Fertilizer Processing Process with a Disc Granulator

fertilizer granulator Aug 29, 2025

The disc granulator is the core equipment in a fertilizer production line, and its standardized processing flow is crucial for producing high-quality fertilizer.

The first step is raw material preparation. Raw materials include organic materials such as animal manure and plant residues, as well as inorganic materials such as urea and ammonium phosphate. These raw materials must be crushed to reduce particle size for subsequent mixing and granulation. Furthermore, they must be accurately weighed according to the formula to ensure an accurate nutrient ratio, and the humidity must be adjusted to 20%-30% to facilitate granule formation.

The second step is raw material loading. The disc is driven by a motor, and the speed can be set according to the raw material characteristics and the desired particle size. The raw material is evenly distributed on the disc, spread toward the edges due to centrifugal force, and then rises along the inner wall due to friction. After reaching a certain height, it falls back due to gravity, forming a circular motion.
The third step is the application of a binder. As the raw materials circulate, a nozzle above the discsprays the binder onto the raw materials. The binder is usually a natural polymer or inorganic substance. When it comes into contact with water, it develops viscosity, causing the fine particles to bind together. The spraying rate must be precisely controlled: too much will result in oversized and dense granules, while too little will make them difficult to form.

The fourth step is granule growth. As the disc rotates continuously, the already bonded small granules continuously absorb the raw materials, growing larger as they rotate. The collision and friction between the granules also make them more compact. The operator must observe the granule state and adjust the rotation speed and tilt angle promptly. The rotation speed affects the residence time and granule size, while the tilt angle changes the movement trajectory and helps shape the granules.
The fifth step is discharge. When the granules reach the desired size and quality, they overflow from the edge of the disc. Freshly formed granules contain moisture, which requires drying to reduce the moisture content and improve stability and storage performance.

Through this series of rigorous processes, the disc granulator machine transforms various raw materials into high-quality granular fertilizers, providing strong support for agricultural production.

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

fertilizer granulator Aug 26, 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.

How to Choose the Right Double Roller Press Granulator for Farms

fertilizer granulator Aug 22, 2025

Due to its unique advantages, double-roller press granulators have become essential equipment for farms to process manure and produce organic fertilizer. When selecting a granulator, you need to consider multiple factors to ensure it meets your production needs.

First, you need to determine your production scale. Small and medium-sized farms have limited daily manure processing capacity, so choosing a small machine with an hourly capacity of 1-3 tons can meet daily granulation needs while avoiding idle equipment. Large-scale farms require a machine with an hourly capacity of 5 tons or more and strong continuous operation capabilities to ensure timely manure processing and stable fertilizer output.

Second, consider the characteristics of the raw materials. Farms primarily use livestock and poultry manure as their raw material, which is high in moisture and contains impurities such as crude fiber. Therefore, the equipment needs to have strong anti-clogging capabilities, and the roller surface should be made of a non-slip and wear-resistant material to prevent slippage and affect granulation efficiency.

Supporting facilities should be planned simultaneously. It’s recommended to use pre-treatment equipment such as dewatering machines and crushers to control the moisture content of raw materials within an appropriate range, and to configure screening devices to grade finished particles to improve fertilizer quality. Furthermore, consider equipment energy consumption, prioritizing energy-efficient models to reduce operating costs.

A balance should be struck between price and after-sales service. Avoid blindly pursuing low-priced equipment, as its materials and workmanship may be defective and increase maintenance costs. Choose a manufacturer that can provide installation and commissioning, operator training, and rapid fault response to ensure stable operation after the equipment is commissioned and minimize losses caused by downtime.

A comprehensive assessment of production scale, raw material characteristics, equipment quality, supporting capabilities, and after-sales service is crucial to selecting a double-roller press granulator suitable for your farm, ensuring efficient resource utilization of manure.

Working principle and characteristics of double roller granulator for dry granulation

fertilizer granulator Dec 11, 2020

Working principle of double roller granulator

When the double roller granulator works, it is forced to roll the material into shape by two opposite moving roller skins of the granulator. Semi circular spherical cavities are regularly distributed on the two cylindrical roller skins. When the roller skin rotates against each other, the two semicircular cavities just form a complete spherical mold, and the materials inside are forced to be extruded into spherical particles. Due to the continuity of extrusion production, the particles and particles are connected together when they are just extruded, forming a cloth full of particles, which needs to be broken up by the crushing roller and divided into small round particles, and then screened from the screen to select the qualified particles.

In the production of granular fertilizer by double roller fertilizer granulation machine, it should be noted that the ball socket on the two roller skins should be in good position. If it is not adjusted in place, there will be a certain dislocation during granulation, which can not produce qualified granular fertilizer. In addition, after the formation of particles, they will be released from the ball and socket of roller skin in time, so as to realize continuous production. If the formed particles do not come out in time, complete particles will not be formed, thus affecting the normal production.

Characteristics of double roller granulator for dry granulation
1. There is no drying process in the organic fertilizer granulation machine. It is granulated at room temperature and formed in one time. It has the advantages of less investment, quick effect and good economic benefit.
2. Compound fertilizer double roll extrusion granulator has small power, reliable operation, no waste discharge, stable operation, convenient maintenance, reasonable process layout, advanced technology and low production cost.
3. The material of the roller extrusion granulator is widely used, not only in fertilizer industry, but also in all kinds of chemical raw materials such as snow melting agent.

Environmental protection granulation process of double roller granulator

fertilizer granulator Dec 11, 2020

The double roller granulator uses the way of forced extrusion to make particles, the whole process does not need drying and cooling, and the equipment investment is small. What’s more important is that this granulation method is a very environmentally friendly production mode because it is made of particles by physical methods, and the whole process has no pollution and no waste.

Environmental protection granulation process of double roller granulator

When the double roller extrusion granulator works, it is forced to roll the material into shape by two opposite moving roller skins of the granulator. Semi circular spherical cavities are regularly distributed on the two cylindrical roller skins. When the roller skin rotates against each other, the two semicircular cavities just form a complete spherical mold, and the materials inside are forced to be extruded into spherical particles. Due to the continuity of extrusion production of organic fertilizer granulation machine, the particles and particles are connected together when they are just extruded, forming a cloth full of particles, which needs to be broken up by the crushing roller and divided into small round particles, and then screened from the screen to select the qualified particles.

The fertilizer granulation machine has the advantages of low investment and good economic benefit. The complete set of equipment is compact in layout, scientific and reasonable, and advanced in technology. Energy saving and consumption reduction, no three wastes discharge, stable operation, reliable operation and convenient maintenance. It is suitable for granulation of various raw materials such as compound fertilizer, medicine, chemical industry, feed and so on.