Advantages and applications of the flat die pelleting machine

fertilizer granulator Nov 21, 2025

The flat die pelleting machine offers significant advantages, with the larger pressure wheel being a key feature. This larger pressure wheel also increases the bearing’s ability to withstand pressure, making the equipment more stable and reliable, and reducing failures caused by pressure. Furthermore, the larger pressure wheel prevents heat generated by extrusion friction from being transmitted to the bearing chamber, ensuring the bearing operates at a low temperature and preventing lubricant leakage, thus extending bearing life. Furthermore, the larger pressure wheel can be repaired two to three times, reducing maintenance costs and increasing project profitability, offering significant advantages over similar equipment.

The flat die pelleting machine is suitable for a wide range of materials. In agriculture, crop straw, such as corn stalks, wheat straw, and rice husks, can be processed into biomass pellet fuel or organic fertilizer. In the domestic sector, some household waste, after sorting and processing, can also be used for pelletizing, achieving resource recycling. In industry, the flat die pelleting machine can easily handle materials such as biofertilizer, coal, carbon black, kaolin, and stone powder, demonstrating its strong material adaptability.

Flat die pelleting machines also play a positive role in environmental protection. On the one hand, they can process large amounts of agricultural and forestry waste, reducing environmental pollution and enabling resource recycling. On the other hand, by converting degradable materials into biodegradable plastic pellets, they provide a new approach to addressing white pollution, promoting the development of environmentally friendly materials and facilitating the achievement of sustainable development goals.

New type two in one organic fertilizer granulator: Efficient integration, simplified production process

fertilizer granulator Nov 21, 2025

The new type two in one organic fertilizer granulator features an integrated “pretreatment + granulation” design, combining two core processes into one. It is the preferred equipment for small and medium-sized organic fertilizer companies to improve efficiency and reduce costs.

The core structure of this new type two in one organic fertilizer granulator consists of two modules: a “mixing and conditioning chamber” and a “granulation and forming chamber,” with the two chambers seamlessly connected. During operation, crushed organic fertilizer raw materials such as straw and fermented manure first enter the upper mixing and conditioning chamber, which is equipped with anti-entanglement stirring paddles. Dual-shaft counter-rotating stirring uniformly mixes the raw materials with a small amount of binder (such as starch residue and humic acid). Furthermore, moisture monitoring and spraying devices installed on the chamber wall ensure real-time adjustment of the raw material moisture to 18%-22%, preventing subsequent mold sticking and loose pellets.

Pretreated raw materials automatically fall into the lower granulation and forming chamber through a built-in material guide channel, eliminating the need for manual transfer. The forming chamber utilizes a flat die granulation core structure, paired with a trapezoidal, non-slip roller and a deep, straight-hole flat die. This not only cuts long fibers in the raw material (preventing them from tangling with the roller) but also achieves low-temperature granulation through vertical extrusion. The formed granules are discharged directly from the outlet, achieving a particle size uniformity exceeding 90%, eliminating the need for secondary screening.

In addition, the new type two in one organic fertilizer granulator is specifically optimized for the characteristics of organic fertilizer raw materials: the mixing chamber agitator is made of a wear-resistant alloy to mitigate frictional losses in fibrous raw materials; the flat die in the granulation chamber can be quickly replaced to accommodate various particle sizes ranging from 2 to 5 mm; and the entire machine is equipped with a variable-frequency motor that adjusts the speed according to the raw material’s moisture and viscosity.

A complete analysis of the application fields of cage crusher

fertilizer granulator Nov 20, 2025

Due to their unique pulverizing mechanism and outstanding performance, cage crushers play an indispensable role in numerous industries and have a wide range of applications.

In the building materials industry, brick and tile factories often use cage grinders to process soft and brittle materials such as shale, industrial slag, and dry clay. After these materials are crushed by cage grinders, a high proportion of fine powder particles is produced, which is crucial for brick forming.

The chemical industry is also an important application for cage crushers. They can grind medium-hard chemical raw materials such as ammonium chloride and ammonium sulfate, ensuring that these raw materials can fully participate in subsequent chemical reactions, thereby improving the production efficiency and quality of chemical products.

In compound fertilizer production, cage crushers are also indispensable for the pulverization of fertilizer raw materials such as urea. This pulverization of raw materials like urea facilitates the even release of nutrients in the fertilizer, enhancing its effectiveness.

In addition, in the production of organic fertilizers, cage crushers can crush organic waste such as sheep manure and straw, so that these wastes can better participate in the fermentation process and be converted into high-quality organic fertilizers, providing a green and environmentally friendly source of fertilizers for agricultural production, helping to improve soil and the healthy growth of crops.

Ring die granulator: Core equipment for efficient granulation in the fertilizer industry

fertilizer granulator Nov 20, 2025

Due to its unique granulation advantages, the ring die granulator has become a key choice for many fertilizer companies to improve production efficiency, providing strong support for the large-scale, standardized production of granular fertilizers.

The core competitiveness of the ring die granulator lies in its excellent molding effect and stable production capacity. Its core component, the “ring die,” efficiently converts a variety of raw materials, such as organic fertilizer and compound fertilizer, into granular products through precise die hole design and uniform extrusion force.

Furthermore, the ring die granulator’s adaptability meets the diverse production needs of the fertilizer industry. Whether processing high-moisture organic fertilizer raw materials or compound fertilizer formulations with varying nitrogen, phosphorus, and potassium ratios, the equipment can adapt to different raw material characteristics by adjusting parameters such as the ring die speed and extrusion pressure, easily achieving mass production.

For fertilizer companies, the ring die granulator is not only a production equipment but also a vital tool for enhancing product competitiveness. Against the backdrop of the growing agricultural demand for efficient, high-quality fertilizers, the ring die granulator will undoubtedly continue to play a key role in driving the fertilizer industry towards higher-quality production models.

Rotary drum granulators promote the resource utilization of organic waste, achieving “waste-to-fertilizer”

fertilizer granulator Nov 19, 2025

This “waste-to-fertilizer” resource utilization approach not only meets the needs of green development but also provides high-quality organic fertilizer for agriculture. In this process, the rotary drum granulator, with its adaptability to diverse organic waste types and efficient granulation capabilities, serves as a crucial bridge between “waste” and “qualified organic fertilizer.”

The core value of the rotary drum granulator lies primarily in its inclusive treatment of diverse organic waste types. For high-fiber waste such as straw, the rotary drum granulator uses the slow tumbling of its tilted drum, combined with the action of its lifting plates, to thoroughly mix the pulverized straw with a binder, evenly dispersing the fibers and gradually entrapping them into granules. This achieves a granulation rate exceeding 80%.

For high-moisture waste (30%-40%) such as poultry and livestock manure, the equipment uses a built-in ventilation device to regulate the humidity within the drum, achieving simultaneous “granulation and initial dehydration.” This eliminates the need for additional dehydration equipment, reducing processing steps and energy consumption. Even when processing food waste with complex composition, the rotary drum granulator’s flexible mixing design prevents impurities from clogging and ensures uniform granule shape.

Rotary drum granulators also enhance the commercial value of organic waste fertilizer. Ungranulated organic waste has a dispersed fertilizer effect, easily clumps, and is expensive to transport and store. However, the granulated organic fertilizer produced by a rotary drum granulator not only maintains a moisture content below 15%, facilitating long-term storage, but also allows for standardized granules to be created by adjusting the die aperture, meeting market demand for organic fertilizer that is easy to apply and has stable fertilizer effect.

Key considerations for fertilizer coating machine selection

fertilizer granulator Nov 18, 2025

When selecting a coating machine, fertilizer companies should consider their own production needs and focus on three key factors to avoid mismatching the equipment with their production.

First, consider compatibility with the particle characteristics. For large fertilizer particles (diameters over 5mm), a wide-channel coating machine with an anti-sticking guide structure is recommended to prevent particle accumulation and blockage within the channel. For particles with high moisture content (above 12%), a conveyor assembly with an anti-stick coating is preferred. For organic fertilizer particles containing fibrous impurities, it is also important to confirm whether the coating machine is equipped with a pre-filter to prevent impurities from entanglement with mechanical components.

Second, consider capacity compatibility. For small-scale production (daily production capacity under 50 tons), a batch coating machine can be selected, offering flexible batch adjustments and suitable for producing a variety of fertilizers in small batches. For large-scale production (daily production capacity over 100 tons), a continuous machine is recommended to ensure that the conveyor speed is synchronized with the material feed rate.

Finally, consider the compatibility of the coating material. If using PE film, confirm that the equipment’s heat-sealing temperature range covers 100-130°C. If using functional coating materials (such as films containing anti-caking agents), check that the equipment’s tension system supports low-tension adjustment to avoid film breakage and impacting performance. Additionally, pay attention to the equipment’s adaptability to film widths and whether it can be flexibly adjusted to accommodate different packaging specifications, minimizing material waste due to film mismatches.

New type two in one organic fertilizer granulator: A powerful tool for reducing costs and increasing efficiency

fertilizer granulator Nov 18, 2025

With the continued expansion of market demand for organic fertilizers, fertilizer companies are increasingly demanding higher efficiency, energy consumption, and space utilization in their production equipment. The emergence of new type two in one organic fertilizer granulators addresses these pain points, making them a key option for organic fertilizer manufacturers upgrading their equipment.

The core advantage of this type of new type two in one organic fertilizer granulator lies in its integration. It combines the functions of at least two pieces of equipment in the traditional granulation process into one, with common designs such as “mixing + granulation” or “granulation + preliminary drying.” For example, the “mixing + granulation” system simultaneously mixes raw materials such as pulverized straw and livestock manure with auxiliary materials. The integrated granulation mechanism then produces granules in one go. This not only reduces material loss by 15%-20%, but also saves approximately 30% of workshop space, making it particularly suitable for small and medium-sized manufacturers or production lines with limited space.

The new type two in one organic fertilizer granulator also offers improved process adaptability. It can process raw materials with a moisture content of 18%-30%, eliminating the need for excessive drying pretreatment. This reduces initial energy consumption and prevents nutrient loss from over-drying.

Furthermore, through optimized internal structure, the equipment ensures a stable pellet formation rate above 90%, resulting in highly uniform pellets with moderate hardness, meeting mainstream market demand for organic fertilizer pellets. Against the backdrop of green agricultural development, this type of highly efficient and energy-saving integrated equipment is driving organic fertilizer production towards greater efficiency and cost-effectiveness.

Controlling pellet strength in ring die pelleting machines: Key to fertilizer transportation and storage

fertilizer granulator Nov 17, 2025

Pellet strength is a core performance indicator for fertilizer products. Ring die pelleting machines require multi-step control to ensure pellets can withstand the pressure of transportation and stacking, minimizing breakage and loss.

First, consider the raw material ratio. If the organic matter content in production is too high (over 60%), binders such as clay and bentonite should be added (control the amount to 3%-5%) to increase the viscosity of the raw materials and lay the foundation for pellet strength.

If the proportion of inorganic fertilizer is high, the moisture content of the raw materials should be controlled between 14% and 16% to avoid pellet brittleness caused by too low a moisture content and easy sticking to the ring die pelleting machine due to too high a moisture content.

Selecting the ring die pelleting machine compression ratio is also crucial. The compression ratio (the ratio of the ring die aperture to the effective thickness) should be adjusted according to the fertilizer type. For organic fertilizers with high fiber content, a low compression ratio of 1:8-1:10 is recommended to prevent pellets from being too hard and easily broken. For compound fertilizers, a high compression ratio of 1:12-1:15 is recommended to enhance pellet density. During production, regular spot checks can be performed using a pellet strength tester. If the strength is insufficient, the steam supply to the conditioner can be temporarily increased (by 10%-15%).

In addition, the gap between the roller and the ring die should be controlled within a range of 0.1-0.3mm. A gap too large will cause the raw material to slip, resulting in insufficient pellet density; a gap too small will increase wear and affect pellet consistency. By synergistically controlling these three factors, the compressive strength of fertilizer pellets can be stabilized at above 20N, meeting transportation and storage requirements.

Rotary drum granulator: Core equipment for continuous granulation and multi-product compatibility

fertilizer granulator Nov 17, 2025

In large-scale fertilizer production, the rotary drum granulator, with its continuous and stable operation and compatibility with multiple fertilizer types, serves as a critical link between raw material mixing and pellet forming. It is particularly well-suited to the efficient production needs of medium- and large-scale enterprises, ensuring consistent pellet quality while reducing manual intervention costs.

Its core advantages lie in its “continuous operation” and adaptability. Firstly, the rotary drum granulator can operate continuously 24 hours a day, processing 5-50 tons/hour without frequent downtime adjustments, perfectly matching the batch production rhythm of fertilizer production lines.

Secondly, by adjusting the binder dosage, drum speed (low speed is suitable for sticky raw materials, high speed is suitable for loose raw materials), and tilt angle (to control material residence time), it can accommodate a variety of fertilizer types, including organic fertilizers, compound fertilizers, and organic-inorganic mixed fertilizers. It can even process organic fertilizers containing small amounts of fiber (the lifting plate design prevents fiber entanglement). In addition, the granule forming rate of the rotary drum granulator can reach over 85%, and the granules are highly rounded and of moderate hardness. No complicated crushing and screening are required afterwards, and they can directly enter the drying stage, which greatly simplifies the production process and provides a cost-effective solution for fertilizer companies to balance “capacity increase” and “quality stability”.

Common drum fertilizer dryer failures and solutions

fertilizer granulator Nov 14, 2025

Drum fertilizer dryers operate frequently during the fertilizer drying process. Improper operation or untimely maintenance can easily lead to problems such as uneven drying, decreased efficiency, and equipment blockage, directly impacting production progress.

1. Uneven Moisture Content of the Material After Drying

One problem is large fluctuations in hot air temperature, resulting in uneven heat transfer. Another problem is that the feed rate fluctuates, resulting in uneven material accumulation thickness within the drum. To address this, first stabilize the heating system and control hot air temperature fluctuations within ±5°C. Then, use a variable frequency feed valve to control uniform feed and ensure a stable material thickness within the drum.

2. Sudden Drop in Drying Efficiency

This is often caused by severe wear of the drum’s internal lifter plates or dust accumulation and blockage in the hot air ducts. To address this, stop the drum fertilizer dryer and inspect the lifter plates. If wear exceeds 1/3, replace them. Clean dust from the hot air ducts to ensure the hot air volume meets the standard. Furthermore, if the drum’s exterior is scaled, perform regular acid cleaning to improve heat transfer efficiency.

3. Drum Blockage

This is mainly caused by the drum tilt angle being too small or residual material hardening and clumping at the discharge port. In this case, the drum fertilizer dryer should be stopped to clean the accumulated material inside the drum. Subsequently, the drum tilt angle should be adjusted to 4°-5°. After each production run, the discharge port should be thoroughly cleaned of any residual material to prevent hardened material from clogging.