fertilizer production line

One-Dry, Two-Cool Process: A Key Core Technology for Upgrading Compound Fertilizer Quality

 “One-Dry, Two-Cool” is a core post-processing technology in the large-scale production of compound fertilizers. Through a closed-loop design of “one precise drying + two gradient cooling,” it precisely controls the moisture content and temperature of the granules, significantly improving the mechanical strength, moisture resistance, and storage stability of the compound fertilizer. It is suitable for various fertilizer types, including NPK compound fertilizers and organic-inorganic compound fertilizers, and is a standard process solution for high-end compound fertilizer production lines.

Core Process Flow and Technical Details

I. Overall Process Link: Wet granules after granulation → First drying (removal of free moisture) → First-stage cooling (rapid cooling and shaping) → Second-stage cooling (precise temperature control and dehumidification) → Finished product screening → Packaging and storage. The entire process achieves the processing goals of “controllable moisture, stable temperature, and dense granules.”

II. Core Configuration and Functions of Each Stage

(I) Primary Drying: Laying the Foundation for Quality

Core Equipment: A Φ2.0×20-meter drum dryer (suitable for 15-20 tons per hour) is selected, employing hot air circulation heating. The heat source can be natural gas, biomass pellets, or steam.

Key Parameters: Drying temperature is controlled at 80-100℃, material residence time is 15-20 minutes, reducing the moisture content of the granulated pellets from 25%-30% to below 12%, with a drying uniformity error ≤2%.

Technical Highlights: The dryer features a built-in spiral lifting plate layout, ensuring thorough material rotation and uniform heating; equipped with temperature and humidity sensors for real-time data feedback, and an automatic adjustment of hot air temperature and drum speed via a PLC system to prevent localized over-drying or incomplete drying.

(II) Primary Cooling: Rapid Shaping and Increased Strength

Core Equipment: A Φ1.8×18-meter counter-current cooler is configured, precisely matched to the dryer’s capacity, employing a room-temperature air counter-current heat exchange design.

Key parameters: Rapidly cools dried granules from 60-80℃ to 35-40℃ in 12-15 minutes, increasing granule strength from 1.5MPa to over 2.5MPa, effectively preventing pulverization during transport.

Technical highlights: The cooler features a built-in air guide device to enhance heat exchange efficiency between airflow and granules; the outlet is equipped with a pulse dust collector to collect dust generated during cooling, with a dust emission concentration ≤10mg/m³.

(III) Secondary Cooling: Precise Humidity Control for Stable Quality

Core equipment: A Φ1.5×15 meter co-current cooler (or fluidized bed cooler) is used as a supplementary optimization step to the primary cooling.

Key parameters: Further reduces granule temperature to room temperature ±3℃, stabilizing moisture content at 8%-10%, while removing trace amounts of residual free moisture from the granule surface, improving moisture resistance.

Technical Highlights: Utilizing a low-temperature, low-wind-velocity design to prevent granule surface cracking; the cooling airflow can be flexibly adjusted according to ambient humidity, adapting to different regional climates and ensuring the finished product is less prone to clumping even in high-humidity environments.

Core Process Advantages and Application Value:

Significantly Improved Quality: Compound fertilizer treated with “one-drying, double-cooling” achieves a granule strength of 2.5-3.0 MPa, reduces moisture absorption by over 40%, and extends shelf life to over 12 months, solving the pain points of conventional processes such as easy pulverization and clumping.

Stable Production Efficiency: The entire process seamlessly integrates with the granulation stage, covering an hourly capacity of 5-30 tons/hour, adaptable to different production lines; high degree of automation, with real-time monitoring of parameters at each stage through a central control system, reducing manual intervention.

Environmentally friendly, energy-saving and highly adaptable: The drying stage adopts hot air circulation technology, which reduces energy consumption by 15% compared with traditional drying processes; the dust removal system in the cooling stage achieves zero dust leakage and meets national environmental protection standards.

Wide Adaptability: It can flexibly adapt to compound fertilizers produced using different granulation processes such as rotary drum granulation and extrusion granulation. Whether it’s high-nitrogen, high-potassium compound fertilizers, or organic-inorganic compound fertilizers, optimal processing results can be achieved through parameter adjustments.

Process Application Precautions:

Parameter Linkage Control: The drying temperature needs to be adjusted in conjunction with the humidity of the granulation raw materials to avoid incomplete drying due to excessive humidity or granule cracking due to excessively low humidity.

Equipment Maintenance Points: The dryer’s inner wall needs to be cleaned regularly to prevent material buildup and maintain heat exchange efficiency. The cooler screen needs to be inspected regularly to prevent damage that could lead to granule mixing.

Raw Material Adaptation Adjustment: For compound fertilizers with high organic content, the drying temperature should be appropriately reduced (≤85℃), and the cooling time extended to prevent the decomposition and inactivation of organic components.

A Critical Stage in High-Quality NPK Fertilizer Production

The “One-Dry, Two-Cool” process is a vital final stage in the manufacturing of high-grade, durable NPK compound fertilizers. This sophisticated post-processing technology ensures the physical integrity and storage stability of the final product, directly impacting its market value and performance in the field.

This drying and cooling system is integrated as the finishing module within a complete npk fertilizer production line. It follows the core manufacturing stages, which begin with precise formulation using an npk blending machine or npk bulk blending machine. The blended materials are then shaped using advanced npk granulation machine technology, via equipment such as an npk fertilizer granulator machine. This entire sequence—blending, granulation, drying, and cooling—forms the complete npk fertilizer manufacturing process. The efficiency and scale of this integrated system, utilizing professional npk fertilizer granulator machine equipment, determine the overall NPK compound fertilizer production capacity and are fundamental to the overall npk fertilizer production technology that defines modern, high-output fertilizer plants.

Therefore, the “One-Dry, Two-Cool” process is not an isolated operation but an essential component that adds critical value within a seamless, technology-driven production chain, transforming raw nutrients into a robust, commercial-grade fertilizer product.

Precise Formulation Empowers African Agriculture! Senegal BB Fertilizer Mixing Production Line

 In July 2025, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. completed the installation, commissioning, and official operation of a BB fertilizer mixing production line tailored for a Senegalese client. This production line focuses on the core needs of precise formulation and efficient mixing of BB fertilizers (blended fertilizers). With scientific equipment configuration, stable operating performance, and customized design to suit local agricultural production, it provides Senegalese fertilizer producers with a large-scale, standardized solution, marking another example of Chinese agricultural equipment supporting the development of green agriculture in Africa.

Core Configuration and Process System of the Production Line

The entire BB fertilizer mixing production line is built around the core process of “raw material storage – precise delivery – uniform mixing – efficient packaging.” Equipment in each stage works in synergy to fully ensure the precision and stability of BB fertilizer production, adapting to the diverse fertilizer formulation needs of the local area.

Raw Material Storage and Conveying Unit

The raw material storage system is equipped with two types of dedicated silos. The main raw material silo is designed with a 4×2.2 meter size and has 5 compartments, capable of storing major fertilizer raw materials such as nitrogen, phosphorus, and potassium. The total storage capacity meets the needs of continuous 8-hour full-load production. The micronutrient silo is 3×2.2 meter with 3 independent compartments, used to store essential micronutrient additives for crops such as magnesium, zinc, and boron. The compartment isolation design avoids cross-contamination between different raw materials, ensuring the purity of the formula.

The material conveying process uses two different lengths of belt conveyors: 17 meters and 9 meters. The conveyor belts are made of food-grade wear-resistant rubber with a non-slip surface treatment, effectively preventing spillage and deviation during material conveying. The equipment is equipped with a variable frequency speed control system, which can precisely adjust the conveying speed according to the feeding requirements of the subsequent mixing unit, achieving dynamic matching between raw material supply and mixing rhythm. The conveying efficiency is increased by 10% compared to conventional equipment, and energy consumption is reduced by 8%.

Core Mixing Unit

The main mixing unit employs a 2×10-meter large-scale twin-shaft horizontal mixer. This equipment is a core component specifically developed for BB fertilizer production. The impellers feature a spiral staggered layout, with the mixing radius covering the entire inner cavity of the drum, ensuring thorough tumbling and cross-mixing of materials during the mixing process. The mixing speed can be flexibly adjusted within the range of 15-30 r/min, and mixing parameters are optimized for different raw material ratios, ensuring a mixing uniformity error of ≤2% for the main raw materials and trace elements, far exceeding the industry average.

The mixer is equipped with intelligent material level monitoring and automatic feeding control. When the material in the drum reaches the set capacity, the raw material conveying system automatically pauses feeding to prevent material overflow or insufficient mixing. After mixing, materials are quickly discharged through the bottom discharge port, reducing the discharge time to 3 minutes per batch, significantly improving production continuity.

Finished Product Packaging Unit

The production line is equipped with four double-bucket scale pellet packaging machines operating in parallel. This equipment uses gravity-based metering principles, coupled with high-precision sensors, controlling the metering error within ±0.1kg, meeting the precise weight requirements for fertilizer packaging in different regions. The packaging machines support rapid switching between multiple specifications such as 25kg, 40kg, and 50kg. Each machine can package up to 80 bags/hour, and the four machines operating together can achieve a packaging capacity of 320 bags/hour, perfectly matching the mixing output efficiency of the production line.

The packaging machines integrate automatic sewing and conveying functions. After metering and bagging, the materials are directly transported to the finished product stacking area via conveyor belt. The entire process is automated, reducing manual intervention and labor intensity while avoiding material loss during packaging. The material utilization rate in the packaging stage reaches 99.5%.

Core Advantages and Adaptability Design of the Production Line

Modular Layout Optimization: The entire production line adopts a modular design. Equipment spacing and layout are designed to fully consider the space conditions of local Senegalese factories, requiring only 600 square meters of floor space. Each equipment unit can be independently disassembled and relocated, reserving space for future capacity upgrades or site adjustments.

Adaptation to Local Raw Material Characteristics: The mixer blade angle and belt conveyor tilt angle have been optimized to address the particle size, moisture content, and other characteristics of local Senegalese fertilizer raw materials. This prevents raw material agglomeration and blockage or conveyor slippage, ensuring stable operation of the production line under different raw material conditions.

Convenient Operation and Maintenance: All equipment is equipped with a bilingual (Chinese and English) operating interface, along with graphical indicators, facilitating quick learning by local operators. Key components adopt standardized designs, and vulnerable parts are highly interchangeable. The company provides detailed maintenance manuals and spare parts supply services, reducing subsequent equipment maintenance costs.

The successful commissioning of this BB fertilizer mixing production line in Senegal not only provides high-quality fertilizer production equipment for local agricultural production but also demonstrates Huaqiang Heavy Industry’s professional capabilities in customized agricultural equipment R&D and overseas project implementation. In the future, the company will continue to focus on the agricultural production needs of different regions, optimize product design and service solutions, provide more targeted fertilizer production solutions for global customers, and help the agricultural industry achieve high-quality development.

Leveraging Blending for Broader Fertilizer Manufacturing

This BB fertilizer mixing line for Senegal demonstrates Huaqiang Heavy Industry’s expertise in providing modular solutions for precise nutrient formulation. While focused on blending, this project is part of a larger ecosystem of fertilizer granulation processes and advanced fertilizer processing machine technology that supports complete fertilizer manufacturing.

The blended product from this line is a key input for various downstream production paths. For clients looking to produce granulated NPK fertilizers, this blended powder serves as the perfect feedstock for the npk manufacturing process. It can be fed into a roller press granulator production line, where a fertilizer compaction machine performs dry fertilizer granules compaction. Alternatively, for a different product shape, the blend could be processed using a rotary drum granulator or an organic fertilizer disc granulation machine to create uniform granules. Each of these fertilizer granulation processes is a specialized application within the broader fertilizer compaction and shaping technology suite, allowing manufacturers to choose the optimal method to transform blended materials into finished products.

Thus, a blending line is not an endpoint but a flexible foundation upon which producers can build more complex, value-added product portfolios, from bulk blends to coated or granulated fertilizers.

Overcoming the challenges of traditional granulation: Roller press granulation production lines drive industry upgrades

In the field of granular product manufacturing, traditional granulation often faces challenges such as insufficient particle strength, uneven particle size, high energy consumption, and failure to meet environmental standards. Roller press granulation production lines, with their optimized design, have become the preferred solution to these problems, widely adaptable to the granulation needs of various industries, including fertilizers, chemicals, and feed.

Traditional fertilizer granulation equipment suffers from limited raw material adaptability and low finished product yield. This is especially true for organic fertilizer granulation, where complex raw materials and fluctuating moisture levels can lead to sticking and clumping. The double roller press granulator utilizes a drying-free, room-temperature granulation technology, eliminating the drying process and resulting in lower energy consumption. It can handle a variety of powder raw materials with moisture content ranging from 8% to 20%, stably granulating both organic fertilizer fermentation materials and special chemical powders.

Balancing environmental protection and efficiency is its core advantage. The dust and noise pollution problems of traditional granulation can be solved by the fully enclosed structure and dust collection device of this production line, effectively controlling dust emissions. Combined with a variable frequency speed control motor and PLC intelligent control system, it enables automated continuous production, reducing manual intervention, improving efficiency, and minimizing operational errors.

Its industry adaptability is extensive: the fertilizer industry can produce organic-inorganic compound fertilizer granules, ensuring uniform nutrient distribution; the chemical industry can process heat-sensitive and corrosive raw materials, preventing deterioration; and the feed industry can produce high-strength granules of additives, preventing breakage during transportation.

Organic fertilizer granulators: Diverse technological approaches enhance fertilizer value

In the organic fertilizer production sector, the diversified development of granulation technology offers a wealth of choices for enterprises of different sizes. From classic rotary drum granulators to innovative new type two in one organic fertilizer granulators, each type of equipment achieves the transformation of powdered raw materials into marketable granules in a unique way.

Rotary drum granulators hold an important position in the industry due to their gentle granulation method. This granulation method is particularly suitable for production scenarios requiring high granule roundness and is easy to integrate with other processes for continuous production. Ring die pelleting machines demonstrate strong forming capabilities. This equipment has wide adaptability to raw materials and can still ensure granule forming quality and output efficiency even when processing organic materials with high fiber content. Flat die pelleting machines are favored by small and medium-sized enterprises for their simple structure and convenient operation. This design effectively controls equipment investment costs while ensuring granulation quality.

In recent years, the emergence of new type two in one organic fertilizer granulators has brought a brand-new solution to the industry. These devices integrate mixing and granulation functions, simplifying the process flow and making them particularly suitable for production sites with limited space.

Different types of granulation equipment have their own characteristics, and companies need to comprehensively consider factors such as raw material characteristics, product positioning, and production scale when making a selection. With the continuous upgrading of the organic fertilizer industry, granulation technology is also constantly improving.

Key equipment for large-scale production of bio-organic fertilizers

Scaling up is a core trend in bio-organic fertilizer production, and efficiency and stability directly determine the competitiveness of the production line. The rotary drum granulator and crawler-type compost turner, as key bio-organic fertilizer equipment, respectively address the efficiency bottlenecks in the fermentation and granulation stages, jointly promoting the efficient and continuous operation of the bio-organic fertilizer production line.

The crawler-type compost turner is the core support for large-scale fermentation. Designed for the large material volume and wide pile area characteristic of large-scale production lines, this bio-organic fertilizer equipment, with its crawler-type walking structure, can flexibly adapt to uneven fermentation sites, achieving deep and wide-ranging turning and mixing. It effectively breaks up material compaction, ensuring ventilation and uniform temperature in the compost pile, enhancing microbial activity, accelerating raw material decomposition, and providing high-quality raw materials for subsequent granulation.

The rotary drum granulator receives the fermented raw materials and is adapted to the needs of large-scale continuous granulation. It boasts advantages such as high processing capacity and strong continuous operation capabilities. In the bio-organic fertilizer production line, the raw materials fermented by the crawler-type compost turner are transported here for uninterrupted granulation, significantly increasing overall production capacity while ensuring stable product quality.

These two pieces of equipment are precisely integrated and work collaboratively, fully leveraging the advantages of large-scale adaptation of bio-organic fertilizer equipment, ensuring efficiency and stability throughout the entire process from raw material fermentation to granule formation.

NPK blended fertilizer quality control: Equipment empowerment in blending and granulation stages

The core of NPK blended fertilizer’s market competitiveness lies in nutrient uniformity and granule stability. Achieving these two key indicators depends on precise control of the two crucial stages in the NPK blending fertilizer production line: blending and granulation. NPK blending machines and BB fertilizer mixers are responsible for establishing the foundation of nutrient uniformity, while NPK fertilizer granulators ensure granule formation quality. Together, they form the quality assurance system of the production line.

The blending stage is the “first line of defense” for nutrient uniformity. NPK blending machines and BB fertilizer mixers need to be selected according to production needs. For large-scale continuous production, NPK blending machines, with their large capacity and high speed, can achieve rapid and uniform mixing of nitrogen, phosphorus, potassium, and trace elements; small and medium-sized production lines or multi-batch, small-volume production are better suited to BB fertilizer mixers, which are flexible in operation and easy to adjust, allowing for quick switching between different formulation schemes, and the mixing uniformity meets conventional production requirements. Regardless of the equipment used, the principle of “fine materials first, then coarse materials, and layered feeding” must be strictly followed to avoid material segregation affecting uniformity.

The granulation stage determines the final quality of the granules. The NPK fertilizer granulator needs to be precisely matched with the blending effect of the preceding stage. After the uniformly blended materials enter the granulator, the granulation speed and pressure need to be adjusted according to the material’s moisture content and particle size characteristics to ensure that the produced granules meet the strength standards and have uniform particle size. If the blending in the preceding stage is uneven, even with precise granulation parameters, fluctuations in nutrient content of the granules will occur.

Solving the challenge of high-fiber cattle manure treatment: An efficient resource utilization solution

Cattle manure, due to its high fiber content, loose texture, and long decomposition cycle, is prone to resource waste and environmental pollution if treated directly. Compared to other livestock and poultry manure, the core of treating high-fiber cattle manure lies in “fiber breakdown first, followed by composting, and then granulation.”

First, pre-treatment and fiber breakdown to reduce subsequent difficulties. Coarse fiber is the core obstacle to treatment. The cattle manure must first be crushed using a high-power fertilizer crusher to reduce the fiber particle size to 3-5 centimeters, while simultaneously screening out stones, weeds, and other impurities. If the moisture content of the cattle manure is too high (exceeding 65%), dry materials such as straw and sawdust can be mixed in to adjust the moisture content to 55%-60%. This balances the carbon-nitrogen ratio (optimizing it to 25:1-30:1) and improves material aeration, paving the way for subsequent fermentation.

Second, enhanced fermentation and composting to degrade coarse fibers. A trough-type compost turner is used for deep turning and mixing. The powerful mixing force of the equipment ensures sufficient ventilation and oxygen supply to the compost pile, maintaining a high temperature of 55-65°C for 25-30 days. The high-temperature environment accelerates microbial activity, efficiently degrading coarse fibers and simultaneously killing pathogens and insect eggs. Specialized composting agents can be added during fermentation to further shorten the composting cycle and improve the degree of decomposition.

Third, shaping and processing to enhance utilization value. The composted cattle manure, with its coarse fibers largely degraded, can be fed into an organic fertilizer granulator(ring die or flat die pelleting machines are preferred, suitable for shaping loose materials) to form high-strength, uniformly sized granular organic fertilizer through extrusion or rolling.

This treatment plan can be implemented by assembling a fertilizer production line with equipment of corresponding specifications based on production capacity requirements. This not only completely solves the problem of treating high-fiber cattle manure but also transforms waste into organic fertilizer rich in organic matter.

Ton Bag Fertilizer Packaging Machine: A Powerful Tool for Large-Capacity Packaging in Mass Production

As the fertilizer and chemical industries develop towards large-scale and intensive production, the demand for large-capacity packaging is increasing daily. Ton bag fertilizer packaging machines (also known as large bag packaging machines), as automated equipment specifically designed for large-capacity packaging, have become core equipment for bulk material packaging due to their precise weighing control, high efficiency, and fully automated operation. They provide comprehensive solutions for enterprises to improve production efficiency, reduce costs, and ensure packaging safety.

The core advantage of the ton bag fertilizer packaging machine stems from its scientifically designed and sophisticated structure, with various systems working together to achieve fully automated operation. The equipment mainly consists of six core parts: a material feeding system, a weighing system, a packaging actuator, a control system, a conveying system, and a dust removal system. The feeding system, comprising a hopper and a screw or vibrating feeder, is responsible for material pretreatment and stable supply, ensuring a continuous and smooth feeding process. The weighing system employs high-precision electronic weighing devices, often equipped with suspended weighing systems, suitable for accurately weighing heavy materials, ensuring that the weight error of each bag is controlled within a reasonable range. The packaging execution mechanism, through the coordinated operation of bag clamping devices, filling mechanisms, and sealing equipment, completes the fixing of the ton bags, material filling, and sealing, ensuring the airtightness and stability of the packaging.

Its workflow is clear and efficient, achieving full automation from empty bag preparation to finished product stacking. First, empty ton bags are precisely transported to the packaging position via a conveyor system and securely fixed by a bag clamping device to prevent displacement or leakage during filling. Then, material is fed into the ton bags at a uniform speed via a feeder, and an electronic weighing system monitors the weight in real time. When the preset weight is reached, the feeding system immediately stops feeding to ensure accurate weight measurement. After filling, the sealing equipment seals the ton bags to prevent leakage during storage and transportation. Finally, the sealed ton bags are transported to a designated area by a conveyor system, where they can be automatically stacked with an automatic stacking system, significantly reducing manual handling.

The ton bag fertilizer packaging machine possesses five core features: high-precision weighing, large-capacity packaging, high automation, strong adaptability, and environmentally friendly design. It is specifically designed for large-capacity packaging needs ranging from 1 ton to several tons, precisely matching the pace of large-scale production. The fully automated operation fundamentally reduces manual operation, lowering labor intensity and labor costs. The equipment is not only suitable for ton bag packaging of various fertilizers but also adaptable to different types of bulk materials such as chemical raw materials and mineral powders, including powdered and granular materials, demonstrating extremely high adaptability. Meanwhile, the dust removal system effectively collects dust generated during the packaging process, preventing environmental pollution and maintaining a clean production environment. The user-friendly human-machine interface makes parameter settings convenient and easy to understand, significantly reducing operation and maintenance difficulties.

In the context of large-scale production, ton-bag fertilizer packaging machines, with their high efficiency, precision, and stable performance, have become the preferred equipment for large-capacity packaging in the fertilizer and chemical industries. Their application not only improves enterprise production efficiency and packaging quality but also promotes the automation and green transformation of industry production models, providing solid support for the back-end support of large-scale production and helping enterprises gain an advantage in fierce market competition.

The Final Link in an Integrated Production Chain

The ton-bag packaging machine represents the essential final stage in a modern, high-volume fertilizer manufacturing operation. Its high-speed, automated operation is critical for efficiently handling the output of a large-scale production facility, completing the value chain from raw material to shippable product.

This packaging unit is designed to receive the finished granules from upstream professional fertilizer manufacturing equipment. For mineral-based products, it would typically be connected to the end of a complete npk fertilizer production line, which includes an npk blending machine for formulation and various granulation options like a disc granulation production line using a disc granulator machine, or a roller press granulator production line. For organic products, it would receive output from an organic fertilizer production line, which might begin with a windrow composting machine and use an organic fertilizer disc granulation machine for shaping. Regardless of the source—be it a bio organic fertilizer production line or a standard NPK line—the high-capacity packager is the common endpoint that prepares the product for bulk logistics, seamlessly integrating into the overall npk fertilizer production process.

Thus, the efficiency of the entire plant, from blending and granulation to packaging, depends on the synergy between each specialized piece of equipment, with the ton-bag packager ensuring the final product is delivered to market efficiently and reliably.

Organic Fertilizer Production Line with Combined Granulation Enables Green Agriculture!

Recently, the organic fertilizer combined granulation production line built by Zhengzhou Huaqiang Heavy Industry successfully completed installation and commissioning, and officially entered large-scale production. This production line innovatively adopts a closed-loop process of “chain crushing + combined granulation + precision drying and cooling,” integrating the entire chain of raw material pretreatment, precise batching, compound granulation, and finished product post-processing. With its efficient and stable operating performance and green and environmentally friendly design concept, it provides a one-stop solution for the resource utilization of organic fertilizer, helping to turn agricultural waste into treasure.

Production Line Full Process Configuration and Core Details

Raw Material Pretreatment Unit: Laying a Solid Foundation for Clean Production

(I) Raw Material Feeding and Crushing

The production line starts with a 2×3 meter loader feeding hopper. Its large-capacity design adapts to the rapid feeding needs of bulk organic raw materials such as livestock and poultry manure, straw, and mushroom residue. The feed inlet is equipped with anti-spillage baffles and impurity filter grids, effectively removing large impurities such as stones and plastics, reducing the risk of equipment failure.

Raw materials are conveyed via a 6-meter belt conveyor to an 800-ton chain crusher. This equipment employs a high-strength chain crushing structure, with wear-resistant alloy blades that achieve a hardness of HRC58 or higher after heat treatment. It can crush large pieces of mature raw materials (particle size ≤100mm) into uniform particles ≤3mm, with a crushing efficiency of 8 tons/hour. The crushed material is then transferred to subsequent stages via a 9-meter belt conveyor. The equipment’s operating noise is controlled below 75dB, meeting industrial production noise standards.

(II) Grading, Screening, and Recycling

The crushed raw materials enter a 1.2×4.0-meter drum screen (document “12X4 meters” specification). This screen uses a single-layer high-precision mesh design, with adjustable mesh apertures to separate substandard coarse particles. Unqualified granules are returned to a 600-ton chain crusher via a 5-meter return conveyor belt for re-crushing, achieving a material utilization rate of 98% and ensuring uniform raw material fineness, thus guaranteeing subsequent batching and granulation. Qualified raw materials are systematically transferred to the batching stage via 7-meter and 9-meter conveyor belts.

Precise Batching and Mixing Unit: Ensuring Nutrient Balance

Equipped with a 4-compartment automatic weighing and batching machine, it can separately store the crushed organic main material, straw charcoal, trace elements, and functional microbial agents. Utilizing variable frequency weighing control technology, it precisely regulates the proportions of each component, with a batching error ≤ ±1%. The organic main material accounts for ≥80%, trace elements are added at 0.1%-0.5%, and functional microbial agents at 0.3%-0.8%, ensuring balanced fertilizer nutrients and compliance with national standards for organic fertilizers.

After batching, the materials are fed into a 400 twin-shaft mixer (described in the document as “400-shaft mixer”) via 11-meter and 13-meter belt conveyors. The equipment employs a counter-rotating impeller design with a wear-resistant coating on the impeller surface. During mixing, the materials undergo strong convection and shearing motion, resulting in a mixing uniformity error of ≤2%. The mixer is equipped with a spray humidification device to precisely adjust the raw material moisture content to 30%-35%, providing suitable humidity conditions for efficient granulation.

III. Core Combined Granulation Unit: Key to Efficient Molding

The mixed materials are temporarily stored in a buffer silo via a 6-meter belt conveyor, a powder feeder, and a 7-meter belt conveyor. The buffer silo stabilizes the material supply, preventing fluctuations in granulation quality due to uneven feeding. Subsequently, the materials are conveyed via an 11-meter belt conveyor to a 1000/1500 combined granulator (described in the document). This equipment is the core of the production line, integrating the advantages of two granulation modes. It adopts a “pre-compression + roll forming” composite process, suitable for organic raw materials with poor adhesion. The granulator features a built-in high-strength double-roller pre-compression device and a drum forming chamber. Loose materials are first pre-compressed into dense flakes, then shaped by the internal lifting plates and collisions within the drum, maintaining a stable granulation rate of over 90%. Particle size is uniformly controlled at 3-5mm, with a compressive strength exceeding 2.0MPa, preventing pulverization and fully meeting the needs of field application and long-distance transportation. The equipment is equipped with an automatic cleaning device to remove adhering materials from the chamber in real time, ensuring continuous operating efficiency.

Post-processing and Finished Product Output Unit: Quality Optimization and Efficient Delivery

(I) Drying and Cooling Solidification

The wet granules after granulation are conveyed via a 13-meter belt conveyor to a 1.8×18-meter dryer (document “18X18 meters” is the standard term). Hot air circulation heating is used, with biomass fuel or natural gas as the heat source. The drying temperature is precisely controlled at 60-80℃ to prevent the inactivation of functional bacteria due to high temperatures. The dryer features a built-in spiral lifting plate design, ensuring uniform heating of the material and reducing the moisture content of the granules from 30% to below 12%, with a drying uniformity error of ≤2%.

The dried granules are then conveyed via 3-meter and 12-meter belt conveyors to a 1.5×15-meter cooler (standard description in document “15X15 meters”). A counter-current cooling process is employed, using ambient air to rapidly reduce the granule temperature from 70-80℃ to room temperature ±3℃, further enhancing granule strength and moisture resistance. The cooling efficiency reaches 9 tons/hour.

(II) Grading, Screening, and Finished Product Storage and Packaging

The cooled granules are then conveyed via a 13-meter belt conveyor to a 1.5×6.0-meter drum screen (standard description in document “15X6 meters”). The double-layer screen design enables precise grading, achieving a 98% pass rate for qualified granules (3-5mm). A small amount of unqualified granules are returned to the granulation front end via a 9-meter return belt conveyor for reprocessing.

Qualified granules are temporarily stored in a sealed silo equipped with dehumidification and ventilation devices to prevent moisture absorption and clumping. The packaging process utilizes an automatic granule packaging scale, supporting rapid switching between 25kg and 50kg sizes, with a measurement error ≤ ±0.2kg and a packaging speed of 100 bags/hour. Simultaneously, the production line is equipped with an automatic powder packaging scale and a dedicated finished product silo, flexibly adapting to the packaging needs of powdered organic fertilizers and achieving dual product output of granules and powders.

Environmental Protection and Auxiliary Units: Green and Stable Operation

Dust Control: Pulse dust collectors are installed in the crushing, screening, and packaging stages, with a total air volume of 15,000 m³/h and a dust collection efficiency of over 99%. The workshop dust concentration is ≤10mg/m³, meeting national environmental protection standards. Collected dust is recycled back to the production process for reuse, reducing material waste.

Intelligent Control: Key equipment on the production line is equipped with operating status monitoring devices that provide real-time feedback on parameters such as equipment speed, material temperature, and material level, facilitating timely adjustments by operators and ensuring stable production. The equipment layout is scientific, with maintenance access provided at each stage, ensuring convenient future maintenance.

Core Advantages and Application Value of the Production Line:

The combined granulation process offers significant advantages, solving industry pain points such as poor cohesion of organic raw materials and low granulation rate. The finished granules are of excellent quality and have stable fertilizer efficacy.

The entire process adopts an environmentally friendly design, with high dust recovery and utilization rates. The drying heat source is compatible with clean energy, meeting the requirements of green agriculture development and contributing to the resource utilization of agricultural waste.

The equipment configuration is compact and reasonable, with a capacity suitable for the needs of small and medium-sized organic fertilizer production enterprises. It can process various organic raw materials and is suitable for multiple scenarios such as livestock and poultry waste treatment and straw resource utilization, with broad market application prospects.

The successful implementation of this organic fertilizer combined granulation production line demonstrates Zhengzhou Huaqiang Heavy Industry’s professional strength in the research and development of complete sets of organic fertilizer equipment. In the future, the company will continue to optimize product performance, providing more customers with customized and environmentally friendly organic fertilizer production solutions, contributing to the green and sustainable development of the agricultural industry.

Building a Complete Fertilizer Production Ecosystem

This successful implementation of a combined granulation line by Huaqiang Heavy Industry underscores the importance of a fully integrated system in modern organic fertilizer manufacturing. It demonstrates how a well-designed organic fertilizer production line is not a collection of isolated machines but a coordinated ecosystem that transforms raw waste into consistent, high-value fertilizer.

The project represents a complete organic fertilizer factory solution. It begins with the crucial upstream process, where effective fermentation composting turning technology ensures the production of high-quality, mature compost. This stable organic matter is then processed through the core organic fertilizer production granulation stage. In this case, a combined granulator is used, but for different product specifications, a dedicated organic fertilizer disc granulation production line could be employed to achieve perfectly rounded granules. For producers focusing on microbial-enriched products, this entire system can be specifically adapted as a bio organic fertilizer production line, integrating the microbial inoculation stage to preserve viable beneficial bacteria throughout processing.

Ultimately, this project illustrates that the key to successful organic fertilizer production lies in seamlessly connecting each stage—from efficient fermentation and precise mixing to advanced granulation—creating a reliable and profitable operation that meets the rigorous demands of today’s agricultural market.

A Powerful Tool for Large-Scale Composting Operations: Crawler-Type Compost Turning Machine

In the field of large-scale organic fertilizer production, the efficiency and stability of the composting fermentation process directly determine the production capacity and profitability of enterprises. Faced with large fermentation sites, diverse organic materials, and complex terrain conditions, traditional turning equipment often struggles to meet the demands of efficient operation. The emergence of the crawler-type compost turning machine, with its unique crawler design and powerful operating performance, has become a core supporting equipment for large-scale composting projects, providing an efficient solution for the resource utilization of large-scale organic waste.

As a heavy-duty self-propelled machine, the most distinctive feature of the crawler-type compost turning machine is its use of rubber tracks as the walking mechanism. This design gives it excellent stability and mobility in soft, rugged fermentation sites. Compared to traditional wheeled equipment, which is prone to slipping and sinking, rubber tracks increase the contact area with the ground, effectively distributing the equipment’s weight. This allows for easy adaptation to uneven terrain and flexible movement in muddy fermentation areas, completely breaking down the limitations of site conditions on composting operations and providing a fundamental guarantee for large-scale windrow composting. Its core function lies in accelerating the maturation of organic materials through three main actions: turning, crushing, and aeration, transforming organic waste such as livestock manure, crop straw, and biochar into high-quality organic fertilizer.

The tracked compost turner has a clear and efficient workflow, achieving full-process adaptation from material pretreatment to fermentation acceleration. The first step is the windrow forming stage, where operators must organize the collected organic waste into long, strip-shaped piles, laying the foundation for subsequent turning operations. Subsequently, the equipment enters the core crawling and turning stage. Operators control the equipment from the cab using simple control devices such as levers, guiding it along the windrows. Simultaneously, the hydraulically driven mixing drum rotates at high speed, its agitating teeth penetrating deep into the pile to lift, thoroughly mix, and disperse the material at the bottom. This process not only turns the material but also achieves two key objectives: first, aeration and oxygenation, providing sufficient oxygen for the aerobic decomposition process, a core requirement for microbial growth and metabolism, directly determining fermentation efficiency; second, breaking up clumps, as the agitating teeth effectively break up hardened clumps in the material, ensuring more uniform mixing and preventing incomplete fermentation or overheating in certain areas, thus guaranteeing stable fermentation quality. The entire operation requires no manual assistance, allowing a single operator to manage large composting sites, significantly improving the operational efficiency of large-scale composting projects.

In large-scale composting operations, the core features and application advantages of tracked compost turners are particularly prominent. High capacity is one of its core competitive advantages. This equipment can process 500-1500 cubic meters or even more organic waste per hour, easily matching the large-scale production needs of industrial composting plants and large farms, significantly shortening the overall fermentation cycle. Stability and adaptability further amplify its application value. The rubber track design allows the equipment to operate stably in various complex terrains, while its wide adaptability to materials allows it to process various organic wastes such as livestock manure, agricultural straw, and biochar, reducing application limitations. In terms of practical application benefits, this equipment not only accelerates the conversion of organic waste into nutrient-rich compost and improves production efficiency, but also improves compost quality through uniform turning, resulting in more uniform organic fertilizer with more balanced nutrients. At the same time, the simple operation reduces labor costs, and the self-propelled design reduces auxiliary operation time, comprehensively reducing costs and increasing efficiency for enterprises.

With the rapid development of organic agriculture and the environmental protection industry, the demand for large-scale organic waste treatment is increasing daily. Tracked compost turners, with their core advantages of high capacity, strong stability, and wide adaptability, as well as their application value in improving efficiency, enhancing quality, and reducing costs, have become indispensable key equipment for large-scale composting projects. They not only promote the industrial upgrading of organic fertilizer production but also help achieve the harmless treatment and resource utilization of organic waste, providing solid technical equipment support for the development of ecological circular agriculture.

A Keystone in Modern Biofertilizer Manufacturing

The crawler-type compost turning machine is a foundational component of industrial-scale fermentation composting technology for organic fertilizer. As a highly efficient self propelled compost production machine, it is specifically engineered to accelerate the organic fertilizer fermentation process for windrow systems, providing the essential aeration and mixing that drive microbial decomposition.

This machine is part of a diverse family of solutions within the broader fermentation composting turning technology sector. Depending on the scale and layout of the operation, producers might choose alternative equipment such as a high-capacity large wheel compost turning machine for wide rows, a precise double screws compost turning machine for controlled mixing, or implement a trough-type aerobic fermentation composting technology system for enclosed environments. Each serves the same vital function: transforming raw organic matter into stable, mature compost. This high-quality compost is the primary raw material for the subsequent equipments required for biofertilizer production, which further process it into commercial-grade organic or bio-organic fertilizers.

Thus, the tracked turner is not a standalone solution but a critical first-stage processing unit that enables the efficient, large-scale creation of the organic base upon which the entire biofertilizer industry depends.