Fertilizer Processing Process with a Disc Granulator

fertilizer granulator Aug 29, 2025

The disc granulator is the core equipment in a fertilizer production line, and its standardized processing flow is crucial for producing high-quality fertilizer.

The first step is raw material preparation. Raw materials include organic materials such as animal manure and plant residues, as well as inorganic materials such as urea and ammonium phosphate. These raw materials must be crushed to reduce particle size for subsequent mixing and granulation. Furthermore, they must be accurately weighed according to the formula to ensure an accurate nutrient ratio, and the humidity must be adjusted to 20%-30% to facilitate granule formation.

The second step is raw material loading. The disc is driven by a motor, and the speed can be set according to the raw material characteristics and the desired particle size. The raw material is evenly distributed on the disc, spread toward the edges due to centrifugal force, and then rises along the inner wall due to friction. After reaching a certain height, it falls back due to gravity, forming a circular motion.
The third step is the application of a binder. As the raw materials circulate, a nozzle above the discsprays the binder onto the raw materials. The binder is usually a natural polymer or inorganic substance. When it comes into contact with water, it develops viscosity, causing the fine particles to bind together. The spraying rate must be precisely controlled: too much will result in oversized and dense granules, while too little will make them difficult to form.

The fourth step is granule growth. As the disc rotates continuously, the already bonded small granules continuously absorb the raw materials, growing larger as they rotate. The collision and friction between the granules also make them more compact. The operator must observe the granule state and adjust the rotation speed and tilt angle promptly. The rotation speed affects the residence time and granule size, while the tilt angle changes the movement trajectory and helps shape the granules.
The fifth step is discharge. When the granules reach the desired size and quality, they overflow from the edge of the disc. Freshly formed granules contain moisture, which requires drying to reduce the moisture content and improve stability and storage performance.

Through this series of rigorous processes, the disc granulator machine transforms various raw materials into high-quality granular fertilizers, providing strong support for agricultural production.

Key Maintenance Points for Disc Granulators in Organic Fertilizer Production Lines

fertilizer granulator Aug 26, 2025

In organic fertilizer production lines, the disc granulator is the core equipment for raw material processing. Its operating condition directly affects product quality and production efficiency. Scientific maintenance can extend equipment life, reduce downtime, and lower costs. The following details maintenance methods from three perspectives: daily, periodic, and long-term.

Daily maintenance requires “cleaning and inspection in tandem.” After each shutdown, promptly clean the discs of residual material to prevent hardening and scratching of the disc surface or increased operating load. Use soft tools to prevent damage to the liner. Also, check the disc’s tilt angle (normally 45°-55°). If offset, correct it using the bracket bolts. Observe the transmission system daily for abnormal noise and check the motor and reducer temperatures. If the temperature exceeds 60°C, shut down the machine for inspection.

Regular maintenance focuses on “component maintenance and lubrication.” Perform a comprehensive weekly inspection, focusing on the meshing of the transmission gears. Adjust and replace any wear or excessive clearance. Inspect the bearing seals to prevent dust intrusion. Replace the bearing grease monthly. Choose a high-temperature, dust-resistant lithium-based grease, filling it to fill 2/3 of the bearing’s internal space. Disassemble and inspect the scraper blade quarterly. If the blade wear exceeds 3mm, polish or replace it. Ensure a 1-2mm gap between the blade and the liner to prevent material adhesion.

For long-term maintenance, maintain “equipment inspection and record keeping.” Perform a comprehensive annual disassembly and inspection. If the liner thickness decreases by 1/3, replace it entirely. Perform a flaw inspection on the frame to identify any weld cracks and repair them. Maintain a maintenance log, recording maintenance times, details, and replaced parts. Use data analysis to predict failures and plan maintenance in advance.

In short, disc granulator maintenance should adhere to the principle of “prevention first, prevention combined.” This involves combining daily cleaning, regular maintenance, and ongoing inspections to ensure optimal equipment operation and a stable and efficient organic fertilizer production line.

The Secrets of the Disc Granulator in an Organic Fertilizer Production Line

fertilizer granulator Aug 25, 2025

At the heart of an organic fertilizer production line, the disc granulator, with its unique operating principle, transforms loose organic raw materials into uniform granules, becoming a key piece of equipment connecting fermentation and finished products. While its seemingly simple operation requires precise control of material properties and mechanical movement, the disc granulator’s core structure consists of a tilted circular disc, the angle of which can be adjusted according to the characteristics of the raw materials. When fermented and pulverized organic materials (such as a mixture of livestock and poultry manure and straw) are fed into the disc, the disc rotates at a constant speed, causing the materials to slide upward along the disc wall under the combined effects of centrifugal force, friction, and gravity. Once they reach a certain height, they fall due to gravity, forming a continuous material circulation.

The key to the granulation process lies in the proper ratio of water to material. As the disc rotates, a spray system evenly applies an appropriate amount of water to the material, forming a moist film on the surface of the organic granules. As the materials collide and squeeze each other during this circulation, the moistened surfaces of the granules attract surrounding fine particles, gradually expanding like a snowball. The operator monitors the granulation process and adjusts the water spray rate and disc speed in real time to ensure uniform particle size.

The disc granulator‘s advantage lies in its adaptability to organic materials. Organic fertilizer raw materials are complex and high in fiber. The gentle rotation of the disc reduces material loss while preserving the activity of beneficial microorganisms. For materials with high humidity, the disc’s tilt angle can be adjusted to reduce the material’s residence time within the disc, preventing sticking and clumping. For dry materials, the disc’s rotation speed can be slowed to prolong agglomeration.

Organic fertilizer granules processed by the disc granulator are not only easy to store and transport, but also enable a slow release of nutrients upon application. With its simple and efficient design, this equipment bridges the gap between raw materials and finished product in the industrial production of organic fertilizer, providing solid technical support for the large-scale development of organic agriculture.

How to improve the granulation rate of the disc granulator

fertilizer granulator Aug 18, 2025

The granulation rate of the disc granulator directly affects the production efficiency and quality of organic fertilizer. When processing organic fertilizer raw materials containing high fiber and impurities, the disc granulator can take the following measures to ensure the uniformity and granulation rate of the particles:

Pretreatment of raw materials: For raw materials with high fiber and many impurities, it is necessary to first remove large impurities and long fibers through crushing and screening to make the material texture more uniform, provide high-quality basic materials for granulation, and reduce granulation failure caused by uneven raw materials.

Adjust the disc parameters: According to the characteristics of the material, reasonably adjust the disc inclination angle and speed. If the angle is too small, the material is easy to accumulate; if the angle is too large, the material residence time is short. Too fast speed will cause the material to be thrown out due to excessive centrifugal force, and too slow speed will make it difficult to fully roll and agglomerate. By repeatedly debugging and finding the appropriate parameters, the material can form a stable rolling track in the disc and promote uniform growth of particles.

Adding binder: By increasing the spraying amount and uniformity of the binder, the bonding of the material can be improved, thereby improving the strength and uniformity of the particles.

Install screening device: Install drum screener machine in the fertilizer production line to separate unqualified particles and impurities in time, return them to the granulator for reprocessing, form a closed loop, reduce the waste of raw materials, and ensure the uniformity of the output particles.

Clean the equipment regularly: Clean the disc and the inside of the disc granulator regularly to prevent the accumulation of impurities from affecting the granulation effect.

Through these methods, the disc granulator can stably maintain a high granulation rate, improve the quality and efficiency of organic fertilizer production, and help produce high-quality granular fertilizer.

Disc Granulator: The Core Powerhouse of Fertilizer Production

fertilizer granulator Aug 12, 2025

In modern fertilizer production lines, the disc granulator acts like a skilled “magician,” transforming various raw materials into perfectly uniform granules. As the core equipment for producing organic fertilizer, organic-inorganic compound fertilizer, chemical fertilizer, and biofertilizer, it is revolutionizing the entire fertilizer manufacturing industry.

When organic fertilizer processed by disc granulator is applied to soil, the organic matter content increases significantly, followed by an increase in soil organic nitrogen. This virtuous cycle not only improves soil structure but also creates an ideal environment for crop growth. The three major advantages of disc granulation—uniform particles, easy moisture control, and high granule strength—make it the preferred choice for fertilizer manufacturers.

The Ingenious Combination of Disc Granulation Line

A complete disc granulation production line is a perfect example of multiple precision equipment working in harmony. Each machine plays an indispensable role in ensuring the excellent quality of the final product:

1. Disc Granulator – The heart of the production line, responsible for transforming mixed materials into uniform granules

2. Horizontal Mixer – Ensures thorough and uniform mixing of various raw materials

3. Drum Screening Machine – Precise grading to ensure consistent particle size

4. Coating Machine – Provides a “protective coat” for granules to prevent caking

5. Multiple Silos Single Weigh Static Automatic Batching System – Accurately controls formula ratios

6. Automatic Packing Machine – Efficiently completes product packaging

Why Choose Disc Granulation Technology?

Compared with traditional granulation methods, disc granulation technology offers incomparable advantages. Its unique tilted rotating design creates ideal rolling motion of materials in the disc, resulting in uniform granulation. Operators can easily control particle size and moisture content by adjusting parameters such as disc inclination angle, rotation speed, and water spray volume to meet different customer requirements.

Even more exciting is the disc granulator’s strong adaptability to raw materials—whether powdered organic matter or chemical materials, it can handle them perfectly. This flexibility allows manufacturers to quickly switch between different product formulations to seize market opportunities.

Investing in a disc granulation production line is not just about purchasing equipment; it’s about injecting strong momentum into your company’s future development. In today’s world of increasingly stringent environmental requirements and booming organic agriculture, this efficient and flexible production system will become your secret weapon to conquer the market!

Main advantages and disadvantages of granulation process and technology of potash fertilizer

fertilizer granulator Oct 21, 2020

The potassium fertilizer is fed into the disc granulator, so that the material gradually piles up by itself until it reaches the required particle size. When the raw materials are piled up on the disc, the binder can be added to support the agglomeration of the materials. Since water will be added to the disc during granulation, additional drying process is required for the fertilizer production line when using this method of rolling raw materials into balls.

Advantages and disadvantages of potash fertilizer granulation

1. The granulation of potash fertilizer has many advantages. This non pressure agglomeration technology can produce particles with smaller density, so that the particles can decompose rapidly. Because most of the potash fertilizer can be used as fertilizer after processing, the ability to decompose and provide nutrition faster is the inducement to choose potash fertilizer particles. It is an ideal product for fertilizer compounds with fixed formula requirements that require rapid nutrient delivery. The round granular potash fertilizer is also easy to handle, and the fineness of potash fertilizer is lower than that of compacted particles.

2. The main disadvantage of potash granulation is that the processing cost is high, and potash particles are considered as high-quality products. Therefore, it is not generally produced like compacted particles. However, it is worth mentioning that the disc granulator is the ideal choice (as opposed to the fertilizer extrusion production process) due to the hardness of potassium salt in the treatment of some potassium salt derivatives.

Granulation technology of potash fertilizer

Disc granulator machine is widely used in the field of potash fertilizer granulation, NPK fertilizer granulator can also be used in the processing of potash fertilizer and a variety of compound fertilizers. The disk type fertilizer granulator is a new type of fertilizer granulator: its granulation rate can reach more than 95%, the main gear of the granulator is quenched with high frequency, the service life is doubled, the disk of the disc pan granulator is of arc structure, lined with high-strength fiberglass, and the bottom of the disk is strengthened by a number of radiation steel plates; it is durable and never deformed. After the potassium fertilizer powder enters into the pelletizing plate, the material continuously rotates and is sprayed by the pelletizing plate, so that the materials stick together to form spherical particles.

Comoparsion with disc granulator and roller press granulator

fertilizer granulator Sep 25, 2020

For organic fertilizer machine, granulation is an indispensiable process link in the production line of organic fertilizer. At present,there are many types of equipment for organic fertilizer granulator. Which one is more suitable for producing the organic fertilizer? The comparsion of disc granulator and roller press granulator.

Through the comparsion of the pelletilizer models, the disc granulator and the roller press granulator are different in the granulation production process, so that users have great differences in the selection of these two models. Today, professional organic fertilizer machine manufacturers give you a detailed disclosure of the disc granulator and the roller press granulator which is more suitable for organic fertilizer granulation. And how to choose the suitable fertilizer granulator machine.

From the perspective of production process, the two kinds of disc granulator have advantages over the double roller press granulator. From the perspective of production process, the processing technologies of disc granulator and opposite roller press granulator are not too complex. For example, the difference between the two equipment in the granulation appearance process is that the particle size of the disc granulator has high degree freedom, good smoothness and roundness, and the particle size of the roller press granulator is relatvely uniform. But there are defects in the appearance. However, it can be made up by the organic fertilizer rounding machine.