Why do fertilizer crushers require special adaptations for bio-fertilizer production?

fertilizer granulator Oct 13, 2025

The core difference between bio-fertilizer production and conventional organic fertilizer and compound fertilizer production lies in the need to preserve the activity of the inoculant. Furthermore, the raw materials often consist of specialized materials such as fungus residue, traditional Chinese medicine residue, and fermented straw. This places special demands on grinding equipment: low temperature, pollution prevention, and precise particle size. Through targeted modifications, fertilizer crushers have become the ideal choice for bio-fertilizer production.

1. Low-temperature crushing preserves inoculant activity

The functional bacteria in bio-fertilizer (such as Bacillus subtilis and phosphate-solubilizing bacteria) are not tolerant to high temperatures. Excessive frictional heat (above 45℃) generated during the grinding process can inactivate the bacteria. High-quality fertilizer crushers optimize the impeller speed (to avoid excessive friction) and some are equipped with a “water-cooling jacket” to circulate cold water to remove heat from the chamber walls, maximizing inoculant activity.

2. Anti-residue design prevents cross-contamination

Bio-fertilizer production often requires switching between different inoculant formulations. If residual material from previous batches remains in the equipment, bacterial strains can mix. The fertilizer crusher‘s “fully open cleaning structure” solves this problem. The grinding chamber door can be fully opened, and the smooth, corner-free interior allows for quick cleaning without disassembling core components, reducing the risk of cross-contamination.

3. Precise Particle Size for Microbial Agent Mixing

Bio-fertilizer production requires uniform particle size (typically 1-3mm) after grinding. Uneven particle size results in incomplete mixing of the microbial agent and raw material, impacting fertilizer efficiency. The horizontal crusher can precisely control particle size deviation within ±0.5mm, providing a high-quality raw material foundation for subsequent microbial agent inoculation and mixing.

Key technology paths for low-energy retrofitting of NPK fertilizer production lines

fertilizer granulator Oct 11, 2025

To achieve the goal of efficient fertilizer production, low-energy retrofitting of NPK fertilizer production lines has become an industry imperative, with key improvements focused on optimizing technologies in high-energy-consuming processes.

In the raw material pretreatment stage, a waste heat recovery system is used to redirect 80-120°C exhaust gases generated during the drying process into the pulverization process, reducing energy consumption by 18%-22% and simultaneously reducing thermal emissions.

In the granulation process, a core energy consumer, traditional steam heating is gradually being replaced by electromagnetic heating, increasing heating speed by 50% and boosting thermal efficiency from 65% to over 90%. This reduces energy consumption per ton of product by approximately 80 kWh.

A closed-loop cooling system is introduced in the cooling process, increasing water reuse from 30% to 95% while minimizing the impact of circulating water on the surrounding environment.

In addition, the NPK fertilizer production line has achieved refined management and control through motor frequency conversion and an intelligent energy consumption monitoring platform. This platform monitors power changes across each device in real time, allowing for timely adjustment of operating parameters and avoiding idle energy consumption. Data shows that after systematic low-energy consumption upgrades, the NPK fertilizer production line can reduce overall energy consumption per ton of NPK fertilizer by 25%-30%, achieving both environmental and economic benefits.

Key points for retrofitting organic fertilizer production lines under environmental compliance requirements

fertilizer granulator Oct 10, 2025

With increasingly stringent environmental protection policies, environmental retrofitting of organic fertilizer production lines has become an industry imperative, focusing on the treatment of “three wastes” and compliance upgrades.

For waste gas treatment, organic fertilizer production lines must be equipped with sealed fermentation chambers and ammonia collection systems. Biofilter technology is used to control ammonia concentrations generated during the fermentation process to within standards. Some areas also require VOC monitoring equipment to ensure real-time upload of emission data.

For wastewater treatment, production lines must establish a recycling system to sediment and filter wash water and condensate before reusing them for raw material moisture conditioning, achieving zero wastewater discharge.

For solid waste treatment, optimized screening processes are employed to re-crush fermentation residues before mixing them back into fermentation, achieving full solid waste utilization.

Furthermore, the environmental impact assessment process imposes stricter requirements on production line site selection and capacity planning, such as requiring them to be at least 500 meters away from residential areas and designing production capacity to match the regional environmental carrying capacity. Although these transformations increase initial investment (usually the transformation cost of a single production line accounts for about 15%-20% of the total investment), the energy consumption of the organic fertilizer production line can be reduced by 12%-18% after the transformation.

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

fertilizer granulator Oct 9, 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.

Benefits of Using a Flat Die Granulator in an Organic Fertilizer Production Line

fertilizer granulator Oct 9, 2025

In organic fertilizer production, the granulator is a core piece of equipment that determines product quality and production efficiency. The flat die granulator, with its unique design, is the preferred equipment for organic fertilizer production lines. Its advantages are primarily reflected in five key areas.

First, it offers excellent adaptability to raw materials. Organic fertilizer raw materials are complex, with common materials like livestock and poultry manure, straw, and mushroom residue exhibiting widely varying moisture and fiber content. By adjusting the pressure of the rollers and the speed of the die, the flat die granulator can easily process raw materials with a moisture content of 15%-30%. This eliminates the need for over-drying or the addition of large amounts of binders, preserving the beneficial microorganisms in the raw materials while reducing pretreatment costs. This makes it particularly suitable for the diverse raw material production needs of small and medium-sized organic fertilizer plants.

Second, the granulation quality is stable and controllable. The flat die granulator utilizes a “fixed die plate, rotating pressure roller” extrusion granulation method, achieving a pellet forming rate exceeding 95%. Pellet diameter can be flexibly adjusted (typically between 2 and 12 mm) by replacing dies with different apertures, meeting the pellet specification requirements for various applications, such as seedling fertilizer and field fertilizer. The pellets have a moderate hardness and are resistant to breakage, making them easy to package, transport, and spread in the field, effectively enhancing the product’s market competitiveness.

Furthermore, they offer low energy consumption and operating costs. Compared to ring die granulators, flat die pelletizers utilize a lower motor power, reducing power consumption by 20%-30% at the same production capacity. Furthermore, their consumable parts (such as the pressure roller and die) are made of wear-resistant alloy, offering a service life of over 3,000 hours. Replacement frequency is low, and the cost of spare parts is only half that of ring die pelletizers, significantly reducing production line operating expenses over the long term.

Furthermore, they are easy to operate and maintain. The flat die granulator boasts a simple and compact structure, a small footprint, and a quick installation and commissioning cycle. Operators can easily master the machine after minimal training. Routine maintenance requires only the regular addition of lubricating oil and cleaning of residual material from the die holes, eliminating the need for complex technical expertise. This significantly reduces labor costs and is particularly suitable for small and medium-sized manufacturers facing a shortage of skilled personnel.

Overall, the flat die granulator, with its high adaptability, cost-effectiveness, and ease of operation, is an ideal choice for improving efficiency, reducing costs, and ensuring quality in organic fertilizer production lines. It provides strong support for the development of small and medium-sized organic fertilizer manufacturers.

Practical Methods for Improving the Granulation Yield of Flat Die Granulators

fertilizer granulator Sep 30, 2025

In organic fertilizer production lines, flat die granulators typically process materials such as livestock and poultry manure and composted straw. These materials contain coarse fiber and experience large moisture fluctuations, which can easily lead to low granulation yields and loose pellets. To improve granulation efficiency, precise optimization in four key areas is necessary, taking into account the characteristics of the organic fertilizer material.

Raw material pretreatment must be tailored to the characteristics of the organic fertilizer. First, the moisture content should be controlled between 25% and 30%, which is the optimal range for organic fertilizer granulation. A moisture content too low can easily result in broken pellets, while a moisture content too high can cause die sticking and clogging. This can be adjusted by airing the material or adding dry straw powder. Secondly, the composted material should be pulverized to ensure that the coarse fiber particle size does not exceed 1/2 the die hole diameter to prevent fibers from wrapping around the die rollers and causing uneven extrusion. Uncomposted lumps should also be removed to prevent clogging. Additionally, 2% to 3% bentonite can be added as a binder to enhance pellet density without affecting the fertilizer’s efficiency.

Equipment adjustments require targeted optimization. Organic fertilizer materials have poor fluidity, so the die roller gap should be adjusted to 0.2-0.4mm, slightly wider than the standard setting, to prevent material from getting stuck. The roller speed should be reduced to 15-20r/min to allow ample time for the coarse fibers to be extruded and formed. For die orifice selection, a tapered die with a diameter of 4-8mm is preferred to reduce material resistance within the die and minimize the likelihood of blockage. Regularly clean the die orifice with a steel brush to remove residual fiber impurities.

Process operations should be tailored to the production scenario. High-temperature preheating is not required before startup. Simply use a small amount of wet material to “prime” the die, forming a thin layer of material on the inner wall of the die orifice to prevent subsequent material from sticking to the wall. Use a spiral feeder with a constant speed to avoid concentrated lumps of material and prevent equipment overload. If fibers are found on the surface of the pellets and they are prone to breakage during production, add binder or adjust the moisture content promptly.

Maintenance should focus on vulnerable areas. Organic fertilizer materials contain corrosive components. The die roller surface should be cleaned weekly, and residual humus should be removed with a wire brush to prevent corrosion. The inner wall of the die hole should be inspected monthly, and burrs caused by coarse fiber wear should be removed with fine sandpaper. The transmission system lubricant should be replaced quarterly, using a corrosion-resistant, specialized oil to prevent component wear caused by humus contamination.

By optimizing these measures for organic fertilizer production lines, the flat die granulator’s pelletizing rate can be increased to over 90%, reducing waste of mature raw materials while ensuring uniform organic fertilizer pellets and ensuring stable and efficient production line operation.

When using windrow compost turning machines in different seasons, pay attention to key details

fertilizer granulator Sep 30, 2025

A windrow compost turning machine isn’t a one-size-fits-all model. Adjusting details according to the season will ensure smooth fermentation of your organic fertilizer.

Spring’s high humidity and fluctuating temperatures can easily lead to a musty odor in the compost. When using a compost turner, increase the frequency of turning the compost. Instead of turning every two days, turn every 1.5 days in spring. Loosen the compost to allow moisture to escape, and monitor the temperature. If the temperature is below 50°C, slow the compost turner’s speed to allow for a more thorough turning, allowing microbial activity to raise the temperature.

Summer temperatures are high, and the compost easily overheats (over 70°C kills beneficial bacteria). Reduce the depth of each turning to avoid bringing all the hot material below to the surface. Turn the compost once a day. Sprinkle a thin layer of soil on the surface after each turning to provide shade and reduce temperatures while preventing rapid evaporation.

Autumn is dry, and the pile is prone to dehydration and cracking. Use a windrow compost turning machine with an atomizer, spraying small amounts of water as you turn to maintain a humidity level of 50%-60%. Slow the turning speed to allow the water and raw materials to mix thoroughly and avoid patches of dryness or wetness.

Winter is cold, and the pile struggles to heat up. Reduce turning frequency to once every three days, avoiding frequent turning to disperse heat. When turning, pile the pile higher (1.2-1.5 meters). Try turning the cold material in the center with the windrow compost turning machine, covering the hot material on the outside to help retain heat and ferment.

How to adapt a BB fertilizer blender to different raw material characteristics?

fertilizer granulator Sep 29, 2025

BB fertilizer raw materials come in a variety of forms (granular, powdered, and fiber-containing). BB fertilizer blenders require targeted adjustments to accommodate these different raw material characteristics and avoid mixing problems.

For pure granular raw materials (such as urea and diammonium phosphate granules), which have relatively small density differences but are prone to rolling and stratification, the BB fertilizer blender should be equipped with guide plates within the mixer drum to guide the raw materials into upward and downward circulation and control the feed order. Adding the denser diammonium phosphate first, followed by the lighter urea, can reduce initial stratification. The speed can be appropriately reduced in the later stages of mixing to prevent excessive collisions between particles that could lead to breakage.

If the raw materials contain powdered ingredients (such as potassium chloride powder or trace element powder), a dustproof seal should be installed at the BB fertilizer blender feed port to prevent dust from escaping. Additionally, an atomizing humidifier (control the humidity to ≤15%) should be installed within the mixer drum. A small amount of humidification can enhance adhesion between the powdered raw materials and the granules, preventing dust from becoming suspended.

When the raw materials contain fiber organic fertilizer (such as fermented straw powder), it is necessary to use a paddle with a shearing function to prevent the fibers from entangled and clumping. At the same time, the fiber raw materials should be crushed to less than 3mm in advance to reduce mixing resistance. During the mixing process, the machine can be stopped and observed every 3 minutes. If fiber clumps are found, the paddle angle needs to be adjusted to enhance the shearing and dispersion effect to ensure that the fibers and granular fertilizer are fully integrated.

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

fertilizer granulator Sep 28, 2025

Pellet strength is a core performance indicator for fertilizer products. Ring die granulators 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 granulator due to too high a moisture content.

Selecting the ring die granulator 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.

How to Improve the Efficiency of a New Two-in-One Organic Fertilizer Granulator

fertilizer granulator Sep 26, 2025

The efficiency of a new type two-in-one organic fertilizer granulator directly affects the production capacity of an organic fertilizer production line. Improper operation can easily lead to problems such as slow granulation and low pelletizing yield. Four optimization strategies can improve both efficiency and quality.

First, proper raw material pretreatment is essential. Strict control of raw material particle size and moisture is crucial: crush the fermented organic fertilizer into a 40-60 mesh fine powder to prevent coarse particles from blocking the equipment’s feed inlet and affecting mixing uniformity. The moisture content should be maintained at a stable 25%-35%. Adjust moisture content by drying or adding dry materials; spray water if too low.

Second, precise adjustment of equipment parameters is crucial. During the mixing process, adjust the agitator speed according to the raw material type: when processing high-fiber raw materials (such as straw fertilizer), adjust the speed to 50-60 rpm to increase shear force; when processing highly viscous raw materials (such as chicken manure fertilizer), reduce the speed to 20-30 rpm to prevent material from sticking to the wall. During the pelletizing process, the pelletizing method should be adjusted to suit different raw materials: for high-viscosity raw materials, use agitator pelletizing, adjusting the disc inclination to 40°-45°; for high-fiber raw materials, use roller compaction pelletizing, increasing the die pressure appropriately.After parameter adaptation, the granulation efficiency of the new type two-in-one organic fertilizer granulator can be increased by 20%-25%, and the granule forming rate is stabilized at more than 90%.

Furthermore, daily maintenance is essential. Before starting the machine daily, inspect the agitator blades and pelletizing die for wear. If blade edge wear exceeds 3mm or the die aperture is deformed, replace them promptly to avoid uneven mixing and uneven pellet sizes caused by aging components. Clean residual material inside the equipment weekly, especially the mixing chamber and the inner wall of the pelletizing disc, to prevent material agglomeration that affects subsequent production. Lubricate transmission components such as bearings and gears monthly to reduce mechanical friction and extend equipment operation.

Finally, optimizing production processes can further improve efficiency. The “immediate recycling of screen residue” model allows the screening of substandard fines directly back to the mixing system through a reflux channel, eliminating the need for manual transfer and reducing waiting time for raw materials. If the organic fertilizer production line requires continuous operation, a raw material buffer can be configured to ensure uninterrupted feeding of raw materials, avoiding frequent equipment starts and stops due to material shortages. After process optimization, the equipment’s effective daily production time can be increased by 2-3 hours, increasing overall production capacity by approximately 15%.