What are the advantages of flat die granulators in specialty fertilizer production?

fertilizer granulator Oct 16, 2025

As the fertilizer industry moves toward precision and functionalization, demand for specialty fertilizers such as organic-inorganic compound fertilizers, functional biofertilizers, and fertilizers for fruits and vegetables has surged. With its unique design, flat die granulators have become a powerful tool for specialty fertilizer production.

1. Suitable for the granulation of multi-component raw materials

Specialty fertilizers often require the mixing of multiple raw materials, each with significantly varying density and viscosity. The flat die granulator’s low-speed extrusion prevents raw material separation caused by high-speed rotation, allowing the multi-component raw materials to fully blend during the extrusion process, ensuring uniform nutrient content in each granule.

2. Low-temperature granulation ensures the preservation of functional ingredients

The core requirement for functional biofertilizers (such as those containing Bacillus subtilis) is to preserve the activity of the inoculum, which can be inactivated by high temperatures. The flat die granulator generates minimal frictional heat during the extrusion process, enabling low-temperature granulation without the need for additional cooling equipment, thus ensuring the fertilizer’s functional effects.

3. Flexible Adaptation to Special Particle Shape Requirements

Specialty fertilizers often require customized granule shapes (for example, fruit and vegetable fertilizers require oblate granules to prevent rolling during watering). The flat die granulator can be customized with various die hole shapes (round, oblate, and square). Changing the die takes only 30 minutes, eliminating the need to adjust the drive system. This allows for quick changes in granule shape to meet diverse market demands.

Flat die granulator: Proper raw material pretreatment increases granulation efficiency by 30%

fertilizer granulator Oct 16, 2025

For small and medium-sized fertilizer companies using flat die granulators, poor granulation results and frequent malfunctions are often not due to equipment issues, but rather to inadequate raw material pretreatment. Flat die granulators are more sensitive to raw material conditions than other granulation equipment. Proper pretreatment not only improves pellet formation efficiency but also reduces equipment wear and tear.

1. Precise Control of Particle Size

The die holes of flat dies typically have a diameter of 2-5mm. If there are still lumps larger than 1mm in the raw material, they can easily become stuck in the die holes, causing blockage and interrupting discharge. It is recommended to add a “fine screening” step before feeding to ensure uniform raw material particle size. This not only reduces the risk of die blockage, but also ensures more complete compression of the raw material within the die holes, resulting in more stable pellet hardness.

2. Dynamic Control of Moisture Content

The flat die granulator is optimally suited for raw material moisture contents of 18%-22%. However, in actual production, the moisture content of fermented organic fertilizers often fluctuates seasonally. If the moisture content is too high, the raw material will easily stick to the flat die surface, requiring frequent machine stops for cleaning. If the moisture content is too low, the pellets will be loose and fragile. During the pretreatment stage, the moisture content can be monitored in real time. If it is high, hot air drying can be used; if it is low, a small amount of spraying can be used to replenish moisture to ensure the stability of the raw material.

3. Targeted Optimization of the Conditioning Stage

Adding conditioning agents tailored to the specific characteristics of the raw material can significantly improve pelletizing results. For example, when processing pure straw fiber raw material, adding 3%-5% bentonite as a binder can enhance the raw material’s viscosity. When producing organic-inorganic compound fertilizers, adding 1%-2% humic acid can improve moldability and increase the added value of the fertilizer.

Key Points for Green Operation of Ring Die Granulators Under Environmental Protection Requirements

fertilizer granulator Oct 15, 2025

With increasingly stringent environmental protection policies, fertilizer companies must not only maintain production capacity but also meet the green requirements of “low dust, low noise, and low energy consumption.” As the core equipment in the production line, the ring die granulator’s operation directly impacts environmental performance.

First, dust source control. The ring die granulator’s fully sealed feed and discharge structure reduces dust spillage. The feed inlet utilizes a “soft-connected sealing sleeve” to prevent raw material leakage during conveying; the discharge outlet connects to a “sealed cooler,” ensuring pellet cooling within a sealed space.

Second, effective noise reduction is required. Mechanical friction and raw material impact during operation of the ring die granulator can easily generate noise, impacting the workshop environment. During routine maintenance, regularly checking the lubrication of the roller bearings and tightening the bolts connecting the ring die to the frame can reduce operating noise to below 75 decibels.

Third, optimizing energy consumption is essential. Green operation of the ring die granulator can be achieved through variable frequency speed regulation. Adjust the ring die speed according to the raw material characteristics and production needs to avoid the motor idling at full load; at the same time, regularly clean the residual raw materials in the ring die hole to ensure that the equipment always operates in the “high efficiency and low consumption” range.

Ring Die Granulator: How to Improve the Commercial Quality of Granulated Fertilizers?

fertilizer granulator Oct 15, 2025

For fertilizer companies, the commercial quality of granular fertilizers directly impacts their market competitiveness. Uniform particle size, a full appearance, and stable hardness make products more attractive on shelves and reduce breakage and loss during transportation. The ring die granulator, with its targeted design, is a key piece of equipment for improving the commercial quality of fertilizers.
First, precise control of particle size uniformity is crucial. The ring die of the ring die granulator utilizes a precision drilling process, ensuring that all die holes have a diameter tolerance within ±0.1mm. This results in highly consistent granule diameters after extrusion. Furthermore, the precise matching of the machine’s blade pitch and die speed ensures uniform granule length, fundamentally eliminating the problem of “mixed large and small granules.”

Second, optimization of granule appearance and gloss is crucial. Ring die granulators precisely control the amount of steam added (or ambient temperature binder) to achieve a “wet and sticky” state before extrusion. This results in a smoother pellet surface after extrusion. Some equipment also briefly polishes the pellets, giving them a fuller, glossier appearance and significantly improving market quality.
Finally, the ring die granulator ensures consistent pellet hardness. The ring die granulator’s adjustable roller pressure design allows for adjustments in extrusion force based on fertilizer type. Combined with the appropriate ring die compression ratio, pellet hardness tolerance is controlled within ±10%, meeting transportation requirements while ensuring optimal disintegration during application.

How can a horizontal crusher “flexibly adjust” to address fluctuations in fertilizer raw materials?

fertilizer granulator Oct 14, 2025

Raw material fluctuations are common in fertilizer production. For example, the raw material for organic fertilizer may switch from “dry straw” to “wet bacterial residue,” or the raw material for compound fertilizer may change from “phosphate rock powder” to “potassium sulfate granules.” These fluctuations in raw material hardness, moisture content, and viscosity can lead to decreased pulverization efficiency and substandard particle size if the horizontal crusher cannot flexibly adjust.

1. Speed Adjustment to Adapt to Hardness Changes

When switching from “soft fibrous materials” (such as dry straw, which has low hardness) to “hard mineral materials” (such as phosphate rock, which has high hardness), the variable frequency motor can adjust the impeller speed to avoid excessive pulverization and dust generation. For hard materials, high speeds enhance impact and shear forces, ensuring effective pulverization. This allows adaptation to different hardness levels without changing equipment.

2. Gap Adjustment to Address Viscosity Differences

When processing high-viscosity raw materials (such as wet mushroom residue with a moisture content of 28%), a small gap between the impeller and the chamber wall can easily cause the material to stick to the wall. When processing low-viscosity raw materials (such as dry cake), a large gap will reduce grinding efficiency. A horizontal crusher can adapt to different viscosities, reducing sticking and ineffective grinding.

3. Screen Replacement to Adapt to Particle Size Requirements

Different fertilizer products require different particle sizes (organic-inorganic compound fertilizers require 3-5mm, powdered fertilizers require 0.8-1.2mm), and fluctuations in raw material quality may make the original screen size unsuitable. A horizontal crusher can quickly change screens with different apertures (commonly 0.5-10mm), flexibly meeting the particle size requirements of different raw materials and products.

Daily maintenance of horizontal crushers in the fertilizer industry

fertilizer granulator Oct 14, 2025

As the core power equipment of a fertilizer production line, a horizontal crusher requires adequate daily maintenance, which directly impacts its operating efficiency and service life.

1. Regular Inspection of Core Components

Stop the horizontal crusher weekly to inspect the condition of the impellers. If the wear-resistant teeth at the end of the impellers are worn more than 1mm or cracked, they should be replaced promptly. Check the main shaft bearings monthly by touching the bearing seat. If the temperature exceeds 60°C or there is any abnormal noise, disassemble and clean the bearings and refill with high-temperature resistant grease. Check the grinding chamber liner quarterly. If the liner is severely worn or dented, replace it to ensure a tight seal.

2. Thorough Cleaning

After each production run, the pulverizing chamber must be cleaned of any residual material (especially after handling high-moisture materials). Compressed air or a special scraper can be used to prevent material agglomeration and corrosion of the chamber walls and impellers. The horizontal crusher casing and motor cooling holes should be cleaned monthly to prevent dust accumulation that could affect motor heat dissipation and cause overload and burnout. Quarterly, the seals at the feed and discharge ports should be inspected. If any seals are aged or deformed, they should be replaced promptly to minimize dust leakage.

3. Standardized Operations to Reduce Losses

Adjust the feed rate strictly according to the characteristics of the raw materials to avoid overloading. If the raw materials to be pulverized need to be changed (for example, from fibrous to hard materials), the residual material in the chamber must be cleared before adjusting the impeller speed and screen. Spare parts should be kept on hand to avoid prolonged downtime due to a shortage of parts in the event of a malfunction.

Chain crusher: Suitable for processing a variety of fertilizer raw materials

fertilizer granulator Oct 13, 2025

In the fertilizer industry, raw materials used for different fertilizer types vary significantly. Organic fertilizers require the processing of straw and fermented livestock and poultry manure, while compound fertilizers often involve hard particles such as phosphate rock and potassium chloride. Chain crushers, with their versatile adaptability, can easily handle the crushing needs of these diverse raw materials.

For fibrous raw materials such as straw and rice husks, common in organic fertilizer production, the chain of a chain crusher uses high-speed impact to sever the fibers, eliminating the “fiber entanglement” problem common in traditional hammer mills. The resulting pulverized material is loose and easy to mix with other raw materials for fermentation. For cake-based raw materials (such as soybean meal and rapeseed meal), the chain’s shear force effectively breaks up lumps and produces uniform crushed particles, eliminating excess powder and reducing raw material waste.

Even for hard mineral raw materials used in compound fertilizer production, chain crushers with high-strength alloy chains can achieve crushing through continuous impact, and the equipment’s lining is made of wear-resistant material, extending its service life.

In addition, it has a higher tolerance for the moisture content of raw materials. Wet materials with a moisture content of about 20% can be directly crushed without additional drying, which greatly simplifies the organic fertilizer production process and reduces the company’s initial investment.

Choosing the right chain crusher for the fertilizer industry

fertilizer granulator Oct 13, 2025

For fertilizer manufacturers, choosing the right chain crusher not only reduces production costs but also ensures stable production line operation. Many companies often make the mistake of focusing solely on throughput when selecting a grinder.
First, consider compatibility with the raw material characteristics. If primarily processing lightweight fiber materials like straw and rice stalks, focus on the density and toughness of the equipment chain to prevent fiber entanglement. If crushing hard, cake-like materials like soybean meal and cottonseed meal, emphasize chain material strength to ensure impact resistance.
Second, consider whether the processing capacity matches the production line. Calculate the equipment’s hourly throughput based on your daily production capacity, allowing for a 10%-15% margin to prevent overload due to feed rate fluctuations.

Finally, consider controllable crushing particle size. Different fertilizer products have different particle size requirements. For example, granular fertilizers require crushing to 2-5mm, while powdered fertilizers require finer particles. When selecting a chain crusher, confirm whether the equipment can adjust the particle size by adjusting the screen aperture and drum speed.
Finally, consider energy consumption and environmental protection. Prioritize equipment that matches motor power and processing capacity to avoid energy waste caused by a “big horse pulling a small cart.” Also, focus on the chain crusher sealing performance to minimize dust spillage during the crushing process and meet environmental protection requirements in the fertilizer industry.

Technical adaptation strategies for organic fertilizer production lines in low-temperature environments

fertilizer granulator Oct 11, 2025

The impact of low temperatures in northern winter on organic fertilizer fermentation efficiency has necessitated low-temperature adaptation of organic fertilizer production lines. Key measures focus on maintaining fermentation temperature and raw material pretreatment.

In terms of bacterial strain selection, production lines must utilize low-temperature-tolerant composite inoculants to ensure viability at temperatures between 5-15°C (with a viable bacterial count retention rate exceeding 85%), shortening fermentation start-up time to within 24 hours.

In terms of workshop design, insulation and a photovoltaic-assisted heating system are required to maintain the fermentation room temperature above 10°C through solar heating. Some organic fertilizer production lines also utilize closed fermentation chambers, utilizing bioheat generated during the fermentation process to maintain a constant internal temperature (temperature fluctuations within ±3°C).

In raw material pretreatment, to address the difficulty of raw materials such as straw degrading at low temperatures, production lines incorporate a pre-crushing step (crushing the raw materials to 0.5-1 cm) and use hot water humidity control (controlled at 30-40°C) to raise the initial raw material temperature and ensure fermentation efficiency.

These adaptation measures have increased the capacity utilization rate of organic fertilizer production lines in northern winter from the original 50% to over 80%, and the organic matter content of finished fertilizers has stabilized at over 55%, effectively ensuring the supply of fertilizers for agricultural production in northern winter.

Moisture proofing adaptation techniques for organic fertilizer production lines

fertilizer granulator Oct 11, 2025

During the rainy season, humidity is high, and organic fertilizer raw materials easily absorb moisture and clump together. This can lead to production line blockages and slow fermentation if not carefully considered. In fact, smooth production can be achieved by making three moisture-proof adjustments to the organic fertilizer production line.
Include a moisture control step in the pretreatment process. Install a small drying device before the pulverizer to reduce the moisture content of raw materials such as straw and manure from over 65% to 55%-60%, preventing wet materials from sticking to the pulverizer blades.
Add a moisture detector to the mixer outlet. If the raw materials are too wet, it will automatically prompt the addition of dry sawdust, eliminating the need for empirical judgment and reducing the risk of subsequent granulation blockages.

The fermentation process requires both rain protection and ventilation. Build a simple canopy over the fermentation pile to prevent rain from directly falling on it. After each turning, place a layer of dry straw on the surface of the pile. This absorbs moisture and allows for ventilation inside the pile, preventing stagnation. If the humidity in your workshop exceeds 80%, install several industrial fans in the fermentation area to improve air circulation and prevent the fermentation cycle from being extended during the rainy season.
The pelletizing process requires timely cleaning. During the rainy season, raw materials are prone to sticking to the pelletizer’s ring die. Every two hours of production, stop the fertilizer granulator and use a special scraper to clean the sticky material from the die holes. Don’t wait until it accumulates.
The conveyor belt at the discharge port can be covered with an anti-stick mat to prevent pellets from sticking, reducing cleaning time. With these adjustments, your organic fertilizer production line can operate as efficiently as normal during the rainy season, eliminating the need to worry about wet raw materials and slow fermentation.