Granulation Process and Equipment Advantages of the New Type Organic Fertilizer Granulator

fertilizer granulator Aug 22, 2025

The new type organic fertilizer granulator utilizes the mechanical agitation force of high-speed rotation and the resulting air dynamics to continuously mix, granulate, spheroidize, and compact fine powders within the machine, achieving the desired granulation effect.

The resulting granules are spherical with a sphericity ≥0.7, a particle size generally ranging from 0.3 to 3 mm, and a granulation rate ≥80%. Particle size can be adjusted appropriately by adjusting the material mixing ratio and spindle speed. Generally, lower mixing ratios and higher spindle speeds result in smaller particles, and vice versa. This machine is suitable for granulating lightweight, fine powders. The finer the basic particles of the fine powder, the higher the sphericity and the better the particle quality. The particle size before granulation is generally required to be less than 300 mesh.

Typical applications of the new type organic fertilizer granulator include chicken manure, pig manure, cow dung, charcoal, clay, kaolin, and other materials. The new type organic fertilizer granulator boasts uniform granulation and a yield rate exceeding 97%, making it the optimal granulation equipment for organic-inorganic compound fertilizers, organic fertilizers, and bio-organic fertilizers. Due to the coarse fiber properties of the material, rotary granulators have a lower granulation rate, while agitator-type granulators cannot process materials with a nitrogen content exceeding 8% (due to sticking to the wall). This granulator overcomes the shortcomings of both, capable of producing both organic and organic-inorganic compound fertilizers with low energy consumption and high-quality granulation.

The new type organic fertilizer granulator‘s housing is welded from thickened, high-quality carbon steel plates. Ancillary equipment includes pulley assemblies, transmission components, a blower head, and a blower tail. The entire machine is sturdy and durable. The core agitator is precision-cast from a high-chromium alloy and undergoes a special heat treatment, resulting in wear resistance over three times greater than that of ordinary steel. It can withstand the high-frequency friction of fine powders for long periods of time. The main shaft and agitator blades feature a modular design and are fastened with high-strength bolts, enabling easy assembly and simple component replacement, reducing maintenance costs. Adjustable support feet on the bottom of the machine adapt to the flatness of the site, ensuring stable operation and reducing vibration-induced noise and component wear.

Cost Analysis of Chicken Manure Fertilizer Processing in an Organic Fertilizer Production Line

fertilizer granulator Aug 21, 2025

Chicken manure is indeed a high-quality organic fertilizer raw material, rich in organic matter, nitrogen, phosphorus, potassium, various trace elements, enzymes, and microorganisms. Through standardized aerobic composting processes, it effectively degrades organic matter, kills parasite eggs and pathogens, and renders it harmless and stable. This can then be produced into commercial organic fertilizer through an organic fertilizer production line, creating economic benefits for chicken farms while fundamentally addressing environmental pollution.

However, processing chicken manure into commercial organic fertilizer does involve certain production costs, which can be primarily categorized into the following aspects. First, equipment investment is the core, one-time investment. A complete production line typically includes fermentation and compost turning equipment, a crusher, a mixer, a granulator, a dryer, a cooler, a screener, and an automatic packaging machine. The choice of granulator significantly impacts cost and product form. For example, a rotary drum granulator offers high output, a disc granulator offers a high granulation rate, and a flat die granulator is suitable for organic materials. Different granulator models have varying prices and energy consumption. Secondly, the costs of the pretreatment and fermentation processes cannot be ignored. Fresh chicken manure is sticky and moist, typically with a moisture content exceeding 70%, while the optimal fermentation moisture content needs to be adjusted to 50%-60%. Therefore, a large amount of auxiliary materials (such as straw, sawdust, and mushroom residue) are often required to adjust the moisture and carbon-nitrogen ratios. The procurement, transportation, and crushing of these auxiliary materials all incur ongoing costs.

The initial equipment investment for processing chicken manure in an organic fertilizer production line is relatively high, and ongoing operations also require ongoing investment. The cost level depends largely on the production scale, the degree of automation, the availability and price of raw materials, and the positioning of the final product. For large-scale chicken farms, although the initial investment is high, in the long run, the comprehensive benefits of addressing environmental pressures and creating economic value by turning waste into resources are significant, making the cost acceptable.

Factors Affecting the Production of Compound Fertilizers Using a Disc Granulator

fertilizer granulator Aug 21, 2025

When producing compound fertilizers using a disc granulator, many factors influence granulation, such as disc diameter, disc speed, disc inclination, nozzle aperture, and moisture content. Generally speaking, disc inclination has a greater impact on the granulation rate, while disc speed has a greater influence on the compressive strength of the granules.

The moisture content of disc granulation significantly influences both the granulation rate and the compressive strength of the granules. When the moisture content of the material is controlled within the range of 16%-20%, the granulation rate and compressive strength of the granules are optimal. Too little moisture results in a low granulation rate; too much moisture causes the material to clump and stick together, resulting in a reduced granulation rate. When the moisture content is too low, the compressive strength of the granules increases with increasing moisture content, which is beneficial for improving the compressive strength of the granules. However, when the moisture content is too high, the excess moisture disrupts the interactions between fertilizer molecules, causing the dried granules to crack and resulting in a decrease in compressive strength. Before using a disc granulator, the optimal moisture content, disc speed, and disc inclination angle should be tested to ensure high fertilizer production line efficiency and high pellet quality. Furthermore, the finer the raw material powder, the better the granulation effect.

Disc granulators are widely used in organic fertilizer production lines and compound fertilizer production lines. Fertilizer production using disc granulators offers low investment, high output, simple process, and intuitive operation, resulting in excellent economic and social benefits.

Current Status and Development Trends of the Rotary Drum Granulator Market

fertilizer granulator Aug 20, 2025

As a key piece of equipment for powder granulation, the current market for rotary drum granulators exhibits distinct characteristics and clear trends.

Currently, market demand for rotary drum granulators is extremely strong. In the agricultural sector, with growing interest in green and environmentally friendly fertilizers, the production of organic and compound fertilizers is expanding, significantly driving demand for drum granulators. Many organic and compound fertilizer manufacturers are investing in advanced rotary drum granulators to improve production efficiency and ensure product quality. In addition to agriculture, industries such as chemicals and feed are also increasing their investment in drum granulators due to demand for granular products.

Market competition is becoming increasingly fierce. The influx of manufacturers has led to a complex product range and varying quality. Large companies dominate the market, leveraging their strengths in technological research and development, quality control, and after-sales service networks. Smaller companies rely on low prices to compete, but lag significantly behind in quality and innovation.

Technically, high-end equipment is becoming the mainstream. Models with automated control, intelligent monitoring, and high-efficiency energy-saving features are increasingly popular. They improve production efficiency and product quality while reducing labor and energy costs, meeting the demands of intelligent and green production.

Future development directions are clear: First,intelligent upgrades: equipment will enhance self-diagnosis and automatic adjustment capabilities, enabling parameter adaptation and unmanned production. Second,deepening energy conservation and environmental protection efforts: adopting advanced technologies and designs to reduce energy consumption and emissions, meeting stringent environmental requirements. Third,specialized segmentation: developing customized products for different industries, raw materials, and needs to meet individual market demands.

In short, the rotary drum granulator market presents both opportunities and challenges. Companies must focus on technological innovation, quality improvement, and service optimization to remain competitive.

The role of uniform feeder in fertilizer production line

fertilizer granulator Aug 20, 2025

In the continuous process of fertilizer production, the uniform feeder is the “nerve center” to ensure the coordinated operation of all links. Whether in compound fertilizer production line or organic fertilizer production line, it can improve the stability of raw material supply by more than 50%, and reduce product quality fluctuations from the source.

The uniform feeder adopts a design combining spiral conveying and frequency conversion speed regulation. The conveying screw is made of wear-resistant alloy material, which can adapt to raw materials with different physical properties such as urea granules, phosphate rock powder, fermented organic fertilizer, etc. The feeding amount can be set with an accuracy of ±2%. It can automatically adjust the conveying speed according to the needs of subsequent crushing, mixing, granulation and other processes to avoid raw material accumulation or feed interruption.

In the compound fertilizer production line, it can accurately convey basic raw materials such as nitrogen, phosphorus, and potassium according to the ratio, so that the nutrient deviation in the mixing link is controlled within 2%, which is much better than 8% of manual feeding. When handling wet organic fertilizer raw materials, its anti-blocking spiral structure combined with the vibration device can effectively avoid material adhesion and blockage, ensuring that the feeding amount per minute is stable at more than 98% of the preset value.

Compared with traditional feeding equipment, the uniform feeder does not require frequent manual adjustment, can reduce 80% of operational intervention, and reduce energy consumption by 30%. The material level sensor equipped with the equipment can monitor the inventory of the silo in real time, automatically start and stop the feeding, and realize unmanned continuous operation.

Whether it is connected to the crushing equipment or the mixer, the uniform feeder can lay a good foundation for the subsequent processes through the stable supply of raw materials. Choosing an appropriate uniform feeder can make the fertilizer production process smoother, the product quality more stable, and demonstrate the core value in large-scale production.

Application of Disc Granulators in NPK Fertilizer Production Lines

fertilizer granulator Aug 20, 2025

In the NPK fertilizer production line, disc granulators are a widely used and highly favored granulation equipment.

The disc granulator‘s structure is relatively simple yet unique. It primarily consists of an inclined disc, a drive mechanism, and a spray system. The disc, the core of the granulation process, is typically constructed of high-strength steel to ensure it can withstand the various forces involved in the granulation process. The drive mechanism provides stable rotational power to the disc, ensuring it rotates at an appropriate speed.

The disc’s operating principle is based on the movement and interaction of the materials within the rotating disc. When the mixed NPK fertilizer raw materials are fed into the rotating disc, the disc’s tilt and rotational motion cause the materials to roll upward along the disc’s inner wall due to a combination of centrifugal force, friction, and gravity. During this rolling process, a spray system applies a binder to the material. The binder acts like “glue,” gradually binding the loose raw material particles together and causing them to aggregate and grow. Over time, these agglomerated particles continuously roll and collide within the disc, further compacting and shaping them, ultimately forming relatively uniformly sized round granules that roll off the disc’s edge, completing the granulation process.

Disc granulators offer numerous advantages. First, they produce fertilizer granules with high roundness, excellent appearance, and strong market competitiveness. Second, they are relatively simple to operate and easy to master, requiring minimal operator skill. Furthermore, disc granulators are highly adaptable and can produce fertilizer granules of varying sizes to meet diverse market demands by adjusting parameters such as disc speed, tilt angle, and binder spraying rate to meet specific production needs.

However, disc granulators also have limitations. For example, compared to some large-scale granulation equipment, their production efficiency may be relatively low, making them less suitable for large-scale industrial production. Furthermore, when processing high-viscosity raw materials, material may stick to the disc, affecting granulation efficiency and equipment operation. Nevertheless, due to their unique advantages, disc granulators still play an important role in the production of NPK compound fertilizers by small and medium-sized enterprises, as well as in production scenarios where the appearance of fertilizer granules is a high priority.

Where are flat die granulators used?

fertilizer granulator Aug 19, 2025

With its unique extrusion molding principle, flat die granulators have demonstrated strong application potential in a variety of fields, making them an ideal choice for small- and medium-scale production. Their core structure consists of a flat die and a pressure wheel. The rotation of the pressure wheel squeezes the material through the die holes, forming cylindrical pellets. This simple and direct operation gives them wide applicability.

Flat die granulators perform exceptionally well in fertilizer production lines. When processing bio-organic fertilizers, they can directly pelletize wet fermented materials without the need for additional drying pretreatment, preserving the activity of beneficial bacteria while streamlining the production process. For nitrogen, phosphorus, and potassium compound fertilizers, their powerful extrusion capabilities can compress mixed powders into high-strength pellets, effectively eliminating the clumping problem associated with traditional pelleting. They are particularly suitable for producing high-concentration specialty fertilizers.

Flat die granulators are also essential for the feed processing industry. For poultry and livestock feed, they can compress raw materials such as straw powder and soybean meal into pellets, reducing feed losses during transportation. High-temperature extrusion kills parasite eggs in the raw materials, enhancing feed safety. In aquatic feed production, pellet density can be controlled by adjusting die hole size to meet the feeding needs of fish in different water layers.

In the environmental protection field, flat die granulators are a valuable aid in solid waste treatment. They can compress municipal sludge, agricultural and forestry waste, and other materials into fuel pellets, realizing waste resource utilization. These pellets have high combustion efficiency and low pollutant emissions, providing new ideas for the development of new energy sources.

The flat die granulator‘s advantages also lie in its flexible operation. By simply replacing dies with different apertures, a wide range of pellet specifications can be produced to meet the needs of diverse industries. The equipment also occupies a small footprint and is easy to install and maintain, making it suitable for small and medium-sized enterprises. As the concept of green production becomes increasingly popular, the flat die pelletizer, with its high efficiency, energy conservation, and versatility, continues to provide a reliable solution for material forming in various fields.

What is the production process of an organic fertilizer production line?

fertilizer granulator Aug 18, 2025

In terms of equipment, an organic fertilizer production line requires a fermentation compost turner, fertilizer crusher, fertilizer mixer, fertilizer granulator, fertilizer dryer, fertilizer cooler, fertilizer screening machine, fertilizer packaging machine, fertilizer conveyor, and fertilizer coating machine.

The raw materials used in organic fertilizer production vary widely, including livestock and poultry manure, municipal sewage sludge, and animal and plant residues. These raw materials are rich in organic matter, nitrogen, phosphorus, potassium, and other nutrients, providing essential nutrients for crop growth and are available at low prices.

How an organic fertilizer production line works:

Organic fertilizer processing primarily involves collecting, crushing, and mixing the raw materials. The raw materials are then mixed according to the desired formula, and the moisture content and carbon-nitrogen ratio are adjusted before the fermentation process begins.

Fermentation compost turning machines: Assist in turning the compost during the fermentation process, provide sufficient oxygen, and control the temperature to ensure uniform and thorough fermentation.

Fertilizer mixers: If the size and state of the fermented material are inconsistent, a semi-wet material grinder can be used for fine grinding.

Fertilizer Granulator: The crushed material is processed into uniformly sized organic fertilizer granules by the organic fertilizer granulator.

Fertilizer Cooler: After granulation, the organic fertilizer still contains approximately 30% moisture. To increase its strength, the granules need to be cooled for later storage and transportation.

Fertilizer Screening Machine: After granulation, a small number of unqualified granules, some too large and some too small, will be produced. The fertilizer screening machine is used to separate these granules. Oversized granules are returned to the fertilizer crusher, while undersized granules are returned to the fertilizer granulator for regranulation. Qualified granules are then sent to the automatic packaging machine.

Fertilizer Packaging Machine: The finished organic fertilizer granules are packaged by the automatic packaging machine, completing the entire process.

It should be noted that the above configuration is for a typical organic fertilizer production line and may not be suitable for all situations. In actual production applications, different manufacturers may have different requirements regarding site and raw materials, and adjustments may be required based on actual needs.  

The secrets of organic fertilizer production line and bio organic fertilizer production line

fertilizer granulator Aug 16, 2025

In agricultural production, the quality of fertilizer directly affects the growth and harvest of crops. Today, let’s take a deep look at the differences between organic fertilizer production line and bio organic fertilizer production line to help you make a better choice.

Organic fertilizer production line mainly uses animal and plant residues, such as livestock and poultry manure, crop straw, etc. as raw materials. After collection, pretreatment is first carried out, such as crushing and mixing, to make the raw materials uniform in texture. Then enter the key fermentation and decomposition link, using natural microorganisms to decompose and transform organic raw materials under suitable temperature, humidity and ventilation conditions. This process often takes several months to make organic matter reach a stable state and finally make organic fertilizer.

Bio organic fertilizer production line goes a step further on this basis. After the raw materials are also collected, pretreated and conventionally fermented and decomposed, wait for the material temperature to drop to a suitable range (usually not more than 40℃), and evenly mix in specific microbial agents, such as Bacillus, yeast, etc. These microorganisms play an important role in the follow-up, and can decompose nutrients such as insoluble phosphorus and potassium in the soil and convert them into plant-absorbable forms. However, since microorganisms are sensitive to the environment, the subsequent storage and transportation conditions must be strictly controlled to prevent inactivation.

From the production process point of view, the bio-organic fertilizer production line adds the addition of microbial agents. It seems simple, but it has higher requirements for equipment and environment, and the production process is more complicated.

In terms of product effect, organic fertilizer can improve soil structure, slowly release nutrients, and provide long-term nutrition for plants; bio-organic fertilizer not only has these functions, but also can prevent and inhibit pests and diseases, enhance plant resistance, reduce the use of pesticides, and improve the quality and safety of agricultural products.

Whether you want to invest in organic fertilizer production or focus on bio-organic fertilizer processing, choosing our equipment can escort your production, help you produce high-quality fertilizers, and seize the opportunity in the field of agricultural planting.

Drum Granulator: A Quartet of Process Innovations

fertilizer granulator Aug 16, 2025

In modern fertilizer production, rotary drum granulators are redefining granulation standards with four innovative features. How do these carefully designed functions work together to create energy-efficient production miracles?

Drum granulators are commonly used in organic fertilizer production because they efficiently form moist organic material into uniform granules through a rotating drum mechanism. They are a key component in organic fertilizer production equipment, which also includes mixers, crushers, dryers, and screening equipment. While granulators specialize in granulation, complete production lines (organic fertilizer production equipment) integrate multiple steps to transform raw organic waste into high-quality fertilizer.

“From steam conditioning to self-cleaning design, each innovation makes granulation more precise and efficient”

Intelligent Steam Conditioning System

The revolutionary steam injection technology acts like precise “thermal therapy” for materials. Steam penetrates the material bed, raising temperature while dissolving salts to form a liquid phase film, enabling ideal liquid phase conditions at low moisture content. This innovation reduces drying evaporation water by 40% and energy consumption by 35%.

⚗️Controlled Ammoniation System

Ammonia gas can be precisely introduced into the drum as needed to promote chemical reactions. This controlled ammoniation technology acts like a “chemical catalyst”, not only adjusting product pH but also improving granule structure, enhancing slow-release performance by 30%.

Self-Cleaning Liner Design

The special rubber or polypropylene liners embedded in the drum wall, combined with cleverly designed air holes, form an intelligent self-cleaning system. When liners rotate to the top, they sag under their own weight, causing adhered materials to fall off automatically. This “self-renewal” mechanism solves traditional granulator sticking problems, reducing maintenance costs by 60%.

Extensive Material Adaptability:

Low-solubility Materials High-solubility Materials Organic Matter Trace Elements

Whether it’s poorly soluble potassium sulfate and potassium chloride, highly soluble urea and ammonium nitrate, or various organic materials and trace elements, this system handles all perfectly. This “non-picky” characteristic reduces formula changeover time by 80%.

Four innovations, four advantages – the drum granulator is driving fertilizer production toward greater efficiency and intelligence with its technological charm.