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.

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%.

The new type two-in-one organic fertilizer granulator’s complete operating process.

fertilizer granulator Sep 25, 2025

The new type two-in-one organic fertilizer granulator features an integrated “mixing + granulation” design, simplifying organic fertilizer production. Its operations are centered around four core steps, ensuring pellet quality and efficiently supporting the organic fertilizer production line.

The first step is raw material pretreatment. Fermented organic fertilizer (such as livestock manure and composted straw) must first be crushed to a 40-60 mesh fine powder with a moisture content of 25%-35%. Excessively coarse raw materials will result in uneven granulation, while inappropriate moisture content will affect the final product. Meeting pretreatment standards is essential for stable equipment operation.

The second step is the core mixing process. Pretreated raw materials enter the integrated mixing system. A high-strength alloy steel agitator shaft drives the wear-resistant blades, while a variable frequency motor precisely controls the speed between 20-60 rpm. If binders such as bentonite are required, they are added simultaneously. The blades shear and stir the powder, achieving over 90% mixing uniformity within 5-10 minutes, preventing uneven nutrient distribution in the pellets.

The third step is targeted granulation. The mixed material automatically enters the granulation system, where the equipment changes its forming method based on the raw material’s characteristics. Highly viscous raw materials (such as chicken manure organic fertilizer) use a stirring granulation mechanism, where paddles knead the material into 2-4mm pellets. High-fiber raw materials (such as straw organic fertilizer) use a roller-type granulation mechanism, where die extrusion forms the pellets. The stainless steel disc can be hydraulically adjusted from a 30° to 50° tilt angle, and a wear-resistant rubber lining reduces sticking to the wall. The pellet formation rate exceeds 90%, and the pellets are uniformly shaped.

Finally, the screen residue is recycled and connected. After granulation, the pellets pass through an integrated screening device. Qualified pellets enter the drying stage (dried to a moisture content of less than 10%), while substandard fines are returned to the mixing system through a recirculation channel for processing with new raw materials. This design achieves a raw material utilization rate exceeding 95%, reducing waste and ensuring continuous production.

The entire process eliminates the need for frequent manual handling. The new type two-in-one organic fertilizer granulator can complete the entire process from raw material input to qualified pellet output, significantly improving the efficiency and convenience of organic fertilizer production.

Applicable to multiple industries, disc granulators offer a wide range of applications

fertilizer granulator Sep 17, 2025

Disc granulators are not limited to fertilizer production. Their outstanding granulation capabilities make them a valuable tool for a variety of industries, including metallurgy, building materials, and chemicals.

In the metallurgical industry, metal ore powders such as iron ore and manganese ore are processed into granules by disc granulators, facilitating subsequent sintering and smelting processes. This not only improves resource utilization, but also reduces production waste and lowers production costs.

In the building materials industry, disc granulators are used to produce cement raw material granules, ceramsite sand, and other building material granules. The granulation of cement raw materials improves their combustion properties, thereby enhancing cement quality.

In the chemical industry, disc granulators can granulate a variety of chemical raw materials, including catalysts, pigments, and detergents. The resulting chemical products exhibit improved flowability and stability, significantly enhancing product performance and meeting the high standards of chemical production.

Tracked design and efficient turning! Technical advantages of the windrow compost turner

fertilizer granulator Sep 16, 2025

The windrow compost turner’s widespread use in organic fertilizer production stems from the significant advantages offered by its unique technical design. The tracked design is a key advantage. Compared to traditional wheeled equipment, it effectively reduces ground pressure, typically to just 0.05-0.1 MPa. This allows for flexible maneuverability even on muddy, soft surfaces, or complex terrain with slopes up to 15°, eliminating the need for dedicated tracks. This significantly improves site utilization, exceeding that of trough-type compost turning machines by over 30%.

The machine also excels in turning performance. Its hydraulic arm allows for flexible adjustment of turning height and width, accommodating windrows ranging from 0.5-2.5 meters in height and 2-6 meters in width. A single unit can process 50-150 tons of material per hour, achieving an efficiency 1.5-2 times that of a single-screw compost turning machine. The turning teeth and spiral blades are forged from alloy steel. Combined with a bottom-up turning mechanism, this achieves a material turning rate of over 95%, preventing localized compaction and uneven fermentation. Material temperature deviation is kept within 3°C, ensuring stable fermentation quality.

Furthermore, the equipment’s electronic control system monitors operating parameters in real time. In the event of abnormal conditions such as overload or excessive hydraulic oil temperature, it automatically issues an alarm and shuts down the machine for protection, ensuring safe and efficient operation.

Synergistic application of NPK fertilizer production lines and BB fertilizer mixers

fertilizer granulator Sep 13, 2025

NPK fertilizer production lines are crucial for compound fertilizer production. As a key piece of equipment, BB fertilizer mixers, when integrated with the production line, significantly improve overall production efficiency and product quality. NPK fertilizer production involves processes such as raw material crushing, mixing, granulation, and drying. The mixing stage directly impacts the nutrient balance of the final product, and BB fertilizer mixers are a perfect fit for this requirement.

In the production line, raw materials processed by the fertilizer crusher are delivered to the BB fertilizer mixer via a fertilizer conveyor. Upon startup, the drive system drives the mixing shaft and blades, evenly mixing nitrogen, phosphorus, and potassium, laying a solid foundation for the subsequent granulation process. Inhomogeneous mixing can result in significantly different nutrient distributions in the granulated fertilizer, impacting product quality.

The BB fertilizer mixer’s control system can be linked with the overall production line control system to synchronize parameters such as mixing speed and time, ensuring a smooth production process. After mixing, the uniform raw materials are discharged through the discharge port and sent to the granulator by conveyor. It works efficiently with subsequent equipment such as dryers and coolers to form a complete NPK fertilizer production chain, helping companies achieve large-scale, high-quality production.

Why is the large wheel compost turner considered an “accelerator” for efficient organic fertilizer production?

fertilizer granulator Sep 12, 2025

In today’s pursuit of efficient production, the large wheel compost turner, with its superior performance, has become an “accelerator” for organic fertilizer manufacturers. Its efficiency advantages are reflected in multiple aspects.

In terms of processing capacity, the equipment utilizes a large wheel structure with a main wheel diameter of 5-10 meters, providing a wide turning coverage area in a single turn. It can process 100-200 tons of material per hour, 3-5 times the capacity of traditional windrow compost turners. For example, a base with an annual production capacity of 10,000 tons of organic fertilizer, which previously required multiple units, can now be met by a single large-wheel compost turner, significantly improving production efficiency.

In terms of fermentation efficiency, it uses centrifugal force to thoroughly turn the material to a depth of 1.5-2 meters, evenly mixing the upper and lower layers of the material, and maintaining a temperature distribution difference of ≤2°C, thus avoiding uneven fermentation. The equipment also accelerates the contact between materials and air, regulates temperature and humidity, and shortens the fermentation cycle to 20-30 days, nearly half the time of traditional equipment.

Furthermore, the equipment boasts a high degree of automation, with an electronic control system and touchscreen operation, allowing one or two people to operate it, reducing labor input. For organic fertilizer companies seeking efficient production, the large wheel compost turner is undoubtedly an ideal choice for enhancing competitiveness.

Application of poultry manure organic fertilizer production line in Xinjiang

fertilizer granulator Dec 10, 2020

The fertilizer production still needs to be operated by professional npk production line. The chicken manure without fermentation and ripening is used as organic fertilizer after drying, which will ferment and ripen in natural state, which may harm crops and is not conducive to crop growth. Chicken manure into organic fertilizer requires fermentation, ripening, granulation and drying process. After high temperature decomposition, it does not contain harmful bacteria and insect eggs, which avoids the disadvantages of farm manure, such as easy to burn seedlings, odor, and many diseases and insect pests.

Treatment mode of small fertilizer production line

First of all, the wheat straw is mechanically crushed by a pulverizer, then poured into the fermentation tank, mixed with water, added with sludge, and then added with chicken manure, sheep manure, rabbit manure, urea, etc. The raw material of organic fertilizer begins to ferment and decompose. After about 15 days of fermentation, the material is processed by the compost turning machine, so that the straw can rot completely and release the fertility, which is absorbed by the sludge, and the fertility of other organic fertilizers is absorbed at the same time.

Then the material is crushed by the semi wet material pulverizer and sent to the drum screening machine for screening. It can be used after 5 days of secondary fermentation. After crushing and screening, the materials can be granulated by rotary drum granulator or other granulating equipment, the appearance of particles is more beautiful and the granulation rate is higher.

The configuration of small organic fertilizer production line directly affects the benefit. Therefore, for fertilizer equipment, we can not blindly choose, to choose the appropriate configuration of fertilizer production line. Huaqiang fertilizer machine price is low, and It has a good quality, which is the first choice for small organic and npk fertilizer plants. The conveying equipment of fertilizer production line adopts belt conveyor and large angle belt conveyor, which not only ensures the smooth transportation system, but also protects the particles, reduces the height of the plant and reduces the infrastructure construction.

Sheep manure organic fertilizer production line

fertilizer granulator Dec 9, 2019

Sheep manure organic fertilizer production line:
First. Mix the sheep manure with the crop straw. The amount of the sheep manure depends on how much the water content of the sheep manure is determined. According to the fermentation process, the water content is required to be within 45%, that is, the material is kneaded into a mass, and the water can be seen. Will not drip down, loosen the group will spread out. Then, the cornmeal and the required strains are added. The reason for the cornmeal is that the sugar content can be increased to promote the rapid fermentation of the strain.

Second, the configured materials are added to the material mixer for mixing, and the mixing is required to be uniform and transparent, and no raw blocks are left.

Third, the mixed materials are piled in a fermentation tank or grooves with a width of 2 to 6 meters and a height of 1.0 meters to 1.5 meters, and are repeatedly turned over and thrown every other day using a compost turning machine.

Four, under normal circumstances, in the fermentation tank, the temperature will rise after stacking for 2 days, and it will be odorless after 2 days. After 3 days, it will become fluffy and loose. After 2 days, compost will emit fragrance, 15 days, it can be fat.
1. In the fermentation tank for 2 days, the temperature will rise to 60 ° C to 80 ° C, which will kill bacteria and remove insects.
2. On the fourth day in the fermentation tank, the odor is eliminated; then on the seventh day, the material in the tank will become loose, dry and covered with white hyphae.
3, fermented in the pool to the ninth day, the nine will emit a fragrance, basically similar to the koji.
4. Fermentation to the tenth day in the tank, the material will be fermented and cooked, and sufficient.
5. On behalf of the end of the fermentation stage, the material can be removed to the next step with a forklift or the like.

Five. The material moved by the forklift to the pulverizing process is pulverized by a semi-wet and high-humidity material pulverizer, and then mixed by a mixer machine, transported to fertilizer granulator machine by a conveyor, and granulated into granules, It is sent to the dryer by the belt conveyor, dried and dried, and then cooled into the cooler. Then the conveyor is sent to the screening machine for screening. The required particles of more than 95% will enter the next process, and about 5%. The granules are transported to the pulverizer for re-pulverization and granulation, and the granules that meet the standards are fed into the coating machine for coating. The coating can maintain the nutrients, and after coating, it is packaged by an automatic packaging machine. In this way, the sheep manure organic fertilizer is processed and packaged and can be sold in the warehouse.All the organic fertilizer production line is done.