The difference between flat die granulator and disc granulator in processing fertilizers

fertilizer granulator May 14, 2025

Both flat die granulators and disc granulators have their own advantages in the field of organic fertilizer granulation.

From the perspective of granulation method, the flat die granulator squeezes the material on the flat die through the pressure roller, causing the material to be extruded into shape through the die hole; The disc granulator allows materials to agglomerate into granules on a rotating disc through the action of multiple forces.

In terms of particle quality, the flat die granulator produces particles with regular shapes, consistent sizes, high strength, and good stability during storage and transportation. The particles produced by the disc granulator are round, but their strength is relatively weak.

In terms of raw material adaptability, the flat die granulator has certain requirements for the humidity and viscosity of the raw materials, but can handle a variety of organic materials. The disc granulator has strict requirements for the humidity of raw materials, and excessive or insufficient viscosity is not conducive to granulation.

In terms of production efficiency, the flat die granulator has a compact structure, a relatively stable production process, and a considerable output per unit time. The continuous production capacity of the disc granulator is strong, but it may take some time to adapt when adjusting parameters such as particle size.

In terms of energy consumption, the flat die granulator mainly consumes energy in the rotation of the pressure roller and material extrusion, with relatively high energy consumption. The energy consumption of the disc granulator is mainly due to the rotation of the disc, which is relatively low.

In terms of equipment maintenance, the flat mold and pressure roller of the flat mold granulator are key components, and the cost of replacement after wear is relatively high, making maintenance relatively complex. The disc granulator has a simple structure, easy maintenance, and low cost of component replacement.

In terms of investment cost, the price of flat die granulator equipment is relatively high, and the initial investment is large. The price of the disc granulator is relatively affordable and suitable for enterprises with limited funds.

Therefore, if we focus on particle strength and shape regularity, have certain screening ability for raw materials, and have sufficient funds, a flat die granulator is more suitable. If you pursue low energy consumption, low cost, and simple maintenance, and do not have strict requirements for particle strength, a disc granulator is a good choice.

Flat die granulator processes fertilizers in a stable manner through extrusion and molding

fertilizer granulator May 14, 2025

The flat mold granulator provides a reliable guarantee for the production of high-quality organic fertilizer granules through stable extrusion and molding during the organic fertilizer granulation process.

The core components of a flat mold granulator are the flat mold and the pressure roller. During operation, the material is evenly conveyed to the surface of the flat mold, and the pressure roller is tightly pressed onto the flat mold under power drive and rotates around the axis. Under the strong squeezing of the pressure roller, the material is extruded through the holes on the flat mold, forming columnar particles. Subsequently, the cutting blade cuts the columnar particles into appropriate lengths, completing the entire granulation process.

This granulation method produces organic fertilizer particles with regular shapes and uniform sizes. The regular shape facilitates the neat stacking of fertilizers during storage and transportation, reducing gaps and scattering caused by irregular particles. Uniform size ensures that each particle carries a relatively consistent amount of nutrients during fertilization, allowing crops to absorb nutrients more evenly and avoiding situations of excessive or insufficient local nutrients, thereby improving the efficiency of fertilizer use.

The stability of the flat mold granulator is extremely high. Its structural design is reasonable, and key components have been carefully selected and processed to withstand long-term, high-intensity workloads. The precision of the combination between the flat mold and the pressure roller is high. During operation, the pressure roller has a stable squeezing force on the material, and there will be no fluctuations in size, which ensures the stable quality of organic fertilizer particles produced in each batch. Whether it is a small organic fertilizer production workshop or a large industrial production enterprise, they can rely on flat die granulators to stably produce products that meet quality standards.

In addition, the flat mold granulator has strong adaptability to raw materials. It can process various organic materials with different properties, such as livestock manure, crop straw, distiller’s grains, etc. As long as these raw materials are properly pre treated and the parameters such as moisture and particle size are adjusted, they can be smoothly granulated in a flat mold granulator. The flat die granulator has become a reliable equipment in organic fertilizer production due to its stable extrusion and forming granulation methods.

How does the organic fertilizer flat mold granulator process organic fertilizers

fertilizer granulator May 14, 2025

The organic fertilizer flat mold granulator is like a skilled craftsman in the production process of organic fertilizer, carefully creating high-quality granules.

Firstly, the organic fertilizer particles produced by the flat mold granulator have high strength. During the granulation process, the material passes through the flat mold holes under the strong pressure of the pressure roller. This tight compression makes the internal structure of the particles dense and enhances the binding force between molecules. Therefore, the produced particles can withstand certain external impacts and friction, and are not easily broken or pulverized during storage and transportation. This not only ensures the integrity of the fertilizer when it reaches the user’s hands, but also prevents nutrient loss caused by particle breakage, ensuring that the fertilizer’s effectiveness is fully utilized.

Secondly, the flat mold granulator can effectively control the porosity of the particles. The appropriate porosity is crucial for organic fertilizers, as it relates to the rate of fertilizer dissolution and nutrient release efficiency in the soil. The flat die granulator forms a uniform pore structure inside the particles through precise extrusion and forming processes. This pore structure is conducive to the rapid infiltration of water, allowing fertilizers to dissolve quickly in the soil, while ensuring slow and sustained nutrient release, providing long-term stable nutrient supply for crops.

Furthermore, the surface of the particles produced by the flat mold granulator is smooth. The smooth surface of the particles not only makes the appearance of the fertilizer more attractive, but also reduces friction with the fertilization equipment during the fertilization process, allowing the fertilizer to pass through the fertilizing equipment more smoothly and improving the uniformity and accuracy of fertilization. At the same time, smooth particles on the surface are less likely to adsorb dust and impurities, maintaining the purity of the fertilizer.

In addition, the flat mold granulator can effectively retain beneficial components and microbial communities in organic fertilizers during the granulation process. Due to its relatively mild granulation process, unlike some high-temperature granulation methods that can damage the active ingredients in fertilizers. This enables the produced organic fertilizer to better utilize its effects of improving soil and promoting soil microbial activity, creating a favorable soil environment for crop growth.

The organic fertilizer flat mold granulator, with its unique granulation method, creates high-quality organic fertilizer particles from multiple aspects such as particle strength, porosity, surface smoothness, and protection of beneficial components, meeting the strict requirements of modern agriculture for high-quality fertilizers.

Different characteristics of disc granulator and roller extrusion granulator during granulation

fertilizer granulator May 14, 2025

In the field of organic fertilizer production, disc granulators and roller extrusion granulators are commonly used equipment, each with its own characteristics.

From the perspective of granulation principle, the disc granulator aggregates materials into granules through continuous rolling on a rotating disc, utilizing centrifugal force, friction force, and gravity, with a relatively gentle process; The roller extrusion granulator relies on strong pressure to forcefully extrude the material through the mold holes, resulting in a more robust granulation process.

In terms of particle quality, the particles produced by the disc granulator have a rounded shape, relatively uniform size, and are more evenly distributed in the soil, which is conducive to the absorption of nutrients by crops. However, its particle strength is average. The particles produced by the roller extrusion granulator have high density and strength, and are not easily crushed and powdered during storage and transportation, but their shape is mostly cylindrical and relatively single.

In terms of raw material adaptability, the disc granulator has strict requirements for raw material humidity and viscosity, as being too dry or too wet can affect the granulation effect. The roller extrusion granulator has stronger adaptability to raw materials, and can handle materials with high viscosity and fiber content well.

In terms of production efficiency, the disc granulator has a simple structure, easy operation, strong continuous production capacity, and is suitable for large-scale production. The production efficiency of the roller extrusion granulator is not low, but the equipment structure is complex and difficult to maintain, which will to some extent affect the continuity of production.

In terms of energy consumption, the disc granulator mainly relies on disc rotation, which has relatively low energy consumption; The roller extrusion granulator requires strong pressure and high energy consumption.

In terms of investment cost, the price of the disc granulator is relatively cheap, and the initial investment is small; The cost of roller extrusion granulator equipment is high, and the cost of mold replacement is also not low.

In summary, if pursuing a beautiful particle appearance, high production efficiency, and low investment cost, a disc granulator is a good choice, suitable for producing organic fertilizers with low requirements for particle strength. If the raw materials are complex and diverse, with high requirements for particle strength and shape control, the roller extrusion granulator can better meet the needs, despite its high energy consumption and cost.

Innovative granulation method of new organic fertilizer granulator leads industry transformation

fertilizer granulator May 14, 2025

In the field of organic fertilizer production, the new type of organic fertilizer granulator has emerged with its unique and innovative granulation method, bringing new opportunities for the development of the industry.

The new organic fertilizer granulator integrates multiple advanced technologies, and its granulation process is exquisite and efficient. Firstly, in the material pretreatment stage, it is equipped with an intelligent detection system that can quickly analyze key indicators such as humidity, viscosity, and particle size of the material, and automatically adjust the material ratio and pretreatment method based on these data to ensure the optimal state of the material entering the granulation process.

Entering the core granulation process, the new organic fertilizer granulator adopts composite force field granulation technology. By cleverly combining mechanical pressure, centrifugal force, and electromagnetic force, materials interact with each other in a complex and orderly force field environment. Mechanical pressure provides the basic compaction effect, causing the material to initially aggregate; Centrifugal force causes particles to continuously roll and break in during rotational motion, resulting in a smoother surface and a more regular shape; Electromagnetic force plays a “micro control” role, enhancing the attraction between charged particles in materials, accelerating the tight bonding of internal structures of particles, and improving particle strength.

During the granulation process, the new granulator also utilizes dynamic temperature control technology. The granulation area is equipped with high-precision temperature sensors to monitor temperature changes in real time. Because temperature has a significant impact on the viscosity and chemical reactions of materials, when the temperature is too high or too low, the system will automatically activate the temperature control device to accurately adjust the temperature through air or water cooling, ensuring that the granulation process is carried out in a suitable hot environment and avoiding unstable particle quality caused by temperature issues.

Moreover, the new organic fertilizer granulator is equipped with a flexible and versatile mold switching system. According to different market demands and product positioning, operators can quickly replace molds to produce various shapes (such as spherical, columnar, and sheet-like) and different sizes of organic fertilizer particles. This flexibility greatly expands the application scope of the product and meets diverse agricultural production needs.

The granulation method of the new organic fertilizer granulator not only improves production efficiency, but also significantly improves particle quality. The organic fertilizer produced has uniform particle size, high strength, smooth surface, and is not easily broken or clumped during storage and transportation. At the same time, this innovative granulation method can better retain nutrients and beneficial microorganisms in the materials, improve the fertilizer efficiency of organic fertilizers, and provide strong support for the green and sustainable development of modern agriculture.

The granulation process of the entire organic fertilizer production line

fertilizer granulator May 10, 2025

Granulation is the core process in organic fertilizer production, which directly affects the physical properties, nutrient release efficiency, and market competitiveness of fertilizers. This article will systematically analyze the complete process of organic fertilizer granulation, covering equipment selection, process parameters, and quality control points.

1、 Pre treatment before granulation

Raw material crushing

After fermentation and maturation, organic materials need to be processed by a semi wet material crusher to crush fiber materials (such as straw and mushroom residue) to a particle size of 3-5mm to ensure granulation flowability.

Key parameters: The moisture content should be controlled at 25% -30%. If it is too high, it is easy to block the mold, and if it is too low, the adhesion is insufficient.

Mixing of ingredients

Add functional excipients (such as humic acid and microbial agents) according to product requirements, and mix evenly (coefficient of variation ≤ 5%) using a dual axis mixer.

Typical case: When producing bio organic fertilizers, microbial agents need to be added in a low temperature (<40 ℃) environment to avoid loss of activity.

2、 Core granulation process

Disc granulator (suitable for small and medium-sized production capacity)

Working principle: The tilted rotating disk (with an inclination angle of 35 ° -55 °) causes the powder to roll and bond into particles under the action of centrifugal force.

Technical points:

Spray an appropriate amount of water or binder (such as lignosulfonate) to promote molding;

The particle diameter is adjusted by disc rotation speed and inclination angle (usually 2-6mm).

Advantages: Low equipment investment (about 50000 to 80000 yuan per unit), suitable for production lines with an annual output of less than 5000 tons.

Drum granulator (suitable for large-scale production)

Working principle: The material forms particles through agglomeration in the rotating drum, and is assisted by hot air for drying.

Technical points:

The rotation speed of the cylinder is 8-15r/min, and the filling rate is controlled at 20% -30%;

It can simultaneously complete granulation and pre drying, with a production capacity of 10-20 tons/hour.

Roll squeezing granulator (low-energy solution)

Applicable scenario: Powdered organic fertilizers with low particle strength requirements can be directly formed without drying.

Advantages: The power consumption is only one-third of that of disc granulation, but the surface smoothness of the particles is poor.

3、 Post processing procedure

Drying and dehydration

Use a drum dryer (hot air temperature 80-120 ℃) to reduce the moisture content of the particles from 30% to ≤ 15% to avoid storage mold.

Energy saving design: Some production lines utilize fermentation waste heat to provide heat sources, reducing energy consumption by more than 20%.

Cooling screening

The vibration cooling machine lowers the particle temperature from 60 ℃ to room temperature, and at the same time, it is classified through multiple layers of sieves (such as 4mm and 6mm aperture) to remove powder and oversized particles.

Encapsulation treatment (optional)

Spray anti caking agents (such as mineral oil) or slow-release film materials on the surface of particles to enhance product added value.

4、 Key points of quality control

Particle strength: ≥ 15N/particle (to avoid transportation breakage);

Molding rate: Disc granulation ≥ 85%, drum granulation ≥ 90%;

Survival rate of microbial agent (bio fertilizer): The granulation temperature should be ≤ 50 ℃, and the survival rate should be>80%.

5、 Innovative technology application

Intelligent control system: Real time monitoring of the humidity and temperature of the granulation disk through sensors, automatic adjustment of water spray volume and speed.

Composite granulation process: organic-inorganic fertilizer mixed granulation, with both fast acting and long-lasting characteristics.

Organic fertilizer granulation is a key link in balancing physical properties and production costs. Enterprises need to choose suitable processes based on the characteristics of raw materials (viscosity, fiber content) and product positioning (ordinary organic fertilizer/high-end biological fertilizer). In the future, with the development of technologies such as low-temperature granulation and precise coating, organic fertilizer particles will continue to upgrade towards functionalization and intelligence.

Organic fertilizer flat mold granulator provides stable guarantee for particle forming

fertilizer granulator May 10, 2025

In the field of organic fertilizer production, the organic fertilizer flat mold granulator provides stable guarantee for particle forming with its unique advantages.

The core components of a flat mold granulator are the flat mold and the pressure roller. During operation, the material is evenly conveyed to the surface of the flat mold, and the pressure roller is tightly pressed onto the flat mold under power drive and rotates around the axis. Under the squeezing action of the pressure roller, the material is extruded through the mold holes on the flat die, forming columnar particles, which are then cut into appropriate lengths by a cutting knife to complete the granulation process.

This granulation method produces organic fertilizer particles with regular shapes and uniform sizes. The regular shape facilitates the neat stacking of fertilizers during storage and transportation, reducing gaps and scattering caused by irregular particles. Uniform size ensures that each particle carries a relatively consistent amount of nutrients during fertilization, allowing crops to absorb nutrients more evenly and avoiding situations of excessive or insufficient local nutrients, thereby improving the efficiency of fertilizer use.

The stability of the flat mold granulator is extremely high. Its structural design is reasonable, and key components have been carefully selected and processed to withstand long-term, high-intensity workloads. The precision of the combination between the flat mold and the pressure roller is high. During operation, the pressure roller has a stable squeezing force on the material, and there will be no fluctuations in size, which ensures the stable quality of organic fertilizer particles produced in each batch. Whether it is a small organic fertilizer production workshop or a large industrial production enterprise, they can rely on flat die granulators to stably produce products that meet quality standards.

In addition, the flat mold granulator has strong adaptability to raw materials. It can process various organic materials with different properties, such as livestock manure, crop straw, distiller’s grains, etc. As long as these raw materials are properly pre treated and the parameters such as moisture and particle size are adjusted, they can be smoothly granulated in a flat mold granulator. This makes the enterprise more flexible in raw material selection, able to fully utilize the abundant organic resources in the local area for production, and reduce production costs.

The organic fertilizer flat mold granulator, with its stable granulation process, regular and uniform particle quality, and wide adaptability to raw materials, has become a reliable particle forming equipment in organic fertilizer production, providing strong support for the stable development of the organic fertilizer industry.

Kitchen waste is gradually becoming an emerging raw material for organic fertilizer granulation

fertilizer granulator May 10, 2025

With the increasing awareness of environmental protection and the emphasis on resource recycling, kitchen waste is gradually becoming an emerging raw material for organic fertilizer granulation, demonstrating enormous potential.

Leftover food is the main component of kitchen waste, which contains abundant organic substances such as carbohydrates, proteins, and fats. These substances are easily decomposed and utilized by microorganisms under appropriate conditions. After classification, collection, and preprocessing, leftover food can enter the fermentation system. Under the action of microorganisms, they are decomposed into small organic molecules, releasing nutrients such as nitrogen, phosphorus, and potassium. Mixing the fermented product with other auxiliary materials and processing it through an organic fertilizer granulator can produce nutrient rich organic fertilizers.

The fruit peel is also a high-quality organic fertilizer raw material. Apple peels, banana peels, orange peels, etc. are rich in various vitamins, minerals, and bioactive substances. During the fermentation process, these substances will gradually decompose and blend into fertilizers, providing unique nutrients for crops. For example, banana peels contain high levels of potassium, and processed organic fertilizers can effectively increase the potassium content in the soil and enhance the stress resistance of crops. Using an organic fertilizer granulator to turn fermented fruit peels into granules facilitates fertilization operations and better preserves nutrients.

Bones can also be used for organic fertilizer granulation after processing. Bones contain a large amount of minerals such as calcium and phosphorus, which can become important sources of nutrients in fertilizers after being crushed and fermented. Especially for some crops that require calcium and phosphorus supplementation, the use of organic fertilizers containing bone components has a significant effect. Processing it into granular fertilizer through an organic fertilizer granulator can not only improve the utilization rate of fertilizer, but also reduce odors and facilitate storage and transportation.

Although waste oil cannot be directly used as organic fertilizer raw materials, after special treatment, it can be mixed with other organic materials to participate in the fermentation process. Waste oil is decomposed by microorganisms to produce fatty acids and other substances, which help improve the physical properties of fertilizers, increase their viscosity, and make the granulation process smoother.

Kitchen waste, as an emerging raw material for organic fertilizer granulation, not only solves the problem of waste disposal, but also provides new fertilizer resources for agricultural production. By proper treatment and processing with organic fertilizer granulators, kitchen waste can be turned into treasure, making positive contributions to ecological agriculture and sustainable development.

The process and characteristics of efficient granulation in NPK fertilizer production line

fertilizer granulator May 10, 2025

As the mainstream product of compound fertilizers, NPK fertilizer’s granulation process directly affects nutrient uniformity, particle strength, and application effectiveness. The modern NPK fertilizer production line achieves precise compound of nitrogen, phosphorus, and potassium elements through scientific proportioning and efficient granulation technology. The following is a typical NPK fertilizer granulation process and key technology analysis.

1、 Raw material pretreatment and batching system

Raw material crushing and screening

Raw materials such as phosphate and potassium salts need to be processed by a chain crusher to a particle size of 1-3mm to ensure sufficient subsequent reactions.

The vibrating screen is used to remove impurities, and the purity of raw materials is required to be ≥ 95%.

Accurate ingredients

Using electronic belt scales and weight loss feeders, the dynamic proportioning error is ≤ 0.5%.

A typical NPK formula (such as 15-15-15) requires precise control of the ratio of urea, monoammonium phosphate, and potassium chloride.

2、 Core granulation process

Steam granulation method (drum granulation)

technological process:

The mixed raw materials enter the rotary drum granulator and are sprayed with saturated steam (pressure 0.3-0.5MPa).

The material is bonded by liquid phase (molten urea) during rolling, forming 1-4.75mm particles.

Key parameters:

Material temperature: 80-100 ℃

Steam consumption: 50-80kg/ton fertilizer

Particle forming rate: ≥ 90%

High tower melt granulation (suitable for high nitrogen formulations)

Process characteristics:

Urea, ammonium nitrate, etc. are melted and sprayed from the top of the tower (nozzle aperture 1.5-3mm).

During the process of particle falling, it cools and solidifies, forming spherical particles (strength ≥ 20N).

Advantages:

Smooth particles that are not prone to clumping

More uniform release of nutrients

3、 Post processing procedure

Drying and Cooling

The drum dryer (hot air temperature 120-150 ℃) reduces the moisture content of particles from 3% to ≤ 1%.

The fluidized bed cooler quickly cools down to below 40 ℃ to avoid nutrient decomposition.

Screening and material return processing

Classification of three-level vibrating screen:

Qualified particles (2-4.75mm) enter the coating section.

Fine powder (<2mm) is returned to the granulator.

Large particles (>5mm) are crushed and reused.

Anti caking treatment

Spray diatomaceous earth or mineral oil onto the wrapping tube (dosage 0.5-1.5kg/ton).

The new polymer coating agent can extend the fertilizer effectiveness period to 3-6 months.

4、 Key points of quality control

Nutrient testing

Real time monitoring of N, P, and K content using an online near-infrared analyzer, with a deviation controlled within ± 0.3%.

Particle physical indicators

Strength ≥ 15N (measured by drum method)

Particle uniformity (over 90% of particles are concentrated in the 2-4mm range)

environmental requirements

The exhaust gas undergoes cyclone dust removal and wet scrubbing, with a dust emission of ≤ 30mg/m ³.

5、 Technological innovation direction

Energy Saving

Adopting a steam condensate water recovery system can reduce energy consumption by 15-20%.

intelligent control

The AI based granulation parameter optimization system can automatically adjust the steam volume and drum speed.

The NPK fertilizer granulation process integrates chemical principles and mechanical technology, among which the steam granulation method dominates due to its low cost and wide adaptability, while the high tower granulation is known for its product quality. By precisely controlling the ingredients, granulation temperature, and post-treatment process, compound fertilizer products with uniform nutrients and excellent physical properties can be produced. In the future, with the development of intelligent and green manufacturing technology, NPK fertilizer granulation will evolve towards a more efficient and environmentally friendly direction.

Characteristics of Organic Fertilizer Flat Mold Granulator in Modern Organic Fertilizer Production Industry

fertilizer granulator May 10, 2025

In the modern organic fertilizer production industry that pursues high efficiency and energy conservation, the organic fertilizer flat mold granulator stands out as the undisputed pioneer in granulation.

From the perspective of production efficiency, the organic fertilizer flat mold granulator has excellent performance. Its unique structural design enables materials to be quickly and fully squeezed between the flat mold and the pressure roller, thereby achieving a continuous and efficient granulation process. The large load-bearing capacity of the flat mold and the high-speed rotation of the pressure roller ensure that a large amount of material is made into particles through the mold holes per unit time. Compared to some traditional granulation equipment, the flat die granulator can complete the same production task in a shorter time, greatly improving the production efficiency of enterprises and meeting the growing demand for organic fertilizers in the market.

In terms of energy conservation, the organic fertilizer flat mold granulator also has excellent performance. It adopts an advanced power transmission system, reducing energy loss during the transmission process. The rolling friction between the pressure roller and the flat mold can effectively reduce energy consumption compared to the sliding friction of some other granulation equipment. Moreover, the flat die granulator can achieve smooth granulation of materials without excessive pressure during operation, which further reduces the power demand of the equipment and saves energy costs.

In addition, the maintenance of the flat die granulator is relatively simple, which indirectly improves its overall operating efficiency and energy-saving effect. The simple structural design enables maintenance personnel to quickly and accurately locate the fault point and carry out repairs, reducing equipment downtime. Regular maintenance work is also relatively convenient, which can ensure that the equipment is always in good operating condition, avoiding energy waste and production efficiency decline caused by equipment aging or failure.

At the same time, the flat die granulator has a high conversion rate of materials during the granulation process, and can almost convert all the input materials into qualified granular fertilizers, reducing material waste and achieving energy conservation and efficiency improvement from another perspective.

The organic fertilizer flat mold granulator, with its efficient production capacity and energy-saving operating characteristics, has reduced production costs for organic fertilizer production enterprises, improved market competitiveness, and become an important force in promoting the efficient and energy-saving development of the organic fertilizer industry.