Advantages of Rotary Drum Granulators over Disc Granulators

fertilizer granulator Sep 22, 2025

When selecting organic fertilizer granulation equipment, both rotary drum and disc granulators are commonly used. However, rotary drum granulators, with their multi-dimensional performance advantages, better meet the efficiency and scale requirements of modern organic fertilizer production lines. The differences between the two are primarily reflected in the following four aspects.

More flexible capacity adaptability meets the needs of large-scale production. Disc granulators are limited by the diameter of their discs, typically with an hourly output of 0.5-5 tons per unit, making them suitable only for small production lines. By adjusting the drum length and diameter, rotary drum granulators can achieve hourly outputs of 1-20 tons per unit. They meet the basic production needs of small and medium-sized enterprises as well as the large-scale production of large factories. They eliminate the need for multiple units in parallel, reducing production line floor space and equipment investment costs.

They offer greater raw material compatibility and reduce pretreatment complexity. Organic fertilizer raw materials have large fluctuations in moisture and composition. Disc granulators must maintain a moisture content of 20%-30%. They also struggle with crude fiber materials, which tend to stick to the disc and produce uneven granules. Rotary drum granulators can process materials with moisture levels of 25%-40%. Leveraging the multi-directional force of the rotating drum, they can smoothly granulate composted straw, livestock manure, and other materials without the need for additional crushing or conditioning, streamlining the process.

The resulting product is more stable and meets standardized requirements. Due to the single direction of centrifugal force, disc granulators produce pellets with a roundness of 70%-80% and large particle size variations. Rotary drum granulators, on the other hand, utilize internal rollers to guide and rotate the pellets, resulting in a fully rolling and shaping process with a roundness exceeding 90% and a precisely controlled particle size of 2-5mm. Furthermore, the granulation process is gentle, does not damage organic matter, and the pellets are of moderate strength. Transportation losses are 15%-20% lower than those from disc granulators.

Operation and maintenance are also simplified, resulting in lower long-term costs. Disc granulators require frequent manual adjustments of inclination and speed, resulting in wear and tear on the disc edges and requiring frequent replacement. Rotary drum granulators, on the other hand, utilize automated control to precisely adjust speed and feed rate, eliminating the need for manual oversight. The drum is constructed of wear-resistant stainless steel, resulting in a 40% lower failure rate and over 30% lower maintenance costs, resulting in superior long-term economics.

In summary, the advantages of the rotary drum granulator in terms of production capacity, raw material compatibility, finished product quality, and cost control make it ideally suited to the diverse needs of organic fertilizer production lines, making it an ideal choice for improving efficiency and competitiveness.

The Core Reasons to Choose a Rotary Drum Granulator for Organic Fertilizer Production Lines

fertilizer granulator Sep 19, 2025

In the granulation stage of organic fertilizer production lines, rotary drum granulators are the preferred equipment for most companies due to their high adaptability to the characteristics of organic fertilizers. Their unique operating principle and performance advantages effectively address key challenges in the granulation process, ensuring product quality and production efficiency.

In terms of granulation adaptability, rotary drum granulators perfectly match the characteristics of organic fertilizer raw materials. Organic fertilizer raw materials, mostly livestock and poultry manure and composted straw, have complex compositions and contain a large amount of fiber. The rotary drum granulator uses the centrifugal force, extrusion force, and friction generated by the rotating drum to granulate loose raw materials without excessive compression, thus preventing the destruction of organic matter and functional microbial activity in the raw materials due to strong compression. The rotary drum granulator also adapts to fluctuations in raw material moisture content (it can handle raw materials with a moisture content of 25%-40%), reducing the tedious pre-treatment process.

The advantages in granulation efficiency and finished product quality are significant. The drum length and diameter of the rotary drum granulator can be flexibly designed to meet production capacity requirements. A single unit can achieve an output of 1-20 tons/hour, meeting the needs of production lines of varying sizes. Its granulation process is gentle and uniform, resulting in highly rounded granules (over 90% roundness). The particle size can be controlled between 2-5mm by adjusting the drum speed and the baffle, meeting standard requirements for organic fertilizer granules. The granules also possess moderate strength, preventing breakage during transportation while slowly disintegrating in the soil, enhancing nutrient release efficiency.

From a cost and environmental perspective, the rotary drum granulator is also competitive. Its simple structure, minimal transmission components, and low failure rate mean ongoing maintenance costs are approximately 30% lower than those of other granulation equipment (such as disc granulators and extrusion granulators). Furthermore, the granulation process does not require the addition of large amounts of binders; granulation is achieved solely through the raw material’s inherent viscosity. This reduces raw material costs while preventing the impact of foreign matter on the purity of the organic fertilizer, aligning with green production principles.

The comprehensive advantages of the rotary drum granulator in adaptability, efficiency, cost and environmental protection make it an ideal choice for the granulation link of the organic fertilizer production line, providing strong support for enterprises to achieve high-quality and high-efficiency production.

New Type Organic Fertilizer Granulator: High-Efficiency Equipment Empowering Multi-Sector Production

fertilizer granulator Sep 16, 2025

In response to the need for industrial upgrading, the new type organic fertilizer granulator (models YSL-60 to YSL-150) was developed by the Agricultural Machinery Research Institute. Leveraging its accumulated experience in compound fertilizer processing and its unique mixing and granulation method, it has become a practical device for granule production in various fields.

In terms of core technology, the new type organic fertilizer granulator utilizes high-speed rotating stirring teeth to stir, impact, and tumble the mixed material within the granulation drum. Friction, centrifugal force, and the material’s viscosity aggregate the material into granules, eliminating the need for complex extrusion equipment and making it suitable for high-viscosity or fibrous materials. Performance parameters include a production capacity of 1-8 tons/hour, motor power of 37-90 kW, and granule diameter of 1-5 mm. The YSL-60 produces 1-2 tons per hour, making it suitable for small and medium-sized operations; the YSL-150 produces 5-8 tons per hour, making it suitable for large-scale production.

It has a wide range of applications. In the fertilizer sector, livestock and poultry manure, straw, and other materials can be transformed into organic, bio-organic, and compound microbial fertilizers, eliminating caking issues while preserving bacterial activity and producing medium and trace element fertilizers. In the chemical industry, it can be used to granulate sticky raw materials; in the pharmaceutical industry, it can process traditional Chinese medicine granules; and in the feed industry, it can produce livestock and aquatic feed, achieving a “one machine for multiple uses.”

The core advantages are significant. Granulated particles are round and uniform, with good flowability, and are less prone to clumping during storage and transportation. Operation is simple, requiring only training. The low motor power and operating costs make the equipment affordable, making it suitable for small and medium-sized enterprises. Furthermore, it preserves fertilizer activity, extending its shelf life to 8-12 months, promoting the recycling of organic waste and achieving both economic and environmental benefits.

Daily maintenance requires three key points: regular inspections: daily inspection of the feed mechanism and transmission system; weekly inspection of agitator tooth wear; monthly bolt tightening and motor temperature monitoring; cleaning the granulation drum after production; lubricating transmission components according to specifications, and timely replacement of worn parts to ensure stable equipment operation.

This new type organic fertilizer granulator, with its multiple advantages in technology, performance and application, is providing strong support for production upgrades in agriculture, chemical industry, medicine, feed and other fields.

Differences in Equipment Selection Between Wet and Dry Granulation in the Fertilizer Industry

fertilizer granulator Sep 15, 2025

In fertilizer production, granular fertilizers are widely used due to their advantages such as ease of application and uniform nutrient release. The differences in equipment selection between wet and dry granulation directly impact fertilizer quality and production efficiency, requiring precise matching based on fertilizer characteristics.

In the fertilizer industry, wet granulation focuses on “liquid-solid granulation,” and equipment selection is designed around nutrient dissolution and granule solidification. Key equipment is a rotary drum granulator or disc granulator. A rotary drum granulator uses a rotating, tilted drum to mix fertilizer powder with liquid raw materials such as phosphoric acid and ammonia, forming granules through the bonding force between the materials. This makes it suitable for producing nitrogen, phosphorus, and potassium compound fertilizers, ensuring uniform coating of multiple nutrients. A disc granulator uses high-speed rotation to generate centrifugal force, which forces the material and binder to form spherical granules. This makes it suitable for fertilizers such as organic fertilizers that require a fluffy structure. A drum fertilizer dryer is required to remove excess moisture from the granules using hot air, preventing fertilizer clumping and nutrient loss. This is a hallmark of wet granulation in the fertilizer industry.

Dry granulation requires no liquid addition, and the equipment used focuses on “physical extrusion shaping,” making it more suitable for heat-sensitive or water-soluble fertilizers. The core equipment is a double roller press granulator, which uses a pair of rollers to press fertilizer powder into dense flakes. This is then crushed and sieved to form granules, preventing moisture from deliquescing in fertilizers like urea and ammonium nitrate, while also minimizing nutrient volatilization. Some high-hardness raw materials require a crusher to pre-process the lumpy fertilizer into a fine powder to ensure uniform feeding. Dry granulation eliminates the need for drying equipment, streamlines the process, and preserves water-soluble nutrients, making it suitable for producing water-soluble or slow-release fertilizers.

When selecting fertilizers, wet granulation equipment is preferred for producing compound fertilizers requiring high nutrient content. Dry granulation equipment is more suitable for processing heat-sensitive, soluble fertilizers. Wet granulation equipment also consumes more energy and is suitable for large-scale production, while dry granulation equipment occupies less space and is more suitable for small- to medium-volume production of specialty fertilizers.

Windrow compost turning machines: What kind of organic fertilizer production line is it suitable for?

fertilizer granulator Sep 10, 2025

In organic fertilizer production, aerobic fermentation is the core process, and compost turning machines are key equipment for efficient fermentation. Among them, the windrow compost turning machine, with its unique design and strong performance, has become the preferred choice for many production lines.

1.Suitable for Large-Scale Continuous Production
windrow compost turners are typically equipped with self-propelled crawler chassis, featuring wide spans and high processing capacity. They can efficiently handle fermentation trenches as wide as 3–5 meters. Therefore, they are particularly suitable for large-scale organic fertilizer plants with an annual output of over 10,000 tons.
2.Ideal for Handling Highly Viscous and High-Moisture Materials
With their large ground contact area and low ground pressure, windrow turners are less prone to sinking. This makes them especially suitable for processing high-moisture, high-viscosity raw materials such as livestock manure, sludge, and kitchen waste. Their sturdy crawler chassis ensure stable operation even under challenging material conditions.

3.Well-Suited for Trench Fermentation Processes
The most common application for windrow compost turners is trench fermentation. They move along pre-laid tracks or fermentation trench walls, evenly turning and tossing the materials in the trench. This ensures adequate oxygen penetration and promotes efficient microbial activity.
4.Suitable for Production Lines Aiming for Low Operating Costs
Although the initial investment in a windrow turner may be relatively high, its durability and low failure rate reduce maintenance costs in the long run.
5.Ideal for Modern Facilities with Neat Spatial Planning
Windrow compost turners usually require well-planned factory layouts. They are best suited for production lines with orderly layouts, sufficiently long fermentation trenches, and a goal of achieving intensive and standardized management of the fermentation process.

In summary, windrow compost turning machines are particularly suitable for large-scale, intensive organic fertilizer production lines dealing with complex raw materials.

Analysis of the working principle of half-wet material crusher in organic fertilizer equipment

fertilizer granulator Sep 8, 2025

In organic fertilizer production lines, crushing is a crucial step. The half-wet material crusher is specifically designed to handle fermented materials with high moisture and fiber content. Its unique design concept combines three primary forces—shearing, tearing, and impact—to achieve efficient crushing.

1.Feeding and Preliminary Crushing
Pre-fermented organic materials (such as livestock manure, straw, sludge, etc.) are fed into the crushing chamber through the inlet. These materials typically have a moisture content of 25%–50%, making them sticky and prone to tangling.
2.High-Speed Rotor Rotation
At the core of the equipment is a heavy-duty rotor that rotates at high speed. Multiple sets of wear-resistant hammer blades or knives are mounted alternately on the rotor. Driven by an electric motor, the rotor generates strong torque and linear speed.
3.Shearing and Tearing
The rotating hammer blades and the wear-resistant tooth plate or liner fixed on the machine body form a narrow gap. As the material enters this gap, it is quickly cut and torn apart by the powerful shearing and tearing forces generated by the high-speed relative motion.

4.High-Speed Impact
Simultaneously, the initially crushed material particles are struck at high speed by the hammer blades inside the chamber, further breaking them down into finer particles.
5.Forced Discharge
The crushed fine particles are forced through the screen mesh at the bottom under the airflow generated by the rotor’s rotation and their own gravity, completing the crushing process. The screen mesh aperture can be replaced to meet the required fineness of the final product.

The half-wet material crusher is an indispensable key equipment in organic fertilizer production. Its unique working principle enables it to effectively process sticky, wet, and tangled organic materials without clogging.

Rotary drum granulator: Usage and working principle for organic fertilizer

fertilizer granulator Sep 8, 2025

The rotary drum granulator is a key piece of equipment in modern organic fertilizer production lines. It’s specifically designed to turn powdered organic raw materials (like livestock manure, straw, and humic acid) into uniform granules. Its high efficiency and low operating costs make it the top choice for large-scale organic fertilizer production.

Working Principle

1.Mixing and Moistening

Pre-treated organic materials enter the rotating drum through the feed inlet. Here, they are thoroughly mixed with a binder (like water or microbial solution) sprayed by the system, forming a moist material base.

2.Rolling and Granulation

Driven by a motor, the drum rotates at a tilt angle of 15-30° (typically at 20-40 r/min). Centrifugal force makes the material tumble and collide. Fine powder gradually clumps into small particles, which then grow larger through a “snowball effect”.

3.Polishing and Drying

In the rear section of the drum, the particles are smoothed and rounded. After being discharged, they can be further dried using a connected dryer to form hard, finished granules that resist crumbling (adjustable size: 2-8mm).

Key Operating Points

1.Raw Material Pre-treatment

Moisture Control: Powder moisture content needs adjusting to 30%-40%. Too high causes clumping; too low reduces granulation success.

Fiber Handling: Long-fiber materials must be pre-crushed to ≤5mm to avoid tangling in the equipment.

2.Optimizing Running Parameters

Speed Adjustment: Adjust the rotation speed based on the required granule size – larger particles need lower speeds.

Tilt Angle Setting: The standard angle is 25°. This can be fine-tuned via bracket bolts to change how long the material stays inside (residence time).

The rotary drum granulator achieves standardized organic fertilizer production through physical granulation. Combined with proper operation, it significantly improves the fertilizer’s commercial appeal and added value.

Essential maintenance for flat die granulators in organic fertilizer plants

fertilizer granulator Sep 1, 2025

In organic fertilizer production lines, the flat die granulator is the core shaping equipment. Its operating condition directly affects pellet quality, production efficiency, and machine lifespan. Proper maintenance reduces downtime, cuts energy use, and extends the equipment’s life.

1.Daily Cleaning and Lubrication
Clean residue after each shift: Use proper tools to remove built-up material from the die plate and roller surfaces to prevent corrosion and clogging.
Check lubrication regularly: Add high-temperature grease to bearings every 8 hours. Lubricate drive gears weekly.
2.Wear Part Monitoring and Replacement
Check die plate wear: Measure die hole diameters weekly. Replace the plate immediately when wear exceeds 10% of the standard size.
Maintain rollers: Inspect roller grooves for every 500 tons of fertilizer produced. Repair or replace rollers if groove wear reaches 3mm deep.
Clean screens regularly: Clear screen blockages every shift. Check screens for damage monthly.

3.Electrical System Preventive Care
Dust control cabinets: Clean dust from electrical components and check terminal tightness quarterly.
Calibrate sensors: Professionally calibrate level sensors and temperature sensors every six months.
4.Seasonal Deep Maintenance
Before peak season: Fully inspect the drive system. Replace worn seals.
During shutdowns: Disassemble and clean the entire machine. Apply anti-rust treatment to rusty parts.
Long-term storage: Drain the lubrication system. Coat key parts with anti-rust oil. Protect the motor from moisture.

Establishing this maintenance system keeps flat die granulators running at their best. Following these steps lowers production cost per ton and ensures consistent product quality.

How to Optimize Your Fertilizer Production Line?

fertilizer granulator Aug 26, 2025

In the competitive world of fertilizer manufacturing, operational efficiency and cost-effectiveness are paramount. Success—whether operating a complex npk fertilizer production line or a robust organic fertilizer production line—hinges on selecting the optimal equipment combination. The key question is: how do you maximize output while minimizing capital and operational expenses? Let’s analyze the strategies for building a profitable and efficient operation.

Key Equipment in a Fertilizer Production Line

1. Fertilizer Crusher– The backbone of any production line, this machine breaks down raw materials into uniform particles, ensuring smoother processing in later stages.
2. Fertilizer Screening Machine– After crushing, this device separates fine particles from oversized chunks, guaranteeing consistent product quality.
3. Fertilizer Dryer & Cooler– Moisture control is critical. The dryer removes excess water, while the cooler stabilizes temperature, preventing nutrient loss.

Boosting Efficiency in NPK & Organic Fertilizer Production

To enhance NPK fertilizer manufacturing, a well-synchronized line should include:

– High-speed crushers for uniform raw material breakdown.

– Multi-layer vibrating screens for precise particle separation.

– Rotary dryers with heat recovery to reduce energy waste.

For organic fertilizer production, integrating a compost turner (like the Large Wheel Compost Turner) before crushing ensures faster decomposition, while low-temperature drying preserves microbial activity.

Cutting Costs Without Sacrificing Quality

To reduce organic fertilizer plant costs, consider:

– Combined drying & cooling systems to save space and energy.

– Adjustable screening machines to minimize waste.

– Automated controls to lower labor expenses.

By optimizing equipment selection and workflow, you can achieve higher yields, better quality, and lower operational costs—making your fertilizer business more competitive and sustainable.

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.