How can you use new type organic fertilizer granulators more efficiently and save energy and materials?

fertilizer granulator Nov 13, 2025

Many organic fertilizer plants are concerned about costs. However, when using new type organic fertilizer granulators, paying attention to two small details can significantly save energy and materials.

To save energy, most new type organic fertilizer granulators are equipped with variable-frequency motors. Avoid running them at maximum speed all the time. For example, when initially feeding, use a low speed of 15 rpm. Once the raw materials have stabilized in the granulation chamber, gradually increase the speed to 20-25 rpm. This prevents the motor from exerting sudden force, saving 10%-15% of energy per hour. Additionally, avoid idling the machine. Do not start the machine until the raw materials are ready. The energy wasted in idling for one hour is enough to generate granules for 20 minutes.

To save materials, the key is to reduce waste. New type organic fertilizer granulators have a return device. Instead of discarding the crushed granules, they are directly returned to the granulation chamber through the return port, where they are mixed with new raw materials and granulated again. This can reduce the waste rate from 10% to less than 3%. Also, do not mix impurities such as stones and iron wire into the raw materials. Impurities will wear out machine parts and crush good particles. Use a sieve before feeding each time to avoid a lot of material waste.

Daily maintenance of flat die granulators to extend the life of consumable parts

fertilizer granulator Nov 13, 2025

The replacement cost of the consumable parts (flat die and roller cover) of a flat die granulator accounts for over 70% of the total equipment operation and maintenance costs. Proper daily maintenance directly impacts the life of these consumable parts.

1. Precise Maintenance of the Flat Die

After each production run, the surface of the flat die granulator and the die holes must be cleaned of any residual raw material. Compressed air can be used to blow out the die holes, followed by a soft-bristled brush to clean the surface of the flat die to prevent scratches caused by hardened raw material during the next machine start-up. If one side of the flat die is severely worn, the die can be flipped over and used. Minor chipping of the die holes can be repaired with a grinding wheel to reduce the frequency of replacement.

2. Regular Inspection and Adjustment of the Roller

Check the roller cover weekly during flat die granulators shutdown to check for wear. Replace any noticeable grooves or cracks. Also, adjust the gap between the roller and the flat die using a 0.2-0.4mm feeler gauge inserted between the two to ensure a uniform gap. Excessive gaps can lead to loose pellets, while too small a gap increases friction between the roller and the flat die, shortening their lifespans.

3. Drive and Lubrication System Maintenance

Check the drive belts between the motor and roller monthly. If the belts are loose, adjust the belt tension. Lubricate the roller bearings with special grease every two weeks. The amount of grease should be sufficient to allow a small amount to overflow from the bearing gap. Excessive grease will result in poor heat dissipation from the bearings.

Ring Die Granulators: How to Reduce Costs and Increase Efficiency Through Routine Maintenance?

fertilizer granulator Nov 12, 2025

Ring die granulators are high-value equipment in organic fertilizer production lines. Routine maintenance not only extends their service life but also reduces downtime, indirectly increasing production capacity.

First, ensure precise maintenance of the ring die and roller. After each production run, clean any remaining raw material from the die hole to prevent it from hardening and caking the die during the next run. Check the gap between the roller and the die weekly. If the gap exceeds 0.5mm, adjust it promptly to prevent insufficient extrusion and loose pellets. Check the ring die surface monthly for wear. If cracks appear along the die hole edge, repair or replace them promptly to prevent degradation of pellet appearance.

Second, ensure maintenance of the transmission system and lubrication. The gearbox and bearings are the core of the transmission. Check the gearbox oil level monthly. If the oil level is below the mark, add special gear oil to prevent gear wear. Fill the roller bearings with high-temperature resistant grease every two weeks to prevent overheating and damage from lack of oil. Be careful not to over-lubricate, as this will result in poor heat dissipation.

The third aspect is raw material pretreatment control: The core of maintenance is prevention. Before raw materials enter the ring die granulator, they must be screened to remove impurities to prevent hard impurities from scratching the ring die and rollers. At the same time, the raw material moisture content (18%-22%) and particle size (≤1mm after crushing) are strictly controlled to minimize equipment overload and component wear caused by unsuitable raw materials, thus reducing maintenance costs from the source.

Horizontal crushers: A reliable helper for fertilizer companies to reduce energy consumption

fertilizer granulator Nov 11, 2025

Electricity costs can account for 15%-20% of fertilizer production costs. As a high-energy-consuming component, controlling the energy consumption of pulverizing equipment directly impacts a company’s cost-saving efforts. Many companies overlook the potential for energy optimization in horizontal crushers. In fact, through structural and operational logic design, these pulverizers can be a reliable tool for reducing energy consumption.

1.Load Adaptation of Variable Frequency Motors

Traditional pulverizing equipment often uses fixed-speed motors, operating at full capacity regardless of the hardness or moisture content of the raw material. This results in a “big horse pulling a small cart” pattern of energy waste. Horizontal crushers equipped with variable frequency motors, however, can adjust their speed based on raw material characteristics, reducing motor energy consumption by an average of 15%-20%.

2.Resistance Optimization of Blade Structure

The optimized horizontal crusher reduces air resistance. The staggered blade arrangement allows the material to enter the shear zone more smoothly, avoiding ineffective impacts. This allows more electrical energy to be converted into crushing kinetic energy rather than resistance losses, reducing energy consumption by an additional 8%-10%.

3.Load balancing reduces energy consumption fluctuations

Uneven feeding of the crusher can cause the motor load to fluctuate (a sudden surge in current during an overload), increasing overall energy consumption over time. A horizontal crusher can be equipped with an “intelligent feed controller” that monitors the motor’s load current in real time and automatically adjusts the feed speed to avoid additional energy consumption caused by load fluctuations.

Chain crushers: Why have they become the “main force” in organic fertilizer raw material crushing?

fertilizer granulator Nov 10, 2025

In the fertilizer production process, raw material crushing is a critical step in determining the quality of the final product. This is especially true for organic fertilizer production, which often processes a variety of materials such as straw, cake meal, and fermented livestock and poultry manure. Chain crushers, due to their unique advantages, have become a common equipment in the industry.

Unlike traditional crushing equipment, the core working component of a chain crusher is a high-strength chain. When the equipment is started, the motor drives the drum to rotate at high speed, and the chain on the drum moves in a circular motion. The impact and shear forces generated by the high-speed chain tear and crush the fertilizer raw materials entering the crushing chamber.

For high-fiber materials such as straw, the chain can penetrate deep into the fibers and sever the structure. For hard materials such as cake meal, the impact force of the chain effectively breaks up clumps, avoiding the problem of material jamming that traditional equipment often encounters.

More importantly, chain crusher can adapt to the diverse raw material characteristics of the fertilizer industry. Whether it is wet materials with a moisture content of 15%-25% or dry block raw materials, stable crushing can be achieved, and the particle size of the crushed materials is uniform, without the need for secondary screening, and can directly meet the requirements of subsequent granulation and mixing processes, greatly improving the production efficiency of organic fertilizers.

Smallholder farmers and large-scale farming: Differentiated designs for organic fertilizer production lines

fertilizer granulator Nov 7, 2025

Organic fertilizer production lines require flexible design based on the scale of the farming entities. Given the dispersed nature of smallholder farming, small-scale organic fertilizer production lines must offer the advantages of low investment, ease of operation, and portability. For example, modular equipment combinations can be used, with a single line’s daily production capacity limited to 10-50 tons. These lines also support on-site assembly and commissioning, adapting to smallholder farmers’ space and funding needs. Operational processes are streamlined, and one-click control systems lower the technical barriers to entry. Some small-scale lines also feature mobile crushing units, allowing for direct processing of straw in the field.

Large-scale farming (such as 10,000-acre orchards or contiguous farmlands) requires continuous production lines equipped with automated batching, intelligent fermentation monitoring, and large-scale cooling and screening systems to achieve 24/7 uninterrupted production, with daily production capacity reaching hundreds of tons. These lines also require supporting raw material warehousing and a cold chain for finished products to meet the continuous demands of large-scale fertilization.

In addition, to meet the “customized small batch” needs of small farmers, the organic fertilizer production line needs to support rapid switching between multiple recipes, while large-scale production lines focus on “standardized large batches” and ensure that the quality error of each batch of products does not exceed 5% through stable process parameters. This differentiated design enables the organic fertilizer production line to meet the needs of different planting entities.

Flat die pelleting machines: Why are they suitable for small and medium-sized organic fertilizer companies?

fertilizer granulator Nov 6, 2025

Small and medium-sized organic fertilizer companies are characterized by moderate production capacity, diverse raw materials, and large batch sizes. The design features of the flat die pelleting machine perfectly meet these needs, making it a cost-effective choice for these companies.

1.Low Equipment Investment Cost

The flat die pelleting machine has a relatively simple structure and does not require a complex transmission system. The purchase cost of a single unit is only 60%-70% of that of similar granulator equipment with similar production capacity. Furthermore, installation does not require a complex foundation, saving small and medium-sized companies from the high initial investment.

2.Flexible Raw Material Adaptability

Small and medium-sized organic fertilizer companies often purchase local raw materials, which can have large fluctuations in moisture and fiber content. The flat die granulator’s wide adaptability allows it to handle high-fiber straw materials, and the vertical compression of the rollers prevents tangling. For fermented materials with slightly higher moisture content, the flat die surface is easy to clean and prevents sticking.

3.Convenient Production Changeover

Small and medium-sized companies often produce a variety of products in small batches, requiring frequent adjustments to pellet size. It only takes 1-2 people to replace the flat die of the flat die pelleting machine, and it can be completed within 30 minutes. In addition, the cost of flat dies with different apertures is low. The company can reserve multiple sets of flat dies and quickly switch product specifications to meet the needs of different customer orders.

How do new type organic fertilizer granulators flexibly cope with small-batch, multi-variety production?

fertilizer granulator Nov 6, 2025

Many small and medium-sized organic fertilizer plants often face the problem of “small batches and a wide variety of products.” Traditional granulators are prone to material waste and time-consuming when changing materials, but new type organic fertilizer granulators offer greater flexibility in this regard.

First, the new type organic fertilizer granulator features a simpler granulation chamber design with fewer dead corners. Before changing recipes, there’s no need to disassemble complex components. Simply empty the chamber of any remaining raw materials and blow compressed air through the feed port for 3-5 minutes. This will completely clear the chamber, preventing the previous material from mixing with the new. For example, switching from straw to mushroom residue can be completed in 10 minutes, saving half an hour compared to traditional machines.

Second, parameter adjustment eliminates the need to start from scratch. The control panel can store 3-5 commonly used recipe parameters. The next time you need a corresponding recipe, simply select the mode and the machine will automatically adjust the speed and pressure, eliminating the need to experiment with parameters step by step. For example, if you’ve made organic fertilizer from chicken manure before, you can simply start the machine directly next time by selecting “Chicken Manure Mode,” making it easy for even beginners to avoid errors.

Finally, there’s “small production capacity, no waste.” Traditional machines tend to idle and consume a lot of power during small batch production. The new type organic fertilizer granulator features a “low-load adaptation” function, allowing it to operate stably even when producing only 3 tons of material at a time. This eliminates the problem of loose or tight pellets caused by low material volume, making it easy for small factories to handle a wide variety of production.

How much work can a small organic fertilizer plant save by using a windrow compost turning machine?

fertilizer granulator Nov 5, 2025

Many small organic fertilizer plants initially used manual compost turning, requiring three people to turn only 20 tons of compost a day. This was tiring and slow. Switching to a windrow compost turning machine can save significant time and reduce waste.

First, it saves labor. A windrow compost turning machine can turn 50-80 tons of compost a day, equivalent to the work of 5-6 workers. Furthermore, there’s no need to carry hoes or push carts. Workers simply operate the machine and follow its route, eliminating the need to run back and forth in the stinking compost yard. This significantly reduces the physical workload and eliminates the worry of heatstroke in the summer or frozen hands in the winter.

Second, it saves time. Manual compost turning requires digging up and stacking the pile piece by piece, taking half a day to complete. A compost turning machine, turning as it goes, can turn a 10-ton pile in 10 minutes, and the turning is more even. Previously, manually turned piles often had “dead corners,” requiring 30 days for fermentation. With a machine, fermentation is complete in 20 days, shortening the production cycle by one-third.

It also saves on raw materials. Manual compost turning can easily miss large chunks of raw materials or spill them outside the pile, wasting about 10%. The windrow compost turning machine’s blades break up large chunks of raw materials and “sweep” spilled materials back into the pile, increasing raw material utilization to over 95%.

How do BB fertilizer companies of different production capacities choose the right mixer operating mode?

fertilizer granulator Nov 4, 2025

The differences in production capacity among BB fertilizer companies (small-scale with daily production capacity below 50 tons, large-scale with daily production capacity above 100 tons) directly influence the choice of BB fertilizer mixer operating mode. Choosing the right mode can improve efficiency by over 30%.

Small-scale companies often operate in batch mode, making the “batch mixing + staged feeding” mode suitable: the single mixing volume is set at 70% of the equipment’s capacity, and feeding is carried out in three batches: 60% base granular fertilizer is added first, followed by 30% powdered raw materials after three minutes of mixing, and finally 10% trace additives. The total mixing time is kept to 10-12 minutes. This mode avoids energy waste caused by idling equipment for small batches of raw materials and facilitates flexible switching of fertilizer formulas.

Large-scale continuous production companies require a “continuous mixing + flow linkage” model: raw materials are continuously fed into the BB fertilizer mixer in proportion via a conveyor belt. The raw material flow rate is linked to the mixing speed. An online detection device is installed at the BB fertilizer mixer outlet to monitor mixing uniformity in real time. If the coefficient of variation exceeds 5%, feedback is immediately provided to adjust the feed ratio. Furthermore, continuous production requires cleaning of the drum wall every four hours to prevent long-term accumulation that can affect the quality of subsequent batches.