Drum screener machine—A grading expert in compound fertilizer production

fertilizer granulator Sep 22, 2025

In the compound fertilizer production process, separating finished products from recycled materials and achieving uniform grading are critical steps in ensuring quality. The drum screener machine is the core equipment in this process. Its unique design and stable performance have made it a key choice for many fertilizer manufacturers to improve production efficiency.

This drum screener machine utilizes a combined screen design, significantly simplifying routine maintenance and facilitating part replacement. It also allows for flexible adjustments based on the screening requirements of different materials, making it suitable for a variety of compound fertilizer production scenarios. During operation, material enters the drum through the feed inlet. The drive mechanism drives the drum to rotate smoothly, while the vibrating mechanism generates uniform vibrations, thoroughly tumbling and dispersing the material within the drum. Finer materials pass smoothly through the screen holes for separation, while coarser materials move along the drum’s inner wall to the discharge port, achieving efficient separation and precise grading.

Its advantages are significant: screening efficiency far exceeds that of traditional equipment, and the processing capacity meets the high-intensity demands of continuous production, avoiding production interruptions. The equipment is also equipped with a specialized sealing device to effectively reduce dust leakage, complying with the environmental protection requirements of modern industrial production and creating a clean and safe working environment.

For compound fertilizer manufacturers, choosing a high-quality drum screener machine can ensure product particle uniformity from the source, enhance market competitiveness, reduce raw material waste due to substandard screening, and save production costs.

Why is the disc granulator the preferred choice for organic fertilizer production lines?

fertilizer granulator Sep 19, 2025

For the granulation stage of organic fertilizer production lines, disc granulators are the preferred equipment for most manufacturers due to their outstanding advantages, including strong adaptability, high granulation quality, and low operating costs. This equipment not only precisely matches the characteristics of organic fertilizer raw materials but also balances production efficiency and product quality, providing critical support for stable production line operation.

In terms of raw material compatibility, disc granulators are far more compatible with organic fertilizer materials than other equipment. Organic fertilizer raw materials are mostly loose, fibrous materials such as livestock and poultry manure and composted straw, which have large moisture fluctuations. By precisely matching the inclination angle and rotation speed, the disc granulator utilizes the dual effects of the material’s own gravity and centrifugal force to gradually roll the loose material into granules. This eliminates the need for excessive compression, which damages the fiber structure. Furthermore, the disc granulator can accommodate raw materials of varying particle sizes, eliminating the need for frequent adjustments to equipment parameters and significantly reducing operational complexity.

Granulation quality is the core reason for choosing a disc granulator. High-quality organic fertilizer granules require a smooth surface, moderate hardness, and good water solubility for easy storage, transportation, and field application. The disc granulator’s granulation process utilizes a “rolling granulation” mechanism, with the pellets continuously tumbling within the disc. This not only ensures uniform nutrient coating but also creates pellets with consistent density, resulting in a high yield rate. Furthermore, the pellet diameter can be flexibly controlled by adjusting the disc speed, meeting the fertilization needs of different crops.

From a cost-effectiveness perspective, the disc granulator also offers significant advantages. Its simple structure, consisting solely of a disc, transmission, and frame, reduces failure rates and reduces maintenance costs compared to extrusion granulators. In terms of energy consumption, the power output of each unit is moderate, and the energy consumption per unit product is significantly lower than other granulation equipment. Furthermore, the disc granulator’s small footprint allows for flexible integration into production lines of varying sizes. Whether small or medium-sized family farms or large organic fertilizer producers, they can choose the appropriate model based on their production capacity needs, maximizing investment returns.

In response to the demand for green agriculture, the disc granulator, through its efficient and energy-efficient granulation method, helps improve the quality of organic fertilizer products, becoming a crucial link between agricultural waste resource utilization and green farming.

Practical maintenance tips for extending the life of a chain crusher

fertilizer granulator Sep 19, 2025

As a critical piece of equipment in a company’s production, the lifespan of a chain crusher directly impacts its return on investment. Proper routine maintenance can effectively extend its service life, reduce equipment replacement costs, and ensure smooth production.

During daily use, it’s important to regularly inspect the condition of all components. Pay special attention to the wear of the chain and hammer heads, as these components are the heart of crushing. Severe wear can reduce crushing efficiency and should be promptly replaced to avoid impacting crushing efficiency and equipment stability.

Also, check the drive system, including the motor’s operating temperature and the tightness of the transmission belt, to ensure the motor and transmission are operating properly, without abnormal noise or overheating. Any problems identified should be addressed promptly to prevent further malfunctions.

Regular equipment cleaning is also crucial. During the crushing process, material dust easily adheres to the equipment’s interior and screen. Failure to clean the screen promptly can cause screen blockage, affecting crushing particle size and discharge efficiency, and accelerating component wear. When cleaning, first turn off the power to the equipment. Once the chain crusher has completely stopped, open the protective door and clean the interior. Use specialized tools to remove any residual material and dust, ensuring the equipment is free of residual material.

In addition, lubricating oil should be added regularly according to the equipment instructions to keep all moving parts (such as the main shaft, bearings, etc.) well lubricated, reduce friction loss between components, improve the smoothness of equipment operation, and further extend the service life of the equipment.

At the same time, the chain crusher should be regularly inspected and repaired to check for potential faults and hidden dangers to ensure that the equipment is always in good operating condition.

How to Choose the Right Disc Granulator for Your Production Line

fertilizer granulator Sep 16, 2025

In fertilizer production lines, the choice of disc granulator directly impacts production capacity and product quality. Combining the technical specifications and application characteristics of Huaqiang Heavy Industry’s disc granulators, a sound selection requires focusing on four key dimensions.

First, precisely matching production needs is crucial. Equipment requirements vary significantly across industries. For the fertilizer industry, when producing organic fertilizer, rubber or polyurethane-lined models are preferred to avoid corrosion and accommodate fermentable materials like livestock and poultry manure. The recommended rotational speed is 10-18 rpm to preserve organic matter activity. For inorganic compound fertilizer production, ensuring uniform feed distribution and a consistent mixing of nitrogen, phosphorus, and potassium is crucial. Production capacity selection should be based on specific parameters. For example, a small workshop with an hourly production capacity of 0.05-0.15 tons should choose the ZL-500 model, while a large factory with a production capacity of 3.5-6 tons should opt for the ZL-3600 model. A 10%-15% capacity margin should be reserved to account for seasonal fluctuations.

Second, pay close attention to the core configuration details of the equipment. The drive system determines operational stability. For example, the ZL-3600 model, equipped with an 18.5kW motor and a 10r/min speed, can accommodate high-load granulation needs. The disc inclination angle should be adjustable from 30° to 60°, allowing for flexible adjustment based on material viscosity. For example, highly viscous mineral powders require a larger inclination angle of around 50° to reduce wall sticking. The water spray system should be equipped with multiple sets of adjustable nozzles to ensure a stable moisture content of 10%-20% to prevent loose particles and agglomeration. This is crucial for the strength of fertilizer pellets and the quality of metallurgical mineral powder pellets.

Furthermore, a comprehensive assessment of the manufacturer’s capabilities is crucial. Prefer companies like Huaqiang Heavy Industry that have comprehensive production capabilities. Their 12 disc granulator models cover varying production capacity requirements and allow customers to visit their factory for a firsthand understanding of the equipment’s production processes and quality control procedures. Also, consider whether the manufacturer offers customized services.

Finally, prioritize after-sales service and supporting support. Confirm whether the manufacturer offers free installation, commissioning, and operator training to prevent production disruptions caused by improper operation. Equipment packaging must meet transportation standards, such as packaging the main unit bare to minimize impacts and plywood boxes for electrical components. Customized wooden boxes can be used for special transportation needs. Furthermore, the inventory cycle and warranty policy for consumable parts such as nozzles and inner linings must be clearly defined to ensure long-term stable operation of the equipment and reduce future maintenance costs.

Common Problems and Solutions for Disc Granulators in Organic Fertilizer Production Lines

fertilizer granulator Sep 15, 2025

Disc granulators are widely used in organic fertilizer production lines due to their advantages, such as uniform granulation and low cost. However, in actual operation, they are susceptible to various factors, leading to various problems that affect production efficiency and product quality.

Improper control of raw material moisture is a primary challenge. If the moisture content is too high, the raw material will easily clump on the inner wall of the disc, forming large, adhered masses. This not only prevents proper granulation but also increases the difficulty of equipment cleaning. If the moisture content is too low, the raw material will have poor flowability, making it difficult to agglomerate into granules, resulting in loose and easily broken granules. To address this issue, precise control of the raw material moisture content using a moisture meter before granulation is required. Typically, the moisture content is maintained at a stable level of 25%-35%. If the moisture content is not within this range, it should be adjusted promptly using a dryer or humidifier.

Improper disc inclination and rotation speed can also cause problems. If the inclination angle is too large, the raw materials will stay in the disc too short, causing the particles to be discharged before they have time to fully round, resulting in irregularly shaped finished particles. If the inclination angle is too small, the raw materials will pile up, easily causing “sticking” and affecting normal equipment operation. Excessive rotational speed will subject the raw materials to excessive centrifugal force, preventing effective agglomeration. Too slow rotational speed will significantly reduce granulation efficiency. Generally, the disc inclination angle should be adjusted to 35°-45° and the rotational speed to 15-20 rpm, depending on the raw material characteristics. These parameters should be gradually optimized through trial production.

In addition, uneven mixing of raw materials can also affect granulation performance. If the organic raw materials and auxiliary materials are not fully mixed, nutrient imbalances in certain areas can lead to poor granulation quality and uneven particle size. This requires the use of high-efficiency mixing equipment before granulation to ensure that the raw materials are mixed uniformly to a level above 90%. Regular inspection of the mixing blades of the mixing equipment should also be performed to prevent blade wear that may reduce mixing efficiency.

In response to these common problems, a complete inspection mechanism needs to be established during production, and the operating status of the equipment and raw material indicators should be checked regularly, and the process parameters should be adjusted in time to ensure the stable operation of the disc granulator and improve the quality of the finished organic fertilizer.

Why are BB fertilizer mixers the preferred choice for fertilizer production?

fertilizer granulator Sep 15, 2025

In the fertilizer production sector, BB fertilizer mixers, with their significant advantages, have become core equipment for many companies. They are primarily used to mix different types of fertilizer raw materials to produce bulk blended fertilizer (BB fertilizer).

Their most critical advantage is uniform mixing. A stirring mechanism within the mixing drum, coupled with paddle or spiral ribbon impellers, shears, tumbles, and disperses the raw materials, ensuring uniform distribution of nitrogen, phosphorus, potassium, and other components. This prevents nutritional imbalances caused by uneven mixing and ensures consistent product quality.

The machine’s high processing capacity is also a key advantage, meeting the needs of various production scales, from basic production capacity for small and medium-sized enterprises to batch production for large factories. This allows for efficient batch reduction and reduces time and cost.

Furthermore, BB fertilizer mixers feature a simple structure and easy operation. The control system accurately monitors parameters such as mixing speed and time, allowing workers to master the process with minimal training. Maintenance is also convenient, with easy access to core components, significantly reducing the probability of equipment failure.

In addition, the BB fertilizer mixer is highly adaptable and can process fertilizer raw materials of varying properties, including solid particles and powders. Its mixing drum and stirring mechanism are designed for easy cleaning, preventing cross-contamination between batches of raw materials. This meets the stringent hygiene and quality requirements of fertilizer production, providing strong support for companies producing diverse fertilizer products.

Why Choose a Disc Granulator for Granulation?

fertilizer granulator Sep 10, 2025

In industries requiring granular materials, such as fertilizers, building materials, and metallurgy, the choice of granulation equipment directly impacts production efficiency and product quality. Disc granulators, with their numerous advantages, have become the preferred equipment for many companies.

In terms of granulation efficiency, disc granulators excel. Their unique disc design allows the material to quickly form a stable trajectory during rotation, shortening the time it takes for the material to aggregate and granulate. For example, in fertilizer production, under similar operating conditions, a disc granulator can process dozens of tons of raw materials per hour, increasing efficiency by over 30% compared to traditional granulation equipment. This significantly reduces production cycle time and meets the needs of large-scale production.

Granulation quality is a key consideration when choosing a granulator, and disc granulators offer significant advantages in this regard. By precisely controlling the disc’s rotational speed, inclination, and material moisture content, they achieve uniform granule size, typically maintaining a stable diameter of 2-5 mm. The granules are also strong and resistant to breakage. This characteristic is particularly important in fertilizer production. High-quality granulated fertilizers are not only easy to store and transport, but also ensure uniform nutrient release, improving fertilizer utilization and enhancing product market competitiveness.

The disc granulator’s wide range of applications is a key factor in its popularity. It can efficiently adapt to applications ranging from organic fertilizer and compound fertilizer production lines to the processing of building materials such as cement and expanded clay, and even to the granulation of metal ore powders. Different materials require only adjustments to relevant parameters, eliminating the need for large-scale replacement of equipment components. This reduces equipment costs associated with producing different products and enhances production flexibility.

Disc granulators also offer advantages in terms of energy consumption and cost. Their relatively simple structure and low power consumption during operation can reduce energy costs per ton of material produced by 15%-20% compared to other types of granulators. Furthermore, the equipment’s low manufacturing and maintenance costs, along with the limited number of wearing parts and easy replacement, reduce ongoing operating expenses and offer significant financial savings.

Overall, the disc granulator‘s advantages in efficiency, quality, applicability, and cost make it an ideal choice for granulation production.

Common Problems with Disc Granulators in Fertilizer Production

fertilizer granulator Sep 5, 2025

Fertilizer granulators are widely used in the fertilizer industry, and disc granulators are particularly common. What are some common problems with disc granulators in fertilizer production? If problems such as material sedimentation and clumping occur during granulator operation, how can you resolve them? Below, we will guide you through resolving these issues.

Precipitation can occur during fertilizer production. Some materials cannot be mixed; when they are mixed and dissolved in water, precipitation occurs. Some fertilizers are soluble in certain proportions, but above a certain concentration, salting out occurs, causing another material to precipitate. Some materials, such as metal salts, are easily soluble in acidic media, but will precipitate. Other materials, such as humic acid, are easily soluble in alkaline media, but will precipitate when dissolved in acidic solutions.

The main methods to prevent precipitation are to properly adjust the pH of the solution, add cosolvents, and increase the solubility of insoluble substances. The raw materials used in NPK fertilizer production lines should be properly proportioned to prevent salting out and oversaturation. Appropriate additives should be added to protect the reaction materials and prevent precipitation. Appropriate raw materials should be selected to prevent precipitation caused by reactions between them.

Bloating in fertilizer production is caused by the release of gas from the reaction of two or more materials. Materials that may cause bloating during fertilizer production include borax, ammonium salts, and fillers. To effectively prevent bloating, the following points should be noted when using a disc granulator to produce pellets: When sourcing qualified raw materials, avoid blindly pursuing low costs; and ensure that raw materials are properly combined to prevent chemical reactions between them.

Clumping in fertilizer production: This problem is primarily related to the raw materials, humidity, temperature, external pressure, and storage time. Organic fertilizer production equipment requires the proper selection of raw materials, meaning those that are less prone to caking.

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

fertilizer granulator Sep 2, 2025

In organic fertilizer production lines, a rotary drum granulator is the core equipment for raw material formation. It has become a mainstream choice because it meets the cohesiveness and granularity requirements of organic fertilizers such as livestock and poultry manure and composted straw. Its operation revolves around “raw material mixing – granule agglomeration – screening and output,” resulting in an efficient and stable mechanism.

The equipment primarily consists of an inclined drum (3°-5° inclination), a transmission system, a spray system, and a scraper assembly. Scrapers on the inner wall of the drum drive the material to tumble, while the spray system regulates moisture. The scraper removes material adhering to the drum wall to prevent clogging.

The first step is “raw material pretreatment and feeding.” Composted and crushed organic fertilizer raw materials (25%-35% moisture) are mixed with auxiliary materials such as clay in a suitable proportion and then fed into the drum through the feed port. The motor drives the drum to rotate at a low speed of 10-15 rpm. The scrapers repeatedly lift and drop the material, forming a uniform layer.

The second step is the core “granule agglomeration and formation” phase. A spray device applies a metered amount of water or adhesive, depending on the moisture content of the raw materials, to create a sticky surface. As the drum rotates continuously, the material particles agglomerate into small particles through collision, friction, and compression. These small particles further absorb the raw materials and grow to qualified granules of 2-5mm. The tilted design of the drum allows the particles to naturally move toward the discharge end, enabling continuous production.

The final step is “granule screening and optimization.” The formed granules are screened to separate fine powder from bulky material. The fine powder is returned to the granulator, while the bulky material is crushed and reused to ensure acceptable yields. Furthermore, a scraper cleans the drum wall of any residue in real time to ensure efficiency and prevent hardened residue from affecting subsequent production.

In short, the rotary drum granulator uses gentle physical agglomeration to adapt to the characteristics of organic fertilizer raw materials, efficiently producing uniform granules and providing a key guarantee for the stable operation of organic fertilizer production lines.

Key Maintenance Points for Disc Granulators in Organic Fertilizer Production Lines

fertilizer granulator Sep 2, 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.