Double axis paddle mixers: The “efficiency champion” of fertilizer mixing

With their symmetrical, staggered paddle structure, double axis paddle mixers play an irreplaceable role in fertilizer mixing production. Adaptable to diverse applications such as BB fertilizers, organic fertilizers, and compound fertilizers, they are core equipment for high-quality fertilizer production.

Strong convection mixing, balancing uniformity and efficiency. The twin shafts rotate in opposite directions, and the staggered paddles create a multi-dimensional convection field, rapidly blending raw materials with different specific gravities and particle sizes. The mixing uniformity far surpasses that of single-shaft equipment, and the nutrient variation coefficient can be controlled within 3%. The mixing cycle is shortened by more than 40%, meeting the batch processing needs of NPK fertilizer production lines and significantly increasing overall capacity.

Outstanding adaptability, solving complex raw material challenges. Compared to ordinary fertilizer mixers, it can easily handle high-humidity, highly viscous raw materials (such as well-rotted organic fertilizers and sludge-based fertilizers). The special angle design of the paddles prevents adhesion to the walls and does not damage the properties of the granular raw materials. In BB fertilizer production, it can achieve uniform mixing of dry powder and small amounts of additives, ensuring precise formulation.

Low-loss and energy-saving, suitable for large-scale production. The extremely small gap between the impeller and the machine cavity results in minimal raw material residue and a material utilization rate exceeding 98%. The dual-shaft coordinated operation saves approximately 25% more energy than traditional equipment. It can also seamlessly integrate with screening and granulation equipment, achieving integrated mixing and pretreatment, simplifying the process.

In summary, the double shaft paddle mixer, with its structural advantages and high efficiency, versatility, and low consumption, has become a powerful tool in fertilizer mixing, stably ensuring fertilizer quality and helping fertilizer production upgrade towards higher efficiency and precision.

Dry granulation double roller press granulator: Injecting new momentum into agricultural development

The dry granulation double roller press granulator, with its core advantages of “no drying, low energy consumption, and wide adaptability,” breaks through the bottlenecks of traditional granulation technology, providing solid support for high-quality agricultural development and becoming a key carrier for the upgrading of modern agricultural equipment.

Solving the pain points of traditional granulation. This equipment does not require high-temperature drying; it directly forms dry powder raw materials through roller pressing, reducing energy consumption by more than 30% and significantly reducing production costs. It is also compatible with various raw materials such as NPK compound fertilizers and mineral fertilizers. After pretreatment by a fertilizer screener machine and mixing by a fertilizer mixer, it can quickly produce high-strength granular fertilizers.

Optimizing fertilizer application efficiency. The granular fertilizers produced by this equipment have uniform strength and are not easily powdered, reducing transportation and storage losses to less than 2%; when applied, it is compatible with mechanized operations, and nutrient release is slow and sustained, effectively improving fertilizer utilization and preventing soil compaction. Especially in large-scale planting, granular fertilizers of different particle sizes can be customized to meet the differentiated needs of crops such as corn and fruits and vegetables.

Empowering green circular agriculture. This equipment can directly process dry powder raw materials made from agricultural waste such as livestock and poultry manure and crop straw, realizing the resource-based transformation of “waste → organic fertilizer.” At the same time, there are no wastewater or exhaust gas emissions, reducing agricultural non-point source pollution and promoting the transformation of agriculture from a “resource-consuming” type to a “circular and efficient” type.

Building a chicken manure organic fertilizer production plant from scratch: A complete practical guide

Chicken manure is rich in nitrogen, phosphorus, and potassium, but it is highly moist, sticky, and has a strong odor. Establishing a chicken manure organic fertilizer production plant requires focusing on the core principles of “harmlessness + resource utilization,” specifically addressing the challenges posed by the characteristics of the raw materials, balancing compliance, efficiency, and quality, and building a closed-loop production system.

Solidify the foundation of raw materials and site. Secure a stable source of chicken manure, sign long-term agreements with farms, and strictly control impurities in the raw materials. The site should be located far from residential areas and water sources, with reserved environmental protection distances. Different functional areas should be planned in zones, equipped with seepage-proof leachate collection ponds and odor treatment facilities to prevent secondary pollution.

Set up the production line with suitable equipment. Equipment configuration based on scale: Pre-treatment uses a solid-liquid separator for dehumidification, paired with a fertilizer crusher and fertilizer mixer to mix chicken manure and straw/sawdust at approximately a 1:2 ratio to adjust the carbon-to-nitrogen ratio; fermentation uses horizontal fermentation tanks or double screws compost turning machines, maturing at 55-65℃ for 7-15 days for sterilization; deep processing includes granulation, screening, and packaging equipment to form a complete organic fertilizer production line.

Improve compliance and process systems. Obtain environmental protection filings, discharge permits, and finished fertilizer registration certificates, and establish a quality testing mechanism. Addressing the odor-prone nature of chicken manure, precisely control oxygen supply and turning frequency, and use microbial agents to accelerate maturation and reduce odor diffusion.

Build an operational closed loop. Control raw material costs and transportation losses, determine finished product types based on market demand, and connect with growers and agricultural input channels. Develop a regular equipment maintenance plan to ensure continuous operation of the production line.

The difference between organic fertilizer and bio-organic fertilizer equipment

The core difference between organic fertilizer production equipment and bio-organic fertilizer equipment stems from different process objectives: the former focuses on the harmless and resourceful transformation of organic waste, while the latter requires additional assurance of the activity of beneficial microorganisms. This directly determines the differences in equipment configuration and process control, adapting to different production needs.

Organic fertilizer equipment processes raw materials such as livestock manure and crop straw, achieving harmless degradation through fermentation and granulation. The core objective is to remove pathogens and insect eggs and transform organic matter to produce ordinary organic fertilizer. Bio-organic fertilizer equipment, on the other hand, adds functional microbial agents to this process, ensuring the activity of the microbial agents throughout the process. The core objective is to balance composting and the preservation of live bacteria.

There are differences in key equipment configuration. Both types of equipment share basic equipment such as solid-liquid separators, fertilizer mixers, and granulators, but bio-organic fertilizer equipment requires additional specialized devices: low-temperature fermentation equipment to prevent high-temperature sterilization, precise microbial agent mixing equipment to ensure even distribution, and low-temperature drying/cooling equipment below 60℃ to preserve microbial activity.

Bio-organic fertilizer equipment requires strict control of fermentation temperature, pH value, and the timing of microbial agent addition; ordinary organic fertilizer equipment has a simpler process, focusing on controlling the degree of raw material decomposition. In terms of application scenarios, the former is suitable for ecological farming, while the latter meets the needs of ordinary organic fertilizer production for conventional soil improvement and fertilization.

Detailed process flow of roller press granulator production line

Roller press granulator production lines, with their advantages of cold pressing, energy efficiency, and wide compatibility with raw materials, are widely used in the processing of compound fertilizers and organic fertilizers. They eliminate the need for high-temperature drying, maximizing the retention of raw material activity and nutrients.

Raw Material Pretreatment: First, the raw materials are precisely proportioned according to a preset ratio. Inorganic raw materials such as urea and monoammonium phosphate, or well-rotted organic materials, are mixed with auxiliary materials and fed into a fertilizer mixer for homogenization, ensuring uniform nutrient distribution. Then, the material is processed by crushing and screening equipment to achieve a particle size of 80 mesh or higher, while simultaneously adjusting the moisture content to 8%-12% to avoid clumping or poor forming.

Roller Pressing: The pretreated material is fed into a double roller press granulator. High pressure is applied by a pair of counter-rotating rollers, pressing the loose material into dense flakes or blocks. The roller pressure needs to be finely adjusted according to the material characteristics. Insufficient pressure will result in brittle particles, while excessive pressure may damage the equipment and affect solubility; precise control is essential.

Post-Processing Screening: The raw material is crushed into irregular particles by a crusher, then classified by a fertilizer screener machine. Qualified particles enter subsequent stages, while unqualified coarse particles and fine powder are returned to the pretreatment stage for reprocessing, forming a closed-loop production process and improving raw material utilization. Finally, qualified particles are quantitatively packaged and sealed for storage.

This process is simple and compact, with low energy consumption and strong environmental friendliness. It is suitable for processing various material combinations and is an ideal choice for small- to medium-capacity fertilizer production lines.

A comprehensive overview of the core raw materials for NPK compound fertilizer production

The core value of NPK compound fertilizer lies in the balanced supply of the three major nutrients: nitrogen (N), phosphorus (P), and potassium (K). The selection of raw materials directly determines its nutrient content, fertilizer efficiency, and applicable scenarios. Production requires an NPK fertilizer production line, precisely matching nitrogen, phosphorus, and potassium source raw materials and a small amount of auxiliary materials according to nutrient requirements.

Nitrogen source raw materials are diverse and highly adaptable. Urea has a nitrogen content of 46%, and its nutrients are pure and easily absorbed, making it the first choice for high-nitrogen compound fertilizers; ammonium chloride is low in cost, and ammonium sulfate can supplement sulfur, respectively suitable for chlorine-loving and sulfur-tolerant crops; calcium ammonium nitrate combines nitrogen and calcium supplementation functions, is safe to use, and is suitable for fruit and vegetable cultivation.

Phosphorus source raw materials mainly come from phosphate rock processing, requiring consideration of both effectiveness and stability. Monoammonium phosphate and diammonium phosphate are the mainstream options; the former has a high phosphorus content and good water solubility, while the latter has excellent nitrogen-phosphorus synergy; superphosphate and triple superphosphate are cost-effective, the former contains sulfur, and the latter has a higher phosphorus concentration, and can be selected according to cost and crop needs.

Potassium source raw materials are divided into chloride and sulfate types. Potassium chloride has a high potassium content and low cost, suitable for field crops, but prohibited for chlorine-sensitive crops; potassium sulfate is suitable for chlorine-sensitive crops and supplements sulfur, and is mostly used for fruits, vegetables, and cash crops; potassium nitrate combines nitrogen and potassium nutrients, acts quickly, and is suitable for critical growth stages of crops.

Auxiliary materials need to include binders and fillers to improve the molding and stability of the fertilizer. During processing, the main and auxiliary materials are thoroughly mixed using a fertilizer mixer, and specialized fertilizer production equipment is used to ensure uniformity.

A comprehensive analysis of the advantages and disadvantages of DAP fertilizer

Diammonium phosphate (DAP) is a high-concentration nitrogen-phosphorus compound fertilizer.  It is both an efficient source of phosphorus and an important raw material in NPK fertilizer production line. Thanks to its high nutrient density and direct fertilizing effect, it is widely used for crops and soils with high phosphorus requirements. However, due to limitations in its nutrient composition and soil adaptability, it has significant drawbacks and requires rational application based on specific circumstances.

Its core advantages are prominent. First, it is rich in nutrients and easily absorbed, containing 18% nitrogen and 46% phosphorus. The phosphorus exists in a water-soluble form, quickly meeting the phosphorus needs of crops during the seedling and flowering stages, promoting root development and flower bud differentiation. Second, it has broad applicability, performing well in alkaline and neutral soils, and can alleviate problems such as weak crop growth and low fruit setting rates caused by phosphorus deficiency. Third, it has excellent physical properties. After processing with professional fertilizer production equipment, the granules are uniform and strong, not easily absorbing moisture or clumping, facilitating storage, transportation, and mechanized application.

However, its disadvantages also need attention. First, the nutrients are limited, containing only nitrogen and phosphorus. Long-term single application can easily lead to potassium deficiency in the soil, causing nutrient imbalance in crops and affecting yield and quality. Second, its effectiveness is reduced in acidic soils, decreasing phosphorus availability and potentially exacerbating soil acidification. Furthermore, excessive application can lead to phosphorus accumulation, wasting resources and inhibiting the absorption of trace elements such as zinc and iron, resulting in excessive vegetative growth and reduced stress resistance in crops.

In summary, diammonium phosphate is an efficient phosphorus source fertilizer, with advantages in rapid phosphorus supplementation and strong adaptability. Due to its limited nutrient composition, in NPK fertilizer production lines, it needs to be thoroughly mixed with potassium fertilizer, organic fertilizer, etc., using a fertilizer mixer. In acidic soils, lime can be added for conditioning. Applying it as needed will maximize its fertilizing effect.

Practical strategies for improving fertilizer production efficiency with fertilizer granulators

Fertilizer granulators are core equipment in fertilizer production lines, and their operating efficiency directly determines overall production capacity. Improving efficiency is not simply about increasing speed; it requires a multi-dimensional approach involving raw material adaptation, parameter optimization, and maintenance support. The goal is to maximize production capacity while ensuring granule quality.

Raw material pretreatment: The moisture content of raw materials should be strictly controlled at 8%-12%. Excessive moisture can lead to sticking and clumping, increasing equipment load, while insufficient moisture makes molding difficult. Simultaneously, the materials should be crushed and screened to a particle size of ≤2mm and thoroughly mixed in a fertilizer mixer to prevent uneven composition, which can cause jamming or poor molding, thus clearing obstacles for efficient granulation.

Precise parameter matching: Based on the characteristics of the raw materials (hardness, specific gravity) and the target granule requirements, adjust the rotation speed, pressure, or inclination angle accordingly: lighter materials can have their speed increased to enhance propulsion, while high-hardness materials require increased pressure and reduced speed to ensure dense granules. Appropriate parameters can stabilize the granulation rate at over 90%, reducing rework losses and directly increasing production capacity per unit of time.

Daily maintenance: Regularly clean residual materials inside the machine, polish worn parts (such as roller surfaces and the inner wall of the disc), and check the transmission and lubrication systems to avoid sudden breakdowns and downtime. Also, match the granulator’s capacity with the preceding and subsequent processes to prevent material accumulation or insufficient supply, thus avoiding efficiency waste.

In summary, improving efficiency requires a comprehensive approach considering raw materials, parameters, and maintenance, forming a closed loop. This allows the equipment to perform at its best while ensuring stable granule quality.

Roller press granulation technology: A reliable choice for improving the strength and uniformity of fertilizer granules

The strength and uniformity of fertilizer granules directly affect their transportation and storage stability and application effectiveness, making them a core indicator of high-quality fertilizers. Roller press granulation technology, with its unique principle of “dry extrusion and die-hole molding,” can precisely control particle characteristics from the molding source, effectively improving strength uniformity.

Roller press granulation uses the synchronized pressure rollers of a fertilizer compaction machine to apply constant pressure to dry powder raw materials that have been mixed by a fertilizer mixer and screened by a fertilizer screener machine. The raw materials are then extruded and molded through die holes. The fertilizer compaction machine’s pressure control is precise, and the roller speed and pressure are constant, ensuring that each granule receives the same extrusion pressure, thus preventing strength differences caused by uneven pressure from the source.

This technology has wide raw material adaptability; NPK compound fertilizers and other materials, after pretreatment, can be stably granulated through the fertilizer compaction machine. At the same time, the precise feeding system of the fertilizer compaction machine can stabilize the raw material supply speed, avoiding local pressure changes caused by feeding fluctuations; secondary screening after molding removes irregular particles, further improving the consistency of finished product particle size and strength.

In practical applications, fertilizer granules produced by roller press granulation have a coefficient of variation in strength of ≤5%, far superior to traditional processes, with a transportation pulverization rate of less than 2%. This meets the high requirements for particle stability in large-scale planting, reducing fertilizer waste and ensuring uniform application. In summary, roller press granulation technology, through precise pressure control and process optimization, can significantly improve the strength and uniformity of fertilizer granules, providing strong support for the production of high-quality fertilizers.

Can urea granulation technology improve agricultural productivity?

Urea, as a core nitrogen fertilizer in agriculture, has an application efficiency that directly impacts crop yield and quality. Urea granulation technology, through morphological optimization and process upgrades, addresses pain points from multiple dimensions and is a key technological support for boosting productivity.

Granulation technology optimizes urea characteristics. After screening raw materials with uniform particle size using a fertilizer screener machine, powdered urea is converted into granular urea with uniform particle size and moderate strength through processes such as rotary drum granulation and spray granulation. This solves the problem of caking during transportation and storage, and also extends the nutrient release cycle. Granular urea releases nitrogen slowly after being applied to the soil, reducing high-temperature volatilization losses, avoiding waste, and providing continuous fertilization.

Granulation technology improves application efficiency. Granular urea is compatible with mechanized fertilization equipment, enabling precise broadcasting and band application, significantly improving efficiency, adapting to large-scale planting bases, and reducing labor input; uniform granules prevent localized nutrient excess that can burn seedlings, ensuring crop growth. Some granulation processes add slow-release agents and efficiency enhancers, extending fertilizer efficiency and reducing the number of fertilizations, indirectly lowering planting costs.

Granulation technology contributes to green agriculture. Granular urea reduces nitrogen loss and pollution to soil and water bodies, aligning with the needs of green transformation; its stable characteristics facilitate mixing with phosphorus and potassium using a fertilizer mixer to produce compound granular fertilizers, achieving balanced fertilization and improving crop yield and quality. High-quality granular urea allows crops to fully absorb nutrients and grow robustly, directly boosting yield per unit area and contributing to increased agricultural productivity.