Disc Pan Granulator – fertilizer production line

Factors Affecting the Production of Compound Fertilizers Using a Disc Granulator

Written by fertilizer production line on August 21st, 2025. Leave a comment

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

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

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

How to improve the granulation rate of the disc granulator

Written by fertilizer production line on August 18th, 2025. Leave a comment

The granulation rate of the disc granulator directly affects the production efficiency and quality of organic fertilizer. When processing organic fertilizer raw materials containing high fiber and impurities, the disc granulator can take the following measures to ensure the uniformity and granulation rate of the particles:

Pretreatment of raw materials: For raw materials with high fiber and many impurities, it is necessary to first remove large impurities and long fibers through crushing and screening to make the material texture more uniform, provide high-quality basic materials for granulation, and reduce granulation failure caused by uneven raw materials.

Adjust the disc parameters: According to the characteristics of the material, reasonably adjust the disc inclination angle and speed. If the angle is too small, the material is easy to accumulate; if the angle is too large, the material residence time is short. Too fast speed will cause the material to be thrown out due to excessive centrifugal force, and too slow speed will make it difficult to fully roll and agglomerate. By repeatedly debugging and finding the appropriate parameters, the material can form a stable rolling track in the disc and promote uniform growth of particles.

Adding binder: By increasing the spraying amount and uniformity of the binder, the bonding of the material can be improved, thereby improving the strength and uniformity of the particles.

Install screening device: Install drum screener machine in the fertilizer production line to separate unqualified particles and impurities in time, return them to the granulator for reprocessing, form a closed loop, reduce the waste of raw materials, and ensure the uniformity of the output particles.

Clean the equipment regularly: Clean the disc and the inside of the disc granulator regularly to prevent the accumulation of impurities from affecting the granulation effect.

Through these methods, the disc granulator can stably maintain a high granulation rate, improve the quality and efficiency of organic fertilizer production, and help produce high-quality granular fertilizer.

How to make organic fertilizer step by step?

Written by fertilizer production line on August 6th, 2025. Leave a comment

Organic fertilizer is the “nutritional cornerstone” of green agriculture. The scientific nature of its production process directly determines its effectiveness. The following details the standardized organic fertilizer production process to help you produce high-quality fertilizer.

Step 1: Raw Material Selection and Proportioning

Select organic raw materials such as livestock and poultry manure, straw, and mushroom residue, and sort them to remove impurities. A precise carbon-nitrogen ratio of 25-30:1 is precisely blended, for example, chicken manure and corn straw should be mixed at a ratio of 6:4. A composting agent is added to activate microbial activity.

Step 2: High-Temperature Fermentation

The mixed raw materials are fed into a fermentation tank and stirred 2-3 times daily using a compost turning machine, maintaining a temperature of 55-65°C. This temperature kills pathogens, insect eggs, and accelerates the decomposition of organic matter.

Step 3: Crushing and Screening

The composted material is crushed to an 80-mesh fineness using a chain crusher, then passed through a vibrating screen to remove impurities and ensure uniform particle size. Achieving the required fineness increases the fertilizer’s contact area with the soil by 30%, improving crop absorption efficiency.

Step 4: Granulation and Drying

A disc granulator is used to granulate the powder into 3-5mm granules. The powder is then dried (60-70°C) to remove excess moisture to less than 15%. A cooling system is also included, increasing granule hardness by 25%, reducing transportation losses.

Step 5: Coating

The dried and cooled granules enter the coating machine, where a specialized coating agent is sprayed onto the granules to form a uniform protective coating. Coating not only reduces moisture absorption and clumping during storage and transportation, but also controls nutrient release, extending the fertilizer’s effective life.

Step 6: Metering and Packaging

The coated product is automatically metered and packaged in 25kg bags. This fully mechanized process reduces manual contact and ensures product cleanliness.

Following this standardized process ensures that organic fertilizers meet national standards while achieving mass production and increased efficiency. Choose professional organic fertilizer production line equipment to enable high-quality organic fertilizers to contribute to sustainable agricultural development.

How is NPK fertilizer manufactured?

Written by fertilizer production line on August 5th, 2025. Leave a comment

NPK fertilizer, a compound fertilizer containing the three key nutrients nitrogen (N), phosphorus (P), and potassium (K), provides comprehensive nutrients for crops. Its production requires multiple precision steps.

First, the raw material pretreatment stage begins. Nitrogen fertilizer raw materials, typically urea and ammonium chloride, need to be crushed into a fine powder of 80 mesh or larger. Phosphate fertilizers, typically monoammonium phosphate and superphosphate, need to be de-agglomerated and ground. Potassium fertilizers, primarily potassium chloride and potassium sulfate, are screened and decontaminated before being crushed. The three raw materials are blended according to crop requirements. For example, a fertilizer specifically for corn might use a 15:15:15 ratio of nitrogen, phosphorus, and potassium.

Next, the mixing and granulation stages begin. The pretreated raw materials are thoroughly agitated in a mixer, and an appropriate amount of water or a binder (such as bentonite) is added to maintain a moisture content of 20% to 30%. The granules are then granulated using wet granulation equipment. Rotary drum granulators are commonly used for this process because they are suitable for large-scale production. The material is rolled and agglomerated within the drum to form granules with a diameter of 2-4 mm. Disc granulators are suitable for small and medium-sized production capacity, and the granule size can be controlled by adjusting the inclination angle.

After granulation, the granules are dried and cooled. They first enter a rotary dryer at 60-80°C to reduce the moisture content to below 5% to prevent clumping during storage. They are then cooled to room temperature in a cooler to prevent condensation during packaging.

Finally, they are screened and packaged. The cooled granules are classified by a vibrating screen. The fine particles are returned to the granulation stage for reuse. Qualified granules enter a film coating machine, where they are sprayed with an anti-caking agent, weighed, and packaged.

The entire process of the NPK compound fertilizer production line requires strict control of the raw material ratio and particle quality to ensure that the nutrients in the finished fertilizer are uniform and the strength meets the standards to meet the nutritional needs of different crops at different growth stages.

Production process of potassium chloride by disc granulator machine

Written by fertilizer production line on November 26th, 2019.

In the production of potassium chloride granular fertilizer, fertilizer granulator can be used to granulate powder. The particles produced by disc granulator are spherical and have good strength, which can be widely used in agricultural production.

Disc Pan Granulator

In the granulation process of disc pan granulator, it is necessary to add a binder to make the granules shape. Binder can be compounded by common inorganic minerals in a certain proportion. Binder has synergistic effect when potassium chloride is pelleted. The effect of pelletizing rate and particle strength is good when the binder is used for pelletizing. Potassium chloride was granulated by disc pan granulator machine, and the granules were spherical.

NPK Fertilizer Production Line

NPK fertilizer production line deals with potassium chloride fertilizer. First, all raw materials are mixed by the batching system, and the material is crushed by chain mill to the appropriate size. The disc granulator makes the powder into granules. After drying and cooling, the granules of potassium chloride are coated with protective film by the fertilizer coating machine to complete the granular processing of potassium chloride.

Disc Granulator NPK Fertilizer Production Line

When applying potassium chloride, attention should be paid to the appropriate period of potassium application. Generally, the application period of potassium fertilizer should be early or not late, and should be used as base fertilizer and early recovery period. When the application amount of potassium fertilizer is less, it can be used as base fertilizer once, and when the application amount of potassium fertilizer is more or the soil texture is lighter, the application effect is better divided into base fertilizer and topdressing fertilizer. Soil nutrients and fertilization status should also be taken into account in determining the suitable application period of potassium fertilizer. In severe potassium deficiency soils, all potassium fertilizers should be used as base fertilizers in medium soil potassium supply, and suitable organic fertilizers should be applied as base fertilizers, combined with topdressing.

Note the method of application of potassium chloride. The concentrated application of potassium fertilizer is beneficial to improve its utilization rate and obtain better results. However, it is not advisable to have direct contact with seeds or seedlings. For general crops, a combination of soil fertilization and foliar fertilization can be used.