fertilizer granulator – fertilizer production line

Benefits of Using a Disc Granulator in Organic Fertilizer Production Lines

Written by fertilizer production line on September 11th, 2025. Leave a comment

Among the core equipment in organic fertilizer production lines, disc granulators are the preferred choice for many companies, especially small and medium-sized production lines, due to their strong adaptability, high-quality granulation, and convenient operation. They significantly improve production efficiency and product quality.

The disc granulator‘s most prominent advantage is its excellent granulation performance. Its unique disc structure uses the synergistic effect of centrifugal force and gravity to create a stable “rolling granulation zone” within the disc, achieving a granulation rate exceeding 90%, far exceeding that of some extrusion granulation equipment. The resulting granules are not only highly rounded and smooth, but also uniform in size (typically controlled within 2-5mm). This not only prevents nutrient loss due to granule breakage during transportation, but also meets the granule shape requirements of mechanized fertilization, significantly enhancing product market acceptance.

Secondly, it offers excellent raw material compatibility. Organic fertilizer raw materials come from a wide range of sources, from decomposed chicken manure and cow dung to straw powder and mushroom residue, with widely varying composition. The disc granulator can easily adapt to different raw material characteristics by adjusting the disc inclination angle (45°-55°), rotation speed (15-20 rpm), and feed rate.

Disc granulators also offer significant advantages in terms of operation and cost. The device boasts a simple structure, with the disc and drive system as its core components. Routine maintenance requires only regular inspections of bearing wear and disc flatness, resulting in maintenance costs approximately 30% lower than those of a drum granulator. Furthermore, its energy consumption is low, with a single unit consuming approximately 5-10 kWh per hour. This makes it suitable for the production needs of small and medium-sized production lines (with a single unit capable of flexibly adjusting daily output to 5-20 tons). The investment threshold is significantly lower than that of large-scale drum granulation equipment, enabling companies to quickly achieve operational and profitability.

Disc granulators also align with green production trends. Their enclosed design reduces dust emission from raw materials, and combined with a spray moisturizing system, they effectively control dust pollution during the production process. Some units can also be integrated into the production line’s waste heat recovery system, further reducing energy consumption. For organic fertilizer production companies that pursue high efficiency, economy and environmental protection, disc granulator is undoubtedly the ideal choice to balance quality and cost.

How does a rotary drum granulator work in an organic fertilizer production line?

Written by fertilizer production line on September 10th, 2025. Leave a comment

In an organic fertilizer production line, a rotary drum granulator is the core equipment for converting powder into granules. Its operating principles revolve around material agglomeration and granulation. Through a combination of physical and mechanical processes, it transforms fermented organic raw materials into granular products that are easy to store, transport, and apply.

After the equipment is started, fermented and pulverized organic materials (such as decomposed cow dung and straw powder) are introduced into the inclined drum of the rotary drum granulator along with an appropriate amount of binder (usually water or starch solution). The drum rotates at a constant speed of 10-15 revolutions per minute. Lifting plates on the inner wall of the drum continuously scoop up and drop the material, creating continuous agitation and mixing. During this process, the binder moistens the surface of the raw material particles, forming a sticky interface and paving the way for particle agglomeration.

As the drum rotates continuously, the material gradually forms tiny “master particles” under the combined effects of gravity, centrifugal force, and friction. These masterbatch particles continuously roll within the drum, attracting surrounding powdered raw materials like a snowball, gradually increasing in size. Furthermore, the drum’s tilt angle (typically 3-5°) ensures that the material moves slowly toward the discharge end, preventing accumulation within the drum and ensuring that each particle is evenly stressed and grows.

To ensure pellet quality, the drum granulator also uses a temperature control system to regulate the drum temperature (typically between 40-60°C). This prevents excessive moisture content from causing pellet adhesion, while also preventing low moisture content from affecting agglomeration. When the pellets reach the preset size (typically 2-5mm, controlled by adjusting the drum speed and residence time), they are discharged from the discharge end and enter the subsequent drying and cooling processes.

Compared with other granulation equipment, the advantages of the rotary drum granulator are large processing capacity (a single device can produce 50-200 tons of fertilizer per day), high particle strength (compressive strength can reach 15-30N), and strong adaptability to raw materials. Whether it is poultry and livestock manure, straw or mushroom residue, it can be granulated stably. It is an indispensable key equipment in large and medium-sized organic fertilizer production lines.

Optimizing ring die granulators: Key measures to boost organic fertilizer output

Written by fertilizer production line on August 30th, 2025. Leave a comment

The ring die granulator is a core piece of equipment in organic fertilizer production lines. Its performance directly affects pellet formation rate, production efficiency, and product quality. Optimizing it not only increases output but also cuts energy use and lowers maintenance costs.

1.Die Hole Size and Compression Ratio
Adjust hole size based on material properties: Different organic raw materials (like livestock manure, straw, or sludge) have varying viscosity and moisture levels, requiring different hole sizes (typically 2.5–6 mm).
Optimize compression ratio: Too high a ratio increases energy use; too low affects pellet hardness. Adjust based on material (generally 1:5–1:8).
2.Raw Material Moisture and Fineness
Control moisture at 20%–30%: Too high causes clogging; too low hampers shaping. Adjust through drying or water spraying.
Keep particle size ≤1mm: Finer material improves granulation, reduces return rate, and boosts output.

3.Roller and Die Compatibility
Set roller gap (0.1–0.3mm): Too wide lowers forming rate; too narrow speeds up wear.
Check roller wear regularly: Uneven wear causes inconsistent pellets. Replace or repair promptly.
4.High-Quality Wear-Resistant Materials
Use alloy steel or carburized rings to improve wear resistance and extend service life.
Apply surface hardening to rollers to reduce friction and replacement frequency.

By rationally adjusting the ring die parameters, optimizing raw material processing, and strengthening equipment maintenance, the output and stability of the fertilizer granulator can be significantly improved. This improves efficiency while lowering operating costs, delivering greater value for producers.

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.