing space requirements and energy consumption while improving output quality.

1. Mixing System: The Perfect Symphony of Raw Materials

The mixing system conducts like an orchestra leader, ensuring harmonious blending:

Intelligent Mixing Core – The mixing shaft made of high-strength alloy steel acts like a baton, working with spiral or paddle-shaped wear-resistant blades at 20-60 rpm to achieve over 90% mixing uniformity. The 1-8 m³ mixing chamber with curved design ensures material flows as smoothly as a symphony.

Mixing Speed: Adjustable 20-60 rpm

Mixing Uniformity:>90%

2. Granulation System: The Magical Transformation Stage

The granulation system is the most magical part:

The granulation disc with adjustable tilt (30°-50°) moves like a flexible dancer, adapting to material characteristics. The stainless steel disc with wear-resistant rubber lining ensures perfect formation of every fertilizer pellet.

Multiple “transformation” options available:

• Tooth Stirring Type: High-speed rotating claws instantly agglomerate loose materials like a magician’s hands
• Roller Press Type: Strong extrusion between rollers and template creates uniform, solid pellets

The powerful 11-45kW drive system provides stable support for this “transformation show.”

3. Intelligent Control System: The Precise Production Commander

The PLC touchscreen control system acts as the equipment’s brain:

It monitors key parameters like material moisture and mixing uniformity in real-time, sounding alarms immediately when abnormalities are detected. Like an experienced production commander, it ensures every process runs at optimal condition.

The level sensor-equipped hopper and variable-frequency screw feeder achieve intelligent “on-demand” material supply. The vibration device at the discharge end ensures smooth pellet conveying.

This 2-in-1 granulator not only saves over 30% of floor space but also increases production efficiency by 50%. It’s sparking a “2-in-1 revolution” in global organic fertilizer production, making the process smarter, more efficient, and more environmentally friendly.

Relationship to Production Lines

The 2-in-1 granulator serves as a central component in both small-scale and industrial organic fertilizer production line setups. Its innovative design eliminates the need for separate mixing and granulation equipment, making the entire organic fertilizer line more compact and efficient. This integration is particularly valuable in bio organic fertilizer production, where precise control over the granulation process is essential for maintaining microbial viability and nutrient content.

Space Efficiency

Combines two processes into one machine, reducing the footprint of the production line by up to 40%.

Energy Savings

Uses 30% less energy compared to operating separate mixing and granulation equipment.

Process Optimization

Eliminates material transfer between machines, reducing processing time and potential contamination.

The Role of Bio-Organic Fertilizer Production Lines in Agricultural Production

fertilizer granulator Aug 21, 2025

Bio-organic fertilizer is a highly efficient, safe, and environmentally friendly microbial-organic compound fertilizer, combining a variety of beneficial microbial flora with organic fertilizer. It combines the advantages of both organic fertilizer and compound microbial fertilizer, effectively improving fertilizer utilization, regulating plant metabolism, and enhancing root vitality and nutrient absorption.

The production process of bio-organic fertilizer production lines surpasses that of conventional organic fertilizers. In addition to adding biological agents to promote the decomposition of organic materials, microorganisms with specialized functions are also added to enhance product quality and performance. To meet the needs of mechanized agricultural production, bio-organic fertilizers are mostly in granular form and are primarily used for food crops, feed crops, cash crops, vegetables, and fruit trees. Bio-organic fertilizer production lines process bio-organic fertilizers into high-quality granular fertilizers for widespread use in agricultural production.

Bio-organic fertilizers can improve crop yield and quality, overcoming the drawbacks of a single nutrient profile and unbalanced fertilizer supply. They emphasize nutrient complementarity, combining bio-organic fertilizers with inorganic fertilizers. Application not only increases crop yields but also effectively improves crop quality and enhances the safety of agricultural products.

Bio-organic fertilizer has gradually become a production trend in the fertilizer industry. The application of bio-organic fertilizer production line will create good conditions for the industrialization of green food and organic food.

ChainCompost Turning Machine: How Does It Transform Waste into Gold?

fertilizer granulator Aug 21, 2025

In modern organic waste treatment, the chain compost turning machine stands as essential fertilizer equipment, working like a tireless magician to transform raw materials into fertile black gold. This sophisticated compost fertilizer machine represents a crucial component in the fertilizer production machine ecosystem. What advanced components enable this efficient operation? Let’s unveil its technical secrets.

Robust Framework: The Art of Support and Mobility

Like the steel frame of a building, the turner’s structure uses high-strength shaped steel precision welding. The carefully designed main frame and traveling frame have distinct roles – the former steadily supports all working components, while the latter, equipped with special wheels and guidance devices, allows this giant to maneuver flexibly through muddy compost yards.

Conveyor System: The Material’s Circular Journey

The heart of the equipment lies in its precision chain conveyor mechanism. Wear-resistant steel plates form the chainboards, which circulate with high-strength roller chains driven by sprockets. Specially designed spiral teeth act like dexterous fingers, continuously lifting and breaking apart materials at adjustable speeds of 0.5-2 meters per minute, performing a magical “turning ballet.”

Power Core: Multi-System Coordination

Three power systems work in perfect harmony: the 45kW travel motor conquers rough terrain, the 75kW drive motor provides powerful chain movement, while the hydraulic system precisely adjusts turning angles. This configuration enables the equipment to handle both sticky food waste and tough agricultural stalks with ease.

Smart Brain: The Mystery of Precise Control

Modern turners have developed intelligent “nervous systems.” Through touchscreens, operators can set parameters as easily as using smartphones. Temperature sensors and current monitors work round-the-clock to ensure optimal performance, even automatically spraying microbial agents to adjust the compost microenvironment.

From robust mechanical structures to sophisticated intelligent controls, every component of the chain compost turning machine tells the technological philosophy of modern organic waste treatment – allowing natural cycles to flourish with new vitality through precise mechanical assistance.

Cost Analysis of Chicken Manure Fertilizer Processing in an Organic Fertilizer Production Line

fertilizer granulator Aug 21, 2025

Chicken manure is indeed a high-quality organic fertilizer raw material, rich in organic matter, nitrogen, phosphorus, potassium, various trace elements, enzymes, and microorganisms. Through standardized aerobic composting processes, it effectively degrades organic matter, kills parasite eggs and pathogens, and renders it harmless and stable. This can then be produced into commercial organic fertilizer through an organic fertilizer production line, creating economic benefits for chicken farms while fundamentally addressing environmental pollution.

However, processing chicken manure into commercial organic fertilizer does involve certain production costs, which can be primarily categorized into the following aspects. First, equipment investment is the core, one-time investment. A complete production line typically includes fermentation and compost turning equipment, a crusher, a mixer, a granulator, a dryer, a cooler, a screener, and an automatic packaging machine. The choice of granulator significantly impacts cost and product form. For example, a rotary drum granulator offers high output, a disc granulator offers a high granulation rate, and a flat die granulator is suitable for organic materials. Different granulator models have varying prices and energy consumption. Secondly, the costs of the pretreatment and fermentation processes cannot be ignored. Fresh chicken manure is sticky and moist, typically with a moisture content exceeding 70%, while the optimal fermentation moisture content needs to be adjusted to 50%-60%. Therefore, a large amount of auxiliary materials (such as straw, sawdust, and mushroom residue) are often required to adjust the moisture and carbon-nitrogen ratios. The procurement, transportation, and crushing of these auxiliary materials all incur ongoing costs.

The initial equipment investment for processing chicken manure in an organic fertilizer production line is relatively high, and ongoing operations also require ongoing investment. The cost level depends largely on the production scale, the degree of automation, the availability and price of raw materials, and the positioning of the final product. For large-scale chicken farms, although the initial investment is high, in the long run, the comprehensive benefits of addressing environmental pressures and creating economic value by turning waste into resources are significant, making the cost acceptable.

Fertilizer screener machines: A key step for high-quality organic fertilizer production

fertilizer granulator Aug 21, 2025

In organic fertilizer production, screening is a critical step to ensure product quality. Fertilizer screener machines precisely separate raw materials and finished products. They remove impurities, control particle size, and directly impact the fertilizer’s uniformity, application effectiveness, and market competitiveness.

1.Why Screening is Key for High-Quality Organic Fertilizer
Remove Impurities: Things like undecomposed coarse fibers, stones, or plastic debris harm fertilizer safety and effectiveness. Screeners efficiently separate these foreign objects.
Grade Particles: Different crops and application methods (like broadcast spreading or machine application) need different particle sizes. Screening ensures uniform particle size, improving usability.
Boost Market Appeal: Finely screened organic fertilizer has a neat, uniform appearance, making it more marketable and increasing its value.
2.Common Organic Fertilizer Screening Equipment and Features
Rotary Screener machine: Good for high-moisture material. Handles large volumes. Allows multi-stage screening.
Vibration Screener machine: High screening precision. Best for fine grading of dry particles.

3.Key Points for Optimizing Screening
Choose the Right Screen Mesh Size: Match the mesh size (usually 2-6mm) to the fertilizer’s use (like base fertilizer or top dressing).
Control Feed Rate: Feed material evenly to avoid blockages and boost efficiency.
Regular Maintenance and Cleaning: Prevents material buildup on screens, which affects grading accuracy.

Precise screening – from raw material cleaning to finished product grading – significantly improves fertilizer efficiency, suitability for machinery, and commercial value.

Common Problems in NPK Fertilizer Production Lines

fertilizer granulator Aug 21, 2025

NPK compound fertilizer is synthesized from chemical raw materials needed by various plants. NPK fertilizer plays a vital role in agricultural production, contributing to increased production and income. So, what are some common problems in NPK fertilizer production lines?

NPK fertilizer production lines naturally require specialized production equipment. However, due to the characteristics of compound fertilizer, fertilizer equipment is susceptible to corrosion. Some frequently used equipment has experienced severe corrosion in less than a year. While normal wear and tear is inevitable, necessary equipment maintenance can extend the lifespan of fertilizer processing equipment.

When crushing raw materials, ensure that they are free of large lumps. Stones or even iron mixed into the compound fertilizer raw materials can cause serious damage to the high-speed mill rotor.

Mechanical equipment relies on motors and reducers for power. Regular lubrication ensures optimal operation. There are many types of lubricants available, and the appropriate grease should be selected based on climatic conditions and mechanical transmission principles.

Equipment varies in production efficiency, and its use should be tailored to that efficiency. For example, during the batching stage, forklifts should be allowed to unload materials slowly to avoid damage. When mixing, avoid overfilling the mixer with raw materials; add them only after the mixer is started.

In short, the smooth operation of an NPK fertilizer production line requires meticulous control of every step. Only by incorporating solutions to these common problems into daily production management can we ensure the maximum stable output of NPK compound fertilizer.

Disc Granulator: 5 Winning Advantages in Fertilizer Production

fertilizer granulator Aug 21, 2025

In NPK fertilizer production, disc granulators stand out as versatile champions. This efficient NPK fertilizer granulator machine has become the preferred choice for manufacturers, optimizing the complete NPK fertilizer manufacturing process. Discover its five secret weapons for superior granulation.

1. Exceptional Pellet Quality

Disc granulators produce pellets with sphericity exceeding 80%, featuring pebble-smooth surfaces. This near-perfect spherical structure not only looks appealing but also ensures pellet strength to withstand transportation and storage challenges. Whether for fine chemicals or agricultural applications, it meets the most stringent quality requirements.

2. Cooking-Simple Operation

As intuitive as adjusting induction cooker settings, operators only need to master three key parameters – rotation speed, tilt angle and moisture – to easily control the entire granulation process. This “foolproof” operation significantly lowers technical barriers, allowing new employees to get started after brief training, dramatically reducing labor costs.

3. The “Transformer” of Material Processing

From fine powders to sticky slurries, from dry minerals to moist organic fertilizers, disc granulators handle all materials with remarkable versatility. This amazing adaptability makes them ideal for multi-variety, small-batch production, helping manufacturers respond flexibly to market changes.

4. Energy-Saving Champion

Compared with other granulation equipment, disc granulators consume 30-40% less energy, thanks to their ingenious utilization of gravity and centrifugal force. With today’s high energy prices, this “power-saving mode” saves substantial operating costs while reducing carbon footprint.

5. Efficient and Stable Productivity

With capacity ranging from several to dozens of tons per hour, disc granulators can meet various needs from family farms to large fertilizer plants. Continuous operation capability ensures uninterrupted production, while consistent output quality gives customers complete peace of mind.

It’s the perfect combination of these five advantages that makes disc granulators stand out in fierce market competition, earning their reputation as star equipment in fertilizer production.

Factors Affecting the Production of Compound Fertilizers Using a Disc Granulator

fertilizer granulator Aug 21, 2025

When producing compound fertilizers using a disc granulator, many factors influence granulation, such as disc diameter, disc speed, disc inclination, nozzle aperture, and moisture content. Generally speaking, disc inclination has a greater impact on the granulation rate, while disc speed has a greater influence on the compressive strength of the granules.

The moisture content of disc granulation significantly influences both the granulation rate and the compressive strength of the granules. When the moisture content of the material is controlled within the range of 16%-20%, the granulation rate and compressive strength of the granules are optimal. Too little moisture results in a low granulation rate; too much moisture causes the material to clump and stick together, resulting in a reduced granulation rate. When the moisture content is too low, the compressive strength of the granules increases with increasing moisture content, which is beneficial for improving the compressive strength of the granules. However, when the moisture content is too high, the excess moisture disrupts the interactions between fertilizer molecules, causing the dried granules to crack and resulting in a decrease in compressive strength. Before using a disc granulator, the optimal moisture content, disc speed, and disc inclination angle should be tested to ensure high fertilizer production line efficiency and high pellet quality. Furthermore, the finer the raw material powder, the better the granulation effect.

Disc granulators are widely used in organic fertilizer production lines and compound fertilizer production lines. Fertilizer production using disc granulators offers low investment, high output, simple process, and intuitive operation, resulting in excellent economic and social benefits.

Anatomy of a BB Fertilizer Mixer

fertilizer granulator Aug 20, 2025

The Heart: Mixing Drum & Blades

Opening any BB fertilizer mixer reveals its mixing drum – this carefully designed enclosed space functions like a miniature ecosystem. Modern designs typically feature U-shaped or cylindrical configurations, where the streamlined structure not only looks elegant but ensures perfect three-dimensional material movement during blending.

In any bulk blending fertilizer line, the mixing device acts as the true “magician’s hand.” The high-strength alloy steel shaft is strategically fitted with various mixing elements like paddles and spiral ribbons. These hydrodynamically optimized components can uniformly blend fertilizer materials of different densities and particle sizes at 30-50 RPM, making it a cornerstone of the NPK bulk blending fertilizer line.

Power & Control Center

The mixer’s drive system resembles the human cardiovascular system:

• High-efficiency motor – IE3 energy class, 7.5-45kW power range
• Planetary gear reducer – 96% transmission efficiency, <75dB noise
• Variable frequency drive – Enables stepless speed adjustment

Modern control panels have evolved into true “smart brains.” Through 7-inch touchscreens, operators can preset 20 formula parameters while monitoring real-time data like current and temperature, ensuring each batch maintains CV values (coefficient of variation) below 5%.

Engineering Excellence in Details

Premium BB fertilizer mixers showcase professionalism in details:

• Quick-open access doors – Simplify maintenance and cleaning
• Pneumatic discharge valves – Open/close in 1 second with zero residue
• Dust-proof sealing – Triple silicone seals with <0.1% dust leakage
• Modular frame – Hot-dip galvanized for 15+ years service life

These seemingly minor designs are precisely what ensure efficient and stable operation, serving as key differentiators between ordinary equipment and industry benchmarks.