fertilizer production line

Common troubleshooting and solutions for double screws compost turning machines

fertilizer granulator Nov 4, 2025

Double screws compost turning machines operate frequently in organic fertilizer fermentation workshops. Improper operation or untimely maintenance can easily lead to problems such as uneven turning, insufficient power, and equipment jamming, impacting fermentation progress.

1.Dead corners remain after turning, and some areas remain uncomposted

The main cause is excessive clearance between the spiral blades and the sidewalls of the fermentation tank (over 10 cm), or the double screws compost turning machine is moving too fast, preventing material from being turned over the edges. To address this, adjust the position of the spiral blades to reduce the clearance to within 5 cm. Also, reduce the double screws compost turning machine’s speed to ensure that every area is thoroughly turned.

2.Motor overload and tripping, insufficient power

This is often caused by excessive moisture content (over 70%) in the raw materials, resulting in increased friction on the spiral blades due to high viscosity, or by large impurities in the raw materials that may be blocking the blades. To address this, adjust the moisture content of the raw materials to 60%-65% before clearing impurities from the fermentation tank. If the compost tank is frequently overloaded, check the tightness of the motor belt and tighten or replace it.

3.Rapid wear of spiral blades, reducing turning capacity

This is primarily due to the presence of hard impurities (such as sand and gravel) in the raw materials, or the blade material not being suitable for wear resistance. To address this, install a screen to filter out hard particles before the raw materials arrive. Regularly inspect the blades for wear. If the blade thickness has decreased by 1/3 or cracks appear, replace them promptly.

Uniform Feeder: The Stable Choice for Industrial Production

fertilizer granulator Nov 4, 2025

Equipment Overview

The uniform feeder is a key device in industrial production that ensures materials enter subsequent processing equipment at a stable and uniform rate. This equipment is widely used in various industries including chemical fertilizer, building materials, cement, chemical industry, coal, mining, ceramics, grain, and feed. Its main function is to avoid production fluctuations caused by uneven material supply, thereby improving production efficiency and product quality.

Equipment Structure and Composition

Core Components:

• Feed Inlet:Open structure design for smooth material flow
• Feeding Mechanism:Core part of the equipment, including spiral feeders, vibrating feeders, belt feeders, etc.
• Regulating Device:Speed controllers, gates, etc., for precise feeding rate adjustment
• Drive System:Motors, reducers, etc., providing power for the feeding mechanism
• Control System:PLC or microcomputer control system for automated control

Working Principle

Taking the spiral feeder as an example, materials enter from the feed inlet, and the spiral feeder rotates under the drive of the motor. The spiral blades push the materials forward. By controlling the rotation speed of the spiral feeder through the adjusting device, precise control of the material supply rate is achieved. This design ensures that materials enter subsequent equipment at a stable and uniform rate, avoiding material accumulation or interruption, and ensuring the continuity and stability of the production process.

Equipment Advantages

Precise Control

Through advanced regulating devices, precise control of material feeding rate is achieved, ensuring uniformity and stability of material supply, providing reliable support for subsequent processes.

Strong Adaptability

Capable of handling various types of materials, including powders, particles, and flakes, suitable for different industrial production environments, meeting diverse production needs.

Automated Operation

Equipped with advanced control systems, achieving automation of the feeding process, reducing manual intervention, improving production efficiency, and minimizing human errors.

Easy Maintenance

Reasonable structural design makes the equipment easy to clean and maintain, reducing downtime, lowering maintenance costs, and extending equipment service life.

Energy Saving and Efficiency

Adopting energy-saving design, effectively reducing energy consumption, improving feeding efficiency, helping to reduce overall production costs, and enhancing enterprise competitiveness.

Industry Application Value

The uniform feeder plays a crucial role in modern fertilizer production systems, ensuring precise material handling across various manufacturing processes. In NPK fertilizer production line operations, it guarantees accurate proportioning for the NPK blending machine, while in organic fertilizer production line setups, it maintains consistent feeding for windrow composting machine operations. This precision equipment serves as the backbone for both conventional and bio organic fertilizer production line configurations, enabling reliable material flow from initial processing to final granulation stages.

Within comprehensive fertilizer manufacturing systems, the uniform feeder’s importance extends to multiple production stages. It ensures stable raw material supply for disc granulation production line operations and maintains consistent feeding for various fertilizer granulator types, including the disc granulator and double roller press granulator. The equipment’s synchronized operation with windrow machine systems in composting phases demonstrates its versatility across different production methodologies within the same NPK fertilizer line.

The stable and reliable performance of uniform feeders not only improves final product quality but also optimizes entire production processes. By ensuring consistent material flow through every component – from blending equipment to granulation machines – these feeders provide solid technical support for the intelligent and automated development of fertilizer production industries. Their integration across various production lines enables seamless coordination between different processing stages, ultimately enhancing overall system efficiency and product consistency.

How do BB fertilizer companies of different production capacities choose the right mixer operating mode?

fertilizer granulator Nov 4, 2025

The differences in production capacity among BB fertilizer companies (small-scale with daily production capacity below 50 tons, large-scale with daily production capacity above 100 tons) directly influence the choice of BB fertilizer mixer operating mode. Choosing the right mode can improve efficiency by over 30%.

Small-scale companies often operate in batch mode, making the “batch mixing + staged feeding” mode suitable: the single mixing volume is set at 70% of the equipment’s capacity, and feeding is carried out in three batches: 60% base granular fertilizer is added first, followed by 30% powdered raw materials after three minutes of mixing, and finally 10% trace additives. The total mixing time is kept to 10-12 minutes. This mode avoids energy waste caused by idling equipment for small batches of raw materials and facilitates flexible switching of fertilizer formulas.

Large-scale continuous production companies require a “continuous mixing + flow linkage” model: raw materials are continuously fed into the BB fertilizer mixer in proportion via a conveyor belt. The raw material flow rate is linked to the mixing speed. An online detection device is installed at the BB fertilizer mixer outlet to monitor mixing uniformity in real time. If the coefficient of variation exceeds 5%, feedback is immediately provided to adjust the feed ratio. Furthermore, continuous production requires cleaning of the drum wall every four hours to prevent long-term accumulation that can affect the quality of subsequent batches.

Oil palm empty fruit bunch: “Green Raw Materials” for organic fertilizer production lines

fertilizer granulator Nov 4, 2025

As a major waste product of the oil palm processing industry, oil palm empty fruit bunch, with their rich organic matter and unique physical properties, have become a high-quality raw material for organic fertilizer production lines. Their deep integration with various stages of the production line not only realizes waste resource utilization but also optimizes the organic fertilizer production process.

In the raw material pretreatment stage, oil palm empty fruit bunch need to be processed by crushing equipment to break them into 1-3 mm granular materials. This removes coarse and hard impurities while retaining an appropriate amount of fiber structure. The crushed material is then mixed with livestock and poultry manure, microbial agents, etc., in a specific ratio. Its loose properties naturally adjust the carbon-nitrogen ratio of the mixture while improving its permeability, laying the foundation for subsequent fermentation.

In the fermentation stage, oil palm empty fruit bunch a highly efficient combination with a compost turning machine. During the composting and fermentation of the mixed materials, the fibrous structure of the oil palm empty fruit bunch prevents the pile from compacting, while the periodic turning by the compost turner further enhances aeration, allowing aerobic microorganisms to multiply rapidly and maintaining the composting temperature at a stable 55-65℃.

In the post-processing stage, the composted oil palm empty fruit bunches are suitable for the forming requirements of organic fertilizer granulators. Their residual fiber toughness enhances granule cohesion, preventing breakage due to compression during granulation and avoiding die clogging, thus improving granulation efficiency. The formed granular organic fertilizer, retaining some of its fibrous structure, possesses both long-lasting fertilizing effects and soil-improving functions.

The deep integration of oil palm empty fruit bunch with the organic fertilizer production line solves the waste disposal problem and optimizes the production process through the characteristics of the raw materials.

Cyclone Dust Collector: Efficient Gas Purification Solution

fertilizer granulator Nov 3, 2025

Equipment Overview

A cyclone dust collector is a dust removal device that uses centrifugal force generated by rotating airflow to separate particulate matter from the gas stream. With simple structure and low operating costs, it is widely used for gas purification in various industrial processes including cement, chemical, metallurgical, power, and food processing industries, effectively removing dust and particulate matter from flue gas.

Equipment Structure and Composition

Core Components:

• Inlet Pipe:Guides dusty gas into the collector, designed tangentially or spirally to promote airflow rotation
• Cyclone Body:Main part of the equipment, cylindrical design with smooth inner walls for generating and maintaining rotating airflow
• Cone Section:Located below the cyclone body, conical structure helps further separate and collect particulate matter
• Exhaust Pipe:Located at the top of the cyclone body for discharging purified gas
• Ash Hopper:Located at the bottom of the cone for collecting and storing separated particles
• Ash Discharge Device:Star-shaped discharge valves, screw conveyors, etc., for regular removal of particulate matter from the ash hopper

Working Principle

Dusty gas enters the cyclone dust collector through the inlet pipe and enters the cyclone cylinder tangentially or spirally, forming a high-speed rotating airflow. Under centrifugal force, heavier particles are pushed toward the cylinder wall and then fall along the wall into the ash hopper, achieving separation from the airflow. Purified gas is discharged through the central exhaust pipe. The rotating airflow continuously decelerates in the cyclone body and cone, further improving separation efficiency and ultimately achieving dust removal goals.

Equipment Advantages

Efficient Separation

High separation efficiency for larger particle sizes, effectively removing dust from industrial flue gas.

Simple Structure

No moving parts, compact structure, low maintenance costs, long service life, suitable for various industrial environments.

Reliable Operation

Easy operation, stable performance, strong adaptability, capable of handling high-temperature and high-dust-concentration gases.

Economical and Practical

Relatively low initial investment and operating costs, particularly suitable for small and medium-sized gas purification needs.

Environmentally Friendly

No secondary pollution, relatively low energy consumption, meeting modern industrial environmental requirements.

Application Value

With its unique working principle and superior performance characteristics, the cyclone dust collector plays an important role in industrial dust control across various fertilizer production facilities. It provides essential environmental protection for complete production lines including the npk fertilizer production line, organic fertilizer production line, and bio organic fertilizer production line. These systems, which incorporate equipment such as the npk blending machine, disc granulator, double roller press granulator, and windrow composting machine, generate significant dust during operation. The cyclone collector effectively controls particulate matter from the disc granulation production line and windrow machine operations, not only improving working environments and protecting employee health but also reducing atmospheric pollution to promote sustainable development. As environmental requirements continue to increase, cyclone dust collectors will remain crucial in creating cleaner production environments for the fertilizer industry, ensuring that fertilizer granulator operations meet the highest environmental standards while maintaining production efficiency.

Efficient Pig Manure Fermentation: Innovative Organic Fertilizer Technology

fertilizer granulator Nov 3, 2025

Technical Background

With the continuous expansion of global animal husbandry, pig manure treatment has become an urgent environmental issue. Traditional composting methods are inefficient and result in significant nutrient loss. This invention provides an innovative pig manure fermentation technology that converts pig manure into high-quality organic fertilizer through a multi-stage fermentation process.

Preparation Process

Stage 1: Strain Cultivation
Mix biological bacteria, molasses and water, ferment for 40-56 hours to prepare efficient strain fermentation liquid

Stage 2: Primary Fermentation
Mix molasses, corn, water with strain fermentation liquid for fermentation to form primary fermentation material

Stage 3: Secondary Fermentation
Mix pig manure, calcium superphosphate with primary fermentation material, add rice husks or sawdust to adjust texture

Stage 4: Composting and Maturation
Conduct composting fermentation of secondary fermentation material, continue fermentation for 72-96 hours to complete maturation

Product Characteristics and Advantages

• High Organic Matter Content: Over 30% organic matter
• Rich Nutrients: 25-30g NPK per kilogram
• Excellent Physical Properties: Good looseness, easy to apply
• Environmentally Friendly: Effectively solves livestock manure pollution

Global Application Value

This innovative technology provides an economical and effective solution for global livestock waste treatment, integrating it into a complete organic fertilizer production line. The process begins with efficient composting using large wheel compost turner and chain compost turner equipment, followed by advanced granulation through specialized machinery like the double roller press granulator, rotary drum granulator, and various fertilizer granulator systems. This comprehensive approach, utilizing both drum granulation and roller press technologies, not only solves environmental pollution problems but transforms waste into high-quality organic fertilizers. The technology is particularly suitable for large-scale farms, where it can be integrated alongside conventional npk production line operations. The resulting organic fertilizer granulator products help reduce chemical fertilizer dependency, improve soil quality, and make significant contributions to global green agriculture development while creating both economic and environmental benefits.

New type organic fertilizer granulator: Unlocking unique advantages of multi-dimensional upgrades

fertilizer granulator Nov 3, 2025

As the organic fertilizer industry transforms towards high efficiency and green practices, the new type organic fertilizer granulator has developed unique advantages over traditional equipment through technological upgrades. It addresses the pain points of traditional granulators while meeting the demands of modern production and the market.

1.Versatile Raw Material Compatibility

The granulator is compatible with not only conventional raw materials such as livestock manure and straw, but also efficiently processes high-fiber (oil palm empty fruit bunch, mushroom residue) and high-moisture (30%-40%) raw materials that are difficult to form. Optimized extrusion structure and die design prevent blockages caused by fiber entanglement and material adhesion.

2.Low Energy Consumption and Environmental Protection

The new type organic fertilizer granulator uses an energy-saving motor and optimized transmission structure, resulting in low energy consumption. Simultaneously, the fully enclosed design, coupled with a dust recovery device, keeps dust generation during the granulation process to extremely low levels, reducing the impact on the workshop environment and operators.

3.Intelligent and Precise Parameter Control

The granulator incorporates a simple intelligent control system that automatically adjusts parameters such as roller pressure and speed based on raw material characteristics (humidity, particle size, viscosity). This eliminates the need for frequent manual adjustments, ensuring stable production of uniform granules with the required hardness.

4.Improved Granule Quality and Production Efficiency

By optimizing the contact method between the rollers and the die, the new type organic fertilizer granulator increases the material forming rate, reducing raw material waste. The formed granules are not only dense and less prone to breakage, but also form a uniform porous structure, facilitating the slow release of nutrients. Simultaneously, the equipment’s anti-clogging design and easy-to-clean structure reduce downtime for maintenance.

The Comprehensive Advantages of Flat Die Pelleting Machines in Fertilizer Production

fertilizer granulator Nov 3, 2025

High-Pressure Molding Technology

Ensures superior product quality foundation for fertilizer granules compaction, creating durable and consistent pellets that outperform those from alternative methods like drum granulation.

Wide Material Applicability

Expands equipment application scope across various NPK fertilizer production process requirements, handling diverse raw materials with exceptional versatility compared to specialized rotary granulator systems.

Superior Particle Uniformity

Enhances product market competitiveness through consistent sizing, a crucial advantage in NPK fertilizer production technology where particle quality directly impacts application efficiency.

Continuous Production Capability

Guarantees high production efficiency for complete fertilizer production machine operations, seamlessly integrating into NPK production line configurations without bottlenecks.

Moderate Energy Consumption

Reduces operational costs significantly compared to other fertilizer compaction machine alternatives, offering economic advantages throughout the NPK manufacturing process.

Compact Design Efficiency

Optimizes space utilization in fertilizer production machine layouts, requiring significantly less floor space than rotary drum granulator systems while maintaining high output capacity.

Environmental Compliance

Meets sustainable development requirements through dust-free fertilizer compaction operations, aligning with modern NPK fertilizer production technology environmental standards.

Integrated Fertilizer Production Technologies

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Synergistic Advantage Integration

These seven advantages form an organic whole where flat die pelleting machine technology creates synergistic benefits throughout the NPK fertilizer production line. While rotary drum granulator systems excel in specific applications, the comprehensive benefits of flat die pelleting machines in fertilizer granules compaction make them the preferred choice for numerous industry users seeking efficiency, quality, and cost-effectiveness in their fertilizer production machine operations. The technology represents an optimal balance in modern NPK fertilizer production technology, particularly for operations prioritizing space efficiency, energy conservation, and product consistency in their fertilizer compaction processes.

Multi-dimensional adaptation requirements of NPK fertilizer production lines for granulators

fertilizer granulator Nov 3, 2025

As NPK fertilizers transition towards “precise formulation and scenario-based adaptation,” granulators, as the core forming equipment in NPK fertilizer production lines, must adapt to customized production requirements involving multiple formulations, multiple forms, and high uniformity. Their performance directly determines the nutrient stability and application suitability of NPK fertilizers.

1.Formulation Compatibility

NPK fertilizer formulations are flexible and varied, not only with significant differences in nitrogen, phosphorus, and potassium ratios but also often including trace elements and slow-release agents. The specific gravity and viscosity of raw materials vary greatly. Fertilizer granulators must have a wide range of raw material adaptability capabilities, handling both free-flowing raw materials such as urea and potassium chloride, and compatible with composite raw materials containing viscous components such as humic acid and amino acids, avoiding granule agglomeration and uneven forming rates due to differences in raw material characteristics.

2.Precise and Flexible Parameter Adjustability

Different crops and different fertilization scenarios have different requirements for NPK granule size, hardness, and dissolution rate. Fertilizer granulators need to support precise control of granule parameters, allowing for rapid switching of granule diameter (1-5 mm) and hardness grade by adjusting parameters such as die size, extrusion pressure, and rotation speed.

3.Low Loss and Environmental Friendliness

NPK raw materials are mostly chemical or compound materials. During granulation, it is necessary to avoid high temperatures or excessive extrusion that could lead to nutrient loss. The granulator must employ a low-temperature molding process to maximize the preservation of raw material activity. Simultaneously, a closed design must reduce dust emission, minimizing raw material waste and environmental impact.

Flat die pelleting machine: Protecting the activity of microbial agents in low-temperature granulation

fertilizer granulator Nov 3, 2025

The core challenge in biofertilizer production lies in ensuring that the granulation process does not destroy the activity of the microbial agent. Most functional bacteria (such as Bacillus subtilis and Trichoderma harzianum) are significantly inactivated at temperatures above 45°C. The flat die pelleting machine, with its low-temperature granulation capabilities, is a suitable choice for biofertilizer production. Its core advantage lies in its low-friction, no-additional-heat granulation process.

The flat die pelleting machine utilizes a vertical extrusion process, with the rollers and the die in contact with each other over a surface area rather than at points. This results in more uniform force per unit area, less frictional heat generation, and a temperature within the granulation chamber typically maintained at 35-40°C, well below the inactivation threshold of the microbial agent.

Furthermore, the machine does not rely on high-temperature conditioning or hot air conditioning; instead, it achieves granulation solely through the viscosity of the raw material and moderate extrusion, eliminating the need for additional heat input.

Furthermore, the flat die granulator’s speed is adjustable (typically 30-50 rpm). For biofertilizer raw materials with high microbial content, the speed can be reduced to below 30 rpm to further reduce frictional heat generation and ensure a microbial survival rate above 85%.

In practical applications, it is even more effective when used with a “room-temperature binder.” This eliminates the need for heating and dissolving the pellets, while also improving the pelletizing efficiency and complementing the flat die pelleting machine‘s low-temperature characteristics. This ensures the biofertilizer’s core function (microbial activity) while producing uniform pellets, meeting the dual requirements of “functionality” and “commerciality.”