npk fertilizer production line – Page 17 – fertilizer production line

Practical methods for reducing raw material waste in ring die granulators

Written by fertilizer production line on September 29th, 2025. Leave a comment

In fertilizer production, raw material waste in ring die granulators primarily stems from substandard pellets and die blockage. Targeted measures can increase raw material utilization by 5%-8%.

First, substandard pellets are recycled. After screening in the pelletizer, broken and large particles are collected and crushed to the required particle size (consistent with new raw material) using a dedicated fertilizer crusher. These particles are then mixed with new raw material at a ratio of 1:5 for re-pelletization. Care should be taken to control the moisture content during mixing. If the moisture content of the recycled material exceeds 18%, it should be air-dried to 14%-16% before mixing to prevent moisture absorption and impact on the overall pelletizing effect. Furthermore, the recycled material mix ratio should not exceed 20% to prevent it from affecting the strength of the new pellets.

Secondly, reduce ring die blockage losses. Before each shutdown, empty the pelletizing chamber of any remaining raw material. Then, introduce a small amount of talcum powder (5-8 kg per ton of raw material). Run the ring die granulator at no load for 5 minutes to allow the talcum powder to adhere to the inner wall of the ring die, forming a protective film to prevent residual raw material from solidifying and clogging. During daily production, check the ring die holes for blockage every four hours. If a small blockage is detected, clear it with a special needle (0.5 mm smaller in diameter than the die hole) to prevent further blockage and material waste.

In addition, polish the edges of the ring die holes every 100 hours to remove burrs and minimize material loss caused by material being stuck in the holes. A magnetic separator should be installed at the pelletizer feed inlet to remove metallic impurities from the raw material, preventing them from damaging the ring die and causing pelletizing problems, further reducing material waste.

Optimizing the linkage between the ring die granulator and front-end raw material processing

Written by fertilizer production line on September 29th, 2025. Leave a comment

The granulation performance of a ring die granulator isn’t solely determined by the equipment itself. Linkage optimization with the front-end crushing, mixing, and conditioning processes can significantly improve production efficiency and pellet quality.
During the crushing process, the raw material particle size must be matched to the ring die aperture. For an 8mm ring die aperture, the raw material particle size should be controlled below 2mm, with a particle size deviation of no more than 0.5mm, to prevent large particles from clogging the die aperture. A grading screen can be installed at the pulverizer outlet, with the screen aperture set to 1/4 the ring die aperture, to ensure uniform particle size and reduce the frequency of granulator downtime for cleaning. If the raw material contains a high amount of coarse fiber (such as straw powder), the pulverizer should use a hammer-type mechanism to enhance crushing efficiency.

The mixing process must ensure uniformity among the raw materials, binders, and nutrients. Uneven mixing can result in insufficient nutrients or insufficient strength in some pellets. A typical requirement for uniformity is a coefficient of variation of ≤7%. This can be achieved by adjusting the mixer speed (30-40 rpm) and mixing time (5-8 minutes). Sampling points should be set up at the fertilizer mixer outlet for hourly testing.
During the conditioning process, the steam supply should be adjusted according to the production speed of the ring die granulator. For example, if the pelletizer processes 5 tons of raw materials per hour, the steam supply should be maintained at a stable 0.3-0.4 tons/hour, monitored in real time by a flow meter. If the pelletizer speed is increased to 6 tons/hour, the steam supply should be increased to 0.45-0.5 tons/hour to prevent the raw materials from being too dry or too wet.
By coordinating the speed and flow of the front-end and pelletizer, production efficiency can be increased by 10%-15%, reducing downtime caused by process disconnects.

How to adapt a BB fertilizer blender to different raw material characteristics?

Written by fertilizer production line on September 29th, 2025. Leave a comment

BB fertilizer raw materials come in a variety of forms (granular, powdered, and fiber-containing). BB fertilizer blenders require targeted adjustments to accommodate these different raw material characteristics and avoid mixing problems.

For pure granular raw materials (such as urea and diammonium phosphate granules), which have relatively small density differences but are prone to rolling and stratification, the BB fertilizer blender should be equipped with guide plates within the mixer drum to guide the raw materials into upward and downward circulation and control the feed order. Adding the denser diammonium phosphate first, followed by the lighter urea, can reduce initial stratification. The speed can be appropriately reduced in the later stages of mixing to prevent excessive collisions between particles that could lead to breakage.

If the raw materials contain powdered ingredients (such as potassium chloride powder or trace element powder), a dustproof seal should be installed at the BB fertilizer blender feed port to prevent dust from escaping. Additionally, an atomizing humidifier (control the humidity to ≤15%) should be installed within the mixer drum. A small amount of humidification can enhance adhesion between the powdered raw materials and the granules, preventing dust from becoming suspended.

When the raw materials contain fiber organic fertilizer (such as fermented straw powder), it is necessary to use a paddle with a shearing function to prevent the fibers from entangled and clumping. At the same time, the fiber raw materials should be crushed to less than 3mm in advance to reduce mixing resistance. During the mixing process, the machine can be stopped and observed every 3 minutes. If fiber clumps are found, the paddle angle needs to be adjusted to enhance the shearing and dispersion effect to ensure that the fibers and granular fertilizer are fully integrated.

Different fertilizer types require special adaptation requirements for ring die granulators

Written by fertilizer production line on September 29th, 2025. Leave a comment

In fertilizer production, ring die granulators must adjust core parameters based on the characteristics of different raw materials, such as organic fertilizer, compound fertilizer, and slow-release fertilizer, to ensure optimal granulation.

For organic fertilizers, whose raw materials often contain fiber components such as straw and fermented manure, ring die granulators require large-aperture ring dies (typically 8-12mm) and anti-entanglement rollers to prevent fiber entanglement and pelletizing stalls. Furthermore, the steam injection time should be appropriately extended during the conditioning stage to enhance the viscosity of the fiber raw material.

If producing bio-organic fertilizers containing live bacteria, a rapid cooling device should be added after granulation to reduce the pellet temperature to below 35°C to prevent high temperatures from killing the live bacteria.

Compound fertilizer raw materials are primarily nitrogen, phosphorus, and potassium powders, which are prone to moisture absorption and agglomeration. Therefore, granulators require ring dies made of wear-resistant materials (such as alloy steel) to minimize wear on the die holes, and the roller pressure must be precisely controlled. Excessive pressure can cause components like nitrate nitrogen in the raw materials to decompose and be lost due to the high extrusion temperature, while too little pressure can cause the granules to become loose.

Slow-release fertilizers, however, contain special ingredients like coating agents, so the ring die granulator requires a lower extrusion temperature (below 30°C). This is usually achieved by reducing the roller speed (from 30 rpm to 20 rpm) and adding a cooling device to prevent high temperatures from damaging the slow-release coating structure and ensure the fertilizer’s slow-release effect.

NPK Fertilizer Production : Granulator Selection & Environmental Compliance

Written by fertilizer production line on September 28th, 2025. Leave a comment

The choice of granulator and its environmental compliance further differentiate NPK fertilizers from bulk mixed fertilizers, impacting production efficiency and sustainability.

Selecting the appropriate fertilizer granulator is crucial for optimizing both production efficiency and environmental performance across different fertilizer manufacturing systems. In an NPK fertilizer production line, the integration of a high-quality fertilizer mixer machine ensures homogeneous nutrient distribution before granulation, which is essential for meeting precise chemical specifications. Meanwhile, in organic fertilizer production line configurations, granulator choice directly impacts product quality and processing efficiency.

The emergence of bio organic fertilizer production adds another dimension to equipment selection, where granulators must preserve microbial viability while achieving proper pellet formation. Environmental compliance begins with proper equipment selection that minimizes dust emissions, optimizes energy consumption, and ensures consistent product quality. The synergy between mixing and granulation technologies across these production lines represents the foundation of sustainable fertilizer manufacturing that meets both agricultural needs and regulatory standards.

The selection of an appropriate NPK fertilizer granulator is a critical decision that shapes the entire NPK production line. This choice directly influences particle size uniformity, nutrient homogeneity, and dissolution rates—key factors that distinguish premium NPK fertilizers from simple bulk blends.

Within the comprehensive NPK fertilizer production process, the granulation stage serves as the quality cornerstone. Advanced granulators enable precise control over the physical characteristics of the final product while ensuring compliance with stringent environmental regulations regarding dust emissions and resource utilization.

Environmental considerations extend beyond emissions control. Modern NPK fertilizer production process designs incorporate resource recovery systems that minimize waste and energy consumption, aligning industrial operations with circular economy principles. This holistic approach to sustainability enhances market competitiveness while reducing ecological footprints.

Traditional Bulk Blending

Simple physical mixing of raw materials with limited nutrient precision and higher segregation potential during handling and application.

Modern NPK Granulation

Chemical bonding through granulation creates homogeneous particles with precise nutrient ratios, reduced dust, and improved handling properties.

NPK Fertilizer Production Process Flow

1.Raw Material Preparation & Mixing

2.Granulation Process (60-100°C)

3.Drying & Cooling

4.Screening & Packaging

Both granulation systems must be integrated seamlessly into the broader NPK production line, with careful consideration of upstream mixing and downstream drying processes. The NPK fertilizer granulator serves as the heart of the operation, determining not only production efficiency but also the final product quality that reaches farmers.

Expert in the crushing process of fertilizer production: chain crusher

Written by fertilizer production line on September 28th, 2025. Leave a comment

In compound fertilizer production lines, the crushing efficiency of raw materials is paramount to final product quality. The chain crusher, an essential fertilizer equipment, operates as a crucial fertilizer production machine that significantly influences granulation uniformity and nutrient consistency. Its robust design delivers superior size reduction for various materials, making it indispensable in NPK fertilizer manufacturing.

In organic fertilizer production, the combination of a chain crusher with a compost fertilizer machine creates a powerful preprocessing system. The crusher efficiently breaks down compost clumps and organic aggregates, ensuring optimal material consistency for subsequent granulation. This synergy enhances decomposition efficiency and produces homogeneous organic fertilizers.

Similarly, in biofertilizer production, the chain crusher plays a vital role among the equipments required for biofertilizer production. It carefully processes carrier materials without generating excessive heat that could harm microbial viability, maintaining the biological integrity while achieving the necessary particle size for effective inoculation and product formulation.

The chain crusher is a vital size-reduction unit in the NPK manufacturing process, expertly crushing hard raw materials like superphosphate and ammonium phosphate to an ideal particle size. This primary crushing is essential for the subsequent NPK blending machine to achieve a homogeneous and uniform nutrient mix. The finely crushed powder is then perfectly prepared for the NPK fertilizer granulator machine, ensuring high-quality, consistently sized granules. Thus, the chain crusher’s robust performance directly underpins the efficiency of the entire blending and granulation stages in NPK production.

Core Advantages of Chain Crusher

✓Efficient Crushing
High-speed rotating chains generate powerful impact force for rapid material crushing

✓Uniform Particle Size
Unique screen design ensures consistent output particle size

✓Strong Adaptability
Can process various materials of different hardness, from organic to inorganic

✓Easy Maintenance
Modular design enables quick and easy replacement of wear parts

Why Choose Chain Crusher?

Compared with traditional hammer crushers, chain crushers have distinct technical advantages. Their unique chain structure not only effectively prevents material clogging but also reduces over-crushing, significantly improving crushing efficiency. More importantly, chain crushers operate smoothly with low noise and minimal dust, creating a more comfortable working environment for operators.

In practical applications, chain crushers are particularly suitable for processing materials with high moisture content. Even under high humidity conditions, their unique structural design ensures stable operation without wall sticking or clogging.

As the fertilizer industry continues to demand higher product quality, chain crushers are becoming the preferred equipment for more and more fertilizer manufacturers due to their excellent crushing performance and stable operation. Investing in a high-quality chain crusher means injecting lasting power into your production line!

New pet of pig farm: feed granulator improves feed utilization and reduces costs

Written by fertilizer production line on September 28th, 2025. Leave a comment

As an important part of animal husbandry, pig industry faces the problems of high feed cost and low feed conversion rate in modern large-scale breeding. In order to improve the economic benefits of pig farms, the new feed granulation technology came into being and became the new pet of pig farms. Through the use of feed granulator, this technology not only improves the utilization of feed, but also effectively reduces the cost of farming.

1. Efficient transformation of Fertilizer Granulating Production Line

The Fertilizer Granulating Production Line uses a series of processes to produce granular feed from various raw materials. Such production lines usually include crushing, mixing, granulation, drying and packaging. In the pig farm, the pellet feed processed by this production line has the advantages of balanced nutrition, easy digestion, reducing waste and so on, thus improving the utilization rate of feed.

2. the recycling of Organic Fertilizer Production Line

In pig farms, manure and waste water are common wastes. Through the Organic Fertilizer Production Line, this waste can be converted into organic fertilizer. This organic fertilizer can not only be used in pig farms to increase crop yields, but also can be sold as a commodity, bringing additional economic benefits to pig farms.

3. Precise granulation of Flat-Die Pellet Machine

The Flat-Die Pellet Machine is the key equipment in the feed pelletizing production line, which can precisely control the grain size and shape of the feed according to the growth stage of different pigs. This precise granulation technology helps to improve the pig’s acceptance of feed, reduce feed waste, and thus improve feed utilization.

4. Strict Screening by Rotary Screening Machine

During the feed pelletizing process, the Rotary Screening Machine is used to screen out unqualified feed particles to ensure uniform size and regular shape of the final product. This not only helps to improve the palatability of the feed, but also reduces feed waste caused by too large or too small particles.

Conclusion

Through the application of feed granulator, pig farms can achieve efficient conversion and accurate supply of feed, and significantly improve the utilization rate of feed. At the same time, through the recycling of organic fertilizer production lines, pig farms can convert waste into valuable organic fertilizers and achieve sustainable use of resources. This innovative feed processing technology not only helps reduce the operating costs of pig farms, but also improves the overall competitiveness of the pig industry.

How to Improve the Efficiency of a New Two-in-One Organic Fertilizer Granulator

Written by fertilizer production line on September 26th, 2025. Leave a comment

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%.

Analysis of Difficulties in Bio-Organic Fertilizer Production Lines

Written by fertilizer production line on September 26th, 2025. Leave a comment

As a crucial pillar of green agriculture, bio-organic fertilizer production lines have standardized processes. However, actual production still faces numerous technical and operational challenges, which directly impact product quality and efficiency.

Raw material pretreatment is the primary hurdle in bio-organic fertilizer production lines. Bio-organic fertilizer raw materials are primarily agricultural waste, such as livestock and poultry manure, straw, and mushroom residue, and their composition is complex and unstable. Moisture content and carbon-nitrogen ratios vary significantly among raw materials, and uneven mixing can lead to low subsequent fermentation efficiency. For example, high moisture content in livestock and poultry manure can easily clump, necessitating the addition of additional ingredients. This not only increases costs but can also disrupt the microbial environment due to improper ingredient ratios. Furthermore, pretreatment is necessary to remove harmful substances such as heavy metals and antibiotics from the raw materials. However, inaccurate testing and screening can result in excessive heavy metal levels in the finished product, failing to meet agricultural safety standards.

Precise control of the fermentation process is a key challenge. Bio-organic fertilizer fermentation relies on microbial decomposition of organic matter, requiring strict control of parameters such as temperature, humidity, and oxygen content. If the temperature rises too slowly during the initial fermentation phase, the composting cycle will be prolonged; excessively high temperatures may kill beneficial microorganisms and lead to nutrient loss. Furthermore, the fermentation process is prone to producing harmful gases such as ammonia and hydrogen sulfide. If the ventilation system is poorly designed, this not only pollutes the environment but also affects the health of workers.

The integration of equipment operation and quality control also presents challenges. In the bio-organic fertilizer production line, the crushing, mixing, and granulation equipment must operate in tandem. Uneven particle size can affect the granulation yield. Improper temperature control in the granulator can easily result in granules that are too hard or too soft, impacting product storage and transportation. Furthermore, relying solely on sampling and testing finished products during quality inspection can hinder timely detection of production process problems, potentially resulting in the rejection of entire batches.

These challenges not only test the technical capabilities of the bio-organic fertilizer production line but also place high demands on the professional expertise of the operators. Only by addressing these challenges in each link can we promote the high-quality development of the bio-organic fertilizer industry and provide strong support for the green transformation of agriculture.

Efficient Operation Strategies for the Conveying Segment of an Organic Fertilizer Production Line

Written by fertilizer production line on September 26th, 2025. Leave a comment

In an organic fertilizer production line, the conveying segment is the “link” connecting the crushing, fermentation, granulation, and packaging processes. Its efficiency directly impacts the production capacity and stability of the entire line. To avoid material accumulation and conveying jams, scientific planning is required from three aspects: equipment selection, layout design, and operation and maintenance.

Rational conveying equipment selection is crucial. Differentiated selections should be made based on the material characteristics of each process. Belt conveyors are ideal for crushed dry materials (such as straw powder). They offer high conveying capacities (up to 5-20 tons per hour), adjustable speeds, and a smooth, easy-to-clean belt surface, minimizing material residue. Bucket elevators are suitable for granular materials. Vertical conveying saves workshop space, and a sealed hopper prevents granules from spilling, accommodating the required height between the granulator and packaging machine. Furthermore, all conveying equipment must be constructed of corrosion-resistant materials, such as stainless steel or galvanized steel, to accommodate the acidic and alkaline properties of organic fertilizers and extend equipment life.

A scientific layout is essential. Conveyor routes should adhere to the principle of “shortest paths and fewer turns” to minimize resistance and energy consumption. Bucket elevator inlets are equipped with buffer devices to prevent particles from impacting and damaging the hopper. Belt conveyors are tilted no more than 15°; for larger angles, corrugated belts with sidewalls are used. Level sensors are installed at key points to automatically warn when material accumulation exceeds the limit, adjusting the conveyor speed to prevent overload and shutdown.

Proper operation and regular maintenance are key. Operators must strictly follow the “pre-startup inspection – ongoing monitoring – post-shutdown cleaning” process: Before starting up, check the conveyor belt tension and wear of the scraper or hopper. During operation, monitor the material conveying status in real time and make timely adjustments if any deviation or jamming is detected. After shutting down, thoroughly clean any remaining material inside the equipment, especially wet and sticky materials, using a high-pressure water jet to prevent caking and blockage. Regular maintenance includes weekly lubrication of conveyor bearings, monthly inspection of the tightness of the scraper and hopper, and timely replacement of worn parts to ensure efficient operation of the conveying chain and maintain stable production capacity of the organic fertilizer production line.