The disc granulator, a core component of the organic fertilizer production line, acts as a “shaping craftsman.” Every step directly impacts pellet quality and safe and stable production. To maximize the performance of this critical piece of equipment, a rigorous and organized standard operating procedure is essential.

The 10 minutes before startup are essential. First, inspect the equipment: check for cracks or loosening on the disc liner, ensure adequate lubrication of transmission components (oil level should be 1/2-2/3 of the mark), and tighten the anchor bolts to prevent loosening. Prepare the raw materials: control the moisture content to 25%-35% (if too high, air dry; if too low, add water). Screen out impurities larger than 5mm to prevent clogging. Finally, perform a safety inspection, clear surrounding debris, securely close the guardrails, test the emergency stop button and overload device, and ensure proper functioning of the electrical circuits and instruments.

The 5-minute startup operation must be performed in a sequential manner. First, start auxiliary equipment such as the raw material conveyor and humidifier. Once these equipment stabilizes, start the granulator’s main motor to avoid damage caused by load. Adjust the disc inclination angle according to the material (lower for clay, higher for organic matter, 45°-55°). Set the speed to 15-20 r/min. Once the disc granulator stabilizes, slowly open the feed valve. Initially, feed at 60% of the rated capacity.

Continuous monitoring is required during operation. Check pellet formation every 10 minutes. Acceptable particle size is 2-5mm. If the pellets are too fine, reduce the feed rate or increase the inclination angle. If there is sticking, reduce the water content. Record parameters every 30 minutes. If the motor current is ≤ 90% of the rated value and the bearing temperature is ≤ 65°C, immediately shut down the machine for investigation.

The minimum shutdown time is 15 minutes. First, close the feed valve, drain the material, turn off the humidifier and main motor, clean any remaining material, inspect components for wear, and keep a maintenance log.

During the entire disc granulator operation, operators must strictly adhere to safety procedures at all times, wear dust masks and hard hats, and never open the guardrail while the machine is running. Only by implementing standardized procedures at every stage can safe and efficient organic fertilizer production be truly achieved.

For the granulation stage of organic fertilizer production lines, disc granulators are the preferred equipment for most manufacturers due to their outstanding advantages, including strong adaptability, high granulation quality, and low operating costs. This equipment not only precisely matches the characteristics of organic fertilizer raw materials but also balances production efficiency and product quality, providing critical support for stable production line operation.

In terms of raw material compatibility, disc granulators are far more compatible with organic fertilizer materials than other equipment. Organic fertilizer raw materials are mostly loose, fibrous materials such as livestock and poultry manure and composted straw, which have large moisture fluctuations. By precisely matching the inclination angle and rotation speed, the disc granulator utilizes the dual effects of the material’s own gravity and centrifugal force to gradually roll the loose material into granules. This eliminates the need for excessive compression, which damages the fiber structure. Furthermore, the disc granulator can accommodate raw materials of varying particle sizes, eliminating the need for frequent adjustments to equipment parameters and significantly reducing operational complexity.

Granulation quality is the core reason for choosing a disc granulator. High-quality organic fertilizer granules require a smooth surface, moderate hardness, and good water solubility for easy storage, transportation, and field application. The disc granulator’s granulation process utilizes a “rolling granulation” mechanism, with the pellets continuously tumbling within the disc. This not only ensures uniform nutrient coating but also creates pellets with consistent density, resulting in a high yield rate. Furthermore, the pellet diameter can be flexibly controlled by adjusting the disc speed, meeting the fertilization needs of different crops.

From a cost-effectiveness perspective, the disc granulator also offers significant advantages. Its simple structure, consisting solely of a disc, transmission, and frame, reduces failure rates and reduces maintenance costs compared to extrusion granulators. In terms of energy consumption, the power output of each unit is moderate, and the energy consumption per unit product is significantly lower than other granulation equipment. Furthermore, the disc granulator’s small footprint allows for flexible integration into production lines of varying sizes. Whether small or medium-sized family farms or large organic fertilizer producers, they can choose the appropriate model based on their production capacity needs, maximizing investment returns.

In response to the demand for green agriculture, the disc granulator, through its efficient and energy-efficient granulation method, helps improve the quality of organic fertilizer products, becoming a crucial link between agricultural waste resource utilization and green farming.

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.

In fertilizer production lines, the choice of disc granulator directly impacts production capacity and product quality. Combining the technical specifications and application characteristics of Huaqiang Heavy Industry’s disc granulators, a sound selection requires focusing on four key dimensions.

First, precisely matching production needs is crucial. Equipment requirements vary significantly across industries. For the fertilizer industry, when producing organic fertilizer, rubber or polyurethane-lined models are preferred to avoid corrosion and accommodate fermentable materials like livestock and poultry manure. The recommended rotational speed is 10-18 rpm to preserve organic matter activity. For inorganic compound fertilizer production, ensuring uniform feed distribution and a consistent mixing of nitrogen, phosphorus, and potassium is crucial. Production capacity selection should be based on specific parameters. For example, a small workshop with an hourly production capacity of 0.05-0.15 tons should choose the ZL-500 model, while a large factory with a production capacity of 3.5-6 tons should opt for the ZL-3600 model. A 10%-15% capacity margin should be reserved to account for seasonal fluctuations.

Second, pay close attention to the core configuration details of the equipment. The drive system determines operational stability. For example, the ZL-3600 model, equipped with an 18.5kW motor and a 10r/min speed, can accommodate high-load granulation needs. The disc inclination angle should be adjustable from 30° to 60°, allowing for flexible adjustment based on material viscosity. For example, highly viscous mineral powders require a larger inclination angle of around 50° to reduce wall sticking. The water spray system should be equipped with multiple sets of adjustable nozzles to ensure a stable moisture content of 10%-20% to prevent loose particles and agglomeration. This is crucial for the strength of fertilizer pellets and the quality of metallurgical mineral powder pellets.

Furthermore, a comprehensive assessment of the manufacturer’s capabilities is crucial. Prefer companies like Huaqiang Heavy Industry that have comprehensive production capabilities. Their 12 disc granulator models cover varying production capacity requirements and allow customers to visit their factory for a firsthand understanding of the equipment’s production processes and quality control procedures. Also, consider whether the manufacturer offers customized services.

Finally, prioritize after-sales service and supporting support. Confirm whether the manufacturer offers free installation, commissioning, and operator training to prevent production disruptions caused by improper operation. Equipment packaging must meet transportation standards, such as packaging the main unit bare to minimize impacts and plywood boxes for electrical components. Customized wooden boxes can be used for special transportation needs. Furthermore, the inventory cycle and warranty policy for consumable parts such as nozzles and inner linings must be clearly defined to ensure long-term stable operation of the equipment and reduce future maintenance costs.