In 2025, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. completed the full-process commissioning of a 10-unit extrusion granulation production line tailored for a customer in Guigang, Guangxi, officially entering a new stage of large-scale mass production. This production line focuses on the ultra-large-capacity production needs of compound fertilizers and organic fertilizers, integrating the entire chain of core processes including batching, crushing, mixing, granulation, screening, coating, and packaging. With its robust configuration of 10 granulation main units operating in parallel, highly automated process design, and stable and reliable operation, it has become a benchmark project for fertilizer production equipment in South China, injecting strong momentum into the upgrading of local agricultural industrialization.
Production Line Full-Chain Configuration and Core Equipment Analysis
The entire production line follows a closed-loop process of “precise batching – raw material pretreatment – efficient granulation – fine processing optimization – finished product output.” The equipment layout is compact and orderly, with seamless connections. Each unit works synergistically, ensuring both ultra-large capacity requirements and strict control over product quality stability.
Precision Batching and Raw Material Pretreatment Unit: Strengthening the Production Foundation
Multi-Compartment Collaborative Batching System: The production line starts with a 4-compartment automatic batching system. Each compartment is independently designed to store nitrogen, phosphorus, and potassium as main raw materials, as well as various additives. The total storage capacity meets the requirements of continuous 12-hour full-load production. Precision metering devices are installed at the bottom of the batching compartments. Combined with a PLC intelligent control system, the system automatically adjusts the amount of each raw material fed according to the preset formula, with a batching error of ≤1%, ensuring accurate fertilizer nutrient ratios.
High-Efficiency Crushing and Uniform Mixing: Raw materials are conveyed to a 90-type horizontal semi-wet material crusher via 2.9-meter and 11-meter belt conveyors. This equipment is specifically designed for high-moisture raw materials, employing wear-resistant alloy cutter discs and a graded crushing structure. It can crush large, agglomerated raw materials (particle size ≤80mm) into uniform fine materials ≤2mm, achieving a crushing efficiency of 15 tons/hour, meeting the stringent requirements for raw material fineness in subsequent granulation. The pulverized material is transferred via a Y-shaped tee and a 14-meter belt conveyor to two 2200-type precision mixers (presumably “precision mixers”). These machines feature a dual-shaft counter-rotating design with wear-resistant coatings on the impellers. During mixing, the material forms a strong convection circulation, ensuring thorough mixing of different components with a mixing uniformity error of ≤2%, laying the foundation for high-quality granulation.
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Core Granulation Unit: 10 Main Units Create Super Capacity
The mixed material is then diverted via a tee and evenly fed by two 2200-type disc feeders to ten extrusion granulators. The feeders employ variable frequency speed control and automatic material level control technology, allowing real-time adjustment of the feed rate based on the granulator’s operating status, preventing granulation quality fluctuations or equipment overload caused by uneven feeding.
The core highlight of the entire production line is the parallel operation of 10 extrusion granulators. Each machine has an hourly output of 3 tons, and their combined operation achieves a total capacity of 30 tons/hour and a daily capacity of 720 tons, far exceeding the capacity of conventional production lines. The granulators employ a high-strength roller extrusion design, with roller skins made of high-chromium alloy. After quenching treatment, the hardness reaches HRC62 or higher, exhibiting extremely high wear resistance and extending the service life to over 10,000 hours. The equipment is equipped with a hydraulic pressure regulation system, allowing precise control of the extrusion pressure within the range of 6-18 MPa to adapt to the granulation needs of raw materials with different moisture content and compositions. The granulation rate remains consistently above 93%, with uniform particle size controlled at 3-5 mm and particle strength reaching 2.8 MPa. The particles are not easily pulverized, meeting the requirements for long-distance transportation and long-term storage.
Post-processing and Finished Product Output Unit: Enhancing Quality + Efficient Shipping
Screening and Coating Optimization: Granulated granules are transferred to a 15x60m drum screen (presumably a 1.5×6.0m standard size) via 7m and 11m belt conveyors. A double-layer screen design separates large, unqualified granules on the upper layer and selects qualified finished products on the lower layer, achieving a screening efficiency of 35 tons/hour. Unqualified granules are returned to the pre-processing unit via 8m and 5m return conveyors for reprocessing, achieving a material utilization rate of 99%. Qualified granules undergo anti-caking pre-treatment in a 16-type spiral duster, followed by a 1.5×6.0m coating machine. Atomized spraying technology evenly coats the granules with a coating agent, forming a dense protective film that effectively improves the fertilizer’s moisture resistance, stability, and slow-release nutrient effect.
Finished Product Storage and Automated Packaging: Wrapped finished products are conveyed to a finished product warehouse via a 12-meter belt conveyor for temporary storage. The warehouse is equipped with a material level monitoring system to provide real-time inventory status feedback. Finally, quantitative packaging is completed using an automatic packaging scale. The equipment supports rapid switching between multiple specifications such as 25kg, 40kg, and 50kg, with a measurement error ≤ ±0.2kg and a packaging speed of up to 200 bags/hour. Combined with a subsequent transfer system, it achieves rapid warehousing and shipment of finished products.
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Core Advantages and Industry Value of the Production Line
Super Capacity Leading the Industry: The innovative configuration of 10 parallel granulation units breaks through the capacity bottleneck of conventional production lines, meeting the quantitative needs of large-scale fertilizer production enterprises and helping customers seize market share.
Intelligent, Efficient, Cost-Effective, and Inefficient: The entire process is integrated with a PLC intelligent control system, achieving automated control of batching, feeding, granulation, and screening, reducing manual intervention and labor intensity. The equipment’s energy consumption is 15% lower than that of conventional production lines with the same capacity, resulting in a significant reduction in overall production costs.
Stable, reliable, and highly adaptable: Core equipment adopts standardized and wear-resistant designs, key components are highly versatile, and maintenance is convenient. The production line can flexibly adapt to the production of various materials such as organic fertilizer, compound fertilizer, and bio-organic fertilizer, and supports product customization with different particle sizes and formulas, demonstrating extremely high adaptability.
The successful commissioning of 10 extrusion granulation production lines in Guigang, Guangxi, not only demonstrates Huaqiang Heavy Industry’s core strength in the R&D and integration of ultra-large capacity granulation equipment, but also provides efficient and stable equipment support for the modernization of agriculture in South China. In the future, Huaqiang Heavy Industry will continue to focus on customer needs, continuously optimize product performance and process solutions, and provide more competitive customized solutions for global fertilizer producers, contributing to the high-quality development of the agricultural industry.
Mastering High-Volume Dry Granulation
This groundbreaking 10-unit production line in Guangxi exemplifies the industrial-scale application of advanced fertilizer granulation technology. Its core innovation lies in the massive parallel deployment of extrusion granulators, a method that falls under the category of dry granulation processes.
The line is a prime example of a roller press granulator production line, where each fertilizer compaction machine (or fertilizer compactor) performs fertilizer granules compaction through high-pressure extrusion. This method of fertilizer compaction is a key fertilizer granulation processes used within the broader npk manufacturing process for specific product types. It stands in contrast to alternative fertilizer processing machine technologies, such as drum granulation using a rotary drum granulator for wet agglomeration. The successful scaling to ten parallel units demonstrates a mastery of this particular fertilizer granulation technology, enabling unprecedented production volumes of dense, low-moisture fertilizer granules.Therefore, this project is not just about capacity; it is a testament to the precision engineering and process control required to reliably scale up dry granulation, providing a model for high-output fertilizer manufacturing that prioritizes product density and energy efficiency.
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