#disk granulator

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Production Process of Bio-organic Fertilizer Equipment

The of bio organic fertilizer equipment production process mainly revolves around the harmless treatment and resource utilization of organic raw materials. The core is to transform waste into nutrient-rich organic fertilizer through microbial fermentation. The specific process can be divided into the following stages:

1. Raw Material Pretreatment

First, organic raw materials such as livestock and poultry manure, straw, and kitchen waste are crushed to remove impurities (such as stones and plastics). Then, they are mixed in a specific ratio, while adjusting the moisture content to 50%-60%.

2. High-Temperature Fermentation

The mixed raw materials are fed into fermentation equipment (tough compost turner or fermentation tank). The turner turns the material regularly (1-2 times daily) to ensure sufficient oxygen supply and maintain the fermentation temperature at 55-65℃ (this temperature kills pathogens and insect eggs) for 7-10 days. Temperature monitoring is necessary during fermentation. If the temperature is too high, the turning frequency needs to be increased to lower the temperature; if it is too low, the turning frequency should be reduced to maintain the temperature.

3. Post-processing: The fermented material is dark brown and odorless. It needs to be dried in a dryer to reduce the moisture content to below 15%. Then, it is graded using a sieve to remove unfermented coarse fibers. Next, it is granulated using a granulator (such as a disc granualtor or roller press granualtor) into granules (2-5mm in diameter for easy application). Finally, it is cooled to room temperature in a cooler to prevent clumping.

4. Finished Product Packaging: After cooling, the granules are sieved to remove debris. An automatic packaging machine weighs and seals the granules before storing them in a warehouse. The packaging must be labeled with nutrient content, production date, and other information, complying with national standards for organic fertilizer.

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What is Organic Fertilizer Dry Granulation?

Organic fertilizer dry granulation of is a technical approach that directly compresses fermented powdered organic raw materials into granules without adding water or drying. Its core equipment is a flat die press granualtor or a roller press granualtor. Using mechanical pressure (20–50 MPa), materials with a moisture content of 15%–25% are forced through die holes or roller gaps, instantly forming and cutting to obtain cylindrical or oblate spherical granules with a diameter of 2–8 mm. Because no drying is required, there is no waste gas or wastewater emission, and energy consumption is reduced by 30%–50% compared to traditional wet processes (disc/drum). A single machine can produce 1–5 tons per hour. Dry granules have high immediate hardness (≥10 N), allowing for immediate screening and packaging, making them suitable for heat-sensitive materials such as organic-inorganic compound fertilizers, carbon-based fertilizers, and microbial fertilizers.

In actual production, to ensure the stability and quality of dry granulation, precise control of the physical properties of the raw materials is necessary. For example, controlling the particle size distribution within a reasonable range is crucial to avoid die blockage due to overly coarse particles or excessive dust due to overly fine particles. Simultaneously, the mechanical pressure parameters during the organic fertilizer dry granulator process of need to be dynamically adjusted according to the proportions and characteristics of different raw materials. For instance, for materials with high fiber content, the pressure can be appropriately increased to enhance particle density; while for materials with high viscosity, the pressure needs to be reduced to prevent excessive particle adhesion. Furthermore, the dry granulation process places extremely high demands on the precision of the granulation equipment's molds. The shape, diameter, and surface smoothness of the mold holes directly affect the granulation rate and appearance. Therefore, the molds must be made of wear-resistant materials and undergo regular inspection and maintenance to extend their service life and ensure consistent granulation results.

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How to measure NPK in fertilizer?

Measuring the NPK content in fertilizers is crucial for ensuring fertilizer quality. This is primarily achieved through targeted chemical analysis, which must be tailored to the production characteristics of NPK fertilizer granulators and other fertilizer equipment to ensure precise integration between testing and production processes.

Nitrogen content detection uses the Kjeldahl method, applicable to all types of fertilizers (covering both organic and inorganic nitrogen). The procedure involves first grinding the fertilizer sample evenly—especially granular fertilizers processed by NPK fertilizer granulators, which require crushing and mixing to avoid sampling bias. The sample is then digested with concentrated sulfuric acid and a catalyst to convert nitrogen into ammonia. After distillation and release, the ammonia is absorbed by acid, and finally, the content is calculated through titration. For field testing or preliminary screening, rapid nitrogen detection kits can be used. These kits use colorimetric reactions to compare concentrations, are easy to operate but have slightly lower accuracy, making them suitable for initial quality control after fertilizer machine production.

Phosphorus content detection commonly uses the molybdenum-antimony colorimetric method. This requires first converting phosphorus in the fertilizer into phosphate, which then reacts with molybdenum-antimony reagent to form a blue complex. The absorbance is measured using a spectrophotometer, and the content is determined by comparing with a standard curve.

Potassium content detection primarily uses flame photometry and atomic absorption spectrophotometry. Flame photometry is simple to operate and moderately costly. It calculates content by detecting the specific spectral intensity of potassium excited in a high-temperature flame, making it suitable for routine fertilizer testing. Atomic absorption spectrometry offers higher precision and is suitable for low-potassium content or complex substrate fertilizers.

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What is the cost of disk granulator machine?

The price of a disc granualtor varies considerably depending on factors such as size, material, and level of automation. Generally, the prices are as follows:

• Small Disc Granulator: Small disc granulators with a diameter of 1.2-1.5 meters typically cost between 15,000 and 30,000 yuan. These machines usually use ordinary carbon steel discs, with manually adjustable tilt angles. They are suitable for small workshops with an annual production capacity of less than 5,000 tons. Feeding and speed adjustment are done manually, and the pelletizing rate can be consistently maintained at 80%-85%.

• Medium Disc Granulator: Medium-sized machines with a diameter of 1.8-2.5 meters cost between 50,000 and 80,000 yuan. Equipped with stainless steel disc edges, hydraulic tilt angle adjustment, and a variable frequency motor, the pelletizing rate can be increased to 85%-90%, with a processing capacity of 3-5 tons per hour. Suitable for small to medium-sized organic fertilizer plants.

• Large Disc Granulator: Large disc granulators with a diameter of 3 meters or more cost between 100,000 and 150,000 yuan. Featuring an all-stainless steel disc granulator and a PLC automatic control system, this granulator can be linked with a feeding machine to achieve fully automated organic fertilizer produciton line. It boasts a pelletizing rate of over 90% and a processing capacity of 8-15 tons per hour, meeting the needs of large-scale production.

Furthermore, small-scale disc granulators for laboratory use are relatively inexpensive, ranging from several hundred to several thousand yuan.

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Safety Management Measures for Double Roller Press Granulators

Safety management of double roller press granualtors requires multi-stage control:

Before operation, check the mechanical components: calibrate the roller gap (0.5~2mm), ensure the transmission system protective cover is intact, and that the emergency stop button is sensitive. For the electrical and hydraulic systems, check the wiring insulation and grounding reliability (resistance ≤4Ω), ensure there are no leaks in the hydraulic oil pipes, and that the pressure is normal (10~20MPa). Raw materials must be screened to remove impurities, and a magnetic separator should be installed. The moisture content should be controlled at 10%~15% to avoid blockages or excessive dust.

During the operation of the organic fertilizer production line, operators must wear dust masks, goggles, and non-slip gloves, and are prohibited from wearing loose clothing. It is strictly forbidden to put hands into dangerous areas while the equipment is running. Blockages must be addressed by stopping the machine and displaying a warning sign. Monitor the roller temperature in real time (≤60℃). Immediately stop the machine to investigate any vibration, abnormal noise, or unusual odor. Use specialized tools to handle any jammed materials.

Regular maintenance is essential: clean roller residue daily, add grease to bearings weekly, calibrate pressure sensors monthly, and replace hydraulic oil filters quarterly. The work area must be well-ventilated and dust-free (wind speed ≥ 0.5 m/s, dust ≤ 10 mg/m³), with a 1.5-meter safety zone and warning signs, and equipped with fire-fighting equipment.

Furthermore, operators must receive regular training and pass assessments before starting work. A "pre-shift inspection - in-shift patrol - post-shift cleanup" system must be established, recording operating parameters and abnormalities to form a closed-loop management system and comprehensively reduce safety risks.

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How to Adjust the Size of Particles Produced by a Disc Granulator?

The size of the particles produced by a disc granualtor can be flexibly controlled by adjusting key parameters. Specific methods are as follows:

1. Adjust the disc angle. The disc angle directly affects the residence time and rolling frequency of the material within the disc: a smaller angle results in a longer residence time, more rolling cycles, and increased particle size due to adhesion; a larger angle results in a shorter residence time, causing particles to be thrown out before sufficient adhesion, leading to smaller finished particles.

2. Control the disc rotation speed. The rotation speed is related to the centrifugal force and friction experienced by the particles: too low a speed results in insufficient rolling force, causing the particles to be loose and small; too high a speed results in excessive centrifugal force, causing the material to be thrown towards the edge of the disc, accelerating adhesion, and resulting in larger particles or even clumping.

3. Adjust the feed rate and moisture content. Excessive feed rate leads to excessive material accumulation in the disc, insufficient rolling space, and increased particle size due to adhesion; insufficient feed rate results in low material collision frequency, hindering particle growth. Feeding should be consistent with the organic fertilizer equipment's capacity (e.g., 1-5 tons per hour) to maintain a stable "bed" of material within the disc.

4. Clean the disc surface and optimize raw materials. If residual material forms scale on the disc surface, it will hinder particle rolling, leading to uneven particle size. Regular cleaning with a scraper is necessary to keep the disc surface smooth.

Through coordinated adjustments of the above parameters, the disc granulator can produce particles of different sizes from 0.5 to 5 mm, meeting the needs of various applications such as organic fertilizer and compound fertilizer. In actual operation, small-batch trial production is recommended to record the correspondence between parameters and particle size before mass production to ensure stability.

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Application Prospects of Disc Granulators in Agriculture

The application prospects of disc granualtors in agriculture are broad, mainly reflected in the following aspects:

1. Improved production efficiency and pellet quality: Disc granulators use rotational motion to gradually aggregate powdery materials into pellets under gravity, achieving a pelleting rate of over 93%. The pellets produced by disc granulators are uniform, with small particle size deviation, high strength, and good compressive strength.

2. Adaptability to various materials and production needs: Disc granulators are suitable for various organic fertilizer and compound fertilizer raw materials, including livestock and poultry manure, crop straw, and sludge. The size and shape of the pellets can be adjusted according to different production needs, making it suitable for producing small- to medium-scale compound fertilizer and organic fertilizer pellets.

1. Reduced production costs and energy consumption: Disc granulators require less investment and can save 30% of the cost compared to other processes for producing compound fertilizer. They are easy to operate and maintain, reducing labor training costs and the maintenance costs of organic fertilizer produciotn lines.

2. Technological Innovation and Intelligent Development: In the future, disc granulators will become more intelligent, incorporating the Internet of Things (IoT) and intelligent control systems to achieve remote monitoring and automatic adjustment, improving production efficiency and ease of operation.

3. Market Demand and Industry Prospects: With the advancement of agricultural modernization, the demand for fertilizers, feeds, and other products is increasing daily. Disc granulators play a crucial role in improving product particle size, enhancing quality, and reducing costs. The market size and growth trend of the disc granulator industry show an optimistic outlook, with broad future development prospects.

In conclusion, disc granulators, with their advantages of high efficiency, energy saving, envionmental friendliness, and strong adaptability, have broad application prospects in the agricultural field, providing better services for agricultural production and promoting sustainable agricultural development.

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Organic fertilizer equipment provides superior services for agricultural production.

Organic fertilizer equipment provides superior services for agricultural production.

Organic fertilizer equipment provides better services for agricultural production, mainly in the following aspects: 1. Increased production efficiency: Modern organic fertilizer equipment achieves automated and intelligent operation, greatly improving production efficiency. For example, organic fertilizer compost turning machines, through automated and mechanized operation, can quickly and evenly process large quantities of organic materials, significantly shortening the fermentation cycle.

2. Optimized fertilizer quality: Organic fertilizer equipment ensures the smooth progress of the fermentation process by precisely controlling fermentation conditions such as temperature, humidity, pH value, and oxygen concentration, thereby improving fertilizer quality. The equipment can adjust the fertilizer composition ratio according to user needs to meet the growth requirements of different crops.

3. Environmental benefits: Organic fertilizer equipment can convert agricultural waste such as livestock and poultry manure and crop straw into organic fertilizer, reducing the pollution of the environment. By recycling agricultural waste, organic fertilizer equipment provides abundant organic fertilizer resources for agricultural production, reducing dependence on chemical fertilizers and helping to improve soil structure. 6. Improved Service Quality: Organic fertilizer equipment can provide customized fertilizer products based on different soil conditions and crop needs, meeting diverse market demands. Some regions have implemented "soil testing and fertilizer matching + precision delivery" services through digital platforms, enabling rapid response to farmers' needs and providing customized fertilizers.