fertilizer production line – Page 16

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.

See how the large wheel compost turning machine controls organic fertilizer production!

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

In the modern organic fertilizer production sector, the wheel compost turner has become an indispensable piece of key equipment due to its exceptional performance and precise engineering design. This highly efficient fertilizer equipment efficiently handles large quantities of compost materials through the coordinated work of multiple precision components, ensuring uniformity and efficiency in the fermentation process.

The main turning disc, as the core working component, is welded from high-strength steel with a diameter of 5-10 meters, evenly distributed with turning teeth along its edge. This innovative fertilizer machine features a hollow design that significantly reduces weight while maintaining structural strength. During operation, the turning disc rotates at 10-20 RPM, using centrifugal force to lift and scatter materials.

The turning teeth, made of wear-resistant alloy steel, are arranged spirally or radially along the edge of the turning disc. These 30-60 cm long teeth are bolted for easy replacement when worn. This advanced compost fertilizer machine, through its optimized tooth design, achieves bottom-to-top turning and dispersion of materials during rotation, ensuring thorough contact with air.

The travel mechanism consists of a drive motor, speed reducer, and travel wheels (or tracks), responsible for moving the entire machine around the fermentation site. Large-diameter wide tires provide low ground pressure, suitable for soft ground operations. The crawler-type travel mechanism adapts to more complex terrain, with adjustable travel speed of 0.2-1 meter/minute through the electronic control system.

The power system utilizes a 30-75 kW turning drive motor and a 15-30 kW travel drive motor, with options for diesel or electric drive depending on site conditions. The support structure comprises a steel frame and rotary support, ensuring smooth rotation of the turning disc while withstanding composite weights of tens of tons.

The intelligent electronic control system features a touchscreen displaying real-time parameters, including temperature sensors monitoring fermentation temperature and pressure sensors monitoring turning load. When abnormalities such as overload or motor overheating occur, the system automatically alarms and shuts down for protection. Auxiliary devices including sprinkler systems, lighting equipment, and dust covers further enhance the equipment’s practicality and environmental performance.

Four Common Problems in NPK Fertilizer Production Lines and Solutions

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

NPK fertilizer production lines involve complex processes and are susceptible to problems due to factors such as raw materials, processes, and equipment. These problems not only affect product quality and production capacity, but can also pose environmental risks and require precise solutions.

Impurities and agglomeration are prominent issues. Stones and metal fragments mixed in with the raw materials can wear the lining of the granulator and clog the screens of the screening machine, causing equipment downtime. Urea and monoammonium phosphate absorb moisture and agglomerate, forming lumps, resulting in uneven mixing and fertilizer nutrient content deviations exceeding 5%. Solutions: Install a magnetic separator and vibration screener machine at the outlet of the raw material silo to separate impurities; equip a pre-crushing system to crush agglomerated materials to 80-100 mesh; and control the humidity in the raw material silo to less than 60% to prevent moisture absorption.

Pelletization and drying are prone to quality problems. Improper moisture content during granulation (less than 15% results in loose granules, while above 18% results in sticking to the pellet wall), as well as imbalanced rotation speed and inclination angle, can lead to uneven granule size and poor roundness (less than 80%). Excessively high drying temperatures (>160°C) can cause nitrogen volatilization (loss rate exceeding 10%), while too low drying temperatures can easily lead to granule agglomeration. Solutions: Install an online moisture meter before granulation to adjust binder dosage in real time; use a frequency converter system to optimize granulator parameters; and equip the drying process with an automatic temperature control system to maintain a stable temperature between 120-150°C.

Dust and wastewater treatment can easily fail to meet standards. Mixing and screening processes generate a lot of dust. If the dust removal equipment’s filter bags become clogged or air volume is insufficient, dust emission concentrations can easily exceed 20mg/m³. Drying condensate and equipment wash water contain nitrogen and phosphorus, which can be directly discharged into water bodies and pollute. Solutions: Clean dust removal filter bags weekly and optimize fan air volume. Establish a wastewater recycling system for treated and reused in granulation to achieve “zero discharge.”

Wear and aging reduce efficiency. Wear and tear of vulnerable components like granulator scrapers and dryer lift plates (e.g., a gap exceeding 15mm between the scraper and the disc) can cause material to stick to the wall and reduce drying efficiency. Oil depletion or aging in the drive system can cause abnormal noise and speed fluctuations. Solutions include establishing a regular inspection system, checking vulnerable parts weekly and replacing them promptly. Lubricate the drive system monthly with specialized lubricant, and perform comprehensive maintenance and calibration quarterly.

Three Core Application Scenarios for Disc Granulators

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

Due to their high pellet formation rate and highly adjustable parameters, disc granulators have expanded beyond the traditional fertilizer sector to diverse applications such as environmental protection and metallurgy, becoming a “universal device” for material formation across multiple industries. Their differentiated adaptability to various application scenarios is their core competitive advantage.

Agriculture is the primary market for disc granulators, with each specific application focusing on its own specific niche. In organic fertilizer production lines, for fibrous materials such as livestock and poultry manure and straw, the equipment requires rubber-lined discs with anti-sticking walls, an inclination angle of 35°-40°, and a humic acid binder to achieve efficient granulation at a moisture content of 15%-18%. Compound fertilizer applications require even higher corrosion resistance. 304 stainless steel discs, combined with an atomizing spray system, precisely control the adhesion of nitrogen, phosphorus, and potassium mixtures, ensuring pellet roundness that meets high fertilization standards.

In the field of environmental solid waste treatment, disc granulators have become a key component in resource utilization. When processing municipal sludge, the equipment first reduces the sludge’s moisture content to below 20% through a preheating system. Then, using bentonite as a binder, the equipment, operating at a speed of 18-20 rpm, converts the sludge into spherical pellets suitable for incineration or landfill. For the treatment of industrial solid waste such as steel slag and slag, wear-resistant ceramic-lined discs can withstand the impact of high-hardness materials. Combined with a powerful scraper, they ensure uniform mixing of the ore powder and binder, effectively improving solid waste utilization.

Mineral powder granulation in the metallurgical industry places stringent requirements on equipment stability. For high-density materials such as iron ore concentrate and manganese ore fines, disc granulators utilize a thickened steel frame with an adjustable tilt angle of 40°-45°. A high-frequency vibrating distributor ensures uniform feeding and ensures the compressive strength of the ore powder pellets meets the feed requirements for blast furnace smelting. Furthermore, for the granulation of rare earth materials, the equipment must be equipped with a sealed dust cover to prevent leakage of ultrafine powder and ensure a safe production environment.

From agriculture to environmental protection to metallurgy, the disc granulator continues to expand its application boundaries through customized adjustments of materials, parameters, and supporting systems. In the future, with the integration of new materials technology, its application potential in refined fields such as medicine and food additives will be further released.

New Type Organic Fertilizer Granulator: A New Benchmark for Green Production?

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

In today’s agricultural sector, which strives for environmental protection and efficiency, the new type organic fertilizer granulator is redefining the production model for organic fertilizer with its innovative design. No longer a single “granulator,” it collaborates with multiple fertilizer equipment types to create a low-energy, high-yield, green production line. Shouldn’t this new equipment set a new benchmark for the industry?

The new organic fertilizer granulator’s unique features are quite striking. It utilizes low-temperature granulation technology to prevent high temperatures from destroying the beneficial microorganisms in the organic fertilizer, ensuring a longer-lasting fertilizer effect.Furthermore, its unique double axis mixer structure ensures more uniform mixing of raw materials, resulting in a pellet formation rate exceeding 96%. The pellets also possess a moderate hardness, making them both easy to transport and easily dissolve and absorb. Even more conveniently, the equipment is equipped with an intelligent control system that allows for real-time adjustment of speed and temperature, allowing operators to easily control production via a screen, significantly reducing labor costs.

Maximizing the value of the new organic fertilizer granulator requires the support of supporting equipment. Initially, the livestock and poultry manure processing machine separates impurities and moisture from the raw materials, providing high-quality raw materials for granulation. The fermentation turning machine, through aerobic fermentation, converts the raw materials into decomposed organic matter, reducing odor emissions.Later, a drum screener machine accurately selects qualified particles, returning the fine powder to the granulator for secondary use, achieving zero resource waste. A low-temperature dryer dries the fertilizer at temperatures below 40°C, further preserving its nutrients. Finally, an automatic metering and packaging machine quickly bags the fertilizer, ensuring a tolerance of no more than 50 grams per bag, meeting standardized production requirements.

With the growing global emphasis on ecological agriculture, this production line, comprised of a new organic fertilizer granulator and supporting equipment, not only addresses agricultural waste pollution but also provides high-quality organic fertilizer for the soil.

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Key considerations for fertilizer coating machine selection

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

When selecting a coating machine, fertilizer companies should consider their own production needs and focus on three key factors to avoid mismatching the equipment with their production.

First, consider compatibility with the particle characteristics. For large fertilizer particles (diameters over 5mm), a wide-channel coating machine with an anti-sticking guide structure is recommended to prevent particle accumulation and blockage within the channel. For particles with high moisture content (above 12%), a conveyor assembly with an anti-stick coating is preferred. For organic fertilizer particles containing fibrous impurities, it is also important to confirm whether the coating machine is equipped with a pre-filter to prevent impurities from entanglement with mechanical components.

Second, consider capacity compatibility. For small-scale production (daily production capacity under 50 tons), a batch coating machine can be selected, offering flexible batch adjustments and suitable for producing a variety of fertilizers in small batches. For large-scale production (daily production capacity over 100 tons), a continuous machine is recommended to ensure that the conveyor speed is synchronized with the material feed rate.

Finally, consider the compatibility of the coating material. If using PE film, confirm that the equipment’s heat-sealing temperature range covers 100-130°C. If using functional coating materials (such as films containing anti-caking agents), check that the equipment’s tension system supports low-tension adjustment to avoid film breakage and impacting performance. Additionally, pay attention to the equipment’s adaptability to film widths and whether it can be flexibly adjusted to accommodate different packaging specifications, minimizing material waste due to film mismatches.

Working principle of a drum fertilizer cooler: Understanding the core logic of material cooling

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

In industrial production, directly stacking high-temperature materials after processing can easily lead to problems such as agglomeration and deterioration. Drum fertilizer coolers are key equipment for addressing this problem. So how do they achieve efficient cooling? Today, we’ll examine their core operating principles from both a structural and process perspective.

The core structure of a drum fertilizer cooler consists of an inclined drum body, a transmission system, a cooling system, and a discharge mechanism. During operation, hot materials enter through the feed port at the upper end of the drum. The transmission system drives the drum to slowly rotate, causing the materials to continuously tumble and move forward within the drum as it rotates.

The cooling system achieves cooling through two methods: one is a cooling jacket installed on the drum shell, through which cold water or air flows, removing heat from the material through heat conduction; the other is a direct flow of low-temperature gas into the drum. The gas fully contacts the hot material, absorbing heat through heat exchange, and is then discharged through the exhaust port. Throughout the entire process, the material is tumbled to ensure uniform heating and avoid incomplete cooling. The drum fertilizer cooler’s tilt angle and rotational speed control the material’s residence time, allowing for flexible adjustment based on the cooling requirements of different materials.

Finally, the cooled material is discharged from the discharge port at the lower end of the drum, completing the cooling process. Whether it’s granular, powdered, or small chunks, this cooling method delivers efficient and stable cooling, widely applicable to production needs across multiple industrial sectors.

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

Written by fertilizer production line on September 25th, 2025. Leave a comment

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

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

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

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

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

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