Working principle and granulation characteristics of flat die granulator

fertilizer granulator Jan 2, 2025

Flat die granulator is a mechanical equipment widely used in the granulation process of organic fertilizers, feed, and other organic materials. Its design is based on the principle of pressure to form particles of specific shapes. The following is a detailed analysis of the working principle and granulation characteristics of the flat mold granulator:

working principle

The core components of a flat mold granulator are a set of rotating molds driven by a power device and parallel arranged pressure rollers. During operation, the raw materials are fed into the machine, and as the mold rotates and the pressure roller rolls, the raw materials are compressed and forcibly extruded through the aperture on the mold to form the desired shape. The specific steps are as follows:

Raw material preparation: Firstly, feed the pre treated organic materials (such as chicken manure, grains, grass powder, etc.) into the machine inlet.

Squeezing molding: The raw materials are subjected to tremendous pressure under the action of the mold and pressure roller, and the air between the raw materials is discharged, reducing the gaps between the molecules and resulting in a tight fit.

Cutting: When the material passing through the mold hole reaches a certain length, it is cut into independent particles by the cutting tool set at the outlet position.

Cooling and shaping: The newly extruded hot particles need to be cooled or blown to reduce temperature, in order to stabilize their shape and prevent softening and deformation.

Granulation characteristics

Pressure granulation: The flat die granulator relies on physical pressure rather than chemical reactions for granulation, which enables it to process various types of materials, including high fiber and low viscosity raw materials.

Diversity: By replacing different mold plates, particles with different diameters and lengths can be produced to meet diverse usage needs.

Easy to operate: Compared to other types of granulators, flat die granulators are more convenient to operate, have lower maintenance costs, and are suitable for small to medium-sized production scales.

Compact structure: Due to the lack of large power sources, the flat die granulator has a small volume and occupies little space, making it particularly suitable for production environments with limited space.

Energy saving and efficient: High operating efficiency, relatively low energy consumption, especially when dealing with raw materials with high humidity, it can still maintain good performance.

Widely applicable: not only suitable for the production of organic fertilizers, but also for the production of animal feed, biomass fuel pellets and other fields.

In short, the flat die granulator has become one of the important tools in industries such as organic fertilizers and feed due to its unique pressure granulation mechanism and wide applicability. Especially for small businesses and individual farmers, it is a cost-effective choice.

What is the operating process of the cow manure organic fertilizer granulator

fertilizer granulator Jan 2, 2025

The operation process of the cow manure organic fertilizer granulator mainly includes multiple steps such as pretreatment, granulation, and subsequent treatment. The following is a detailed process description:

1. Preprocessing stage

A. Material preparation

Collect cow manure: Collect fresh or partially dried cow manure from breeding farms or centralized processing points.

Add auxiliary materials such as straw, straw, sawdust or other organic materials, mix them in a certain proportion, adjust the C/N ratio (carbon nitrogen ratio) to facilitate fermentation.

B. Adjust moisture content

Measure the moisture content of cow manure and adjust it to a suitable moisture range, usually 40% -60%, by adding water or drying if necessary, which helps the organic fertilizer granulator to work effectively.

C. Crushing and mixing

Use a grinder to crush cow manure and auxiliary materials into fine pieces, then mix thoroughly and evenly to ensure that each part is fully processed.

2. Granulation stage

D. Selection of Organic Fertilizer Granulator

Choose the appropriate type of granulator based on the required particle size, production requirements, and personal preferences, such as drum granulator, ring die granulator, or extrusion granulator.

E. Perform granulation

Send the pre processed material into the organic fertilizer granulator, start the machine, and begin the granulation process. During this process, humidity may be further regulated through methods such as adding water mist to ensure optimal granulation effect.

3. Follow up processing

F. Forming screening

After granulation, use a screening machine to remove irregular or oversized particles to obtain a uniform and consistent product.

G. Dry cooling

Using a dryer to reduce the moisture content of particles, usually to 10% -20%, for long-term storage and transportation.

Then, the temperature of the particles is lowered to near room temperature through a cooler to prevent mold or clumping during storage.

H. Packaging

The final step is to weigh and package the qualified particles, which is usually done using an automatic packaging machine for easy sales and use.

matters needing attention

Throughout the entire operation process, safety always comes first. Ensure that all operators have received training and understand the safe operating procedures of the machine. At the same time, regularly inspect and maintain equipment, keep it clean and lubricated, to extend equipment life and ensure production efficiency.

Correctly operating the cow manure organic fertilizer granulator and following the above process can efficiently produce high-quality organic fertilizers, providing strong support for agricultural production.

Equipment configuration of the entire sheep manure organic fertilizer production line

fertilizer granulator Jan 2, 2025

A complete sheep manure organic fertilizer production line aims to convert sheep manure into high-quality organic fertilizer, typically consisting of multiple stages and corresponding equipment. The following is a general configuration plan to illustrate the entire production process:

Primary processing equipment

Forklift/loader: used to collect and transport fresh sheep manure to the primary processing area.

Sorting platform: manual or mechanical sorting to remove impurities such as stones, grass roots, plastic bags, and other non organic substances.

Organic fertilizer grinder: Grind large pieces of sheep manure and possibly mixed hay or other coarse feed to a particle size suitable for fermentation.

Fermentation processing equipment

Organic fertilizer mixer: Mix the crushed sheep manure with auxiliary materials (such as rice husks, sawdust, etc.) evenly, adjust the C/N ratio and moisture, and create a good environment for fermentation.

Fermentation tank/fermenter: provides enclosed or semi enclosed space for aerobic fermentation, accelerating the decomposition of organic matter.

Organic fertilizer turning machine: During the fermentation process, the material is regularly turned to provide oxygen, control temperature, and promote uniform fermentation.

Finished product processing equipment

Screening machine: Screen the fermented material to remove large chunks that have not been completely decomposed. Drying machine: By using hot air or solar energy, the moisture content of the material is reduced to achieve the required humidity for granulation.

Organic fertilizer granulator: according to demand, the dried organic materials are made into granules or powders.

Organic fertilizer cooler: Quickly cool the freshly granulated fertilizer to prevent moisture and deformation of the particles.

Organic fertilizer screening machine: Re screen to ensure uniform particle size.

Packaging machine: Quantitatively pack finished organic fertilizers into bags, seal them, and prepare them for sale.

auxiliary equipment

Deodorization system: deals with the foul odors generated during the fermentation process to protect the environment.

Ventilation system: Ensure air circulation in the workshop and control indoor temperature and humidity.

Dust removal system: Capture the dust generated in the production line and maintain a hygienic working environment.

Control system: Monitor and regulate the operational status of the entire production line to achieve automated management.

The above is only the basic configuration. The specific equipment model and quantity need to be determined based on the actual production scale, raw material characteristics, and target output. In addition, environmental protection supporting projects such as wastewater treatment facilities and waste recycling systems need to be considered to ensure the green and sustainable operation of the production line.

Organic fertilizer granulator suitable for processing fertilizers in chicken farms

fertilizer granulator Jan 2, 2025

There are various types of organic fertilizer granulators available in the market to meet the needs of chicken farms. Each type has its unique advantages and is suitable for different processing requirements and scales. The following are several common types of organic fertilizer granulators suitable for chicken farms and their applicable scenarios:

1. Drum granulator

characteristic:

Strong flexibility: Suitable for various organic materials such as chicken manure, cow manure, pig manure, plant residues, etc.

Easy to operate: easy to maintain, running smoothly.

Continuous operation: suitable for large-scale industrial production, continuous feeding and discharging.

Application scenarios:

Suitable for medium to large chicken farms, especially commercial grade organic fertilizer production enterprises that pursue yield and efficiency.

2. Ring mold granulator

characteristic:

High pressure forming: suitable for high-density and high-strength granulation, suitable for high hardness materials.

Particle uniformity: The finished product has good consistency in size and a smooth surface.

Strong durability: wear-resistant and corrosion-resistant, with a long service life.

Application scenarios:

In situations where there are strict requirements for particle strength, or where long-distance transportation and storage are required.

3. Spiral extrusion granulator

characteristic:

Wide adaptability: Suitable for organic materials with various humidity and viscosity.

Energy saving and efficient: The extrusion process does not require external adhesive, saving costs.

Self cleaning function: The machine’s built-in automatic cleaning system reduces maintenance frequency.

Application scenarios:

Small and medium-sized chicken farms, especially those seeking low-cost and easy to maintain solutions.

4. Flat mold granulator

characteristic:

Small footprint: Compact structure, suitable for limited space.

Flexible operation: easy to move, suitable for use scenarios where the venue is not fixed.

Fast startup: It starts up quickly and is suitable for operating environments with frequent startup and shutdown.

Application scenarios:

Small chicken farms or family farms, or places with strict space restrictions.

5. Particle shaping machine

Although not directly pelletized, the pellet shaping machine can be used to improve the quality of existing pellets, making them more aesthetically pleasing and uniform.

characteristic:

Improving appearance: making the particles more rounded and plump, enhancing the value of the product.

Secondary processing: Optimize particles that are not perfect after the initial granulation.

Application scenarios:

Chicken farms that pursue high-quality organic fertilizer products use them after granulation to enhance the market competitiveness of the final products.

When choosing an organic fertilizer granulator, factors such as the actual needs of the chicken farm, material characteristics, production scale, and budget should be comprehensively considered to select the most suitable equipment. In addition, understanding the professional services and support of suppliers is also crucial. Good after-sales guidance and maintenance services can significantly extend the lifespan of machinery and improve overall efficiency.

Processing fertilizers with cow manure organic fertilizer granulator promotes agricultural income increase

fertilizer granulator Jan 2, 2025

The fertilizer produced by the cow manure organic fertilizer granulator has a significant effect on promoting agricultural yield increase, due to the unique advantages of organic fertilizer and the nutritional value of cow manure itself. By using a professional granulator to convert cow manure into granular organic fertilizer, not only can fertilization efficiency be improved, but soil quality can also be enhanced, thereby directly or indirectly promoting the increase of crop yield.

The advantages of cow manure organic fertilizer

Rich nutritional components: Cow manure contains abundant trace elements such as nitrogen, phosphorus, potassium, and organic matter, which are crucial for plant growth.

Improving soil structure: Organic matter can increase the soil’s ability to retain water and nutrients, improve soil permeability and water permeability, and promote root development.

Promote microbial activity: The microbial community in organic fertilizers can decompose complex compounds in the soil, release more nutrients, inhibit pathogens, and reduce disease occurrence.

Long term benefits: Compared to the short-term effects of chemical fertilizers, organic fertilizers have a more lasting effect and can maintain soil fertility for many years.

The importance of pelletizing machine processing

Convenient application: The fertilizer processed by the organic fertilizer granulator has a regular form, which facilitates mechanized fertilization, saves manpower, and improves work efficiency.

Dosage control: Granular fertilizers are easier to accurately control the dosage, avoid waste, and also reduce the risk of excessive application.

Extended shelf life: Granulation can reduce the impact of weather, storage conditions, and other factors on organic fertilizers, extending their shelf life.

Actual case analysis

In many parts of China, especially large-scale agricultural parks and family farms, fertilizers made from cow manure organic fertilizer granulators have been widely used. For example, a certain agricultural technology company in Shandong Province has introduced advanced granulation equipment to process cow manure produced by local animal husbandry into organic fertilizer, which not only solves the problem of cow manure treatment, but also provides high-quality organic fertilizer for surrounding farmland. This measure not only alleviates environmental pressure, but also significantly improves crop yield and quality, achieving a win-win situation of economic and social benefits.

The pelletizing machine for cow manure organic fertilizer is an environmentally friendly and efficient agricultural input that can improve soil environment, promote crop growth, and is an indispensable part of modern agriculture. With the advancement of technology and the improvement of environmental awareness, the application of cow manure organic fertilizer granulators will become increasingly widespread in the future, making greater contributions to agricultural yield increase and sustainable development.

Common problems in the fermentation process of chicken manure organic fertilizer compost turning machine

fertilizer granulator Dec 27, 2024

During the fermentation process of chicken manure organic fertilizer, especially when using an organic fertilizer turner for mechanized fermentation, some common problems may be encountered. Understanding these problems and their solutions is crucial for ensuring fermentation quality and efficiency:

Common problems and solutions

Fermentation temperature does not rise:

Possible reasons: The moisture content of the raw materials is too high, the aeration is poor, or there is a lack of sufficient microorganisms.

Solution: Adjust the moisture content of chicken manure to a suitable range (approximately 50% -60%), increase the frequency of ventilation and overturning, and supplement efficient fermentation agents if necessary.

Serious odor:

Possible reasons: Insufficient oxygen in the fermentation pile leads to anaerobic fermentation, or incomplete decomposition of certain protein substances.

Solution: Strengthen ventilation, increase the number of flips, and ensure sufficient oxygen inside the reactor; Adsorbents such as rice husks and sawdust can also be added to help deodorize.

Slow fermentation rate:

Possible reasons: Low environmental temperature and decreased microbial activity; Or the C/N ratio of the raw materials may be unbalanced.

Solution: Insulation should be provided in winter, and manual heating may be necessary; Adjust the raw material combination, add an appropriate amount of carbon source, and maintain a suitable C/N ratio (usually 20:1-30:1).

Poor effectiveness of finished fertilizer:

Possible reasons: incomplete fermentation and insufficient conversion of nutrients; Or excessive fermentation can lead to nutrient loss.

Solution: Accurately grasp the fermentation cycle, regularly monitor key indicators such as pH value and ammonia nitrogen, and avoid prolonged high temperatures.

Serious clumping of the heap:

Possible reasons: Improper water control or failure to loosen in a timely manner after fermentation.

Solution: Moderately adjust the moisture during the fermentation process, disperse immediately after fermentation is complete, and fully air dry.

Frequent equipment malfunctions:

Possible reasons: Improper operation and inadequate maintenance.

Solution: Regular maintenance, follow the manufacturer’s operating instructions, perform necessary cleaning and lubrication, and replace worn parts in a timely manner.

preventive measure

Regularly monitor various parameters of the fermentation environment, such as temperature, humidity, and oxygen concentration;

Strengthen employee training to ensure correct operation and maintenance of the organic fertilizer turning machine;

Select high-quality fermentation agents to improve the success rate of fermentation;

Maintain good hygiene in the fermentation area to avoid bacterial infections;

Adjust fermentation strategies according to seasonal changes to cope with the impact of extreme weather.

Through these targeted measures, it is possible to effectively prevent and solve potential problems that may arise during the fermentation process of chicken manure organic fertilizer turning machines, ensuring a smooth fermentation process and producing high-quality organic fertilizers.

Process flow of organic fertilizer production by sheep manure organic fertilizer granulation equipment

fertilizer granulator Dec 27, 2024

Introduction to the production process of sheep manure organic fertilizer by sheep manure organic fertilizer machine:

The recovered sheep feces are directly fed into the fermentation area. After primary fermentation, secondary aging and stacking, the odor of livestock and poultry manure is eliminated. At this stage, a fermentation auxiliary agent can be added to decompose the crude fiber, so that the particle size after pulverization meets the particle size requirements of granulation production.

The fermented material that has completed the secondary aging and stacking process is crushed and enters the mixing and stirring system. Before mixing and stirring, according to the formula, N, P, K and some other trace elements are added to the mixing and stirring system to start mixing.

 

Introduction to the production process of sheep manure organic fertilizer with sheep manure organic fertilizer equipment

The mixed materials are transported to the sheep manure organic fertilizer production line system, granulated into the cooling system after the dryer, the materials are brought to room temperature and then sieved, the granules that meet the requirements enter the coating machine to wrap the coating film and start packaging The granules that do not meet the requirements are crushed by the pulverizer and returned to the granulation system to continue granulation. The fertilizer granulator used in this sheep manure organic fertilizer production line is a NPK and organic fertilizer granulator.

Process flow of organic fertilizer granulation equipment for processing fertilizers

fertilizer granulator Dec 27, 2024

The whole organic fertilizer granulation equipment is used to process the fermented organic fertilizer into granules, which is more convenient for storage, transportation, and use. The following is the basic process flow of organic fertilizer granulation:

technological process

Raw material preparation: Firstly, it is necessary to prepare organic fertilizer raw materials that have been fermented and properly dried. The moisture content of the raw materials should be controlled within a certain range, as being too high or too low can affect the granulation effect.

Preliminary crushing: If the organic fertilizer particles after fermentation are large or have clumping, they may need to be pre treated with an organic fertilizer crusher to be evenly crushed for subsequent granulation.

Ingredients: According to the formula requirements, it is sometimes necessary to mix different types of organic fertilizers in proportion, add an appropriate amount of binder (such as bentonite), and additives (such as trace elements) to improve the physicochemical properties of the fertilizers.

Granulation: This is the core process of the entire process, which forces the powdered organic fertilizer into shape through equipment such as drum granulators, disc granulators, or extrusion granulators. Among them, the drum granulation method is the most commonly used, which uses a rotating drum to drive the raw materials to roll and form spherical particles.

Drying: After granulation, the fertilizer also needs to go through a dryer to remove excess moisture, in order to prevent deformation or adhesion of the particles during storage and transportation.

Screening: After drying, the fertilizer is separated into particles that do not meet the size requirements through a vibrating screen for secondary granulation or recycling as powder.

Cooling: In order to prevent the fertilizer from deteriorating due to internal heat accumulation during storage, the cooler will lower the temperature of the fertilizer particles to a safe range.

Packaging: The final step is to weigh and package the qualified organic fertilizer particles for storage and sale.

matters needing attention

The entire process should strictly control the moisture content of raw materials and products to avoid being too high or too low, so as not to affect product quality.

The amount of additives and adhesives used should be moderate, too much may lead to difficulty in granulation, and too little may make it difficult to form strong particles.

The selection and operation of equipment must be adjusted according to specific fertilizer characteristics and production needs to ensure optimal results.

Operators should receive professional training, be familiar with the safety operating procedures of the equipment, regularly maintain and clean the equipment, and ensure production continuity and efficiency.

Through the above process, the organic fertilizer granulator can process fermented organic fertilizers into standard granules, which not only facilitates agricultural applications but also increases the commercial value of fertilizers, promoting the sustainable and healthy development of organic agriculture.

What are the benefits of using an organic fertilizer composting machine to ferment fertilizers

fertilizer granulator Dec 27, 2024

The benefits brought by organic fertilizer composting machine are comprehensive, covering multiple aspects such as environmental protection, soil health, crop growth, etc., as follows:

Impact on the environment

Reducing pollution: During the fermentation process of organic fertilizers, a large amount of agricultural waste such as livestock manure and crop residues are converted into useful fertilizers, reducing environmental pollution caused by direct emissions, especially greenhouse gas emissions, and contributing to the fight against global climate change.

Water and energy conservation: Compared to traditional chemical fertilizer production, the production process of organic fertilizers consumes relatively less water and energy, which is more in line with the concept of green and low-carbon living.

Effect on soil

Improving soil structure: The abundant organic matter in organic fertilizers can improve the physical properties of soil, increase the stability of soil aggregates, enhance water and fertilizer retention capacity, and create a more stable growth environment for crop roots.

Activating soil microbial communities: Organic fertilizers contain a large number of beneficial microorganisms, which can promote the increase of microbial diversity in soil, enhance soil self-cleaning ability and self-healing function.

Alleviating soil degradation: Long term use of organic fertilizers can gradually improve soil acidification, salinization, heavy metal pollution, and other problems caused by excessive cultivation and chemical fertilizer abuse, restoring and enhancing soil vitality.

Benefits to crops

Provide comprehensive nutrients: Organic fertilizers contain the main nutrients (such as nitrogen, phosphorus, potassium) and trace elements required for plant growth, while also slowly releasing nutrients to avoid damage to crops caused by excessive fertilizer concentration.

Enhancing stress resistance: Microbial activity in organic fertilizers can generate various plant hormones, enhance crop immune systems, improve crop resistance to pests and diseases, and reduce pesticide use.

Improving the quality of agricultural products: Organic grown fruits and vegetables usually have better taste, color, and nutritional value, which are highly favored by consumers and help enhance market competitiveness.

Socio economic benefits

Increasing farmers’ income: The market demand for organic agriculture and organic products is growing day by day, and the prices of agricultural products grown with organic fertilizers are generally higher, bringing more economic benefits to farmers.

Energy conservation and emission reduction: The production process of organic fertilizers reduces dependence on fossil fuels, which is in line with the trend of sustainable development. The government often provides certain subsidies and support to reduce costs.

Employment opportunities: The development of the organic fertilizer industry chain has created new job opportunities in every link from production to sales, promoting economic development in rural areas.

In summary, the organic fertilizer composting machine is not only an effective means to solve agricultural waste, but also a comprehensive measure to improve soil health, promote healthy crop growth, protect the ecological environment, and increase agricultural income, reflecting the sustainable development direction of modern agriculture.

What organic fertilizer equipment should be paid attention to when preparing to build an organic fertilizer production line?

fertilizer granulator Dec 27, 2024

 Today, organic fertilizer production line manufacturers come to tell you what to focus on when buying organic fertilizer manufacturing equipment.
1. Determine the size of the organic fertilizer equipment: For example, how many tons of organic fertilizer can be produced per year, or how many tons can be produced per hour, can the price be determined.
2. To determine the shape of the particles is to choose what kind of granulator: powder, column, oblate or standard round. Commonly used equipment for granulating organic fertilizers are: disc granulator, drum granulator, wet granulator, roller extrusion granulator, flat die granulator, ring film granulator. The selection of the organic fertilizer granulator should be decided according to the local fertilizer sales market. The particle shape is different, the process of the organic fertilizer equipment is also different, and the price of the organic fertilizer equipment is also different.

3. Determine the configuration level of the organic fertilizer equipment: the configuration level is different, the price of the organic fertilizer equipment is different, the amount of labor used is different, and the stable and high yield of the organic fertilizer equipment is also different: the general configuration is high, the automatic batching device, automatic Packing device, automatic quantitative feeding device, cyclone dust removal and water dust removal.
4. Determine the type of fertilizer produced. For the same output, organic fertilizer equipment generally takes into account the high water content and the strains are not resistant to high temperatures, and the model is generally larger than the compound fertilizer model.
5. The selection of fermentation compost turning machine: the general fermentation forms are: stack fermentation, shallow tank fermentation, deep tank fermentation, tower fermentation, rotary drum fermentation, different fermentation methods, and different fermentation organic fertilizer equipment. Generally, the shallow trough turning machine is more suitable for the principle of aerobic fermentation (the advantages of the shallow trough turning machine: it is more in line with the principle of aerobic fermentation, it is not easy to form anaerobic, the fermentation is fully complete, and the fermentation speed is fast).
6. Determine the level of environmental protection requirements: places with low environmental protection requirements generally choose heavy dust removal and less investment in organic fertilizer equipment; places with high environmental protection requirements generally choose heavy dust removal and ink dust removal, which can meet the national air emission quality standards.