Common process flow of organic fertilizer production line for livestock and poultry manure

fertilizer granulator May 8, 2024

In general, organic fertilizer mainly includes granular and powder fertilizers, pure organic fertilizers, bio organic fertilizers, and organic-inorganic compound fertilizers. The organic fertilizer production line is a complete set of equipment and processes for fertilizer production, including manure maturation and fermentation, raw material mixing, particle processing, drying, packaging, etc. It includes all equipment for producing organic fertilizer using animal manure as raw material, adding wood chips, mushroom residue, sugarcane bagasse and other accessories for stacking fermentation.

The organic fertilizer production line includes fermentation equipment, granulation equipment, crushing equipment, stirring equipment, screening equipment, cooling equipment, drying equipment, coating equipment, automatic packaging equipment and other process flows.

Introduction to the technology scheme and process for producing organic fertilizer from livestock and poultry manure:

The main method is to ferment and decompose the organic matter mixture, add trace elements such as nitrogen, phosphorus, and potassium according to the formula requirements, crush them, and stir them in a mixer. After thorough stirring, the material is granulated, dried, cooled, and screened, and the finished particles are sent to the finished product silo. The packaged organic fertilizer is made into brown or grayish brown granular form, without mechanical impurities and odor.

1. Disc granulation production line

The disc granulation production line has a high granulation rate, low maintenance rate, smooth operation, sturdy and durable equipment, long service life, and low investment, making it the equipment of choice for many users.

2. Stock conversion and granulation production line

Large production capacity, low maintenance rate, and low energy consumption. We can design organic fertilizer production line equipment with a production capacity of 1-3 million tons according to customer requirements and provide a complete set of organic fertilizer production equipment.

3. Roller granulation production line

Easy to operate, low technical requirements, relatively simple process flow, low investment, strong adaptability to environmental conditions, stable operation, and low noise.

4. BB fertilizer production line

The BB fertilizer production line is designed and manufactured according to the requirements of compound fertilizer factories and fertilizer distributors, with a production capacity of 1-20000 tons. It adopts the process of directly feeding into the lifting tank and discharging from the mixer.

The granulation process of roller extrusion granulator in compound fertilizer production line

fertilizer granulator May 8, 2024

The raw material route of extrusion granulation to produce compound fertilizer is relatively wide, which can be used in npk compound fertilizer production line and npk production line. At present, there are more than 20 kinds of materials that have been successfully used in extrusion granulation: nitrate in nitrogen fertilizer Ammonium, urea, ammonium chloride, calcium nitrate, etc. Phosphate fertilizers include ammonium phosphate, common calcium, heavy calcium, phosphate rock powder, etc. Potash fertilizers include potassium chloride, potassium sulfate, etc., and trace elements such as boron, iron, copper, etc. can be added. Zinc, manganese, etc. Extrusion granulation has no special requirements on the particle size of raw materials. Both 1-4mm granular materials and fine powder materials can be used. Powder materials and powder products with unqualified particle size are better to use. Can reduce costs.

The main equipment included in the double roller granulator production line: automatic batching system, roll extrusion granulator, disc mixer, trommel screening machine, belt conveyor, packaging scale, etc.

Extrusion granulation production process:

1. storage, metering

Mixed fertilizer raw materials such as urea, ammonium phosphate, potassium chloride, etc. are transported to the storage silo by bucket elevator and belt. The number of storage bins, the complexity of metering and mixing techniques, is related to the number of components in the product formulation.

2. extrusion

The mixed fertilizer mixture is extruded by a roller extruder, the principle of which is to shape the material by extrusion. The mixed material is fed into the gap between the two oppositely rotating roller shafts through a vertical screw feeder. During the extrusion process, the pressure of the material gradually increases. When the gap between the two shafts is small, The material is relatively compressed, and then gradually decreases until it reaches 0.

3. Crushing and grading

The slabs formed in the double roller granulator  are further broken up and classified to the desired particle size.

4. Polishing and finishing

Typically, the final product undergoes one or two steps of polishing.

The working principle and granulation process of the roller extrusion granulator

fertilizer granulator May 8, 2024

The roller squeezing granulator is a commonly used fertilizer granulation equipment, especially suitable for the granulation production of organic and compound fertilizers. The following is a brief introduction to the working principle and granulation process of the roller extrusion granulator:

operational principle

Extrusion molding: The core part of the roller extrusion granulator is composed of a pair of relatively rotating pressure rollers, which have grooves on the surface. When the material is fed between the two rollers, it is compressed to form a strip shape.

Shear cutting: After the extruded strip material passes through the pressure roller, it is usually cut by a fixed or rotating tool to form the required length of particles.

Adjustment control: By adjusting the gap and speed between the pressure rollers, the size and shape of the particles can be controlled.

Granulation process

Raw material preparation: Firstly, suitable raw materials need to be prepared, such as powder of organic fertilizers or mixtures of compound fertilizers.

Moisturizing and mixing: In order to improve the granulation efficiency, the raw materials usually need to be moistened and mixed with an appropriate amount of water and binder to improve their plasticity.

Conveying and feeding: The mixed materials are uniformly fed into the feeding area of the roller squeezing granulator through conveying equipment.

Squeezing: The material is compressed into strips under the high pressure of the pressure roller, and excess water is squeezed out.

Cutting: The extruded strip material is cut or cut into particles of the desired length.

Drying: Newly formed wet particles contain high moisture and require drying treatment through drying equipment to reduce moisture content, improve particle hardness and stability.

Screening and grading: The dried particles are screened through screening equipment to remove particles that do not meet the requirements and ensure product quality.

Cooling: The screened particles usually require further cooling to ensure their stability during storage and transportation.

Packaging: Finally, the qualified granular fertilizer is automatically weighed and packaged before leaving the factory.

The roller extrusion granulator has been widely used in the field of fertilizer granulation due to its advantages of high efficiency, energy saving, and strong adaptability. By optimizing process parameters and equipment maintenance, the production efficiency and product quality of fertilizer particles can be effectively improved.

The process and price of producing organic fertilizer from livestock and poultry manure

fertilizer granulator May 8, 2024

Powdered organic fertilizer is commonly used to improve soil and provide the nutritional value components required for crop growth. When they enter the soil, they can also be quickly decomposed and release nutrients quickly. Due to the slower absorption rate of powdered solid organic fertilizers, powdered organic fertilizers have a longer storage time than liquid organic fertilizers. The use of organic fertilizers greatly reduces damage to plants themselves and soil environment.

The process flow of producing organic fertilizer from livestock and poultry manure:

1. Raw material ratio: Various animal feces such as chicken manure, pig manure, cow manure, biogas residue, or fermentable and fertilizer effective raw materials are prepared in a certain proportion;

2. Raw material mixing: Mix the prepared raw materials evenly to improve the overall uniform fertilizer efficiency of the fertilizer particles;

3. Raw material granulation: The evenly mixed raw materials are fed into a fertilizer granulator for granulation;

4. Particle drying: Feed the particles made by the granulator into the fertilizer dryer to dry the moisture inside the particles, increase their strength, and facilitate storage;

5. Particle cooling: The temperature of the dried fertilizer particles is too high, making them prone to clumping. After cooling, they are easy to pack, store, and transport;

6. Particle classification: The cooled particles are classified, and the unqualified particles are crushed and re granulated to screen out the qualified products;

7. Finished product coating: Coating qualified products to increase the brightness and roundness of particles;

8. Finished product packaging: Bag the finished product particles and store them in a ventilated place.

The above are the process steps of the organic fertilizer production line for the treatment of livestock and poultry manure. Of course, the specific operation also involves different processes and equipment choices, which need to be adjusted according to the specific site and actual situation. Because the production capacity requirements of each project, the ground processing site, and the configuration of the entire set of organic fertilizer production equipment are not fixed, there are often many different situations, so the specific price depends on the situation. You need to consider factors such as equipment power, production capacity, automation level, and additional functions. For some special equipment or high-end large-scale production lines, the price may be higher. It is recommended that you conduct market research and communicate with multiple suppliers before making a purchase to ensure that you can obtain the most suitable production line for your needs and budget.

How is the disc granulator used in fertilizer production lines for granulation

fertilizer granulator May 8, 2024

Common organic fertilizer granulators include: double roller granulator, stock granulator, disc granulator, new organic fertilizer granulator, etc. The disc granulator is widely used and can be used for npk fertilizer production line , organic fertilizer production, bio-organic fertilizer production line, etc. Today, let’s understand the working principle of the disc granulator.

The organic fertilizer disc granulator machine is a new type of inclined granulation equipment. The granulation rate of this disc granulator machine  is about 90%. The reducer and motor in the machine are transmitted by a flexible belt, which makes the disc granulator start smoothly, slows down the impact force, and improves the service life of our equipment. The bottom of the granulator disc is reinforced with a variety of radiant steel plates, which are firm and durable and not easy to deform. This thickened and heavier base design is relatively firm, does not require anchor bolts to fix, and is relatively stable. When the disc granulator is running, the granulation is uniform and the spheroidization rate is high. Not only does it run smoothly, but the device is sturdy and durable.

How does the organic fertilizer disc granulator machine work? First, the main motor drives the pulley and belt. The pinion gear is driven by the reducer, and the pinion gear is engaged with the large gear fixed on the ground. The large gear is installed on the main shaft on the frame adjustment disc through a special and reasonable design to support the work of the entire granulation disc. After the material enters the granulation disc, the disc granulation equipment continuously rotates the spray device to make the material evenly bonded to form round spherical particles. The upper part of the disc granulation equipment is designed with an automatic cleaning device, which prevents the material from sticking to the wall and improves the service life of the machine. The motor continuously rotates and the material enters continuously, which can not only realize mass production, but also easily meet the needs of continuous work.

Advantages of Organic Fertilizer Tank Type Flipper for Fermentation of Raw Materials

fertilizer granulator May 8, 2024

The organic fertilizer tank type flipper is a device used for treating and fermenting organic waste. It improves the ventilation conditions of compost and accelerates the fermentation process through flipping action. The slot type tipping machine is particularly suitable for large-scale composting operations, especially in organic fertilizer production lines. The following are some advantages of the slot type flipper for fermenting raw materials:

1. Improve fermentation efficiency: The trough type flipper increases the ventilation of the compost by flipping it, providing sufficient oxygen for microorganisms and accelerating the decomposition rate of organic matter.

2. Uniform fermentation: The flipping machine can mix fresh materials in the compost with already fermented materials, ensuring a uniform fermentation process throughout the entire compost pile.

3. Reduce odor: Due to the fact that the flipping machine can accelerate the decomposition of organic matter, it reduces the production of ammonia and other odor gases, thereby reducing the odor problem during the composting process.

4. Space saving: The slot type tipping machine usually works in a fixed fermentation tank, which saves space and is easy to manage and control.

5. Reduce manpower: The automated flipping process reduces reliance on manpower, lowers labor intensity and production costs.

6. Improve product quality: Through the uniform flipping of the slot flipping machine, more consistent quality organic fertilizers can be produced.

7. Easy to control: The operation of the slot flipping machine is usually relatively simple, making it easy to control the frequency and depth of flipping, and can be adjusted according to the needs of fermentation.

8. Strong adaptability: The flipping machine can handle various organic waste, such as livestock and poultry manure, crop residues, food processing waste, etc., with strong adaptability.

9. Improving soil structure: Fermented organic fertilizers help improve the physical structure of the soil, increase the organic matter content of the soil, and enhance the soil’s water and fertilizer retention capacity.

10. Environmental protection: The use of slot type tipping machines helps to convert organic waste into valuable fertilizers, reducing waste disposal issues and making it an environmentally friendly treatment method.

11. Improve compost maturity: Through the uniform flipping of the flipper, the organic matter in the compost can be more fully decomposed, producing more mature compost.

12. Reduce pathogens and weed seeds: During the high-temperature fermentation process, the flipper helps maintain the high-temperature state of the compost, thereby killing pathogens and weed seeds, ensuring the safe use of organic fertilizers.

The slot flipper is an important part of the organic fertilizer production line. Through its efficient fermentation treatment, it can produce high-quality organic fertilizers and provide support for agricultural production.

How much does the complete set of equipment for producing organic fertilizers cost?

fertilizer granulator May 8, 2024

The price of a set of organic fertilizer production equipment generally ranges from 200000 to 10 million yuan, and the specific price depends on factors such as the type, scale, technology, equipment quality, and brand of the fertilizer. At the same time, it is also necessary to consider transportation costs, installation costs, after-sales service costs, etc. Therefore, when purchasing organic fertilizer production equipment, one should choose appropriate equipment based on their own needs and budget, and comprehensively consider various factors to achieve the best economic and usage benefits.

1. The type of fertilizer is an important factor affecting the price of organic fertilizer production equipment.

Different types of fertilizers require different raw materials and production processes, so equipment prices may also vary. For example, the production equipment prices for organic fertilizers and bio organic fertilizers are generally higher because they require more raw materials and more complex production processes. The production equipment price of organic-inorganic compound fertilizer is relatively low because its production process is relatively simple, only requiring the mixing of organic and inorganic materials for granulation.

2. Scale is also one of the factors affecting the price of organic fertilizer production equipment.

Larger scale equipment requires larger venues, more workers, and more equipment, so prices are usually higher. Smaller devices are relatively cheaper, but their production is also relatively low.

3. The quality of technology and equipment is also a factor that affects prices.

Powder organic fertilizer processing equipment: flipping machine (used for composting process) – vertical crusher (crushing larger blocks in organic fertilizer) – screening machine (screening out non compliant organic fertilizers and returning them) – batching machine (adding other required nutrients to organic fertilizer in a certain proportion, which is an optional device) – horizontal mixer (mixing different materials evenly and using it in combination with batching machine) – single bucket packaging machine (used for quantitative packaging of finished organic fertilizer)

Granular organic fertilizer processing equipment: tipping machine – vertical crusher – drum screening machine (optional here) – batching machine and horizontal mixer (used in combination, belonging to optional equipment) – disc granulator – dryer and cooling machine – drum screening machine – round throwing machine (optional) – wrapping machine (optional) – single bucket packaging machine.

Different processes and equipment quality can lead to differences in production efficiency, product quality, and equipment lifespan. Therefore, equipment with higher prices usually adopts more advanced processes and high-quality materials to ensure production efficiency and product quality.

Daily maintenance methods for organic fertilizer equipment after granulation

fertilizer granulator May 8, 2024

1. Keep the workplace clean. After the production of the organic fertilizer equipment is completed, the granulating blades and the residues inside and outside the double roller granulator should be cleaned, the glue sand and splashes scattered or splashed on the organic fertilizer equipment should be cleaned, the mechanically exposed processing surface of the organic fertilizer equipment should be scrubbed, and the anti-corrosion should be brushed. Anti-rust paint, and cover it with a corresponding protective cover to prevent the dust workers from invading again.

2. The organic fertilizer equipment has no external oil holes, gears, and worm gears to be lubricated with special grease for organic fertilizer equipment. The upper and lower gears are added with ternary grease once a quarter, and the gearbox cover and gearbox gear cover can be opened respectively when refueling. The lubricating oil should drip into the sliding surface that supports the hinge joint between the gearbox and the bracket. The worm gear case and bearings have been filled with sufficient transmission grease at the factory. However, the transmission should be cleaned once a year and the protective lubricant replaced.

3. Always pay attention to the operation of chicken manure organic equipment during organic fertilizer production or npk manufacturing process, without serious abnormal noise and dry sound, and without metal friction sound. If there is an exception, close the check. After troubleshooting, it can be used. If no appropriate cause is found, the machine cannot start. If there is a metal friction sound, please check the gap between the organic fertilizer equipment first.

4. Regularly check the standard clearance between organic fertilizer equipment.

5. During the maintenance of organic fertilizer equipment, the working gap should be re-measured every time, and adjusted several times before it can be used normally.

6. If the controller cannot operate the chicken manure organic equipment according to the program, check whether the power supply voltage, power plug socket and connecting plug socket are normal, and check the internal fault of the controller.

How much investment is needed for the equipment of sheep manure organic fertilizer production line

fertilizer granulator Apr 29, 2024

Sheep manure is a high-quality organic fertilizer production raw material, with a long-lasting and pollution-free effect. It can not only improve soil compaction, but also provide rich nutrients for crops for a long time. Sheep manure organic fertilizer contains a large amount of organic matter, rich in various beneficial trace elements, providing sufficient nutrition for crops, and its performance in increasing yield and income is particularly outstanding, which is favored by a large number of farmers. Moreover, the source of raw materials is abundant and the acquisition cost is low, which not only solves the problem of environmental pollution in breeding farms, but also processes them into green ecological organic fertilizers, which is in line with development. So how much does it cost to invest in purchasing equipment for the sheep manure organic fertilizer production line?

Granular organic fertilizer production line: sheep manure dewatering machine, fermentation overturning machine, semi wet material crusher, horizontal mixer, granulator, dryer, cooling machine, drum screening machine, coating machine, packaging equipment, belt conveyor, etc.

There are many models of complete sets of equipment for producing organic fertilizer from sheep manure, and different models have different parameters such as yield and size, as well as different prices. When purchasing equipment, it is necessary to choose the appropriate model.

The equipment investment for an annual production line of 5000 tons of sheep manure organic fertilizer is around 150000 to 250000 yuan. The required equipment includes organic fertilizer fermentation and flipping machine, horizontal mixer, semi wet material crusher, organic fertilizer granulator, organic fertilizer screening equipment, etc. Only these types of organic fertilizer equipment can form a complete organic fertilizer production line.

The profit per ton of sheep manure organic fertilizer is generally around 200 yuan, and the total profit for an annual production of 5000 tons can reach 1 million yuan, minus equipment investment of 200000 yuan, factory construction of 400000 yuan, and other expenses. In recent years, there has been a strong promotion of the production of organic fertilizers, and there are certain support and subsidy policies. As long as we identify business opportunities and make sufficient preparations and understanding. Opening a sheep manure organic fertilizer factory to make money is a good choice.

Process and configuration of powdered organic fertilizer production line

fertilizer granulator Apr 29, 2024

Generally speaking, to configure a production line for 100 tons of powdered organic fertilizer, the following equipment needs to be considered. Firstly, there is the raw material processing equipment, which includes fermentation turners, organic fertilizer crushers, organic fertilizer mixers, drum screening machines, and packaging machines.

The process flow of the powdered organic fertilizer production line is as follows:

1. Send qualified organic raw materials into the speed regulating silo using a loader;

2. Transported to a vertical crusher for crushing to 10-60 mesh size;

3. Transported to the drum screening machine for sorting raw materials and impurities; Mixing equipment can also be added.

4. Transported to a powder organic fertilizer packaging machine (dedicated) for weighing, packaging, sewing, and storage.

Composition of equipment for organic fertilizer powder production line:

The main equipment of the organic fertilizer powder production line includes six parts: speed regulating feeding bin, feeding belt conveyor, vertical crusher, drum screening machine – quantitative packaging machine, and distribution cabinet;

Suitable for small and medium-sized organic fertilizer production processes with compact layout, scientific and reasonable matching, energy-saving and consumption reduction, no three emissions, automated control, stable operation, reliable operation and convenient maintenance, wide adaptability of raw materials, suitable for various ratios of organic compound fertilizers, bio organic fertilizers, urban sludge, household waste organic fertilizer production, etc. The annual production capacity can be designed according to production needs, ranging from 10000 to 100000 tons.

As for the price of the production line for 100 tons of powdered organic fertilizer per day, the price of different equipment may vary. Based on experience, the equipment budget for the entire 100 ton/day powdered organic fertilizer production line may range from 300000 to 400000 yuan, taking into account factors such as brand, scale, and quality of different equipment.