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.

The “Pre-treatment Powerhouse” of bio-organic fertilizer production lines

fertilizer granulator Dec 10, 2025

In the bio-organic fertilizer production process, the efficiency of the pre-treatment stage directly determines the quality of subsequent production, and the half-wet material crusher is the core equipment in this stage. As one of the key pieces of bio-organic fertilizer equipment, it perfectly solves the problem of processing high-humidity materials, ensuring the stable operation of the bio-organic fertilizer production line.

Traditional dry crushers often encounter problems such as clogging and low efficiency when processing wet materials such as wet straw and composted organic fertilizer due to material adhesion. However, the half-wet material crusher, with its special design, can easily handle wet materials with a moisture content of 30%-60%. Its built-in anti-clogging device prevents material adhesion, and the high-speed rotating crushing elements quickly crush the wet material into uniform particles through impact, cutting, and grinding. This not only reduces equipment failures but also improves the efficiency of subsequent fermentation and granulation processes.

In a complete bio-organic fertilizer production line, the half-wet material crusher usually connects the raw material pre-treatment and fermentation stages. For example, when processing agricultural waste, it first crushes wet straw, livestock manure, and other raw materials to a suitable particle size, increasing the contact area of the materials and allowing for more thorough microbial fermentation; when used in conjunction with other bio-organic fertilizer equipment such as chain crushers and horizontal crushers, it can flexibly adapt to different raw materials and meet diverse production needs.

In addition, this equipment also has the advantages of convenient maintenance and controllable particle size. For organic fertilizer production enterprises, choosing a high-quality half-wet material crusher can effectively improve the overall production capacity of the production line and contribute to the development of green agricultural circular economy.

From equipment to process, how to choose the right NPK fertilizer production line?

fertilizer granulator Dec 10, 2025

In the process of agricultural modernization, the demand for high-quality compound fertilizers has surged, making NPK fertilizer production lines core equipment for fertilizer companies expanding production. However, faced with a variety of equipment and processes, choosing a production line that suits their specific needs is a challenge for many industry professionals.

First, let’s look at the core equipment configuration. A complete NPK fertilizer production line needs to cover key stages such as raw material processing, mixing, granulation, drying, and cooling. In the raw material processing stage, a fertilizer crusher can crush large raw materials to a suitable particle size, and with a precise batching system, the proportion of nitrogen, phosphorus, and potassium components can be strictly controlled; for the mixing stage, a fertilizer mixer machine is recommended, and a double shaft paddle mixer can achieve a raw material mixing uniformity of over 95%; granulation is the core process, with disc granulators suitable for small and medium-sized capacities, while double roller press granulators are suitable for high-hardness granule requirements, and companies can choose according to their needs. Subsequent drying, cooling, and coating machines, along with fertilizer screener machines, ensure that the finished granules are uniform and have a qualified moisture content, and finally, automatic packaging is achieved through packaging machines, improving production efficiency.

At the process level, automation is key. A high-quality NPK fertilizer granulation process requires a PLC control system for full monitoring, precisely adjusting parameters from raw material proportioning to drying temperature, ensuring stable nutrient content in the finished product and reducing energy consumption. Choosing the right NPK fertilizer production line is not just about purchasing a set of equipment, but also laying the foundation for the long-term development of the enterprise. Combining capacity, finished product requirements, and manufacturer services will allow the production line to truly become a profit engine.

Optimizing double roller press granulator process to boost organic fertilizer production

fertilizer granulator Dec 10, 2025

Double roller press granulators are key equipment in modern organic fertilizer production lines. Optimizing their process directly impacts a company’s output and economic benefits. With the rapid growth of organic farming, how to improve organic fertilizer production through technical upgrades to these granulators has become a major focus for many manufacturers.

1.Optimizing Raw Material Pre-treatment

Grind raw materials to 40-60 mesh. Control moisture content between 20%-25%. Adding suitable binders like bentonite or lignin can significantly improve granulation rate and reduce return material. This is expected to increase output by around 15%.

2.Precise Adjustment of Roller Parameters

For general organic fertilizer production: Set the nip gap between 1.5-2.5mm. Maintain roller pressure at 8-12MPa. Control line speed at 0.8-1.2m/s. Installing pressure sensors and automatic adjustment systems allows for dynamic optimization, improving particle formation rate.

3.Die Selection and Maintenance

Hole Size: 3-6mm suits most organic fertilizers. Open Area Ratio: Maintain between 30%-40%. Regular polishing extends die life. Recommend professional maintenance every 500 tons of material processed to ensure smooth discharge.

4.Coordinated Optimization of Supporting Equipment

Precise batching system (error <1%). Efficient mixer (mixing uniformity >95%). Energy-saving dryer (thermal efficiency >65%). Systematic upgrades like this can increase the entire line’s output by 30%-50%.

Through comprehensive optimization of the double roller press granulator process, organic fertilizer producers can significantly boost production without adding more machines.

When fertilizer meets extrusion: The art and science of granulation

fertilizer granulator Dec 10, 2025

In modern fertilizer production, fertilizer compaction machines and flat die pelleting machines are quietly changing the form and future of fertilizers. Unlike chemical reaction equipment, they don’t attract attention, but with their unique mechanical charm, they transform powdered fertilizer into uniform granules.

Stepping into the production workshop, you’ll see fertilizer compaction machines working steadily. They use powerful mechanical pressure to “compress” loose powdery raw materials into dense ribbons. This process involves no high temperatures and no binders.

The flat die pelleting machine, on the other hand, showcases another kind of ingenuity. The horizontally placed die acts like a precision sieve; the material, under the pressure of the rollers, passes through the holes in the die, instantly becoming uniformly sized granules.

The combination of these two devices creates surprising possibilities. Powdered fertilizers that are prone to clumping become more fluid, easier to store and apply. Active ingredients are firmly locked inside the granules, reducing drift loss during use and making nutrient release more controllable.

More importantly, this physical granulation method has opened new doors for the development of specialty fertilizers. Whether it’s a compound fertilizer requiring the addition of trace elements or a special fertilizer for specific crops, it can all be achieved by adjusting the mold and process parameters. On the path to sustainable agricultural development, equipment like fertilizer compaction machines and flat die pelleting machines are playing a unique role.

Facilitating efficient organic fertilizer production and promoting green agricultural development

fertilizer granulator Dec 10, 2025

In the field of organic fertilizer production, a highly efficient and reliable granulation equipment is crucial, and the organic fertilizer disc granulator is a highly favored choice. As the core organic fertilizer granulation equipment, it can accurately convert fermented organic raw materials such as livestock and poultry manure and straw into granular organic fertilizer, injecting strong momentum into green agricultural development.

The organic fertilizer disc granulator offers significant advantages. Its granulation rate exceeds 95%, far surpassing ordinary granulation equipment. The main gear is treated with high-frequency quenching, doubling its service life and reducing equipment replacement costs. The equipment adopts an inclined disc design, coupled with adjustable rotation speed and inclination angle, allowing it to adapt to different types of organic raw materials. Whether the material is powdery or slightly viscous, it can be efficiently granulated, fully demonstrating its strong material adaptability.

From a workflow perspective, it is simple and scientific to operate. First, the organic raw materials are pre-processed, crushed to a particle size of 0.1-1mm and thoroughly mixed, and then evenly fed into the disc by the feeding device. At the same time, the water spraying device precisely sprays an appropriate amount of water to maintain the material’s moisture content at 10%-20%. As the disc rotates, the materials tumble and bond under the action of centrifugal force, friction, and gravity, gradually forming granules with a sphericity exceeding 80%. Finally, after screening, unqualified granules are returned for reprocessing, ensuring the quality of the finished product.

This equipment is not only suitable for small and medium-sized organic fertilizer production plants but can also be integrated into large-scale organic fertilizer disc granulation production lines, working in conjunction with supporting equipment such as fertilizer crushers, mixers, and dryers to build a complete organic fertilizer production equipment system. The resulting granular organic fertilizer has uniform nutrients, high strength, is easy to store and transport, and can also improve soil structure and enhance soil fertility.

Chain compost turning machines: An efficient tool for organic waste treatment

fertilizer granulator Dec 9, 2025

In the context of green agricultural development and the resource utilization of organic waste, the chain compost turning machine has become a core piece of equipment for large-scale organic fertilizer production plants and composting facilities, providing strong support for aerobic fermentation processes.

This equipment is specifically designed for processing organic waste such as livestock manure and crop straw, efficiently addressing the problems of low efficiency and long fermentation cycles associated with traditional composting methods. Compared to simple compost turning machines and hydraulic compost turning machines, the chain compost turning machine, with its unique chain-driven turning mechanism, can penetrate deep into the compost pile, achieving uniform material mixing and significantly improving oxygen supply efficiency, thus accelerating the decomposition and transformation of organic materials.

In bio-organic fertilizer production lines, the role of the chain compost turning machine is particularly crucial. Its automated control system can precisely adjust the turning frequency and depth, and with the optional oxygen supply system, it allows organic waste to ferment rapidly under suitable conditions, transforming into high-quality organic fertilizer in just a few weeks. The equipment is also highly adaptable, seamlessly integrating with organic fertilizer production lines and assisting in the environmentally friendly and large-scale operation of agricultural waste treatment projects, reducing pollution while creating economic value.

For companies pursuing efficient production, the advantages of the chain compost turning machine are significant: its durable chain structure is suitable for long-term, high-intensity operation, its flexible walking system can adapt to irregular sites, and its automated operation reduces labor costs. Whether used in conjunction with windrow compost turning machines for multi-scenario operations or independently in large-scale composting projects, it can drive the upgrading of the organic fertilizer industry with its stable performance, injecting momentum into the development of green agriculture.

Vibration screener machine: The core equipment for efficient screening in fertilizer production

fertilizer granulator Dec 9, 2025

In the fertilizer production process, material screening is a critical link that determines product quality. Vibration screener machines, with their high efficiency and precision, have become the equipment of choice for many manufacturers. As a core material screening device, it is not only suitable for the entire fertilizer production process but can also be widely used in mining, building materials, chemical industry, and other fields, providing solutions for material classification in multiple industries.

The core advantages of the vibration screener machine lie in its “efficiency” and “precision.” Its vibrating motor generates high-frequency vibrations, allowing materials to quickly complete projectile motion on the screen surface. Materials smaller than the screen mesh are precisely separated, achieving both classification and impurity removal, significantly improving production efficiency. Considering the specific requirements of fertilizer production, the equipment can be adjusted by changing the screen mesh size and vibration parameters to adapt to different materials, such as granular materials produced by fertilizer granulators and mixed materials after mixing in fertilizer mixers. The screening accuracy far exceeds that of traditional equipment.

At the same time, the sealed design of the equipment is also a significant advantage, effectively reducing dust leakage during fertilizer production, meeting environmental protection requirements and protecting the workshop environment. Its compact structure requires a small footprint and can be flexibly integrated with different production lines, such as NPK fertilizer production lines and organic fertilizer production lines, reducing the difficulty of workshop layout.

For fertilizer companies, choosing a high-quality vibration screener machine can not only improve product qualification rates but also reduce material waste, contributing to efficient production. Whether processing coarse materials after being processed by a fertilizer crusher or conveying qualified finished products to a packaging machine, the vibration screener machine, with its stable performance, is an indispensable key equipment in the fertilizer production chain.

NPK fertilizer production line: Scientific ratios help boost vegetable yield and quality

fertilizer granulator Dec 9, 2025

NPK fertilizer is a scientifically blended combination of the three core nutrients – Nitrogen (N), Phosphorus (P), and Potassium (K) – designed specifically to meet vegetable growth needs. Modern NPK fertilizer production lines use precise blending processes to create high-efficiency compound fertilizers. These fertilizers can significantly improve vegetable yield, quality, and disease resistance.

1.Promotes Rapid Vegetable Growth

Nitrogen is key for leaf and stem growth in vegetables. Adequate nitrogen fertilizer speeds up leaf development in leafy greens like spinach and lettuce, helping plants thrive with vibrant green color.

2.Boosts Root Development, Flowering, and Fruiting

Phosphorus encourages root growth. It’s especially vital for fruiting vegetables like tomatoes and cucumbers, improving fruit setting rates and shortening the ripening cycle.

3.Enhances Stress Tolerance and Quality

Potassium fertilizer strengthens a vegetable’s resistance to drought and disease. It also improves the sweetness and taste of fruits. Crops like peppers and eggplants develop brighter colors and better storage and transport tolerance after application.

The Technical Edge of NPK Fertilizer Production Lines

Modern NPK fertilizer production lines use computer-controlled dosing systems. This ensures precise ratios of nitrogen, phosphorus, and potassium (like 16-16-16 or 20-10-10) and allows for adding trace elements (such as calcium and magnesium). This meets the specific nutritional needs of different vegetable varieties. The granulation process creates slow-release fertilizer pellets, reducing nutrient loss.

Scientifically blended NPK fertilizer is key to high vegetable yields and quality. Modern production line technology further improves fertilizer efficiency, helping growers achieve both economic and ecological benefits.