Double roller press granulators are an efficient and stable choice for fertilizer granulation

fertilizer granulator Oct 21, 2025

In fertilizer production, the granulation process directly impacts fertilizer application convenience, storage stability, and nutrient utilization. Due to its unique technological advantages, double roller press granulators (commonly known as fertilizer compaction machines) are the preferred equipment for many production scenarios. They can transform a variety of fertilizer raw materials into uniform granules without complex pretreatment, offering both adaptability and practicality.

The operating principle revolves around “physical extrusion.” Crushed and mixed fertilizer raw materials are conveyed between two pairs of counter-rotating extrusion rollers at the core of the equipment. Under pressure from the roller surfaces, the raw materials are compressed into continuous flakes. These flakes then enter a crushing unit, breaking them into irregular particles. Screening equipment then selects the finished product that meets the required particle size.

The core advantages of double roller press granulators lie in their flexibility and energy efficiency. Requiring no binders, granulation relies solely on the raw materials’ inherent physical properties, preserving the natural properties of organic fertilizers or the nutrient purity of compound fertilizers. This eliminates the high-temperature drying step required in traditional granulation. Whether processing organic fertilizer, compound fertilizer, or functional bio-fertilizer, stable granulation can be achieved by simply adjusting parameters such as extrusion pressure and roller speed, providing an efficient solution for fertilizer production.

Rotary drum granulators optimize the nutrient content and application experience of organic fertilizer granules

fertilizer granulator Oct 21, 2025

The core value of organic fertilizer lies in nutrient supply and convenient application, and granule shape directly impacts these two properties. Insufficient nutrient retention reduces fertilizer efficiency, while uneven granules increase the difficulty of field application. By optimizing process details, rotary drum granulators can reduce nutrient loss during the granulation process while creating granule shapes that meet field needs.

In terms of nutrient retention, the rotary drum granulator’s low-temperature granulation is particularly advantageous. Relying on physical tumbling to form granules, the granulator eliminates the need for high pressure and maintains an internal temperature below 35°C, maximizing the retention of active ingredients in the raw materials. Its nutrient retention rate is 5%-8% higher than that of traditional equipment.

In terms of granule application experience, granules produced by rotary drum granulators better meet field needs. On the one hand, the equipment can produce uniform granules with a diameter of 2-5mm by adjusting the drum speed and die aperture, making it easier for farmers to apply fertilizers using seed drills and reducing the unevenness of manual spreading. On the other hand, the moderate hardness of the granules (compressive strength of 10-15N) prevents them from breaking down during transportation and slowly disintegrates in the soil, achieving “slow-release fertilizer supply” and avoiding the root burn caused by concentrated nutrient release.

For organic fertilizer companies pursuing “high quality and low price,” the high-nutrient, easy-to-apply granules produced by the rotary drum granulator can significantly enhance their product’s market competitiveness.

Bio-organic fertilizer equipment selection and maintenance: Helping reduce costs and increase efficiency

fertilizer granulator Oct 20, 2025

For bio-organic fertilizer manufacturers, selecting and effectively utilizing bio-organic fertilizer equipment is crucial for achieving sustainable profitability.

When selecting equipment, consider your production capacity and the characteristics of your raw materials. If your company uses livestock manure as its primary raw material, you should prioritize equipment with strong pretreatment capabilities to avoid high moisture content that could affect fermentation. If your production capacity is under 5,000 tons/year, you can choose small or medium-sized complete sets of equipment to reduce initial investment. If your production capacity exceeds 10,000 tons, you should consider highly automated production lines to reduce labor costs.

Secondly, pay attention to the bio-organic fertilizer equipment’s durability. Equipment for core processes like fermentation and granulation should be constructed of corrosion and wear-resistant materials to withstand the corrosive nature of organic fertilizer raw materials and extend their service life.

Daily maintenance is equally crucial. After use, promptly clean any residual material from components like fermentation tanks and granulators to prevent it from clumping and becoming moldy, potentially contaminating the raw materials during the next use. Regularly check the lubrication of the equipment’s transmission components. Oil depletion can lead to increased wear and tear, increasing the likelihood of failure.

Scientific selection and operation and maintenance can not only reduce the downtime of bio-organic fertilizer equipment and ensure production continuity, but also reduce maintenance costs and improve product qualification rate.

Bio-organic fertilizer equipment: A key link to unlocking green fertilizer production

fertilizer granulator Oct 20, 2025

With the growing adoption of green agricultural development, market demand for bio-organic fertilizer continues to rise due to its ability to improve soil quality and crop quality. Bio-organic fertilizer equipment has become the core link between raw materials and qualified products, directly determining production efficiency and quality.

In the bio-organic fertilizer production process, equipment plays a crucial role throughout. During the raw material pretreatment stage, crushing and mixing equipment refines and evenly distributes raw materials like livestock manure and straw, laying the foundation for subsequent fermentation. The fermentation stage is crucial. Specialized fermentation equipment can maintain a stable fermentation temperature within a range suitable for microbial activity through temperature, humidity, and ventilation control. This not only shortens the fermentation cycle but also effectively eliminates insect eggs and pathogens in the raw materials, reducing the risk of farmland diseases.

Subsequent granulation, drying, and screening equipment determine the product’s form and purity. Granulation equipment can convert loose fermentation materials into granules, facilitating storage and transportation while minimizing nutrient loss. Drying equipment can control the product’s moisture content to below 15%, preventing clumping and mold. Screening equipment can remove impurities and ensure uniformity of organic fertilizer particles.

In addition, high-quality bio-organic fertilizer equipment incorporates environmentally friendly features, such as deodorization and dust removal devices, to reduce exhaust and dust emissions during production, helping companies achieve green production.

Double screws compost turning machine routine maintenance extends equipment life

fertilizer granulator Oct 18, 2025

Double screws compost turning machines are high-frequency equipment for organic fertilizer fermentation. Proper routine maintenance directly impacts their service life and operational stability.

1.Precise Maintenance of Spiral Blades

After each operation, clean any sticky material from the blades (a high-pressure water jet can be used to prevent wear and tear from hardening). Check the blade fastening bolts weekly and tighten any loose bolts immediately to prevent vibration and increased wear. Derust the blades and apply a wear-resistant coating quarterly to extend double screws compost turning machine’s service life.

2.Transmission and Travel System Maintenance

Check the lubricating oil level in the motor and reducer monthly and add specialized lubricant to prevent wear and tear on gears and bearings due to lack of oil. Regularly clean debris from the travel tracks and crawler tracks to prevent jamming. If the double screws compost turning machine deviates, adjust the track parallelism or crawler track tension promptly to ensure smooth movement.

3.Electrical System Safety

Fermentation workshops are characterized by high humidity. Regularly check the seals of motors and control cabinets to prevent moisture-induced short circuits. Clean dust from electrical components, check for loose connections, and tighten terminal blocks. Perform a no-load test run monthly to test the operating status of motors and inverters. Detect and address any anomalies promptly to avoid prolonged downtime caused by electrical failures.

Why are double screws compost turning machines the preferred choice for large-scale organic fertilizer production?

fertilizer granulator Oct 18, 2025

The fermentation process of large-scale organic fertilizer production (processing over 500 tons of raw materials daily) faces the challenges of high processing volume, tight fermentation cycles, and high labor costs. The double screws compost turning machine’s design features perfectly meet these requirements, making it a core piece of equipment for large-scale production.

1.Efficient and Continuous Operation

The double screws compost turning machine continuously moves along the fermentation tank, turning the compost without frequent downtime and adjustments. A single unit can process up to 100-200 tons per hour, meeting the continuous fermentation needs of large-scale production lines and ensuring timely composting.

2.Stable and Uniform Compost Turning Quality

Large-scale production requires high consistency in fertilizer quality. The double screws compost turning machine’s two spirals work in tandem, ensuring uniform mixing of the material, both vertically and horizontally, and ensuring even oxygen exposure. Fertilization temperature fluctuations are controlled within ±3°C, preventing uneven fermentation and causing uneven fertilizer quality.

3.Significantly Reduced Labor Costs

Traditional manual compost turning can only process 5-10 tons of material per person per day. A single double screws compost turning machine can replace 20-30 workers. The machine operates without human intervention (it supports automatic movement and compost turning), eliminating the efficiency fluctuations associated with manual operation.

How can routine drum fertilizer dryer operation and maintenance achieve energy savings and cost reduction?

fertilizer granulator Oct 17, 2025

Drum fertilizer dryers account for 25%-30% of a fertilizer production line’s total energy consumption. Whether routine operation and maintenance are effective directly impacts a company’s operating costs.

1. Accurate Maintenance of Thermal Efficiency

Hot air is the core energy source of a drum fertilizer dryer. The pipes connecting the hot air furnace and the drum must be regularly inspected. Damaged pipe insulation can lead to heat loss (up to 10% or more) and require prompt repair or replacement. Clean accumulated slag in the hot air furnace to ensure complete fuel combustion, increase thermal efficiency to over 75%, and reduce fuel waste.

2. Dynamic Adjustment of Drum Operating Parameters

Adjusting operating parameters based on changes in raw material moisture content can avoid inefficient energy consumption. When the moisture content of the wet material is low, appropriately reduce the hot air temperature and increase the drum fertilizer dryer speed (shortening the dwell time). When the moisture content is high, adjust the opposite direction. This ensures that every unit of energy consumed is used for effective dehydration, avoiding the waste of high energy consumption processing low-moisture materials.

3. Preventive Replacement of Wear Parts

Worn drum seals (such as the seals at the feed and discharge ports) can cause cold air to infiltrate and hot air to leak, increasing the heating load. Check the seals monthly and replace any signs of aging or deformation. Also, regularly inspect the lift plate. If loose or worn, tighten or replace it promptly. Simple preventive maintenance can significantly reduce future failures and energy costs.

Drum fertilizer dryers: Why can they adapt to the different drying requirements of organic and compound fertilizers?

fertilizer granulator Oct 17, 2025

In the fertilizer industry, the drying requirements of organic and compound fertilizers differ significantly. Organic fertilizers require rapid dehydration and fiber clumping prevention, while compound fertilizers require gentle drying to prevent particle breakage.

For drying organic fertilizers, drum fertilizer dryers offer two key design advantages: First, they utilize a “high-speed + multiple lifter” combination. High speed combined with dense lifters effectively lifts fibrous materials, preventing entanglement and clumping. Hot air also directly penetrates the material layer, quickly removing moisture. Second, an anti-stick coating on the inner wall of the drum reduces wet organic fertilizer from sticking to the wall, reducing cleaning frequency and ensuring continuous production.

For drying compound fertilizers, the drum fertilizer dryer emphasizes “gentle temperature control + low speed”: steam heating is used, keeping the temperature between 120-150°C to avoid direct contact with high temperatures that could cause cracking on the particle surface. Furthermore, a reduced drum speed reduces particle friction within the drum, keeping the particle breakage rate below 3%.

Even when processing temperature-sensitive biofertilizers, the drum fertilizer dryer can adapt to these needs through a “low-temperature hot air modification.” This reduces the hot air temperature to 60-80°C, prolonging the material’s residence time. This allows for slow dehydration while maintaining a microbial survival rate above 85%, truly achieving “one device, multiple fertilizers.”

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.