Practical methods for reducing raw material waste in ring die granulators

fertilizer granulator Sep 29, 2025

In fertilizer production, raw material waste in ring die granulators primarily stems from substandard pellets and die blockage. Targeted measures can increase raw material utilization by 5%-8%.

First, substandard pellets are recycled. After screening in the pelletizer, broken and large particles are collected and crushed to the required particle size (consistent with new raw material) using a dedicated fertilizer crusher. These particles are then mixed with new raw material at a ratio of 1:5 for re-pelletization. Care should be taken to control the moisture content during mixing. If the moisture content of the recycled material exceeds 18%, it should be air-dried to 14%-16% before mixing to prevent moisture absorption and impact on the overall pelletizing effect. Furthermore, the recycled material mix ratio should not exceed 20% to prevent it from affecting the strength of the new pellets.

Secondly, reduce ring die blockage losses. Before each shutdown, empty the pelletizing chamber of any remaining raw material. Then, introduce a small amount of talcum powder (5-8 kg per ton of raw material). Run the ring die granulator at no load for 5 minutes to allow the talcum powder to adhere to the inner wall of the ring die, forming a protective film to prevent residual raw material from solidifying and clogging. During daily production, check the ring die holes for blockage every four hours. If a small blockage is detected, clear it with a special needle (0.5 mm smaller in diameter than the die hole) to prevent further blockage and material waste.

In addition, polish the edges of the ring die holes every 100 hours to remove burrs and minimize material loss caused by material being stuck in the holes. A magnetic separator should be installed at the pelletizer feed inlet to remove metallic impurities from the raw material, preventing them from damaging the ring die and causing pelletizing problems, further reducing material waste.

Optimizing the linkage between the ring die granulator and front-end raw material processing

fertilizer granulator Sep 29, 2025

The granulation performance of a ring die granulator isn’t solely determined by the equipment itself. Linkage optimization with the front-end crushing, mixing, and conditioning processes can significantly improve production efficiency and pellet quality.
During the crushing process, the raw material particle size must be matched to the ring die aperture. For an 8mm ring die aperture, the raw material particle size should be controlled below 2mm, with a particle size deviation of no more than 0.5mm, to prevent large particles from clogging the die aperture. A grading screen can be installed at the pulverizer outlet, with the screen aperture set to 1/4 the ring die aperture, to ensure uniform particle size and reduce the frequency of granulator downtime for cleaning. If the raw material contains a high amount of coarse fiber (such as straw powder), the pulverizer should use a hammer-type mechanism to enhance crushing efficiency.

The mixing process must ensure uniformity among the raw materials, binders, and nutrients. Uneven mixing can result in insufficient nutrients or insufficient strength in some pellets. A typical requirement for uniformity is a coefficient of variation of ≤7%. This can be achieved by adjusting the mixer speed (30-40 rpm) and mixing time (5-8 minutes). Sampling points should be set up at the fertilizer mixer outlet for hourly testing.
During the conditioning process, the steam supply should be adjusted according to the production speed of the ring die granulator. For example, if the pelletizer processes 5 tons of raw materials per hour, the steam supply should be maintained at a stable 0.3-0.4 tons/hour, monitored in real time by a flow meter. If the pelletizer speed is increased to 6 tons/hour, the steam supply should be increased to 0.45-0.5 tons/hour to prevent the raw materials from being too dry or too wet.
By coordinating the speed and flow of the front-end and pelletizer, production efficiency can be increased by 10%-15%, reducing downtime caused by process disconnects.

Practical optimization directions for energy saving and consumption reduction in fertilizer coating machines

fertilizer granulator Sep 28, 2025

Currently, fertilizer companies are focusing on controlling production costs. Through proper optimization, coating machines can achieve energy savings and consumption reduction, helping companies lower operating costs.

First, energy saving in the heating system. Some coating machines utilize a waste heat recovery design. A heat exchanger is installed at the heat sealing channel outlet to collect the exhaust hot air and preheat the incoming cold air, reducing heat consumption in the heating tubes. This design reduces heating energy consumption and is particularly suitable for companies with continuous production, with significant energy savings over the long term. Furthermore, variable frequency heating tubes are used, which automatically adjust power based on particle flow rate. For example, when production capacity drops to 50%, heating power is also reduced, avoiding high-temperature operation and wasting energy during idle periods.

Second, motor frequency conversion modification. The equipment’s conveyor belts, film reels, and other motors utilize variable frequency control. During production, the PLC system is linked to a particle flow sensor to automatically adjust motor speed based on particle flow rate. Compared to traditional fixed-speed motors, variable-frequency motors can save 10%-12% of electricity, operate more smoothly, and reduce noise by 5-10 decibels, improving the workshop working environment.

Third, film utilization is improved. Some coating machines support adaptive film width adjustment. When changing films of different widths, manual adjustment of the film guide mechanism is eliminated, and the optimal wrapping width is automatically matched. This reduces material loss during the commissioning process. Long-term use can significantly reduce raw material procurement costs, supporting enterprises in reducing costs and increasing efficiency.

How do fertilizer coating machines solve the problem of pellet clumping?

fertilizer granulator Sep 28, 2025

Fertilizer pellets are prone to clumping during storage and transportation. Through scientific design, coating machines address this issue at its root, focusing on the following key aspects.
First, uniform film coating and protection. The coating machine uses vibrating feeders, combined with guide plates, to evenly distribute pellets. Even pellets of varying sizes are diverted by the guide plates, ensuring that every pellet contacts the film. The symmetrical film guide mechanism wraps the pellets from all sides, creating a complete seal that blocks moisture from reaching the pellets and prevents moisture absorption and clumping. Furthermore, the film tension is precisely controlled, with an error within ±2N. This prevents over-tightening of the pellets, keeping them loose and facilitating even spreading during subsequent fertilization.

Second, precise temperature control is crucial. During the heat-sealing stage, the coating machine uses an intelligent thermostat to maintain a stable temperature of 100-150°C and monitors temperature fluctuations in real time, with fluctuations within ±5°C. This ensures that the film adheres tightly to the pellets, forming a strong protective layer. It also prevents high temperatures from damaging anti-caking components in the fertilizer (such as the coating agents in some slow-release fertilizers), preserving the pellets’ inherent anti-caking properties. The hot air circulation design also ensures a uniform temperature throughout the packaging, preventing uneven shrinkage of the film and damaging the protective layer. Even the slightest movement of the pellets within the package prevents the film from rupturing.

Energy-saving optimization of drum fertilizer coolers: Practical methods to reduce operating costs

fertilizer granulator Sep 26, 2025

With the general trend of reducing costs and increasing efficiency in industrial production, energy-saving optimization of drum fertilizer coolers has become a key focus for many companies. In fact, without major equipment modifications, adjusting operating parameters and optimizing system configuration can effectively reduce energy consumption and operating costs.

First, optimize cooling medium recycling. A circulation device can be added to the cooling system. For example, warm water discharged from the jacket can be directed to a cooling tower for cooling and then recirculated back to the jacket for reuse, reducing fresh water usage. For forced air cooling, the warm exhaust air can be cooled through a heat exchanger before being re-circulated into the drum as cooling air, reducing fan energy consumption.

Second, adjust drum fertilizer cooler operating parameters to suit production needs. Parameters can be dynamically adjusted based on the material’s real-time temperature and processing volume. For example, if the material feed temperature is lower than expected, the drum fertilizer cooler speed can be appropriately reduced to extend the material’s residence time and reduce the cooling medium flow rate to avoid overcooling. When processing volume decreases, the drive motor speed can be reduced to reduce motor energy consumption.

Third, add insulation to reduce heat loss. If the drum shell is exposed to air for extended periods, it will dissipate heat into the surrounding environment, increasing the load on the cooling system and causing energy loss. Installing an insulation layer (such as rock wool or aluminum silicate fiber) between the drum shell and the jacket can reduce heat radiation from the shell. Also, insulate the pipes at the feed and discharge ports to prevent the material from absorbing ambient heat during transportation, which would increase the cooling load.

Drum fertilizer coolers offer a variety of applications

fertilizer granulator Sep 26, 2025

Drum fertilizer coolers, with their high efficiency and adaptability, have been widely used in various industrial fields, becoming a powerful cooling tool for material handling.
In the chemical industry, drum fertilizer coolers are crucial equipment for fertilizer and pigment production. For example, the temperature of granular compound fertilizer can reach 80-120°C immediately after pelleting. If directly packaged, it can easily clump, affecting product quality. Using a drum fertilizer cooler, the material temperature can be reduced to 30-40°C, preventing caking and reducing moisture absorption, extending storage life. For heat-sensitive pigments, the drum fertilizer cooler’s indirect cooling methods (such as jacket cooling) prevent discoloration caused by sudden temperature drops, ensuring stable product color.

In the grain processing and feed industries, drum fertilizer coolers solve the cooling challenges of pelleted feed and grain. Pelletized feed is hot after pressing, and direct storage can easily breed microorganisms and cause mold. A drum fertilizer cooler can reduce the feed temperature from over 60°C to near room temperature in 10-15 minutes, while also removing some moisture and extending the shelf life of the feed. For grains such as corn and wheat, if the moisture content is high after harvest, a drum fertilizer cooler can be used in conjunction with drying equipment to cool them down first and then dry them, reducing drying energy consumption.

In-depth comparison of flat die granulators and other pelletizing equipment

fertilizer granulator Sep 24, 2025

Comparison of Ring Die Granulators

In terms of roller design, the rollers of flat die granulators can be enlarged arbitrarily, enhancing the bearing’s pressure-bearing capacity. However, due to the limited diameter of the ring die, the rollers of ring die granulators cannot be enlarged, resulting in a smaller bearing chamber and relatively weaker pressure-bearing capacity. Regarding the mold, flat die granulators are relatively easy to replace and less expensive; while the molds of ring die granulators are complex, difficult to replace and more expensive. Regarding equipment stability, the evenly distributed rollers of flat die granulators ensure smoother operation, while ring die granulators are prone to vibration and noise during operation.

Similarities and Differences between Disc Granulators

Disc granulators form pellets by rolling the material on a rotating disc, while flat die granulators form pellets by squeezing the material between rollers and a flat die. Regarding pellet shape, disc granulators produce irregular spherical pellets, while flat die granulators produce cylindrical pellets. In terms of production efficiency, disc granulators offer higher output but relatively lower pellet strength; flat die granulators offer moderate output but higher pellet strength. In terms of applicable materials, disc granulators are more suitable for viscous materials, while flat die granulators have a wider range of applications.

Analysis of Rotary Drum Granulators

Rotary drum granulators tumble the material in a rotating drum and spray a binder to form pellets. Their structure is relatively complex. Flat die granulators are more compact, using direct extrusion between a roller and a die to form pellets. In terms of granulation quality, rotary drum granulators produce pellets with irregular shapes and uneven sizes, while flat die granulators produce pellets with regular shapes and uniform sizes. In terms of energy consumption, rotary drum granulators consume relatively high energy due to their large size and numerous operating parts, while flat die granulators consume less energy.

Large wheel compost turners: Boosting the organic fertilizer industry’s upgrade

fertilizer granulator Sep 23, 2025

In the development of the organic fertilizer industry, large-wheel compost turners, with their superior performance, have provided a powerful impetus for industrial upgrading. They play an irreplaceable role in improving fermentation efficiency, ensuring fertilizer quality, and reducing production costs.

1.Improving fermentation efficiency and shortening cycle times

The large wheel compost turner’s efficient turning operation allows the material to fully come into contact with air, creating optimal conditions for microbial growth and reproduction. Its unique wheel design and powerful power system enable rapid cutting, spreading, and mixing of the material, allowing aerobic microorganisms to quickly activate in an aerobic environment, accelerating the decomposition and conversion of organic matter.

2.Ensuring uniform composting

Uniform composting is crucial to ensuring the quality of organic fertilizer. The large wheel compost turner evenly turns the material during operation, ensuring that all layers of the material are fully fermented. Organic fertilizer processed by the large wheel compost turner achieves uniform composting and a more balanced nutrient distribution.

3.Reduce production costs and increase profitability

From an energy-saving perspective, some large wheel compost turners utilize advanced energy-saving technologies such as variable frequency drive (VFD). These technologies automatically adjust motor speed and power based on the material’s conditions, avoiding energy waste. Regarding labor costs, large wheel compost turners are highly automated; simply setting parameters allows them to automatically complete the turning process, reducing the need for frequent manual operation and significantly lowering labor costs.

Windrow compost turner: A powerful tool for organic fertilizer production in various scenarios

fertilizer granulator Sep 17, 2025

The windrow compost turner, with its excellent adaptability, plays a vital role in a variety of organic fertilizer production scenarios, making it a valuable tool for projects of varying scales and types.

In large-scale organic fertilizer production bases, the equipment’s high efficiency and scalable processing capabilities are highly valued. These bases typically process large quantities of raw materials. A single windrow compost turner, with a processing capacity of 50-150 tons per hour and a multi-zone rotational operation mode, can meet the base’s continuous, large-scale fermentation needs. Combined with other equipment, it forms a complete production line, enabling the base to achieve industrialized production.

For large-scale farms, the equipment can process raw materials such as livestock and poultry manure and straw locally, eliminating the need for long-distance transportation and reducing costs. Its tracked design allows it to move freely across muddy farm sites, allowing for flexible fermentation operations and transforming farm waste into organic fertilizer, achieving resource recycling while reducing environmental pollution.

At municipal organic waste treatment sites, equipment is crucial for reducing and repurposing organic waste. For dispersed and complex materials like kitchen waste and landscaping waste, windrow compost turners can be used for centralized processing in open-air areas. Through turning and fermentation, they are transformed into high-quality organic fertilizer, contributing to urban ecological and environmental improvements.

In sludge treatment projects, qualified sludge is turned by the equipment to stabilize its properties, eliminate odors and pathogens, and transform it into safe organic fertilizer. This achieves harmless and resourceful sludge treatment, expanding sludge disposal options.

Organic fertilizer production lines contribute to green agricultural development

fertilizer granulator Sep 16, 2025

With the deepening promotion of the concept of green agricultural development, demand for organic fertilizer, an environmentally friendly and efficient type of fertilizer, is growing. By reusing resources such as agricultural waste and livestock manure, organic fertilizer production lines not only reduce environmental pollution but also provide high-quality fertilizer for agricultural production, becoming a key force in promoting green agricultural development.

The core processes of an organic fertilizer production line include raw material fermentation, crushing, mixing, granulation, drying, and screening. The performance of key equipment in these processes directly determines the quality and production efficiency of organic fertilizer. Fertilizer crushers are responsible for breaking fermented raw materials into uniform granules, laying the foundation for subsequent mixing and granulation. Fertilizer mixers ensure uniform mixing of various raw materials, ensuring a balanced nutritional profile in the organic fertilizer. Fertilizer granulators transform the mixed raw materials into granular organic fertilizer that meets specific requirements for storage and application.

Fertilizer dryers and coolers also play an important role in organic fertilizer production. The dryer removes excess moisture from the granulated organic fertilizer, preventing it from clumping and deteriorating. The cooler quickly reduces the temperature of the dried organic fertilizer, facilitating subsequent screening and packaging. These devices work together to form a complete organic fertilizer production process, ensuring efficient and stable production.

The promotion and application of organic fertilizer production lines not only recycles agricultural waste and reduces the damage to the soil and environment caused by chemical fertilizer use, but also improves the quality of agricultural products and contributes to sustainable agricultural development.