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.

Roller press granulation production line: The preferred solution for high-efficiency granulation

In the chemical, fertilizer, pharmaceutical, and food industries, the demand for granular products is increasing due to their ease of storage, transportation, and use. The roller press granulation production line, with its unique technological advantages, has become the ideal choice for producing high-strength, uniform granules.

This production line utilizes high-pressure extrusion technology to transform powder or fine-grained raw materials into high-quality granules. The equipment is scientifically designed and includes raw material pretreatment equipment, the core double roller press granulator, and optional fertilizer crushers, screening machines, packaging equipment, and a PLC control system. Pretreatment ensures suitable raw material particle size and freedom from impurities; the double roller press granulator extrudes the raw materials into strips or sheets before cutting them into granules; subsequent crushing and screening ensure uniform particle size; the packaging equipment provides automated weighing and packaging; and the PLC control system monitors and adjusts parameters to ensure efficient and stable production.

The granulation process is standardized: from raw material pretreatment, optional mixing and humidity adjustment, to roller press extrusion granulation, crushing and screening, and then optional drying and cooling, and finally packaging and monitoring, every step is precise. The process features are significant: it produces high-density, high-strength granules, meeting high mechanical strength requirements; the granules have uniform particle size, improving product consistency; it has wide raw material adaptability, capable of processing various raw materials such as fertilizers and pesticides; and it boasts low energy consumption, high efficiency, simple operation, and a high degree of automation, reducing manual intervention and ensuring stable product quality.

Whether it’s producing organic fertilizer granules in the fertilizer industry or processing special chemical granules in the chemical industry, the roller press granulation production line plays a vital role, providing efficient and reliable solutions for granular production in various industries.

Turning waste into treasure: A practical guide to making granules from mushroom and herbal medicine residues

With the widespread adoption of environmental protection concepts, mushroom mycelium residue and traditional Chinese medicine residue can be transformed into practical granules for use in agricultural fertilization, biofuels, and other fields. The following are the key steps for efficient granulation.

Raw material pretreatment is fundamental. Fresh mushroom residue has a water content exceeding 70%, so it needs to be air-dried or oven-dried to 30%-40%, with frequent turning to prevent mold. Herbal medicine residue should be screened to remove impurities; hard lumps of roots and stems need to be crushed to a particle size of less than 5 mm using a fertilizer crusher. The two are mixed in a ratio of 3:1 or 2:1 (increasing the proportion of mushroom residue for fertilization, and increasing the proportion of herbal medicine residue for fuel), and a small amount of straw powder or bran is added to adjust the hardness and improve granulation stability.

The granulation process requires attention to operational details. Select a flat die pelleting machine or ring die pelleting machine, and preheat the mold to 60-80℃ before starting to prevent sticking. Feed the material at a uniform speed; if the granules are loose and easily broken, spray a small amount of water (not exceeding 2% of the total raw material); if the hardness is too high, reduce the moisture content. Regularly check the particle diameter and adjust the mold aperture to obtain standard 5-8 mm granules.

Finished product processing and application are also crucial. Newly made granules need to be spread out and cooled to room temperature, and then screened with a fertilizer screener machine to remove broken pieces (broken pieces can be returned to the machine for reprocessing). After cooling, pack them in sealed bags and store them in a dry and ventilated place; the shelf life is 6-8 months. In agriculture, they can be used directly as organic fertilizer to improve soil; they can also be used as feed additives for livestock and poultry (provided the herbal medicine residue is tested for harmful residues); and they can also be used as fuel, burning efficiently with low pollution.

This method not only achieves the resource utilization of waste but also reduces production costs. Whether for farmers or small processing plants, this method can be tried according to actual needs, truly achieving “turning waste into treasure.”

How to improve the operating efficiency of trough-type compost turning machines?

Trough-type compost turners are core equipment in the organic fertilizer fermentation process, and their operating efficiency directly affects the composting cycle, maturation quality, and production efficiency. Many production scenarios experience problems such as insufficient turning, high energy consumption, and frequent equipment failures. However, these issues can be significantly improved through scientific and standardized operation and management.

First, ensure proper raw material pretreatment. The moisture content, particle size, and ratio of composting raw materials are fundamental. The moisture content of the materials should be controlled at 55%-60%, and a fertilizer crusher should be used to adjust the particle size of raw materials such as straw and livestock manure to 2-5 centimeters. Simultaneously, carbon and nitrogen sources should be mixed evenly in the correct proportions.

Second, standardize operating procedures and paths. During operation, a reasonable turning path should be planned, using a “reciprocating progressive” turning method to ensure that the material in each area is fully turned, avoiding missed or repeated turning. The speed of the trough-type compost turning machine should be controlled, and the rotation speed should be adjusted according to the width of the trough and the thickness of the material to ensure that the turning depth meets the standard (generally 30-50 centimeters).

Third, strengthen daily equipment maintenance. Regularly inspect key components of the compost turning machine, such as the blades, tracks, and transmission system. Replace worn blades promptly and tighten loose connections; add lubricating oil as required to ensure smooth operation of the transmission system.

Finally, accurately match the operating frequency. Adjust the turning frequency according to changes in composting temperature. During the high-temperature fermentation period (55-65℃), turning can be performed 1-2 times a day; when the temperature is below 50℃, the frequency should be appropriately reduced. Accurately matching the frequency can meet the oxygen demand of microbial fermentation without wasting energy due to excessive turning.

Flat die pelleting machine: The preferred equipment for small and medium-scale organic fertilizer production lines

In the field of organic fertilizer production, the efficiency and quality of the finished product of an organic fertilizer production line depend critically on the rational configuration of the organic fertilizer production equipment. The fertilizer granulator, as a core piece of equipment, is particularly crucial in this selection process.

As one of the mainstream fertilizer granulators, the flat die pelleting machine plays a core granulation role in organic fertilizer production lines. Pre-treated organic raw materials such as livestock and poultry manure and fermented straw are fed into this equipment after being mixed and adjusted for nutrients by a fertilizer mixer machine. Through the extrusion action of the pressure roller and the flat die, the loose materials are compressed into columnar or flake-shaped granules, without the need for additional large amounts of water or binders, which perfectly suits the characteristics of organic fertilizer raw materials.

The flat die pelleting machine, as a practical organic fertilizer production equipment, has significant advantages. It has a compact structure and a small footprint, making it suitable for small and medium-capacity scenarios with limited space; it has a wide adaptability to raw material moisture content, capable of processing materials with a moisture content of 12%-20%, reducing energy consumption in the pre-treatment stage; it has a high granulation rate, and the finished granules have good strength, meeting the storage and transportation needs of organic fertilizers. In addition, it can be easily connected with supporting equipment such as fertilizer crushers, screener machines, and packaging machines, allowing for the rapid construction of a complete organic fertilizer production line.

Whether processing pure organic fertilizer or producing organic-inorganic compound fertilizer, the flat die pelleting machine can adapt to the needs with its flexible adjustment capabilities. It not only lowers the equipment investment threshold for small and medium-scale organic fertilizer production but also guarantees production efficiency and product quality, becoming an important equipment support for promoting the popularization of the organic fertilizer industry.

Fallen leaves become a source of fertilizer! A practical guide to large-scale composting

The accumulation of fallen leaves in late autumn, often considered a nuisance, has become a valuable, low-cost raw material for organic fertilizer plants. Utilizing fallen leaves for composting not only solves the environmental problem of leaf disposal but also enriches the supply of organic fertilizer raw materials and reduces production costs.

Step 1: Raw Material Collection and Pre-treatment.

Organic fertilizer plants need to collect healthy fallen leaves in bulk from gardens, scenic spots, and other locations, avoiding diseased, moldy, or oil-contaminated leaves. The leaves are transported to the pre-treatment workshop via conveyor belts. Screening equipment is used to remove stones, branches, and other impurities, and then a fertilizer crusher is used to shred the leaves to a particle size of 2-3 centimeters to increase the surface area and accelerate the decomposition process.

Step 2: Scientific Proportioning and Mixing.

Fallen leaves are a carbon source material and need to be combined with nitrogen source materials such as livestock and poultry manure and fermentation agents at a carbon-to-nitrogen ratio of 25:1-30:1. A fertilizer mixer machine is used to uniformly mix the shredded leaves, nitrogen sources, and an appropriate amount of composting microorganisms. Water is sprayed to adjust the moisture content to 55%-60%, providing a suitable environment for microbial fermentation.

Step 3: Large-Scale Fermentation and Management.

The mixed materials are transferred to fermentation tanks, using either windrow or trench composting methods. An organic compost turning machine is used for regular turning to ensure proper aeration of the compost pile. The pile temperature is monitored throughout the process, maintaining a high temperature of 55-65°C for 15-20 days. This kills pathogens and insect eggs while promoting the decomposition of organic matter.

Step 4: Post-Composting Processing.

Once the compost turns dark brown, becomes loose in texture, and has no odor, the composting process is complete. After screening to remove undecomposed impurities, the compost can be mixed with other nutrient materials according to market demand. A organic fertilizer granulator is used to produce granular organic fertilizer, which is then dried, cooled, and packaged before being stored in the warehouse as a qualified commercial organic fertilizer.

A powerful and efficient granulator for multiple applications: The ideal choice for organic fertilizer production

In the field of pellet processing, disc granulators have become popular equipment due to their superior performance, especially in organic fertilizer production. They are a core component of organic fertilizer disc granulation production lines, providing efficient solutions for pellet processing across multiple industries.

This organic fertilizer disc granulator boasts significant advantages, achieving a pelleting rate exceeding 95%. Its main gear undergoes high-frequency quenching treatment, effectively doubling its service life and significantly reducing maintenance costs. Its core component is an adjustable tilting disc with an adjustable tilt angle (30°-60°) and rotation speed (5-30 rpm). The disc’s inner wall is lined with wear-resistant material, allowing it to adapt to materials with different properties—from livestock manure and fermented straw in organic fertilizer production to iron ore powder in the metallurgical industry and cement raw materials in the building materials industry—all can be efficiently converted into pellets.

In the organic fertilizer production process, its operating logic is clear and efficient. First, the organic raw materials are pulverized to 0.1-1mm using a fertilizer crusher. After thorough mixing in a fertilizer mixer machine, they are evenly fed into a disc by a feeding device. Simultaneously, a water spraying device precisely controls the moisture content, maintaining the material’s moisture content at 10%-20%. As the disc rotates, the material is rolled into spheres under centrifugal force and friction. Particles with a sphericity exceeding 80% are screened by a fertilizer screener machine. Qualified products proceed to the subsequent drying stage, while unqualified particles are returned for reprocessing, ensuring stable finished product quality.

Besides organic fertilizer, it is also widely used in the metallurgical, building materials, and chemical industries: in metallurgy, it is used for granulation of mineral powder to facilitate subsequent sintering and smelting; in building materials, it is used to produce cement raw material granules to improve cement quality; and in chemicals, it is used for granulation of catalysts and pigments to enhance product flowability.

Chain crusher: From equipment structure to applications in medium-hard material crushing

In agricultural organic fertilizer production and chemical raw material processing, selecting a suitable and efficient fertilizer crushing equipment is crucial. Chain crushers, with their excellent crushing capabilities for medium-hard materials, have become the first choice for many companies. To choose the right equipment, it’s essential to first understand the structure of the chain crusher and then determine its suitability based on your specific needs.

The chain crusher’s structure and components work together to support its stable operation: a robust steel chassis withstands impact vibrations during crushing, protecting the internal rotor assembly; the rotor’s main shaft, chain, and hammers are the core of the crushing process, directly affecting crushing efficiency; adjustable-aperture screens allow for flexible control of the output particle size to meet different production requirements; the inlet and outlet design ensures smooth material flow, while protective devices safeguard operational safety. Understanding these structural elements helps companies determine whether the equipment meets their production intensity and safety standards during the selection process.

As a high-efficiency fertilizer crusher, two points need to be considered when selecting a chain crusher: First, the characteristics of the material. If it is necessary to process medium-hard materials or materials with a certain degree of moisture and stickiness, the adaptability advantage of the chain crusher can be fully utilized. Second, the production capacity requirements. Combine the parameters such as the motor power and rotor speed of the equipment to match your own production scale. Choosing the right organic fertilizer production equipment can not only improve the efficiency of material pretreatment, but also lay a stable foundation for subsequent production processes, helping enterprises reduce costs and increase efficiency.

Key equipment maintenance for NPK blending fertilizer production lines

The NPK blending fertilizer production line is the core of compound fertilizer production. The condition of its equipment directly affects product quality and production efficiency. Proper, science-based maintenance not only cuts unplanned downtime but also significantly extends equipment life and lowers production costs.

1.Raw Material Pretreatment System

Fertilizer crushers and screening equipment are the front-end critical units. Poor maintenance here causes problems later. Check hammer heads and screen mesh wear weekly. Replace them when wear reaches one-third of the original thickness. Clean out leftover material inside the equipment thoroughly after each day’s production to prevent caking and corrosion.

2.Mixing System

The double axis paddle mixer is the heart of blending. Pay special attention to paddle wear and shaft end seal condition. Measure the gap between paddles and the mixing chamber monthly. Adjust or replace paddles if the gap exceeds 5mm. Replace seals every six months to prevent lubricant leaks contaminating the product.

3.Packaging and Conveying Equipment

Automatic packing scales and belt conveyors directly impact packing accuracy and NPK blending fertilizer production line continuity. Calibrate packing scale sensors monthly using standard weights to keep weighing errors within ±0.2%. Check conveyor idler rollers quarterly for smooth rotation. Seized rollers significantly increase motor load.

Implementing these maintenance steps can greatly reduce equipment failure rates and boost the overall efficiency of the NPK blending fertilizer production line. This provides a solid foundation for stable product quality and controlled production costs.

Building the core strength for efficient and environmentally friendly fertilizer production

Under the general trend of green agricultural development, the demand for organic fertilizers is growing due to their ability to improve soil quality and enhance crop quality. Efficient organic fertilizer production equipment has become crucial for achieving large-scale and standardized production.

Organic fertilizer production equipment comes in a wide variety of types, covering the entire production process. Among them, the organic fermentation compost turning machine is the core of the initial stage. It can regulate temperature and aeration by turning the fermented materials, accelerating the decomposition of raw materials such as straw and livestock manure, preventing odor generation, and laying a high-quality foundation for subsequent production. In the processing stage, the fertilizer crusher can crush the decomposed materials to a uniform particle size, solving the problem of clumping; subsequently, the fertilizer mixer machine can accurately mix various auxiliary materials to ensure balanced nutrition in the organic fertilizer.

The granulation stage relies on organic fertilizer granulators, such as disc granulators and rotary drum granulators, which can process the mixed materials into granules. This not only facilitates storage and transportation but also controls the nutrient release rate. After granulation, the fertilizer dryer and cooler work together to remove moisture from the granules and stabilize their shape. The fertilizer screener machine then screens out products of the qualified particle size, and unqualified particles can be crushed and reused, reducing waste. Finally, the fertilizer packaging machine achieves automated quantitative packaging, improving production efficiency.

When choosing organic fertilizer production equipment, it is necessary to consider your own production capacity needs and raw material characteristics. For example, small farms can choose compact single-unit equipment, while large production enterprises are suitable for complete organic fertilizer production lines. High-quality equipment can not only increase output but also reduce energy consumption and pollution, meeting environmental protection requirements.