Benefits of Using a Disc Granulator in Organic Fertilizer Production Lines

fertilizer granulator Sep 11, 2025

Among the core equipment in organic fertilizer production lines, disc granulators are the preferred choice for many companies, especially small and medium-sized production lines, due to their strong adaptability, high-quality granulation, and convenient operation. They significantly improve production efficiency and product quality.

The disc granulator‘s most prominent advantage is its excellent granulation performance. Its unique disc structure uses the synergistic effect of centrifugal force and gravity to create a stable “rolling granulation zone” within the disc, achieving a granulation rate exceeding 90%, far exceeding that of some extrusion granulation equipment. The resulting granules are not only highly rounded and smooth, but also uniform in size (typically controlled within 2-5mm). This not only prevents nutrient loss due to granule breakage during transportation, but also meets the granule shape requirements of mechanized fertilization, significantly enhancing product market acceptance.

Secondly, it offers excellent raw material compatibility. Organic fertilizer raw materials come from a wide range of sources, from decomposed chicken manure and cow dung to straw powder and mushroom residue, with widely varying composition. The disc granulator can easily adapt to different raw material characteristics by adjusting the disc inclination angle (45°-55°), rotation speed (15-20 rpm), and feed rate.

Disc granulators also offer significant advantages in terms of operation and cost. The device boasts a simple structure, with the disc and drive system as its core components. Routine maintenance requires only regular inspections of bearing wear and disc flatness, resulting in maintenance costs approximately 30% lower than those of a drum granulator. Furthermore, its energy consumption is low, with a single unit consuming approximately 5-10 kWh per hour. This makes it suitable for the production needs of small and medium-sized production lines (with a single unit capable of flexibly adjusting daily output to 5-20 tons). The investment threshold is significantly lower than that of large-scale drum granulation equipment, enabling companies to quickly achieve operational and profitability.

Disc granulators also align with green production trends. Their enclosed design reduces dust emission from raw materials, and combined with a spray moisturizing system, they effectively control dust pollution during the production process. Some units can also be integrated into the production line’s waste heat recovery system, further reducing energy consumption. For organic fertilizer production companies that pursue high efficiency, economy and environmental protection, disc granulator is undoubtedly the ideal choice to balance quality and cost.

How does a rotary drum granulator work in an organic fertilizer production line?

fertilizer granulator Sep 10, 2025

In an organic fertilizer production line, a rotary drum granulator is the core equipment for converting powder into granules. Its operating principles revolve around material agglomeration and granulation. Through a combination of physical and mechanical processes, it transforms fermented organic raw materials into granular products that are easy to store, transport, and apply.

After the equipment is started, fermented and pulverized organic materials (such as decomposed cow dung and straw powder) are introduced into the inclined drum of the rotary drum granulator along with an appropriate amount of binder (usually water or starch solution). The drum rotates at a constant speed of 10-15 revolutions per minute. Lifting plates on the inner wall of the drum continuously scoop up and drop the material, creating continuous agitation and mixing. During this process, the binder moistens the surface of the raw material particles, forming a sticky interface and paving the way for particle agglomeration.

As the drum rotates continuously, the material gradually forms tiny “master particles” under the combined effects of gravity, centrifugal force, and friction. These masterbatch particles continuously roll within the drum, attracting surrounding powdered raw materials like a snowball, gradually increasing in size. Furthermore, the drum’s tilt angle (typically 3-5°) ensures that the material moves slowly toward the discharge end, preventing accumulation within the drum and ensuring that each particle is evenly stressed and grows.

To ensure pellet quality, the drum granulator also uses a temperature control system to regulate the drum temperature (typically between 40-60°C). This prevents excessive moisture content from causing pellet adhesion, while also preventing low moisture content from affecting agglomeration. When the pellets reach the preset size (typically 2-5mm, controlled by adjusting the drum speed and residence time), they are discharged from the discharge end and enter the subsequent drying and cooling processes.

Compared with other granulation equipment, the advantages of the rotary drum granulator are large processing capacity (a single device can produce 50-200 tons of fertilizer per day), high particle strength (compressive strength can reach 15-30N), and strong adaptability to raw materials. Whether it is poultry and livestock manure, straw or mushroom residue, it can be granulated stably. It is an indispensable key equipment in large and medium-sized organic fertilizer production lines.

Several basic granulation methods of NPK fertilizer

fertilizer granulator Dec 9, 2020

Mixing granulation of different NPK fertilizers is the core of compound fertilizer processing. Fertilizer production line generally uses the following methods to granulate:

1. Extrusion granulation is a method of making dry powder or wet powder containing binder into cylindrical, spherical or sheet shape by mechanical processing such as extrusion, roller extrusion or pressing. The technology of dry granulation is used in the flat die pellet mill, the ring die pelleting machine and the double roller granulator.

2. Agglomerating granulation, which is under the action of rotation, vibration, agitation and so on, makes the wet powder in motion agglomerate. Or use the fluidized bed to make the material obtain the cohesive force by supplying the spray liquid binder) so as to grow into the appropriate particles. This method is used in disc granulator and rotary drum granulator.

3. Crushing granulation, which is to crush the block material into particles of appropriate size.
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4. Melt granulation, which is a method of cooling and hardening molten liquid for granulation.

5. Spray granulation. It is a method of directly forming granules after concentrating the solid in the liquid.

6. The method of crystallization and granulation in liquid phase is to make materials precipitate and crystallize in liquid phase, at the same time, agglomerate into spherical particles by the action of liquid bridging agent and agitation. This technology is widely used in pharmaceutical industry. Because the shape of the particles is spherical, it is also called spherulite granulation, which is called spherulite granulation for short. Spherulite is a kind of spherical particle formed by the crystallization and aggregation of pure materials. It has good fluidity, filling and compression formability. In recent years, the technology has been successfully applied to functional pellets.

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3-5 t/h Bio-organic Fertilizer Projects and Machinery

fertilizer granulator Dec 9, 2020

Production Conditions of 3-5 t/h Bio-organic fertilizer manufacturing process

Using livestock and poultry manure and agricultural straw waste, the production technology of bio-organic fertilizer can reach 3-5 tons per hour.

3-5 t/h Organic Fertilizer Production Process

1. Floor stacking composting, using windrow turning machine. Or the fermentation tank to put the material, using the trough compost turning machine.
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2. Sprinkle fungicides evenly into the fermentation products, mix the materials with the dumper, and compost to achieve the purpose of heating, smelling, maturing and killing weed seeds.

3. Fermentation for 10-15 days. According to the local temperature, the number of treatments of compost dumper is different.

4. Material that is completely fermented and decomposed is fed into organic fertilizer production equipment.

5. Preliminary screening of materials by drum screening machine (the screened powdery organic fertilizer can be sold directly).

6. After the screened bulk materials are crushed by a crusher, they are re-screened.

7. Adding trace elements to powdery organic fertilizer and mixing with horizontal mixer.

8. Granulation with the new type NPK fertilizer granulator.

9. Fertilizer granules are fed into rotary dryer and rotary cooler.

10. Screening of qualified granules by fertilizer drum screener machine.

11. Bio organic fertilizer enters the coating machine.

12. Products can be sold after being packed by automatic packing machines.

Bio-organic fertilizer production and fermentation equipment

Ground windrow turner or trough compost turning machine
The ground turner does not need to build a trough, but directly stacks the materials in strips and uses a material dumper for dumper fermentation.
The use of trough compost turning machine, according to your scale of production to build fermentation tank, fermentation products are continuously put into the fermentation tank, the use of turning machine for turning fermentation, can play the purpose of water regulation and even mixing, thus saving a lot of labor. It can also achieve the purpose of full ripening.

Investment Projects in 3-5 tons of organic fertilizer manufacturing process

1. Facilities investment

Semi-finished products, raw material warehouses, office sites. According to the local construction cost budget.
When the fermentation tank is built, the ground fermentation tank is not needed.

2. Equipment investment

In the selection of fertilizer production equipment, Huaqiang fertilizer granulator manufacturers can configure models and functions according to customer requirements. The annual output of organic fertilizer production process is determined by the customers themselves. The material connection in our fertilizer production line is accomplished by belt conveyor. The length and number of belt conveyor can be designed according to the actual site.

Production process of potassium chloride by disc granulator machine

fertilizer granulator Nov 26, 2019

In the production of potassium chloride granular fertilizer, fertilizer granulator can be used to granulate powder. The particles produced by disc granulator are spherical and have good strength, which can be widely used in agricultural production.

Disc Pan Granulator

In the granulation process of disc pan granulator, it is necessary to add a binder to make the granules shape. Binder can be compounded by common inorganic minerals in a certain proportion. Binder has synergistic effect when potassium chloride is pelleted. The effect of pelletizing rate and particle strength is good when the binder is used for pelletizing. Potassium chloride was granulated by disc pan granulator machine, and the granules were spherical.

NPK Fertilizer Production Line

NPK fertilizer production line deals with potassium chloride fertilizer. First, all raw materials are mixed by the batching system, and the material is crushed by chain mill to the appropriate size. The disc granulator makes the powder into granules. After drying and cooling, the granules of potassium chloride are coated with protective film by the fertilizer coating machine to complete the granular processing of potassium chloride.

When applying potassium chloride, attention should be paid to the appropriate period of potassium application. Generally, the application period of potassium fertilizer should be early or not late, and should be used as base fertilizer and early recovery period. When the application amount of potassium fertilizer is less, it can be used as base fertilizer once, and when the application amount of potassium fertilizer is more or the soil texture is lighter, the application effect is better divided into base fertilizer and topdressing fertilizer. Soil nutrients and fertilization status should also be taken into account in determining the suitable application period of potassium fertilizer. In severe potassium deficiency soils, all potassium fertilizers should be used as base fertilizers in medium soil potassium supply, and suitable organic fertilizers should be applied as base fertilizers, combined with topdressing.

Note the method of application of potassium chloride. The concentrated application of potassium fertilizer is beneficial to improve its utilization rate and obtain better results. However, it is not advisable to have direct contact with seeds or seedlings. For general crops, a combination of soil fertilization and foliar fertilization can be used.

The technology of organic and inorganic fertilizer production

fertilizer granulator Nov 12, 2019

The inorganic non-chemical produced by chemical method has the advantages of high nutrient content, fast fertilizer efficiency, convenient storage and transportation, and convenient application. Organic-inorganic compound fertilizers are not a simple blend of organic and inorganic fertilizers. In order to produce organic-inorganic compound fertilizer stably and efficiency, it is necessary to solve the granulation property of the mixture. The organic fertilizer production line is mainly divided into two major steps: one is the fermentation of organic matter; the other is the mixing of organic fertilizer and inorganic fertilizer after fermentation. The materials that need to be deal with organic fertilizer include poultry manure, wheat straw, rice husked. These materials are needed to be broken first, and the livestock manure must be fermented in order to move out the odor. The fermented organic fertilizer is mixed with inorganic fertilizer to granulate.

The fertilizer granulating production:
Making the raw material aftermentating by using the fermentation compost turner machine put into the fertilizer mixer machine to mix and then add some N,P,K, to fermentation again. After that making the material to be dried using the drum dryer and then enter the fertilizer granulator to make fertilizer granules. At the time the temperature is high and we need to use the drum dryer to dry the water to the requirement of producing the organic-inorganic fertilizer granules. After cooling ,using the drum screening machine to separate the fertilizer granules which don’t meet the requirements of the fertilizer size and make them into the fertilizer granulator machine to be granulated again.