There may be various problems encountered during the granulation process of organic fertilizers, which may affect granulation efficiency, particle quality, and the operational stability of the entire production line. The following are several common problems and their solutions in the granulation process of organic fertilizers:

1. Insufficient particle strength

Reason: The moisture content of the raw materials is too high or too low, the fiber content in the raw materials is insufficient, and the pressure setting of the organic fertilizer granulator is improper.

Solution strategy: Adjust the moisture content of the raw materials to a suitable range (usually 25% -35%), increase the binder or fiber content appropriately, and optimize the pressure and speed settings of the granulator.

2. Irregular particle shape

Reason: Uneven particle size of raw materials and improper setting of granulator parameters.

Solution: Use a crusher to ensure consistent particle size of the raw materials, adjust the speed of the organic fertilizer granulator and the gap between the pressure rollers to obtain a uniform particle shape.

3. Excessive dust

Reason: The raw materials are too dry or crushed, and the sealing of the granulator is poor.

Solution strategy: Control the moisture content of raw materials, avoid excessive crushing, check and improve the sealing of the granulator, and install a dust collection system.

4. Low granulation efficiency

Reason: Improper pre-treatment of raw materials, insufficient maintenance of organic fertilizer granulator, and unreasonable production parameter settings.

Solution strategy: Optimize the raw material pretreatment process, regularly maintain and clean the granulator, adjust production parameters to improve efficiency.

5. Different particle sizes

Reason: The parameters of the granulator are unstable, and the raw materials are mixed unevenly.

Solution: Use a vibrating screen to screen the particles, ensuring uniform mixing of raw materials and stable working parameters of the granulator.

6. Surface cracks or breakage of particles

Reason: Low moisture content in raw materials, excessive granulation pressure, and improper cooling process.

Solution strategy: Increase the moisture content of the raw materials appropriately, adjust the granulation pressure, ensure uniform cooling of the particles, and avoid sudden temperature changes.

7. Production line malfunction

Reason: Equipment aging, improper operation, and insufficient maintenance.

Solution strategy: Regularly maintain and inspect production line equipment, train operators, and replace worn parts in a timely manner.

8. Cost control

Reason: High energy consumption, waste of raw materials, and low equipment efficiency.

Solution strategy: Adopt energy-saving equipment, optimize production processes, reduce raw material loss, and improve equipment utilization.

Solving these problems requires a comprehensive understanding of the organic fertilizer production line, including raw material characteristics, equipment performance, and operating standards. By continuously optimizing production processes and equipment maintenance, the efficiency and product quality of organic fertilizer granulation can be effectively improved.

The disc granulator is one of the key equipment in organic fertilizer production lines, mainly used to process uniformly mixed organic fertilizer raw materials into spherical particles. The granulation process and characteristics are as follows:

Granulation process

Raw material pretreatment: Before entering the disc granulator, the raw materials need to undergo pre wetting, preheating and other treatments to reach the appropriate moisture content and temperature, in order to improve granulation efficiency and particle quality.

Entering the disc: The pre processed raw materials enter the disc from the top center of the disc granulator, and the disc tilts at a certain angle and rotates at a certain speed.

Granulation process: Under the rotation of the disc, the raw materials begin to roll into clusters and gradually form particles through their own gravity and centrifugal force. At the edge of the disc, particles are ejected due to centrifugal force and enter the subsequent processing stage.

Particle forming: During the rolling process, due to the viscosity of the raw material, the particles gradually increase until they reach the desired size and shape.

Granulation characteristics

High granulation efficiency: The continuous granulation method of the disc granulator can quickly and efficiently process raw materials into granules, improving production efficiency.

Particle uniformity: By precisely controlling the rotation speed, tilt angle, and humidity of the raw materials, particles of uniform size and shape can be produced, which is beneficial for the uniform application and storage of fertilizers.

Easy to operate: The disc granulator has a simple structure and is relatively easy to operate and maintain, making it suitable for large-scale production.

Strong adaptability: capable of handling various types of organic fertilizer raw materials, including powdered, granular, and partially fibrous raw materials, suitable for granulation needs with different raw material characteristics.

Low energy consumption: Compared with other granulation methods such as extrusion granulation, the disc granulator has lower energy consumption during the granulation process, which helps to reduce production costs.

Good particle strength: By adjusting the parameters during the granulation process, the hardness and compressive strength of the particles can be controlled, ensuring that they are not easily broken during transportation and use.

Easy to adjust particle size: By changing the tilt angle, rotation speed, and feed rate of the disc, the particle size can be flexibly adjusted to meet the needs of different fertilizer products.

The disc granulator plays an important role in organic fertilizer production lines. Its efficient granulation ability and adaptability to various raw materials can significantly improve production efficiency and product quality, making it one of the indispensable key equipment in organic fertilizer production lines.

Organic fertilizer trough type turner is a commonly used fermentation equipment in the production process of organic fertilizers, mainly used for composting solid organic waste. The fermentation principle and advantages are as follows:

Fermentation principle

The fermentation principle of the trough type flipping machine is mainly based on the aerobic fermentation process. In the fermentation tank, organic waste (such as livestock manure, crop straw, etc.) is piled up into a certain height of material pile. Under the action of microorganisms, organic matter is decomposed, releasing heat and raising the temperature of the pile. This process requires sufficient oxygen to maintain microbial activity and fermentation efficiency.

The trough type flipping machine flips the materials from the surface of the pile to the inside and from the inside to the surface, ensuring that the entire pile can come into contact with fresh air and provide sufficient oxygen for microorganisms to carry out aerobic fermentation. Flipping can also promote uniform temperature distribution inside the stack, avoid local overheating, and help remove odor gases produced during fermentation.

advantage

Improve fermentation efficiency: By regularly flipping and throwing, ensure sufficient oxygen supply inside the heap, accelerate the decomposition of organic matter, and shorten the fermentation cycle.

Uniform fermentation: The flipping process ensures that the entire pile of materials can participate in fermentation evenly, avoiding incomplete or excessive local fermentation.

Temperature control: Flipping helps to control the temperature of the pile, avoid local overheating that may lead to a decrease in microbial activity, and ensure the stability of the fermentation process.

Reduce odors: By flipping and throwing, odors such as ammonia and hydrogen sulfide generated during the fermentation process can be promptly eliminated, improving the working environment.

Improving fertilizer quality: A uniform fermentation process helps to increase the nutrient content of organic fertilizers, reduce harmful substances, and enhance fertilizer quality.

High degree of automation: The trough type flipping machine can achieve automated operation, reduce manual intervention, and improve production efficiency.

Strong adaptability: The trough type flipping machine is suitable for the fermentation treatment of various organic wastes, such as livestock manure, crop waste, etc., with a wide range of applications.

In summary, the trough type turner improves the efficiency and effectiveness of organic waste composting treatment by optimizing fermentation conditions, and is an indispensable key equipment in organic fertilizer production.

The granulation process of organic fertilizer production line is a key step in processing organic raw materials into granular fertilizers, which usually includes multiple stages to ensure the quality and stability of the final product. The following is a typical granulation process for processing fertilizers in an organic fertilizer production line:

1. Raw material pretreatment

Raw material collection and crushing: Collect fresh or dry organic materials, such as livestock manure, crop straw, etc., and use a crusher to crush them to a particle size suitable for granulation.

Raw material mixing: Mix the crushed raw materials with additives (such as microbial agents, nutrients, etc.) evenly to enhance the nutrient content and biological activity of the fertilizer.

2. Fermentation treatment

Raw material fermentation: The mixed raw materials are stacked in a fermentation tank or fermentation chamber, and through natural or controlled fermentation, organic matter is decomposed by microbial action to produce high-temperature sterilization, while converting the nutritional components in the raw materials.

3. Drying and cooling

Material drying: After fermentation, the material needs to be dried using a dryer (such as a drum dryer or belt dryer) to remove excess moisture for granulation and subsequent processing.

Material cooling: The dried material has a high temperature and needs to be cooled to near room temperature using a cooling machine (such as a cooling drum) to prevent material adhesion during subsequent granulation processes.

4. Granulation

Pre treatment before granulation: Depending on the type of organic fertilizer granulator, further crushing or pre wetting of the cooled material may be required to meet the feeding requirements of the granulator.

Granulation: The pre treated material is sent to a granulator (such as a disc granulator, a roller extrusion granulator, a drum granulator, etc.), where it forms particles with a certain shape and size under the action of the granulator.

5. Particle screening and crushing

Particle screening: Use vibrating screens and other equipment to screen out particles that do not meet the size requirements, and perform secondary granulation or crushing treatment.

Crushing large particles: For the selected oversized particles, use a crusher to crush them to the desired particle size.

6. Particle post-treatment

Particle drying: For particles with high moisture content, it may be necessary to dry them again to ensure the stability and storage conditions of the final product.

Particle cooling: The dried particles need to be cooled to avoid excessive dust generation during the packaging process.

7. Packaging and Storage

Quantitative packaging: Use an automatic packaging machine to quantitatively package cooled particles into bags or boxes for easy sales and transportation.

Finished product storage: Packaged organic fertilizer products should be stored in a dry and ventilated warehouse to avoid moisture and contamination.

The granulation process of organic fertilizer production line is a systematic engineering, with each link closely connected and interdependent. It needs to be reasonably configured and adjusted according to the characteristics of raw materials, production scale, and final product requirements to ensure the efficiency of the production process and the high quality of the products.

The process flow of processing granular organic fertilizers in organic fertilizer production lines usually includes multiple key steps aimed at converting organic raw materials into high-quality granular organic fertilizers. The following is the general process flow for processing granular organic fertilizer on an organic fertilizer production line:

Raw material pretreatment:

Collection and classification: Collect various organic raw materials, such as livestock manure, crop straw, food processing waste, etc., and classify them.

Crushing and mixing: Crushing the raw materials for subsequent fermentation and granulation. Then mix the crushed raw materials in a certain proportion to ensure balanced nutritional content.

Fermentation:

Composting fermentation: The mixed raw materials are stacked into a fermentation pile, which is then flipped using equipment such as a chain plate flipping machine. The temperature and humidity are controlled to promote the decomposition and fermentation of organic matter. The fermentation process can be aerobic fermentation or anaerobic fermentation, and the appropriate fermentation method should be selected based on the type of raw materials and the characteristics of the target fertilizer.

Fermentation cycle control: Based on the characteristics of the raw materials and the quality of the target fertilizer, the fermentation cycle is controlled, usually ranging from several weeks to several months.

dry:

Preliminary drying: The fermented material needs to undergo preliminary drying to reduce moisture content and facilitate subsequent granulation. Drying can be done through natural air drying or using a dryer.

Granulation:

Raw material pre wetting: According to the requirements of the granulator, pre wet the dried material and adjust its moisture content to facilitate granulation.

Granulation: Use granulators, such as drum granulators or disc granulators, to process pre wetted materials into granules. The granulator forms uniform particles of powdered raw materials through physical extrusion or chemical bonding.

Particle screening: After granulation, use a screening machine to screen the particles, remove unqualified particles, and ensure uniform particle size of the product.

Cooling and coating (optional):

Cooling: After granulation, the particles need to be cooled to room temperature to prevent clumping due to high temperature during storage and transportation.

Coating: In order to improve the storage stability and appearance of fertilizers, the cooled particles can be coated with organic or inorganic materials such as paraffin, organic acids, microbial agents, etc.

Finished product packaging:

Weighing and packaging: Weigh the cooled and coated granular organic fertilizer according to standard weight, then pack it into a packaging bag, seal it, and prepare it for sale or storage.

quality testing:

Finished product inspection: Conduct quality inspection on packaged organic fertilizers to ensure that the products meet national standards and industry requirements, including nutritional composition, microbial indicators, moisture content, etc.

Through the above process, organic raw materials are converted into high-quality granular organic fertilizers, which not only improve the physical properties and application effects of fertilizers, but also promote the resource utilization of agricultural waste, which is of great significance for the sustainable development of agriculture.

The working principle of the horizontal organic fertilizer mixer is mainly based on its internal mixing device and unique structural design. Through the action of mechanical force, various fertilizer raw materials are evenly mixed. The specific working principle is as follows:

1. Material entry

The material enters the cylinder of the horizontal organic fertilizer mixer through the feed inlet at one end or top of the mixer. The cylinder is usually placed horizontally or slightly inclined to facilitate the flow and mixing of materials.

2. Mixing device operation

The mixer is equipped with mixing devices inside, commonly including propeller type, blade type, double axis spiral type, etc. When the mixer is started, the motor drives the mixing device to rotate at high speed, and through the blades, screws, or other forms of mixing elements on the mixing device, the materials inside the cylinder are sheared, rolled, and mixed. The design of these stirring elements ensures that the material moves in multiple directions within the cylinder, thereby achieving uniform mixing.

3. Material mixing

The rotating belt of the stirring device forms a complex flow pattern of animal materials inside the cylinder, where friction and collision occur between material particles, allowing various components to fully contact and mix. At the same time, the shape and inclination angle design of the mixer cylinder also contribute to the flow and uniform distribution of materials.

4. Material discharge

When the materials are mixed for the required time and uniformity, the mixer stops stirring and the materials are discharged through the discharge port at the other end of the cylinder, entering the next production process.

5. Self cleaning or manual cleaning

In order to ensure that the next batch of materials is not contaminated, some horizontal mixers are designed with self-cleaning function, which removes residual materials on the inner wall of the cylinder through reverse rotation or other mechanisms. Without self-cleaning function, operators need to perform regular manual cleaning to ensure the hygiene and mixing effect of the equipment.

The horizontal organic fertilizer mixer, with its efficient mixing capacity and adaptability to various materials, can quickly and evenly mix various fertilizer raw materials, and is one of the indispensable key equipment on the organic fertilizer production line.

The market prospects for processing fertilizers on chicken manure organic fertilizer production lines are very broad, mainly due to the following reasons:

1. The demand for sustainable agricultural development

With the increasing global emphasis on sustainable agriculture, the use of organic fertilizers to replace or reduce the use of chemical fertilizers has become a trend. Chicken manure organic fertilizer is rich in various essential nutrients such as nitrogen, phosphorus, and potassium for plants. It can also improve soil structure, enhance soil microbial activity, and play an important role in promoting crop growth, improving agricultural product quality, and achieving sustainable agricultural development.

2. Promotion of environmental policies

Many countries and regions have introduced a series of environmental protection policies to encourage the resource utilization of agricultural waste such as livestock manure and reduce environmental pollution. The organic fertilizer production lines for chicken manure can not only solve the problem of chicken manure treatment, reduce the pressure on the environment, but also convert it into valuable agricultural resources, which is in line with policy guidance.

3. Increased market demand

With consumers’ increasing concern for food safety and agricultural product quality, the market demand for organic food continues to grow, driving an increase in demand for organic fertilizers. Chicken manure organic fertilizer, as an important source of organic food production, has also expanded its market demand.

4. Technological progress and cost reduction

With the continuous advancement of processing technology in chicken manure organic fertilizer production lines, such as fermentation technology, granulation technology, etc., processing costs have gradually decreased, production efficiency and product quality have been improved, which further promotes the market competitiveness of chicken manure organic fertilizer.

5. Government subsidies and support

In some regions, the government provides a series of subsidies and support policies to promote the use of organic fertilizers and the development of organic agriculture, such as subsidies for the purchase of organic fertilizers and training in organic agriculture technology, which provides strong support for the market promotion of chicken manure organic fertilizers.

6. Diversified agricultural planting needs

With the diversification of agricultural planting structures, different crops have varying demands for fertilizers. Chicken manure organic fertilizer, due to its rich nutritional content and good soil improvement effect, can meet the growth needs of different crops. Therefore, it has a wide range of application prospects in diversified planting modes.

In summary, the market prospects for processing chicken manure organic fertilizer production lines are very optimistic. With the continuous promotion of sustainable agricultural development, environmental policies, technological progress, and market demand, its market potential will continue to be released, making important contributions to agricultural production and environmental protection.

The production line for organic fertilizers from livestock and poultry manure is an efficient system for converting organic waste such as livestock and poultry manure into organic fertilizers. This process not only solves the pollution problem in animal husbandry, but also promotes the recycling of resources and provides high-quality organic fertilizers for agricultural production. The following are the detailed steps for processing organic fertilizer on the livestock and poultry manure organic fertilizer production line:

1. Fecal pretreatment

Collection and classification: Firstly, collect fresh or semi dry animal manure from livestock and poultry farms, and conduct preliminary classification as needed to remove impurities such as plastics, stones, etc.

Crushing: Use a grinder to crush feces into small particles for subsequent fermentation and granulation.

2. Fermentation

Composting fermentation: The crushed livestock and poultry manure is piled into a fermentation pile, which is regularly turned by a turning machine to ensure oxygen supply and temperature control during the fermentation process, promote microbial activity, and accelerate the decomposition of organic matter. The fermentation process can last for weeks to months, depending on the characteristics of the raw materials and fermentation conditions.

3. Post fermentation treatment

Drying: The fermented material may contain a high amount of moisture and needs to be dried naturally or using a dryer to reduce the moisture content to a suitable level for granulation.

Screening: Use a screening machine to remove large particles or undecomposed impurities, ensuring the smooth progress of the subsequent granulation process.

4. Mixing and granulation

Raw material mixing: As needed, fermented animal manure can be mixed with other organic or inorganic materials (such as straw, peat, phosphate powder, etc.) to adjust the nutritional composition of fertilizers.

Granulation: Use a granulator, such as a drum granulator or a disc granulator, to process the mixed material into granules. During the granulation process, it may be necessary to add a certain amount of water or adhesive to assist in particle formation.

5. Cooling and coating

Cooling: The granulated fertilizer needs to be cooled by a cooling machine to prevent the particles from deforming or sticking due to high temperature.

Coating (optional): In order to improve the physical properties of fertilizers, such as moisture resistance and storage stability, coating machines can be used to coat fertilizer particles.

6. Finished product processing

Screening: Use a screening machine to screen out particles that do not meet the size requirements, ensuring the quality of the finished product.

Packaging: The screened fertilizer particles are quantitatively packaged using an automatic weighing and packaging machine, ready for sale or storage.

Through the above steps, the organic fertilizer production line for livestock and poultry manure can convert the potentially environmentally polluting livestock and poultry manure into valuable organic fertilizers. This not only solves the pollution problem in livestock and poultry farming, but also provides a sustainable source of fertilizer for agricultural production, achieving a win-win situation for economic and environmental benefits.

When using a horizontal organic fertilizer mixer, in order to ensure the normal operation of the equipment, extend its service life, and ensure the safety of operators, the following points need to be noted:

1. Equipment inspection and maintenance

Regular inspection: Regularly inspect the wear and lubrication of key components such as the motor, transmission parts, bearings, mixing shaft, and blades of the mixer to ensure that the equipment is in good condition.

Cleaning and maintenance: After each use, the residual materials inside the mixer should be cleaned to avoid material clumping that affects the next use, while reducing corrosion and wear.

Maintenance records: Establish equipment maintenance records, including inspection dates, maintenance content, identified issues, and solutions, in order to track the health status of the equipment.

2. Operating procedures

Train operators: Ensure that operators have received professional training and are familiar with the equipment’s operation manual and safety operating procedures.

Pre start inspection: Before starting, check whether the equipment is in a safe state, confirm that there are no foreign objects inside the mixer, and that all components are securely connected.

Correct feeding: Feed according to the maximum loading capacity specified by the equipment to avoid overload operation, while ensuring uniform distribution of materials and avoiding unbalanced loading.

3. Safety measures

Wear protective equipment: Operators should wear appropriate protective equipment such as work clothes, safety shoes, goggles, and gloves.

Emergency stop: Ensure that there is an emergency stop button near the equipment, and the operator should be familiar with the emergency stop procedure so that they can respond quickly in case of abnormal situations.

Avoid contact with rotating parts: During equipment operation, operators are strictly prohibited from touching the inside or rotating parts of the mixer to avoid safety accidents.

4. Environmental and material adaptability

Environmental adaptation: Ensure that the operating environment of the mixer meets the equipment requirements and avoid prolonged operation in extreme temperature, humidity, or corrosive environments.

Material adaptation: Understand the adaptability of the equipment to materials, avoid using materials that are too viscous, too hard, or have a high water content to prevent clogging or damage to the mixer.

5. Quality control

Uniform mixing: Ensure that the materials are thoroughly mixed during the mixing process to achieve the expected mixing uniformity, and adjust the mixing time and speed appropriately if necessary.

Monitoring the mixing effect: Regularly sampling and checking the quality of the mixed materials to ensure that the composition of the final product is uniform and consistent.

6. Energy conservation and environmental protection

Reasonable use: Adjust the operating parameters of equipment according to production needs to avoid energy waste.

Dust control: Take effective measures to control dust emissions during the mixing process, protect the health of operators and the environment.

Following the above precautions can ensure the safe operation of the horizontal organic fertilizer mixer, improve production efficiency, extend equipment service life, and ensure the safety and health of operators.

The benefits of processing chicken manure organic fertilizer production line fertilizers for agriculture are multifaceted, not only improving soil quality and crop yield, but also promoting sustainable development of agriculture. Specific benefits include:

1. Improve soil structure and fertility

Chicken manure organic fertilizer is rich in various nutrients such as organic matter, nitrogen, phosphorus, potassium, etc. After application, it can significantly increase soil organic matter content, improve soil structure, enhance soil water and fertilizer retention capacity, thereby enhancing soil fertility and providing a good soil environment for crop growth.

2. Improve crop yield and quality

The nutrients in organic fertilizers can be effectively absorbed and utilized by crops, promoting crop growth and increasing crop yield. At the same time, organic fertilizers can improve crop root development, enhance crop stress resistance, reduce the occurrence of pests and diseases, and thus improve crop quality.

3. Reduce the use of fertilizers and protect the environment

The use of chicken manure organic fertilizer can replace some chemical fertilizers, reduce the pollution of soil and water caused by chemical fertilizers, and lower the impact of agriculture on the environment. Microorganisms in organic fertilizers can also promote the transformation of heavy metals and harmful substances in soil, reducing their harm to crops and the environment.

4. Promote agricultural circular economy

The chicken manure organic fertilizer production line transforms chicken manure, an agricultural waste, into a valuable resource, reducing the pollution of livestock and poultry manure to the environment and promoting the recycling of agricultural resources, in line with the concepts of circular economy and sustainable development.

5. Enhance soil microbial activity

Chicken manure organic fertilizer contains abundant microorganisms, which can increase the number and diversity of microorganisms in the soil after application, promote the balance of soil ecosystem, enhance soil biological activity, and facilitate the recycling of soil nutrients.

6. Reduce greenhouse gas emissions

Compared with fertilizer production, the production process of organic fertilizer has lower greenhouse gas emissions. At the same time, organic fertilizer can promote the fixation of carbon in soil, which helps to reduce greenhouse gas emissions in the agricultural sector and address climate change.

7. Enhance the safety of agricultural products

The nutrients in organic fertilizers are more easily absorbed by crops, reducing the risk of fertilizer residue and thus improving the safety and nutritional value of agricultural products, meeting consumers’ demand for healthy food.

Processing fertilizers through the chicken manure organic fertilizer production line not only solves the problem of livestock and poultry manure treatment, but also provides a safe, efficient, and environmentally friendly fertilizer source for agricultural production. It is of great significance for promoting sustainable agricultural development, improving agricultural economic benefits, and protecting the ecological environment.