Core supporting equipment for bio-organic fertilizer production lines

fertilizer granulator Dec 11, 2025

Under the trend of green agricultural development, the intelligent and efficient operation of bio-organic fertilizer production lines has become a goal pursued by the industry. As a key piece of equipment in bio-organic fertilizer production, the fertilizer crusher’s performance directly impacts the final quality and production efficiency of organic fertilizers. Whether for the reuse of agricultural waste or large-scale organic fertilizer production, it plays an irreplaceable and crucial role.

The fertilizer crusher boasts strong adaptability, capable of processing various raw materials such as straw, livestock and poultry manure, and composted materials, perfectly addressing the shortcomings of traditional crushing equipment in handling wet and mixed materials. In the bio-organic fertilizer production line, it connects the raw material pretreatment stage, crushing large raw materials into uniform particle sizes. This not only increases the contact area between the material and microorganisms, improving subsequent fermentation efficiency, but also lays a solid foundation for the subsequent granulation process, avoiding problems such as poor particle formation caused by uneven raw material particle size.

As one of the core pieces of bio-organic fertilizer equipment, it can be used in conjunction with chain crushers, horizontal crushers, and other equipment, flexibly adapting to different production needs such as bio-organic fertilizer production lines and NPK fertilizer production lines. By adjusting crushing parameters according to different raw material characteristics, it can precisely control the output particle size, meeting the production requirements of various fertilizer products such as powder fertilizers and granular fertilizers.

For organic fertilizer production enterprises, a high-quality fertilizer crusher not only improves the overall production capacity of the production line but also offers the advantages of convenient maintenance and low energy consumption, helping enterprises reduce production costs.

A path to quality improvement and efficiency for small and medium-sized fertilizer enterprises

fertilizer granulator Dec 11, 2025

For small and medium-sized fertilizer enterprises, the performance of NPK fertilizer production lines directly determines their market competitiveness. Choosing the right compound fertilizer production equipment and optimizing production processes are crucial for reducing costs and increasing efficiency. Many companies have achieved a transformation from “extensive production” to “precise and efficient production” by upgrading their production lines.

The core of upgrading production lines for small and medium-sized fertilizer enterprises is to balance practicality and cost-effectiveness. A basic NPK fertilizer production line requires essential equipment: in the raw material processing stage, a fertilizer crusher can crush large pieces of phosphate rock, potash fertilizer, and other raw materials to a suitable particle size, and a precise batching system can prevent deviations in nutrient ratios; a fertilizer mixer machine is used in the mixing stage to ensure uniform mixing of nitrogen, phosphorus, potassium, and auxiliary materials, laying the foundation for subsequent granulation. A fertilizer granulator can be selected based on production capacity. Subsequent drying, cooling, and coating machines, and fertilizer screener machines can screen out qualified granules, and then an automatic packaging machine completes the packaging process, significantly reducing labor costs.

Process optimization is equally indispensable. A high-quality NPK fertilizer granulation process can improve the finished product qualification rate. Automated compound fertilizer production is now mainstream; a simple PLC control system can monitor parameters such as drying temperature and granulation speed in real time, reducing human error.

Small and medium-sized fertilizer enterprises do not need to blindly pursue high-end equipment; they should choose a suitable solution based on their production capacity and product positioning. Prioritize manufacturers with comprehensive after-sales service to ensure that equipment problems can be resolved promptly.

Explanation of the production process of fertilizer granules processed by flat die pelleting machine

fertilizer granulator Dec 11, 2025

The flat die pelleting machine is a key piece of equipment in modern organic fertilizer production, valued by fertilizer manufacturers for its efficient and stable processing capability.

1.Raw Material Pre-treatment Stage

Ingredient Mixing: Raw organic materials (like livestock manure, straw) and additives (like bentonite, microbial agents) are mixed according to the recipe. Moisture content is usually maintained at 30-40%.

Crushing: A fertilizer crusher grinds the mixture to a particle size of 3-5mm, ensuring uniformity for the next step.

2.Core Granulation Process

Feeding System: Pre-treated material is evenly fed into the flat die pelleting machine’s inlet via conveyor belt. Feed rate is typically 2-3 tons per hour (depending on the machine model).

Compression Molding: Under vertical pressure, the material is forced through holes in the flat die (usually 4-8mm in diameter). The gap between the rollers and flat die is kept at 0.1-0.3mm, with working pressure maintained between 8-15MPa.

Cutting: Rotating knives cut the extruded material into standard pellets, 5-15mm long.

3.Post-processing

Initial Drying: The newly formed pellets enter a dryer. Temperatures are kept at 60-80°C to reduce moisture content below 15%.

Cooling and Screening: After cooling, a vibration screener machine separates out qualified pellets (typically within ±1mm diameter tolerance). Unqualified pellets go back for re-granulation.

Coating: An anti-caking coating can be applied as needed to improve storage stability.

Flat die pelleting machines are especially suitable for small-to-medium organic fertilizer plants due to their simple structure, strong adaptability, and low energy consumption. Optimizing these production stages significantly improves pellet formation rate and product quality while lowering production costs.

Rotary drum granulator: The core art of large-scale fertilizer production

fertilizer granulator Dec 11, 2025

In modern fertilizer granulation workshops, the rotary drum granulator stands out with its unique operating method. Through continuous tumbling and enveloping, it transforms fine powder materials into uniform and firm granules.

This slowly rotating behemoth is a typical representative of large-scale production. Its internal structure is simple and efficient; the material rises and falls continuously under the rotation of the drum, forming an ideal granulation motion.

Compared to other granulation technologies, rotary drum granulation exhibits unique advantages. Compared to the dense granules directly formed by fertilizer compaction machines through molds, granules produced by rotary drums are typically more rounded and regular. Unlike the high-density granules formed by ring die pelleting machines under mold constraints, the granules produced by rotary drum granulation often have a more porous structure. And compared to the flexibility of flat die pelleting machines suitable for small to medium production volumes, rotary drum granulators demonstrate irreplaceable value in large-scale continuous production.

This granulation method is particularly suitable for the production of bulk fertilizer products. From compound fertilizers to organic-inorganic blended fertilizers, rotary drum granulators can process materials with various formulations, adapting to different production requirements. Their excellent granulation properties and high production capacity make them the preferred equipment for many fertilizer companies.

In today’s pursuit of sustainable agricultural development, rotary drum granulation technology continues to play a vital role. It not only improves the physical properties of fertilizer products but also provides reliable equipment support for precision fertilization and efficient agriculture.

What is the working principle of an organic fertilizer disc granulation production line?

fertilizer granulator Dec 11, 2025

In the field of organic fertilizer production, the organic fertilizer disc granulation production line has become the preferred equipment for small and medium-sized enterprises due to its short process and low investment. So, how does this equipment transform loose organic raw materials into uniform granules?

The entire production line’s workflow revolves around the organic fertilizer disc granulator, the core equipment, and works in conjunction with a multi-bin single-scale static automatic batching system, belt conveyors, coating machines, and other equipment. First, after the raw material pretreatment stage, the multi-bin single-scale static automatic batching system precisely proportions the nitrogen, phosphorus, potassium, and organic raw materials according to production needs, ensuring that the nutrient content meets the 20%-48% standard. This step lays the foundation for granule quality.

Next, the proportioned raw materials are uniformly transported to the disc granulator via a belt conveyor. The disc granulator adopts a large-angle tilt design (usually 30°-50°). When the motor drives the disc to rotate, the raw materials inside the disc are subjected to the combined action of centrifugal force, friction, and gravity, constantly tumbling and colliding. At the same time, according to the moisture requirements of the raw materials, the equipment precisely sprays an appropriate amount of binder, allowing the raw materials to gradually agglomerate into small particles. As the disc continues to rotate, the small particles continuously adsorb surrounding raw materials, gradually growing into uniform granules of 2-5mm – this is the key to the disc granulation process.

After the granules are formed, unqualified fine powder is separated through a screening device at the bottom of the disc and returned to the granulation process. Qualified granules are then transported to the coating machine for surface treatment to improve granule stability and moisture resistance. Finally, they are transported via belt conveyor to subsequent stages, completing cooling, packaging, and other processes, ultimately becoming finished organic fertilizer products ready for shipment.

Disc Granulator: Specialist in Spherical Particle Production

fertilizer granulator Dec 11, 2025

In the fields of fertilizer production and industrial manufacturing, disc granulators have become key equipment for producing high-quality spherical particles through their unique rolling granulation technology. This traditional yet efficient granulation method transforms powdered raw materials into uniform spherical particles through clever mechanical design, widely applied across multiple industries including fertilizer, metallurgy, and building materials.

Innovative Working Principle

The core working principle of disc granulators is based on synergistic effects of centrifugal force, friction, and gravity. When the inclined disc rotates at 5-30 revolutions per minute, materials roll and collide along specific trajectories within the disc. By spraying appropriate amounts of water or binders, powdered materials gradually adhere to form small particles, which then absorb more materials during continuous rolling, eventually forming regular spherical particles.

The ingenuity of the equipment lies in its adjustability. The disc’s inclination angle can be adjusted between 30°-60°, while rotation speed can also be regulated as needed, enabling the equipment to adapt to characteristics of different materials. This flexibility allows disc granulators to produce particles with sphericity exceeding 85%, providing great convenience for subsequent storage, transportation, and usage.

Wide Range of Application Fields

Disc granulators play important roles in multiple industries. In fertilizer production, they are particularly suitable for manufacturing organic and compound fertilizers. Spherical particles are not only aesthetically pleasing but, more importantly, possess good flowability and uniformity, facilitating mechanized and precise fertilization. In metallurgical industries, the equipment can transform mineral powders into particles suitable for sintering and smelting.

The building materials and chemical industries also represent important application fields for disc granulators. From cement raw materials to catalysts, from refractory materials to pigment particles, this equipment provides efficient production solutions. Differences in requirements across industries can be met by adjusting equipment parameters and using lining materials of different compositions.

Efficient Production Process

The production process of disc granulators is meticulously designed to ensure high efficiency and quality. Production begins with raw material pretreatment, including crushing, mixing, and moisture adjustment. Materials are then uniformly fed into the rotating disc while appropriate amounts of water are added through precisely controlled spraying systems.

During pellet formation, controlling material moisture content between 10%-20% is crucial. Excessive moisture causes particle agglomeration, while insufficient moisture makes formation difficult. Operators observe particle formation conditions in real-time, adjusting disc angle, rotation speed, and water spray volume to ensure optimal pelletization results. Granulated particles undergo screening and post-processing, ultimately becoming qualified finished products.

Significant Technical Advantages

Disc granulators possess multiple technical advantages. Firstly, the spherical particles produced have excellent flowability, facilitating mechanized operations. Secondly, the equipment structure is relatively simple, with both operation and maintenance being relatively easy, lowering usage thresholds. Thirdly, the equipment demonstrates strong adaptability to raw materials, capable of processing various material types.

Regarding economic benefits, disc granulators also demonstrate excellent performance. Equipment investment is relatively low with controllable maintenance costs, suitable for enterprises of different scales. Production efficiency is high, with single units capable of producing 1-20 tons of particles per hour, meeting large-scale production demands.

Scientific Maintenance Management

To ensure long-term stable equipment operation, scientific maintenance management is crucial. Daily maintenance includes equipment checks before startup, condition monitoring during operation, and cleaning work after shutdown. Regular inspection of wear part conditions and timely replacement of worn components are key to maintaining equipment performance.

With continuous technological development, disc granulators are also constantly innovating and improving. New material applications extend equipment lifespan, while introduction of intelligent control systems improves production efficiency. In today’s global pursuit of sustainable development and efficient production, disc granulators will continue playing important roles in particle production across various industries, providing reliable technical support for industrial production and agricultural development.

Integrating Disc Granulation into Comprehensive Fertilizer Manufacturing Systems

The disc granulator, a core machine for disc granulator for shaping spherical particles, plays a specific role within the broader spectrum of fertilizer granulation processes. In a complete npk fertilizer production line, powder prepared by a npk blending machine is often granulated using such equipment. The disc granulator machine is central to a disc granulation production line, which is one type of fertilizer granulator system suited for materials requiring high sphericity.

For organic fertilizers, the production chain is different. It often begins with a windrow composting machine for biodegradation before the material enters a separate organic fertilizer production line or a bio organic fertilizer production line. Here, the disc granulator may also be used, but alternative technologies like the double roller press granulator in a roller press granulator production line offer dry granulation options. This diversity in equipment—from disc granulators for wet forming to roller presses for dry compaction—highlights the sophistication of modern fertilizer granulation processes, allowing manufacturers to select the optimal technology, whether for an npk fertilizer line or an organic system, to produce high-quality, application-ready fertilizers efficiently.

How Organic Fertilizers Can Revive Ethiopia’s Soils

fertilizer granulator Dec 11, 2025

In sub-Saharan Africa, particularly in Ethiopia, farmers face a severe long-term challenge: their land is becoming increasingly “thin.” Soil acidification, nutrient depletion, and declining organic matter content act like invisible shackles, constraining crop yields and affecting the food security of millions. Chemical fertilizers once offered hope for boosting production, but their high cost, unstable supply, and long-term detrimental effects on soil structure and the environment have exposed their limitations. So, where is the way forward?

Mounting evidence points to an ancient yet renewed answer: organic fertilizers. By transforming agricultural waste into a valuable resource, Ethiopian farmers are exploring a path to restore soil health and achieve sustainable agriculture.

Soil “Hunger” and the Loss of Organic Matter

The Ethiopian Highlands, known as Africa’s “water tower,” are facing a soil crisis. Continuous cultivation, soil erosion, and overgrazing are rapidly depleting the soil’s organic matter and essential nutrients. Soil organic carbon is the core of soil fertility, acting like the soil’s “savings account” for nutrients and water. However, under tropical conditions, organic matter decomposes quickly, and this “account” is being severely overdrawn.

The traditional solution—chemical fertilizers—can quickly replenish elements like nitrogen and phosphorus, but it’s akin to giving the soil only a “stimulant.” It fails to address the fundamental issues of damaged soil structure and organic matter deficiency. It is expensive and does not provide the “food” needed by soil microbes. In the long run, soil health continues to deteriorate.

The Treasure at Hand: Overlooked Agricultural Waste

Surprisingly, the resources to solve the problem are right around the farmers. Crop residues, livestock manure, processing waste… These materials, often seen as “trash,” are actually rich in organic matter and various nutrients. Ethiopia’s diverse agro-ecological zones, from the humid highlands to the arid lowlands, all generate substantial amounts of such organic resources. In the past, these resources were either discarded or burned openly, their value left untapped.

Now, there is a growing recognition that scientifically processing this waste can transform it into “black gold” that nourishes the soil. This not only reduces environmental pollution but also saves farmers money on fertilizer purchases, creating a low-cost, sustainable model of circular agriculture.

Turning Waste into Wonder: Three Key Transformation Technologies

Transforming agricultural waste into effective organic fertilizers primarily involves three popular and smallholder-friendly technologies:

Composting: This is the most traditional and widely used method. Manure, straw, weeds, and other materials are layered in piles. Over several months, through the action of microorganisms, they decompose into a stable, mature, and odorless dark brown substance—compost. Compost improves soil structure and releases nutrients slowly, but the production cycle is long, and nutrients (especially nitrogen) can be lost if not managed properly.

Vermicomposting: This is a more efficient and “smarter” method. It uses earthworms (particularly species like Eisenia fetida) to digest organic waste. The excreted castings of the worms, known as “vermicompost,” are a fine, granular fertilizer. Rich in beneficial microbes and plant growth hormones, vermicompost has higher nutrient content and is more readily available to plants, earning it the title “king of organic fertilizers.” It significantly enhances soil biological activity.

Biogas Digestion: This is a “two-birds-one-stone” process. Manure and other organic materials are anaerobically fermented in a sealed biogas digester. This produces clean biogas for cooking and lighting, while the byproduct—bioslurry—is a high-quality liquid organic fertilizer. Bioslurry has comprehensive nutrients, is fast-acting, and can even help with disease and pest control. The government is actively promoting household biogas digesters to address both energy and fertilizer needs simultaneously.

Visible Benefits: Nourishing Land, Boosting Yields

Research shows that using these organic fertilizers brings tangible benefits to soil and crops:

Soil Improvement: They act like soil “prebiotics” and “binders,” increasing soil organic matter, loosening compacted soil for better aeration, and enhancing water and nutrient retention.

Balanced Nutrition: Organic fertilizers contain not only nitrogen, phosphorus, and potassium but also calcium, magnesium, sulfur, and various trace elements, providing a more comprehensive diet for crops and avoiding the nutrient imbalances caused by single-chemical fertilizers.

Activating Life: They provide abundant food for beneficial soil organisms like microbes and earthworms, helping to establish a healthy, vibrant soil ecosystem—the foundation for long-term fertility.

Increased Yield and Resilience: Numerous field trials confirm that the judicious application of organic fertilizers, or their combined use with small amounts of chemical fertilizers, can steadily increase the yields of staple crops like maize, wheat, and teff. More importantly, healthy soil allows crops to better withstand climatic shocks like drought.

Challenges and the Future

Of course, promoting organic fertilizers is not without challenges. Farmers need to master proper production and application techniques. Organic fertilizers are bulky, requiring more labor for transport and application. Their nutrient release is slower, necessitating better alignment with farming schedules.

However, faced with the dual pressures of volatile fertilizer prices and soil degradation, investing in the valorization of organic waste is undoubtedly a wise choice for Ethiopian agriculture to move towards sustainability. It is not just a technical issue but a shift in mindset: from relying on external inputs to tapping into and recycling resources within the farming system itself.

By turning “waste” into “wealth,” Ethiopian farmers are using their wisdom to awaken the sleeping land, writing a hopeful chapter for food security and ecological restoration. This path proves that the most effective solutions are often embedded within the natural cycles of farming tradition itself.

Scaling Up Organic Fertilizer Production for Sustainable Agriculture

The on-farm practices of composting, vermicomposting, and biogas digestion in Ethiopia demonstrate the foundational principles of organic fertilizer manufacturing. These decentralized methods of organic fertilizer fermentation can be scaled up through more systematic approaches. Modern fermentation composting turning technology, utilizing equipment like the chain compost turning machine for smaller operations or the large wheel compost turning machine for larger windrows, significantly improves the efficiency and consistency of the decomposition process.

To transform locally produced compost into a standardized, marketable product, the material can be integrated into a formal organic fertilizer production line. This line would include an organic fertilizer granulator—such as a new type two in one organic fertilizer granulator that combines mixing and shaping—to create uniform pellets. For enhanced biological value, this process can be part of a bio organic fertilizer production line, inoculating the compost with beneficial microbes before granulation. This hybrid model, connecting localized waste collection and initial processing with centralized, efficient manufacturing, offers a scalable pathway to produce high-quality organic fertilizers that can restore soil health, boost yields, and build agricultural resilience across Ethiopia and similar regions.

Large Wheel Compost Turner: Core of Large-scale Organic Fertilizer Production

fertilizer granulator Dec 11, 2025

In the field of large-scale organic fertilizer production, the large wheel compost turning machine is becoming a key equipment for ten-thousand-ton production lines. This heavy-duty turning equipment provides efficient solutions for resource utilization of large-scale organic waste through innovative design concepts and powerful processing capabilities, promoting the development of the organic fertilizer industry toward scale and intelligence.

Revolutionary Design Principle

The core design of the large wheel compost turning machine lies in its oversized disc structure, typically reaching 5-10 meters in diameter. This design enables the equipment to cover 5-8 meter wide windrows in a single pass, greatly improving operational efficiency. The turning teeth installed on the disc edge utilize centrifugal force during rotation to lift materials from the bottom upward and disperse them outward, creating comprehensive mixing effects.

Compared to traditional turning equipment, the large disc design’s advantages lie in its extensive coverage range and powerful turning capability. Under centrifugal force, the contact area between materials and air increases by 3-5 times, significantly improving oxygen supply efficiency and creating ideal conditions for active metabolism of aerobic microorganisms. This perfect combination of physical effects and biological processes significantly enhances fermentation efficiency.

Exceptional Large-scale Processing Capacity

The most prominent feature of the large wheel compost turning machine is its astonishing processing capacity. A single unit can process 500-1000 tons of organic material daily, 5-10 times that of traditional equipment. This capability makes it particularly suitable for large-scale production scenarios such as large livestock farms, municipal sludge treatment plants, and industrial organic waste processing centers.

The equipment demonstrates good adaptability to various organic raw materials, including livestock manure, crop straw, industrial organic waste, and municipal sludge. Through scientific pretreatment and parameter adjustment, materials with different characteristics can achieve ideal fermentation effects in this equipment. This flexibility is an indispensable characteristic in large-scale organic waste treatment.

Intelligent Operation Control

Modern large wheel compost turning machines are equipped with advanced electronic control systems, achieving intelligent and convenient operation. Through touchscreen interfaces, operators can monitor various operational parameters in real-time, including disc rotation speed, travel speed, material temperature, and humidity. Sensor systems can automatically detect equipment status and fermentation progress, promptly alerting and taking protective measures when abnormalities occur.

Increased automation significantly reduces operational difficulty and labor requirements. Traditional organic fertilizer fermentation required substantial manual involvement in turning operations, while large wheel compost turning machines require only 1-2 operators to complete fermentation management for large-scale production lines. This efficiency improvement not only reduces production costs but also enhances operational safety and consistency.

Optimized Fermentation Process

The application of large wheel compost turning machines requires coordination with scientific fermentation processes. From raw material pretreatment to windrow stacking, then to phased turning fermentation, each stage requires careful design and strict control. The equipment can automatically adjust working parameters according to different fermentation stages, ensuring efficient progress throughout the fermentation process.

During fermentation, material temperature can be stably maintained within the ideal range of 60-70°C. This temperature not only accelerates organic matter decomposition but also effectively eliminates pathogenic microorganisms and weed seeds. After 20-30 days of scientific management, raw materials can be transformed into high-quality organic fertilizer, achieving complete resource utilization of waste.

Maintenance and Sustainable Development

To ensure long-term stable equipment operation, scientific maintenance is crucial. Regular lubrication, wear inspection, and cleaning work can extend equipment service life and reduce failure rates. Wear parts like turning teeth adopt modular designs and can be individually replaced after wear, significantly reducing maintenance costs.

In today’s global consensus on sustainable development, large wheel compost turning machines not only solve the treatment challenges of large-scale organic waste but also provide high-quality organic fertilizer for agricultural production. This recycling model reduces environmental pollution, improves soil quality, and promotes sustainable agricultural development. With continuous technological advancement, this equipment will continue to play important roles in organic fertilizer production and environmental protection.

Integrated Systems for Modern Organic Fertilizer Manufacturing

The large wheel compost turner is a cornerstone of efficient fermentation composting technology for organic fertilizer. This specialized fermentation composting turning technology, particularly within trough-type aerobic fermentation composting technology systems, optimizes the organic fertilizer fermentation process. Often used alongside other essential pre-composting processing equipment, such as a multiple silos single weigh static batching system for precise raw material formulation, it forms part of the core equipments required for biofertilizer production. The combination of precise batching and efficient turning creates the ideal conditions for rapid and uniform biodegradation.

Following complete fermentation, the matured organic matter proceeds to granulation. A disc granulator for shaping is commonly used in the subsequent processing line to transform the compost into uniform, market-ready pellets. This integrated approach—from initial weighing and mixing through optimized fermentation to final shaping—demonstrates the sophistication of modern organic fertilizer manufacturing. It enables the efficient, large-scale conversion of diverse organic waste streams into valuable, high-quality biofertilizers, closing nutrient loops, improving soil health, and supporting sustainable agricultural systems on a global scale.

The Water-Drinking Smart Fertilizer: Performance of double-layer coated slow-release NPK compound fertilizer

fertilizer granulator Dec 11, 2025

 In farmland, water and fertilizer are the lifeblood of crop growth. However, traditional agriculture faces a serious challenge: a large portion of applied fertilizer nutrients are washed away by rain or evaporate before crops can absorb them. This not only causes enormous resource waste but also pollutes the environment.

Scientists have been searching for a smarter way to fertilize. Recently, an innovative “water-drinking smart fertilizer” has brought new hope.

The Shortcomings of Traditional Fertilizers

Conventional chemical fertilizers are like a downpour—they come quickly and leave quickly. Statistics show that the utilization rate of nitrogen fertilizer is typically only 30%-60%, and phosphorus fertilizer is even lower, at 10%-20%. Significant nutrient loss means farmers spend money without seeing the desired results, while rivers and lakes bear the burden of eutrophication.

The Ingenious Design of Double-Layer Coating

The core design concept of this new fertilizer is the combination of “controlled release” and “water retention.” Its structure is like a carefully designed sandwich:

Sturdy Core: The innermost part is a standard compound fertilizer granule rich in nitrogen, phosphorus, and potassium, providing the basic nutrients for crop growth.

Smart Inner Layer (Chitosan Coating): The core is wrapped in a layer of natural, biodegradable chitosan film. This material, extracted from shrimp and crab shells, acts like an intelligent valve, controlling the slow and sustained release of internal fertilizer nutrients, allowing crops to absorb them in a “steady stream.”

Super Outer Layer (Water-Absorbent Composite Coating): The outermost layer is a special material made from cross-linked polyacrylic acid and diatomite composite. This is where the real “black technology” lies:

Super Water Absorption: It can absorb up to 75 times its own weight in water, like countless miniature reservoirs.

Strong Water Retention: Even under pressure, the absorbed water is not easily lost.

Dual Protection: This sturdy outer coating also protects the inner chitosan film from mechanical damage.

Why Is It So Effective?

This double-layer design cleverly combines the advantages of various materials:

The Ingenious Use of Diatomite: Diatomite is a natural mineral with a porous structure and low cost. Incorporating it into the polymer not only enhances the material’s water absorption and retention capabilities but also reduces costs and improves its applicability in saline soils.

Eco-Friendly and Biodegradable: Both the inner and outer coating materials (chitosan and modified polymer) can degrade naturally in the soil without causing secondary pollution.

Precise Controlled Release: The nutrient release curve better matches the crop growth cycle, significantly improving fertilizer utilization efficiency.

Experiments show that this fertilizer can absorb 75 times its own weight in water after soaking in tap water for 2 hours and can slowly release nutrients over weeks or even months.

Addressing Global Challenges

This “water-drinking smart fertilizer” is particularly suitable for regions facing water scarcity. It can:

Reduce irrigation frequency and water usage by up to 30%-50%

Improve fertilizer utilization efficiency, reducing the amount of fertilizer needed

Provide a continuous buffer of water and nutrients for crops during dry seasons

Decrease the environmental impact of agricultural production

A New Direction for Future Agriculture

Moving from the laboratory to the fields, this innovative fertilizer represents the development direction of precision agriculture and green agriculture. It is not just a technological advancement but also a shift in agricultural production thinking—from extensive management to refined and sustainable resource utilization.

As the global population grows and climate change intensifies, such smart fertilizer technologies are expected to help us produce more food under limited land and water resources while protecting the ecological environment we depend on for survival.

From Innovative Coating to Industrial Production: The Future of Fertilizers

The development of smart, water-retaining fertilizers depends on sophisticated industrial processes to become a reality. The core nutrient pellet must first be produced using established npk fertilizer manufacturing process technology. This begins with precise raw material formulation in a npk blending machine, followed by the transformation of powders into uniform granules. Advanced npk granulation machine technology is employed, utilizing equipment like the disc granulator machine or a specialized fertilizer roller press machine, depending on the formulation and desired granule characteristics.

These core granules, produced on a complete npk fertilizer production line, are then ready for the advanced coating process that imparts the smart, water-absorbing properties. The integration of innovative material science with precision npk fertilizer production technology illustrates the future of agricultural inputs. It demonstrates how advancements in coating and controlled-release mechanisms must be paired with efficient, large-scale manufacturing—encompassing everything from initial blending in npk bulk blending machine systems to final granulation in npk fertilizer granulator machine equipment—to deliver next-generation fertilizers that address critical challenges of water scarcity, nutrient efficiency, and environmental sustainability in global agriculture.

What is the process of wet granulation?

fertilizer granulator Dec 11, 2025

Wet granulation is a key process in fertilizer production, transforming fine powders into uniform, stable pellets. This method not only improves the physical properties of fertilizers but also enhances their efficiency in storage, transportation, and application. For global agriculture, uniform granular fertilizers mean more precise fertilization and higher crop yields. Below, we explore step-by-step the specific workflow of wet granulation in fertilizer manufacturing.

Raw Material Pretreatment: Laying the Foundation

It all starts with preparing the raw materials. Common fine powder materials in fertilizer production, such as urea, phosphates, or potash salts, are first screened and weighed. Using vibrating screens or air-jet sieves, lumps and impurities are removed to ensure purity. Controlling initial moisture content is crucial—typically kept below 5% to prevent caking or degradation in subsequent steps. This stage sets a stable foundation for the entire granulation process.

Binder Preparation: Providing Cohesion

The binder acts as the “glue” in wet granulation, bonding powders together to form pellets. In the fertilizer industry, common binders include natural materials like starch or synthetic ones like polyvinyl alcohol. The binder is usually dissolved in water due to its low cost and environmental friendliness; for moisture-sensitive materials, organic solvents like ethanol may be used. Through heating and mixing in a stirrer, a uniform binder solution is formed and then cooled to room temperature. The concentration and viscosity of the binder directly affect pellet quality and strength.

Mixing and Granulation: Creating Pellets

This is the core step where raw materials and binder come together. In large-scale rotary granulators or high-shear mixers, dry fertilizer powders are first briefly mixed to ensure homogeneity. Then, the binder solution is gradually added via a spraying system while the equipment continues to agitate. As the liquid wets the powder, fine particles begin to agglomerate into small pellets. Operators must closely monitor the process to avoid over-wetting (which can cause clumping) or under-wetting (leading to fragile pellets). In fertilizer production, this step often emphasizes efficiency and large-scale processing, resulting in preliminary wet granules.

Wet Screening: Ensuring Uniformity (Optional Step)

To achieve consistent pellet size, wet granules may be sieved through vibrating screens. This step breaks down oversized lumps and controls pellets within an ideal range (e.g., 10-20 mesh). It promotes more even drying and enhances the final product’s aesthetics and functionality. In small-scale production, manual sieving may also be used.

Drying: Solidifying Pellet Structure

Wet granules contain significant moisture and need drying to solidify and stabilize them. In the fertilizer industry, fluidized bed dryers are commonly used, fluidizing pellets with hot air for rapid and uniform drying. Drying temperatures are typically controlled between 40-80°C to avoid thermal degradation of active ingredients (such as nitrogen). The goal is to reduce moisture content to 1-3%, ensuring pellet hardness and storage stability. Drying time and air velocity are adjusted based on pellet size and material properties.

Dry Screening and Milling: Refining the Final Product

Dried pellets undergo final sieving using 16-40 mesh screens to separate pellets that meet specifications. Oversized pellets can be crushed in hammer mills and re-sieved, while fine powder is recycled and mixed with new raw materials to re-enter the granulation process, minimizing waste. This step ensures uniform particle size distribution in the fertilizer, leading to more consistent coverage and dissolution during application.

Applications and Advantages

Fertilizers produced via wet granulation offer improved flowability for mechanical sowing, higher bulk density to save storage and shipping space, and controlled dissolution rates to suit different crop needs. Additionally, pellets reduce dust, making them more environmentally friendly and safe. From home gardening to large-scale agriculture, this process supports sustainable global food production.

In summary, wet granulation is both a science and an art in transforming fertilizer powders into efficient pellets. Through precise step control and parameter optimization, it delivers more powerful and reliable fertilizer products, driving global agriculture toward an efficient and green future.

Diverse Granulation Technologies in Modern Fertilizer Manufacturing

The detailed workflow of wet granulation processes represents one of the two primary pathways in modern fertilizer formation. In contrast, dry granulation processes rely on physical fertilizer granules compaction using specialized equipment like the fertilizer compaction machine, avoiding liquid binders entirely. Both methods are integral to different stages of the npk manufacturing process, with equipment selection depending on raw material properties and final product requirements.

Within a complete fertilizer production machine system, wet granulation often employs equipment like the rotary drum granulator for large-scale processing, while dry methods utilize a roller press granulator production line. Similarly, the organic fertilizer manufacturing process may use a disc granulation production line for shaping composted materials. The choice between these fertilizer processing machine technologies—whether utilizing fertilizer compaction or liquid binding—allows manufacturers to optimize for efficiency, product quality, and specific agricultural applications, ensuring a steady supply of effective and user-friendly fertilizers to support global food production.