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Dry or wet method? Process selection and equipment matching for chicken manure granulation

Chicken manure is notoriously difficult to granulate for organic fertilizer production; its high moisture content, high viscosity, and uneven fiber structure frequently frustrate newcomers to the industry. When selecting a chicken manure pellet machine, one must look beyond mere production capacity figures and understand how the dry and wet processing methods handle the material’s specific characteristics.

Dry extrusion granulation—exemplified by the fertilizer roller granulator—forces material through die holes or compresses it into sheets. It requires no added water or hot-air drying, resulting in dense granules and lower investment and operating costs. However, it imposes strict requirements on raw material moisture content, typically necessitating levels below 20%. Even after air-drying, chicken manure often retains 35%–50% moisture; attempting direct extrusion without intensive pre-treatment leads to slippage and plummeting output, or even clogged die holes.

Wet granulation takes a different approach. Disc granulators—a common type of organic fertilizer granulator—allow wet material with 25%–50% moisture content to be formed directly into spherical granules. While the resulting granules are round, the process demands high material fineness. Additionally, wet granulation requires auxiliary drying and cooling equipment, leading to higher total investment and energy consumption.

Regardless of the equipment chosen, moisture content remains the central challenge in chicken manure granulation. The dry method demands low moisture, while the wet method accommodates higher moisture but still requires downstream drying. The key to reducing moisture content lies in the initial fermentation stage.

Regarding equipment selection, given the wide variety of fertilizer granule making machine available, it is advisable to follow the logic of “assess moisture first, then determine the process.” If moisture content can be consistently reduced to below 20%, the dry method offers savings on investment and energy; if moisture remains high and the budget allows, the wet method combined with a drying system can produce spherical granules. Testing moisture levels, examining fiber content, and defining capacity requirements before selecting a machine is far more important than simply asking for price quotes.

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Wet disc granulation vs. Dry compaction: Two granulation routes for NPK production lines

In an NPK fertilizer production line, the choice of granulation process directly impacts the line’s configuration and operating costs. Disc granulation technology and fertilizer compaction machines represent two distinct approaches-wet and dry-and understanding their differences is essential for effective production line planning.

Disc granulation is a wet process in which materials roll within an inclined, rotating disc; water or steam is applied to cause fine powders to adhere and grow layer by layer. This method achieves a granulation rate exceeding 90%, producing round, uniform granules that enjoy high market acceptance. While it is relatively flexible regarding raw material moisture content and fineness, the process requires downstream drying, cooling, and hot-air furnace units for moisture removal. Drying equipment alone accounts for 25%–35% of the total investment, and fuel consumption represents a significant long-term operating cost.

In contrast, fertilizer compaction machines granulate material through purely physical means: powder is fed between two counter-rotating rollers and squeezed under high pressure into dense sheets, which are subsequently crushed and screened into granules. The entire process requires no water, binders, or hot-air drying, eliminating the need for heavy equipment such as dryers and coolers. This results in fewer pieces of equipment, a 30%–40% reduction in required factory floor space, and total energy consumption that is only 30%–50% of that required for wet processes. Compacted granules are dense and possess high compressive strength, resulting in low breakage rates during storage and transport; furthermore, the ambient-temperature operation makes the process suitable for heat-sensitive materials.

When planning an NPK fertilizer production line, disc granulation paired with a drying system is a reliable choice if the market prefers round granules, raw material moisture content is controllable, and the budget is sufficient. Conversely, if minimizing investment scale and operating energy consumption is the priority-and raw materials meet low-moisture requirements-the dry route centered on compaction technology offers a compelling alternative.

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(FAQ)What characteristics should a cow manure fertilizer production line possess?

Urea is a mainstream fast-acting nitrogen fertilizer, characterized by its hygroscopic, melting, and caking properties. Therefore, it places specific and stringent requirements on the production line’s environment, equipment, processes, and safety control. A qualified urea fertilizer production line must not only meet basic production needs but also be adapted to the material’s characteristics to stably produce high-quality, compliant agricultural urea fertilizer.

Firstly, there are environmental requirements. Given urea’s strong hygroscopicity, the production line must utilize a closed workshop with strict temperature and humidity control to prevent the raw material from becoming damp, deteriorating, and caking. A fully enclosed transportation, proportioning, and processing system minimizes material contact with air, effectively preventing dust pollution, reducing raw material loss, and ensuring continuous and stable production.

Secondly, there are process and equipment compatibility requirements. Urea is prone to decomposition and nutrient loss at high temperatures; therefore, the production line must employ low-temperature molding and low-temperature drying processes. It should also be equipped with a precise metering and batching system to flexibly adjust the production formula and ensure uniform nutrient content across batches. The molding equipment must be adapted to the characteristics of urea to ensure that the finished product has uniform granules and moderate hardness, reducing the generation of broken particles and powder.

Furthermore, there are requirements for finished product quality control. The urea fertilizer production line needs to be equipped with screening, dust removal, and cooling equipment to remove substandard particles, lower the finished product temperature, and prevent clumping during storage.

Finally, there are safety and maintenance requirements. Urea dust poses a safety hazard, so the production line needs to be equipped with comprehensive dust removal and explosion-proof facilities. The equipment structure needs to be simple and easy to clean to reduce material residue and mold growth, and be suitable for large-scale continuous production.

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(FAQ)What is the status of ammonium sulfate granules compaction technology?

Ammonium sulfate is a widely used, fast-acting, sulfur-containing nitrogen fertilizer. Its powdered raw material is highly prone to moisture absorption, caking, and dust generation, creating significant inconveniences for storage, transportation, and mechanized application. The ammonium sulfate granules compaction technology employs a dry physical forming process that eliminates the need for wetting or high-temperature drying; instead, it relies on purely mechanical pressure to transform the powder into dense, uniform solid granules. This simple, efficient process represents the mainstream method for the industrial production of ammonium sulfate fertilizer.

The core of this technology lies in the principle of high-pressure plastic forming. A fertilizer granules compaction machine applies constant, high pressure to the powdered ammonium sulfate, forcing the particles to bond tightly and form stable crystalline bridges, thereby achieving solidification without chemical reactions.

Raw material pretreatment and parameter control are crucial for ensuring product quality. During production, the moisture content of the ammonium sulfate powder must be maintained within an optimal range, and a small amount of eco-friendly binder is often added to improve plasticity and enhance the granulation rate. Additionally, precise adjustment of the equipment’s roll gap—tailored to the specific properties of the ammonium sulfate—prevents issues such as loose, broken, or unevenly sized granules, ensuring product uniformity.

The complete process flow encompasses raw material screening, material blending, high-pressure extrusion, granule shaping, and classification screening. The resulting ammonium sulfate granules are hard, resistant to pulverization, and exhibit significantly improved moisture resistance, effectively eliminating the problems of dust and caking associated with the powder form. These uniform granules are ideal for mechanized application, offering a steady, even release of nutrients that maximizes fertilizer efficiency.

In summary, ammonium sulfate granules compaction technology offers low energy consumption and consistent product quality, balancing production efficiency with practical value. It is highly versatile and economically advantageous, suitable for both pure ammonium sulfate granulation and the production of sulfur-containing compound fertilizers.

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(FAQ)What are the unique advantages of the BB fertilizer mixer?

As a core piece of equipment in blended fertilizer production, the BB fertilizer mixer is specifically designed for the uniform mixing of various granular fertilizers. It holds an irreplaceable position in the field of formulated fertilizer production, and its unique structure and working principle give it multiple differentiated advantages.

In terms of production efficiency, its fastest mixing speed and largest batch capacity are its most prominent advantages. The equipment adopts a dual-shaft paddle or drum structure, where multiple particles undergo convection, shearing, and diffusion mixing within the machine. Uniform mixing can be completed in just 2 to 3 minutes, with a single batch capacity of several tons to tens of tons. This makes it suitable for flexible production modes with multiple varieties and small batches, significantly improving the overall output efficiency of the production line.

In terms of finished product quality, it achieves non-destructive mixing of granular fertilizers. The BB fertilizer mixer’s paddle speed is optimized, resulting in a gentle mixing process that does not damage the original shape and strength of the particles, effectively avoiding breakage, powdering, and grading. The finished particles are intact with uniform nutrient distribution, ensuring accurate nutrient ratios in each granule and stable and reliable fertilization effects.

In terms of operating costs, its low energy consumption and simple maintenance are significant advantages. The dry mixing process eliminates the need for heating and drying, resulting in relatively low equipment power consumption and significantly lower energy consumption per unit output compared to wet processes such as drum granulation. The equipment features a simple structure, few vulnerable parts, low daily maintenance costs, and convenient cleaning and material replacement. Changing the formula only requires simple cleaning of the machine trough, eliminating cross-contamination.

In terms of market flexibility, it supports rapid formula switching, precisely meeting the soil testing and formulation needs of different regions and crops. Companies can adjust the ratio of nitrogen, phosphorus, potassium, and micronutrients at any time to produce customized fertilizer formulas. This customization capability is the core market competitiveness of BB fertilizer products.

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(FAQ)Which materials are best suited for mixing with a double axis paddle mixer?

A double axis paddle mixer relies on paddles arranged in a staggered pattern on two parallel shafts to simultaneously create radial scattering and axial flow of materials, forming a three-dimensional circulating mixing effect. This unique mechanism determines its adaptability to different materials.

Dry powder granular fertilizer raw materials are the most suitable. Urea, monoammonium phosphate, potassium chloride, potassium sulfate, and other NPK inorganic salt crystals or powders have good flowability, similar density, and low moisture content, quickly forming a uniform convective mixture under the scattering action of the paddles. These materials are not prone to sticking to the walls and clumping, achieving a high degree of mixing uniformity within 3 to 5 minutes, with clean discharge and no residue.

Materials containing a certain amount of moisture or slight viscosity are within a good suitable range. Preliminary fermented and pulverized organic materials, mixed powders with added binders, and compound fertilizer formulations with a moisture content of less than 10%, although their flowability is slightly inferior to dry powder, the strong shearing action of the paddles effectively breaks up slight clumps, ensuring uniform mixing. Simply extending the mixing time appropriately and discharging promptly will ensure stable operation.

High-fiber, high-moisture, and highly viscous materials have a limited range of compatibility. Fresh livestock and poultry manure, highly moist straw residue, and viscous paste-like materials have poor flowability and are prone to sticking to the mixing walls and clumping, which will significantly reduce the mixing effect and may even cause material sticking to the mixing shaft and mixing dead zones. If these materials need to be used, their moisture content must be reduced beforehand or diluted with dry powder, and the cleaning frequency should be increased.

In summary, double shaft paddle mixers are best suited for dry powder granules, and well suited for powders with moderate moisture content. High-moisture and highly viscous materials should be selected with caution.

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(FAQ)What are the characteristics of NPK fertilizer produced by double roller press granulators?

As a representative technology for dry granulation, double roller press granulator imparts distinct characteristics to the resulting NPK compound fertilizer regarding physical form, nutrient structure, and application performance.

In terms of physical properties, the most notable features of roller-extruded NPK fertilizer are high granule hardness and high compressive strength. Raw materials are formed through high-pressure bonding (crystal bridging), resulting in a dense granule structure that resists pulverization and minimizes losses during transport and storage. The granules are uniform and consistent in size, making them ideal for precise application via mechanized equipment. With a moisture content generally below 2%, the product is resistant to moisture absorption and caking, resulting in a longer shelf life.

Regarding chemical properties, nutrient content is flexibly adjustable, allowing for great freedom in formulation. The production process eliminates the need for high-temperature drying, thereby retaining nearly all active ingredients from the nitrogen, phosphorus, and potassium raw materials and minimizing nutrient loss. Various formulations—such as high-nitrogen, high-phosphorus, or high-potassium types—can be precisely achieved by adjusting raw material ratios. The double roller press granulator process is highly compatible with secondary and trace elements; nutrients like boron, zinc, and magnesium can be directly incorporated during extrusion, facilitating the production of comprehensive, balanced-nutrition fertilizers.

From an agronomic perspective, the fertilizer offers steady nutrient release and long-lasting efficacy. The dense granule structure ensures a moderate dissolution rate in the soil, preventing excessive early-stage nutrient supply that could cause “fertilizer burn” while guaranteeing a continuous nutrient supply throughout the crop’s growth cycle. Granular fertilizer also reduces losses due to volatilization and leaching, thereby improving fertilizer use efficiency; it is particularly well-suited for field crops and cash crops with long growing seasons.

In terms of production economics, the process is streamlined and energy-efficient, eliminating the need for drying and cooling stages and offering significant cost advantages. Overall, high hardness, low moisture content, flexible formulation, and steady fertilizer efficacy are the four core characteristics of roller-extruded NPK fertilizer.

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This NPK fertilizer production line aims to efficiently and accurately mix various raw materials, and through processes such as granulation, drying, cooling, and screening, produce NPK fertilizer granules with uniform particle size, stable nutritional content, and easy storage and use.

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The hydraulic roller granulator is a high-pressure forming device widely used in mature dry granulation processes. Powered by a hydraulic system, it utilizes counter-rotating rollers to directly compress powdered materials into granules, eliminating the need for water addition and drying steps.

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The working principle of a windrow compost turning machine is that organic materials are stacked on the ground, and the equipment moves on the material pile through the track walking mechanism.

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The double screws compost turning machine is an efficient flipping equipment designed specifically for aerobic fermentation of organic materials such as livestock manure, crop straw, food processing waste, etc.

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The working principle of the hydraulic trough type compost turning machine is: organic materials are stacked in the fermentation tank, and the flipping machine moves along the tank through a walking mechanism. At the same time, the flipping and stirring mechanism penetrates deep into the material pile, using the power provided by the hydraulic system to flip and stir, fully mixing the upper and lower layers of materials, increasing oxygen supply, promoting microbial activity, and accelerating the decomposition and transformation of organic materials. The oxygen supply system supplies oxygen to the fermentation tank according to the fermentation requirements, ensuring the smooth progress of the fermentation process. Through regular flipping and oxygen supply, organic materials undergo aerobic fermentation under suitable conditions, ultimately producing mature organic fertilizers or bioenergy raw materials.

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Trough type compost turning machine, also known as trough type fermentation compost turning machine, is a mechanical equipment specifically used for aerobic fermentation treatment of organic materials.

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Compaction granulation: An underrated dry process in NPK production

Among the various granulation methods available for NPK fertilizer production lines, compaction granulation is often viewed as a “niche” option. However, this dry process—centered on the fertilizer compaction machine—is demonstrating irreplaceable value in specific scenarios thanks to its unique cost advantages and product characteristics.

The principle behind fertilizer granules compaction differs fundamentally from that of wet granulation. Compaction granulation relies purely on high-pressure physical force. Powdered raw materials are fed between two counter-rotating rollers, where they are squeezed into dense sheets under pressures of 10–30 MPa; these sheets are subsequently crushed and screened to produce the final granules.

The workflow of an extrusion-based NPK line is far simpler than that of a wet process: after automatic proportioning and uniform mixing, the material is fed into the fertilizer compaction machine by a forced-feeding device, pressed into sheets by rollers, and then crushed, granulated, and screened. On-spec granules proceed to packaging, while undersized fines are returned to the granulator via a recycle system for re-compaction. Extrusion lines eliminate the need for dryers, coolers, hot-air furnaces, and large dust-removal towers, resulting in fewer pieces of equipment and a smaller footprint. Equipment investment costs can be reduced by 30%–40%, and total energy consumption is only 30%–50% of that required for wet processes.

Granules produced via compaction possess a dense internal structure, with a crushing strength of 10–20 N per granule; breakage rates during packaging and transport can be kept below 5%, and nutrient release in the soil is more gradual. The process operates entirely at ambient temperature, making it particularly suitable for heat-sensitive materials. The recycle ratio can be controlled between 30% and 50%, achieving a finished product yield of 70%–80%.

Of course, compaction granulation has its specific scope of application; it is best suited for raw materials with a moisture content below 5%–10% and a fine powder consistency. For small-to-medium-scale NPK projects where raw material moisture can be controlled, the dry-process route centered on compaction offers a viable path characterized by lower investment, reduced energy consumption, and differentiated product quality.

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Technical details in NPK production lines: From batching precision to granulation control

The ability of an NPK fertilizer production line to consistently yield high-quality products depends on the precise control of process parameters. Configuring such a line is not merely a matter of assembling equipment; it is a systems engineering process centered on the core requirements of NPK fertilizer production technology.

Batching precision is the lifeline of quality for the entire line. The nutrient content of NPK compound fertilizer is directly determined by the formula, and any weighing error for a specific raw material will be reflected in deviations in the final product. Utilizing a loss-in-weight automatic batching system—which offers precision of up to ±0.2%—effectively ensures batch-to-batch consistency. If batching precision is inadequate or calibration is not performed in a timely manner, the product will struggle to meet standards, regardless of how refined the subsequent granulation process may be.

Parameter control during the granulation stage is equally critical. Taking drum granulation as an example, factors such as steam pressure, water spray flow rate, drum rotation speed, and drum inclination collectively determine the granulation rate and particle size distribution. Excessive pressure leads to oversized granules, while insufficient pressure results in an increase in fine powder. Operators must adjust parameters based on the real-time state of the material, complementing the automated control systems.

Technical handling of screening and material recycling cannot be overlooked. After granulation, the material undergoes screening; qualified granules proceed to packaging, while undersized and oversized particles are returned to the granulation section via a recycling system. Fluctuations in the recycle load directly impact the material balance within the granulator; consequently, high-quality NPK fertilizer lines typically incorporate recycle buffer bins and flow regulation devices.

From the perspective of the entire NPK fertilizer production line, long-term stable operation is achievable only when the three key technical aspects—batching precision, granulation parameters, and recycle control—are effectively implemented. When selecting technology, complexity is not the goal; rather, the priority is finding a solution that best aligns with the specific raw materials and product positioning.

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BB fertilizer mixers and compaction machines: Two critical quality control stages in the process chain

The BB fertilizer production process centers on physical mixing, where granular nitrogen, phosphorus, and potassium base fertilizers are precisely weighed according to a formula and then directly blended and packaged. Although the process is streamlined, it entails significant quality risks. Differences in particle size and specific gravity among raw materials mean that improper mixer selection can lead to segregation—where lighter particles float to the top and heavier ones sink to the bottom during discharge—potentially causing nutrient deviations exceeding 5%. Furthermore, friction during storage and transport can generate fine dust, compromising both appearance and nutrient release characteristics. These two critical quality control stages are managed by the BB fertilizer mixer and the fertilizer compaction machine, respectively.

The mixer is the core piece of equipment in BB fertilizer production. Since the raw materials are already finished granules, the mixer must strike a balance between achieving thorough blending and avoiding granule damage. Excessive rotational speeds can crush granules and generate fines, while speeds that are too low extend mixing times and reduce efficiency. Specialized BB fertilizer mixers typically employ horizontal ribbon or drum designs, operating at low speeds of 20–40 rpm with a mixing cycle of just 1–2 minutes.

If the mixer ensures “internal uniformity,” the fertilizer compaction machine is responsible for enhancing “external quality.” Loose, mixed granules are prone to pulverization and disintegration during storage and transport. The compaction machine applies gentle physical pressure to the mixture, increasing granule density without compromising nutrient content; this boosts granule strength from under 10 N to 12–20 N, effectively reducing breakage losses during handling and mechanical sowing.

Viewed as a complete process, the mixer guarantees uniform nutrient distribution, while the compaction machine enhances the stability of the granules during storage and transport. When effectively integrated, these two machines prevent product non-compliance caused by nutrient segregation and minimize losses during storage and transit.

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The cost economics of dry granulation: Why more factories are choosing the extrusion route

The choice of fertilizer granulation method directly impacts investment scale and operating costs. Compared to wet drum granulation, the double roller press granulator is becoming the preferred option for an increasing number of factories.

Wet granulation involves multiple stages, including mixing with water, steam heating, hot-air drying, and cooling. The drying process alone requires a hot-blast stove, a rotary dryer, and an induced-draft fan; this entails high equipment procurement costs and imposes a long-term burden regarding fuel consumption. For a NPK fertilizer production line with an annual capacity of 50,000 tons, annual fuel costs for the drying stage alone can reach hundreds of thousands of yuan.

Dry extrusion granulation, however, is completely different. A double roller press granulator uses a forced-feeding system to convey mixed powder between two counter-rotating rollers, compressing it under high pressure into dense sheets; the final product is then obtained through crushing, granulating, and screening. The entire process requires neither liquid binders nor heat sources for drying. The surfaces of the fertilizer compactor’s rollers can be machined with hemispherical pockets or grooves, which directly determine the shape and size of the granules. Operating at ambient temperature makes this type of fertilizer compact machine particularly suitable for heat-sensitive materials.

In terms of equipment investment, dry granulation lines eliminate the need for dryers, coolers, hot-blast stoves, and large dust-removal towers, reducing equipment procurement costs by 30%–40%. Regarding civil engineering, there is no need for large-span factory buildings, and the required floor area is reduced by nearly half. With the elimination of fuel consumption, overall energy consumption drops by more than 50%.

Overall, for mid-to-high-end compound fertilizer projects where raw material moisture content can be controlled, the dry extrusion route—centered on the double roller press granulator—offers significant reductions in both investment and operating costs.