the fertilizer granulator

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Strategies to Accelerate Return on Investment for NPK Blending Fertilizer Production Lines

The speed of ROI for NPK blending fertilizer production lines hinges on five key areas: minimizing initial investment, strictly controlling operating costs, expanding revenue streams, capitalizing on policy incentives, and maximizing equipment utilization. Compared to granulation-based compound fertilizer lines, the BB fertilizer process is simpler and allows for flexible upgrades, potentially shortening the payback period by 10–18 months.

I. Adopt a phased, lean investment approach to alleviate upfront financial pressure. Instead of opting for a fully equipped, all-in-one solution from the start, utilize modular, staged procurement: initially install core units for basic ingredient handling, mixing, and packaging, then add storage silos and automatic palletizing equipment later based on sales volume—thereby reducing initial equipment investment by 30%. Prioritize leasing existing warehouse space to simplify civil engineering requirements and avoid the high costs associated with infrastructure for drying and granulation processes. For NPK bulk blending machine, conduct price comparisons and negotiations to select low-energy, intelligent models, cutting long-term electricity and maintenance costs by over 10%. Simultaneously, secure low-interest agricultural loans and equipment financing options to minimize the initial drain on cash flow and accelerate capital turnover.

II. Compressing Operating Costs Across the Entire Process to Boost Per-Ton Profit: Source raw materials directly from major manufacturers to lock in bulk prices and bypass intermediaries, saving 40–80 RMB per ton; stockpile low-cost nitrogen, phosphorus, and potassium materials during off-seasons to hedge against price hikes during peak seasons. Implement fully automated PLC batching systems requiring only 1–2 inspectors, eliminating manual labor for batching and weighing. Use pulse dust collection systems to recover and re-blend spilled fines, keeping raw material loss below 0.5%. Perform regular maintenance on conveyor belts, mixing blades, and load cells to minimize downtime and production losses; utilize energy-efficient motors and eliminate the drying stage to drastically reduce electricity expenses. III. Optimize equipment operational efficiency and minimize waste. Install anti-bridging vibration devices on storage silos to ensure uninterrupted material discharge; utilize sealed mixing equipment to prevent material segregation and reduce rework and waste; and employ intelligent systems for one-touch recipe switching, cutting production changeover time by 70% and enabling an additional 2–3 batches per day. Strictly control batching accuracy to prevent the loss of entire batches due to substandard nutrient levels, stabilize finished product output, maximize daily production, and accelerate the recovery of equipment investment costs.

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Key Factors Determining the Output of Roller Press Granulation Production Lines

The actual capacity of a roller press granulator produciton line depends on more than just the specifications of the main machine; it is determined by five core conditions: raw material characteristics, roll shell configuration, auxiliary pre-treatment fertilizer production machine, downstream screening and material recycling, and operational control. A bottleneck in any of these areas can significantly reduce actual output.

Raw material pre-treatment is a fundamental determinant. Material moisture content, fineness, and impurities directly limit capacity. For chemical fertilizers, keeping moisture below 5% and ensuring fine, clump-free powder allows for smooth feeding and full-load production; conversely, organic fertilizers with high moisture (>25%), high coarse fiber content, or impurities like hard lumps and stones cause sticking and clogging, necessitating slower feeding speeds and cutting output in half.

Roll shell and main machine configuration are critical. Roll diameter, pocket size, and material composition determine the output per extrusion cycle. Large-diameter, wide-face rolls process more material per cycle, yielding higher capacity; shallow pockets or severely worn rolls result in poor forming and excessive fines, forcing a large volume of material to be recycled for reprocessing and drastically reducing effective output. Improper roll gap adjustment also hampers hourly output: a gap that is too narrow causes the machine to stall or trip due to overload, while a gap that is too wide produces loose granules and increases the recycle rate. Insufficient main motor power leads to speed reduction or overload when handling sticky materials, causing a simultaneous drop in capacity.

Daily maintenance and process control ensure stability. Failure to promptly clean material sticking to the rolls, increased resistance due to lack of bearing lubrication, and frequent equipment breakdowns reduce effective production time. Only by properly managing the dosage of binders in the formula—thereby minimizing roll sticking, clogging, and downtime—can the equipment consistently maintain its rated capacity.

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The Necessity of Intelligent Upgrading for BB Fertilizer Production Lines

Against the backdrop of widespread soil-testing and formula-based fertilization, stricter industry regulations, and rising production costs, the shortcomings of traditional manually operated production lines have become increasingly apparent. Consequently, the intelligent upgrading of BB fertilizer production lines has become an inevitable choice for enterprises seeking to improve quality, reduce costs, and ensure regulatory compliance—addressing multiple pressing practical needs.

First, it ensures precise nutrient content, meeting both agricultural standards and national regulations. Traditional manual batching relies on manual control of material discharge, leading to significant weighing errors and a high risk of failing to meet N-P-K nutrient specifications, which can result in product scrapping and market penalties. Intelligent production lines utilize high-precision weighing modules and dynamic compensation algorithms to correct weight deviations caused by clumping or uneven discharge in real-time, keeping the mixing ratio error consistently within 0.5%. The system can store hundreds of soil-specific formulas, allowing for one-touch switching without the need for manual recalculation; it also automatically adds secondary and trace elements—such as calcium, magnesium, and boron—to meet diverse regional planting needs and ensure consistent fertilizer quality.

Second, it reduces labor input and continuously lowers operating costs. Traditional production lines require multiple personnel to monitor different stages—such as batching, inspection, and packaging—resulting in high labor expenses. Intelligent fertilizer production machine integrates the entire line—including batching, conveying, mixing, and packaging—through linked controls, automatically triggering warnings and slowing down operations in the event of material shortages, blockages, or tolerance deviations. Simultaneously, the system automatically tracks data on energy consumption and raw material loss per ton of fertilizer, assisting managers in balancing production schedules to minimize power waste from idling and reduce raw material loss due to dust, thereby significantly lowering the comprehensive production cost per ton over the long term.

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Key Advantages of the Open-Lid New Type Two in One Organic Fertilizer Granulator

 Compared to traditional closed-cylinder models, the open-lid new type two in one organic fertilizer granulator offers significant advantages in four main areas: cleaning, maintenance, formula changing, and troubleshooting. It is perfectly suited for producing organic fertilizer from high-moisture, high-fiber livestock and poultry manure, significantly reducing downtime losses and maintenance costs.

First, convenient internal cleaning prevents material mold and clumping. Well-rotted cow manure and straw organic fertilizers are highly sticky and moist, easily accumulating dirt and grime on the inner wall of the cylinder and agitator teeth after shutdown. Traditional closed-cylinder models can only be cleaned through small openings at both ends, which is time-consuming and labor-intensive. The open-lid model allows direct opening of the cylinder cover, enabling manual cleaning with a high-pressure water gun and brush to thoroughly clean all residual materials inside the cylinder. This eliminates cleaning dead spots, preventing long-term fermentation, foul odors, and bacterial growth. It also prevents material mixing when switching between different raw material formulas, ensuring the purity of nutrients in each batch of fertilizer, while reducing carbonization and wear on the impellers caused by accumulated material inside the cylinder.

Second, significantly improved efficiency in the maintenance and replacement of core components. The open-top design allows direct access to the main shaft, mixing blades, and seals. Worn blades and oil seals can be repaired without disassembling the entire machine, allowing for quick replacement by a single person. Issues such as bearing noise, shaft blockage, and blade deformation can be directly observed and located, significantly reducing downtime for maintenance and improving the continuous operation rate of the bio-organic fertilizer produciton line.

Thirdly, it facilitates real-time monitoring of the granulation process, enabling precise process adjustments. During production, the open-top design allows for direct observation of material mixing and pelletizing status. Feed speed and moisture addition can be adjusted instantly based on the dryness/wetness and agglomeration effects, eliminating the need for reverse judgment based on the finished product output. This allows for rapid process optimization and improved pelleting rate. The equipment features a hydraulic pneumatic spring for easy opening and closing, and a safety power-off interlock automatically cuts off power after opening, preventing accidental restarts during maintenance. In summary, the open-top design balances production efficiency, maintenance costs, and production safety, making it the preferred model for large-scale organic fertilizer production.

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Disc Granulator Cat Litter Processing Technology

 The disc granulator can process tofu cat litter, bentonite cat litter, and organic fertilizer mixed cat litter. It forms the litter using a rolling process, which consists of five steps: raw material pretreatment, feeding and humidification, rolling and forming, disc cleaning and discharge, and drying, cooling, and screening.

The raw materials are first crushed and proportioned. Tofu cat litter is mainly composed of soybean residue and corn starch, while bentonite cat litter is mixed with mineral powder and a binder. All materials are crushed to a fine powder of 80-100 mesh. Lumpy materials are pre-screened and broken to ensure a fine and uniform powder, preventing hollow particles after molding. After proportioning, the powder is fed into the granulation disc. The dry powder is non-sticky, so a spray system is used to atomize and spray water. The starchy raw materials become sticky when they come into contact with water, forming small core pellets.

The tilted disc rotates at a uniform speed. The material continuously tumbles under the action of gravity, centrifugal force, and friction. The core pellets continuously absorb the outer layer of powder, growing larger layer by layer. The particle size is controlled by adjusting the disc's rotation speed, tilt angle, and water spray volume. Too little moisture results in loose granules and excessive dust; too much moisture causes them to clump together, sticking to the pan walls and reducing the yield. Side scrapers continuously remove accumulated material from the pan walls to prevent thick clumps from interfering with rolling.

The formed granules overflow from the edge of the pan and are fed into a drum dryer. The drying temperature for cat litter is higher than that for organic fertilizer; bentonite cat litter is dried at around 120℃, and tofu cat litter at 90-110℃, thoroughly reducing moisture content and improving granule hardness and water absorption/clumping performance. After drying, the granules are cooled by a cooler and then screened for standard particle size using a grading sieve. Excessively large or small pieces are returned to the pan for secondary granulation.

During production, wear-resistant, thickened scrapers are required because the raw material contains high-hardness mineral powder, causing ordinary scrapers to wear out faster. Ultra-fine atomizing nozzles are used for spraying to reduce localized water accumulation and material adhesion. The entire process is highly continuous, producing rounded cat litter granules with less dust. The equipment investment cost is low, making it suitable for mass production in small to medium-sized cat litter processing plants.

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What should be considered when setting up a fertilizer roller press granulator production line?

Setting up a fertilizer roller press  granulator production line requires attention to seven key aspects: raw material compatibility, equipment selection, foundation layout, power supply, process matching, installation and commissioning, and safe operation and maintenance.

I. Raw material compatibility is a prerequisite. Extrusion granulation is a dry, room-temperature granulation process. The moisture content of the raw material needs to be controlled between 12% and 20%. Too high a moisture content will cause sticking to the rollers, while too low a moisture content will result in a low granulation rate. It is recommended that 90% of the material be passed through 60-80 mesh. Impurities and hard lumps must be removed to avoid damaging the rollers. The mixing uniformity should be ≥95%, and a horizontal mixer is preferred to ensure consistent nutrients and stable granule strength.

II. Fertilizer produciton machine selection must match production capacity and formula. The core is the doublr roller press granulator. The roller diameter, roller width, and pressure range (10-30MPa) must be selected according to the hourly output (1-10 tons). The supporting equipment includes: batching system → crusher → mixer → granulator → screening machine → return material system → packaging machine, forming a closed loop. The return material ratio should be controlled at **15%–25%**.

III. Workshop Layout and Foundation Must Be Stable. The total length of the production line is approximately 20–30 meters, arranged in a straight line or U-shape according to the sequence of "raw materials → batching → mixing → granulation → screening → finished product". The main unit requires an independent concrete foundation of C30 or higher, with a horizontal error ≤3mm/m, and anti-vibration pads to prevent vibration from causing bolt loosening and roller misalignment. A maintenance space of **≥1 meter** should be left around the perimeter, and sufficient height should be reserved for hoisting positions.

IV. Power Supply and Supporting Facilities Must Be Sufficient and Stable. The main unit has a large installed power and requires 380V three-phase power with voltage fluctuations ≤±5%. An independent distribution cabinet and reliable grounding are required. Compressed air (0.4–0.6MPa) is used for pneumatic valves and packaging, and circulating water is used to cool rollers and bearings.

V. Strict Process Parameters and Installation/Debugging: Roller gap must be controlled within 0.2–0.5 mm, with consistent gaps at both ends to avoid uneven pressure and particle size distribution. Perform a 2-hour no-load test run; if no abnormal noises and normal temperature rise are observed, gradually increase the load, monitoring particle yield (≥90%), particle strength (≥20N), and return material amount.

VI. Maintenance and Safety Cannot Be Neglected: Regularly check roller surface wear, bearing temperature, and belt tension; keep roller surfaces clean to prevent material adhesion and uneven loading. Ensure emergency stop devices, protective covers, and warning signs are in place; unauthorized manual cleaning of the roller surface is strictly prohibited.

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What raw materials are suitable for BB fertilizer production lines?

BB fertilizer production lines rely on physical blending processes, primarily using granular raw materials. They have specific requirements regarding material morphology, hardness, and flowability. The main applicable types are conventional granular fertilizers, but functional additives can also be used. Some materials require pretreatment.

The core raw materials are various granular single-element fertilizers and compound fertilizers. Granular urea, granular potassium chloride, potassium sulfate, monoammonium phosphate, and diammonium phosphate are the most commonly used raw materials. These materials have uniform particle size, good flowability, and do not easily separate after mixing, resulting in optimal compatibility. In addition, granular ammonium chloride, calcium magnesium phosphate, potassium nitrate, magnesium sulfate, and other medium-element granular fertilizers can also be added as needed to formulate different nutrient compositions.

Functional additives are widely used, including granular humic acid, amino acids, seaweed extract, chelated trace elements, and silicon-calcium fertilizers, which can be directly blended to produce functional BB fertilizers. Some slow-release and controlled-release granular fertilizers can also be used to create long-acting blended fertilizers.

There are specific restrictions and precautions regarding the use of raw materials. Materials that are prone to chemical reactions must not be mixed. For example, mixing urea with nitrate nitrogen fertilizer or strong acid fertilizer with strong alkaline fertilizer is prone to moisture absorption, clumping, and nutrient loss. Direct addition of large quantities of powdered raw materials is not recommended, as it easily causes stratification of the finished product and increased dust. If powdered materials must be added, pre-granulation is recommended.

The moisture content of raw materials must be uniformly controlled between 8% and 12%. Excessive moisture will cause material adhesion, bridging in the silo, and uneven mixing. Simultaneously, the particle size should be as close as possible; excessive particle size differences will cause stratification during transportation and stacking, affecting nutrient uniformity.

Overall, this production line is compatible with most granular nitrogen, phosphorus, and potassium fertilizers and granular functional additives. Its flexible formulation adjustment is a key reason for its wide application range and high market penetration.

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Maintenance of Blades in the New Type Two in One Organic Fertilizer Granulator

 The blades are core wear parts of the pre-crushing chamber of the new type two in one organic fertilizer granulator. They are subjected to long-term shearing and impacting of materials such as straw and manure, and are also susceptible to corrosion from damp fertilizer powder. Proper maintenance can stabilize crushing and granulation effects and extend the service life of the parts.

After each shift, it is essential to thoroughly clean the blades and shaft to remove any wet material and clumps of fertilizer sludge. Long-term adhesion of sticky materials increases the operating load, accelerates blade wear, and can easily cause feed blockage and motor overload. Avoid striking the blades with hard objects during cleaning to prevent chipping or curling.

During operation, conduct regular inspections to observe the blade's operating status. Increased equipment vibration, uneven output particle size, and decreased granulation rate are often caused by worn or loose blades. If a single set of blades is found to be loose, immediately stop the machine and tighten the bolts. If the blade edge becomes thin and rounded, it can be flipped for use depending on the degree of wear. If both sides are worn, replace the entire set immediately to ensure that all blades experience consistent force and impact.

For raw materials containing a large amount of straw and vines, pre-cutting is necessary to reduce the entanglement and pulling of long fibers on the blades, thus minimizing abnormal wear. Raw materials must be equipped with impurity removal devices; stones or hard metal objects entering the cavity can easily crack or break the blades, causing safety malfunctions.

Lubrication and protection are also crucial. The blade spindle bearings and connecting bushings should be lubricated periodically to prevent dust intrusion and jamming. During long-term shutdowns in the off-season, clean the material from the blade surface, apply anti-rust grease, and store in a dry environment to prevent moisture and corrosion.

It is recommended to conduct a comprehensive inspection of blade wear and tightness every two weeks, and sharpen or replace as needed. Proper maintenance not only reduces replacement costs but also ensures the fineness of material grinding, allowing for the continuous and stable operation of the subsequent bio-organic fertilizer granulation process.

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Development Trends of Organic Fertilizer Disk Granulators machine

Organic fertilizer disk granulator machines are upgrading towards intelligent precision, high efficiency and energy saving, wide applicability, green and low consumption, and integrated operation. The core focus is on improving granulation quality, reducing operation and maintenance costs, and adapting to diverse raw materials, meeting the needs of large-scale and standardized organic fertilizer production.

Intelligent and precise control has become a core trend. New models are equipped with PLC control systems, IoT modules, and online monitoring equipment to collect parameters such as rotation speed, tilt angle, material moisture, and granulation rate in real time. AI algorithms automatically optimize the operating curve, replacing traditional experience-based operation. Equipped with near-infrared online moisture and particle size detection, it automatically filters and returns unqualified particles, achieving a stable granulation rate of ≥95%, a particle uniformity variation coefficient of ≤10%, and a finished product qualification rate exceeding 98%. A remote operation and maintenance platform enables fault warnings and remote parameter adjustment, reducing labor and maintenance costs.

Structural optimization and efficiency improvement continue to advance. The disc surface uses a wear-resistant, non-stick coating, combined with a quick-disassembly design, significantly shortening the replacement time of vulnerable parts. With the widespread adoption of variable frequency drives, precise load matching is achieved, reducing unit energy consumption by 20%–30%. Larger disc diameters and adjustable tilt angles make them suitable for high-moisture, high-fiber, and high-viscosity materials (moisture content 25%–45%), increasing raw material utilization to over 95%.

Green environmental protection and integration are accelerating. Fertilizer production machine is becoming more airtight, equipped with dust and odor removal systems to reduce dust and odor emissions. Seamless integration with crushing, drying, and screening equipment forms a fully automated production line, eliminating intermediate transfers and increasing efficiency by over 40%. Some models integrate crushing and granulation functions, achieving one-step forming and adapting to small and medium-sized production capacity needs.

In the future, disc granulators will deeply integrate big data and AI technologies to further enhance their intelligence level, while expanding into the resource utilization of solid waste such as sludge and bacterial residue, contributing to the high-quality development of the organic fertilizer industry.

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Performance Enhancement Solution for Bio-organic Fertilizer Production Lines

To increase output, stabilize live bacteria, reduce malfunctions, and minimize losses in bio-organic fertilizer production lines, a systematic upgrade and transformation can be implemented in five areas: fermentation, crushing and mixing, granulation, automation, and corrosion protection. This will comprehensively improve the stability of the production line and the quality of the finished product.

First, optimize the fermentation section to improve the uniformity of composting. Existing compost production machine can be upgraded to a hydraulically adjustable turning structure, automatically adjusting the turning depth and frequency according to the dryness and wetness of the material to avoid localized suffocation and incomplete fermentation. Adding exhaust ventilation, dust removal, and dehumidification systems to the workshop reduces moisture accumulation, minimizes material acidification, odor, and loss of live bacteria, resulting in more stable organic matter and microbial activity in the semi-finished product.

Second, upgrade the crushing and mixing systems to solve the problems of uneven particle size and mixing. Replace ordinary crushers with denser, wear-resistant hammers and screens to strictly control the material fineness to within 2mm; upgrade ordinary mixers to a weighted ribbon structure to increase material convection mixing, resulting in more uniform mixing of microbial agents and trace elements, eliminating problems such as fluctuating nutrient levels and uneven distribution of live bacteria in the finished product.

The granulation section underwent targeted upgrades to improve molding stability. Feed moisture content was uniformly controlled at 8%–12%, and a variable frequency, uniform-speed forced feeding system was installed to eliminate problems such as roller sticking, granule rot, and excessive return material caused by inconsistent feeding speeds. The roller skins are made of high-wear-resistant alloy steel, improving molding rate, reducing particle dust, and resulting in higher finished product hardness, better storage and transportation resistance, and no caking.

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Raw Material Requirements for Roller Press Granulator Production Lines

Dry granulation in roller press granulator produciton lines does not rely on glue or require water drying. Raw material parameters directly affect the granulation rate; moisture content, fineness, and ingredient ratio are key. The overall moisture content of the raw materials is optimally controlled between 8% and 12%. Moisture content below 6% results in loose powder that is difficult to extrude and granules that are easily crushed. Moisture content exceeding 15% easily clogs the rollers and die holes, leading to frequent roller blockages and production stoppages. Raw materials with excessively high moisture content must be pre-dried or mixed with dry fine materials for adjustment.

Regarding material fineness, all raw materials should be pulverized to within 2 mm, with fine powder accounting for more than 70%. Fine powder acts as a binder and carrier. Coarse fiber straw and long grass clippings must be pulverized and sieved. Excessive coarse fiber content will clog the roller grooves, resulting in loose, non-granulated extruded flakes. When producing organic-inorganic compound fertilizers, organic raw materials are combined with nitrogen, phosphorus, and potassium powders, and appropriate amounts of humic acid and bentonite are added. The raw materials themselves are physically extruded and bound together, eliminating the need for additional binders.

When the proportion of salty raw materials, such as ammonium chloride and potassium chloride, is high, large crystals should be minimized, and large-particle fertilizers should be crushed in advance to prevent hard objects from scratching the roller skin. Hard impurities such as stones and iron blocks in the raw materials must be removed by iron removal and screening in advance to prevent them from entering the roller gaps and damaging the roller skin and bearing housing.

Daily batching should be kept as stable as possible. Frequent changes in raw material ratios can easily lead to inconsistent pelleting results. Proper control of raw materials ensures a stable pelleting rate of over 85%, reduces undersize return material, lowers the load on fertilizer production machine, and effectively extends the service life of vulnerable parts such as roller skins and bearings.

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Measures to Delay Corrosion and Aging of BB Fertilizer Production Line Equipment

BB fertilizer raw materials often contain saline fertilizers such as potassium chloride and ammonium chloride, which are highly susceptible to moisture absorption and corrosion of fertilizer production machine. Therefore, delaying rust and aging of the BB fertilizer produciton line requires measures focusing on four aspects: material selection, daily cleaning, environmental control, and maintenance. Prioritize the use of 304 stainless steel for material contact surfaces. Replace carbon steel components on the inner walls of the silos, mixer blades, and discharge chutes. Apply corrosion-resistant and anti-corrosion paint to exposed carbon steel frames to reduce the rate of salt corrosion at the source.

Persist in cleaning the silos and machines every shift. Empty the silos of residual material after production ends. Residual saline fertilizer, when exposed to moisture, will form scale that continues to corrode the silo walls and seals. Before switching to different formulas, clean the remaining material inside the mixer to prevent salt accumulation. Wipe away any powder adhering to belts and flexible discharge connections promptly to prevent fertilizer buildup from corroding rubber and metal bases.

Strictly control the humidity in the workshop environment. Ensure the raw material warehouse is protected from rain and moisture. Dry any damp, clump-forming raw materials before feeding them into the workshop to reduce the dispersion of high-humidity dust. Install exhaust systems in the workshop to reduce the concentration of salt spray and moisture in the air, minimizing corrosion of steel structures and electrical control boxes. Use corrosion-resistant grease for all transmission bearings and add grease regularly to prevent dust and moisture intrusion.

Regularly inspect, remove rust, and touch up paint. Promptly grind and remove rust spots and repaint exposed steel frames. Replace belts, sealing rings, and other rubber and plastic parts as needed to prevent damage, leakage, and further corrosion. Calibrate the batching scale monthly and promptly repair leaks in silos and chutes to prevent fertilizer leakage and prolonged immersion of equipment. Systematic management can effectively extend equipment life by two to three years and reduce replacement costs.

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Wet granulation process of the new type two in one organic fertilizer granulator

The wet granulation process of the new type two in one organic fertilizer granulator consists of five steps: raw material pretreatment, premixing, primary granulation, secondary rounding, and screening for recycled materials. The raw materials have a high moisture content and are suitable for composted livestock and poultry manure, straw, and sludge.

In the raw material pretreatment stage, the fermented material is crushed to within 2mm using a pulverizer, with a moisture content adjusted to 52%–58%. Excessive moisture content can cause sticking and clogging, while insufficient moisture makes it difficult to form granules. Large pieces of debris and hard impurities are removed through screening, and excessively long coarse fibers are pre-crushed to prevent entanglement in the internal agitator. Various auxiliary materials are pre-mixed to ensure uniform material texture.

After the material is fed into the feed hopper of the organic fertilizer granulator machine, it is forcibly fed into the primary granulation chamber at a uniform speed by an internal spiral feeder. Inside the chamber, high-speed rotating agitators repeatedly knead, shear, and compress the material, forming irregular columnar primary granules based on the inherent viscosity of the organic matter. The particle size is controlled by the rotation speed of the main unit.

The nascent granules enter the secondary polishing chamber, where continuous tumbling and friction between the cylinder and the lifting plates polishes their edges and compacts them, gradually transforming them into rounded spherical granules. This completes the integrated granulation and shaping process, eliminating the need for separate rounding equipment.

The finished product exits from the discharge port and is sent to a drum screen for grading. Particles of 2-4mm are considered qualified finished products. Undersize fine powder and oversize large particles are collected and returned to the pretreatment process for re-granulation, achieving closed-loop powder recycling.

Production control focuses on moisture content and rotation speed. If the material is too wet, the feed rate is reduced and the chamber rotation speed is lowered; if the raw material is too dry, a small amount of atomized water can be added. The inner wall of the cylinder is cleaned after each shift, and worn stirring teeth are replaced regularly to maintain a stable forming rate above 85%. This process requires no pre-drying, has a short equipment series connection, and is widely used in small and medium-sized bio-organic fertilizer production line.

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Working Principle of Organic Fertilizer Disc Granulator Machine

The organic fertilizer disc granulator machines relies on the combined effects of gravity, centrifugal force, and friction to naturally agglomerate powdery organic materials into spheres. It is a wet agglomeration granulation device.

The disc surface of the equipment is tilted and fixed. During operation, the material moves in a circular motion with the disc surface. The material slides down under its own weight, while simultaneously being pressed against the disc wall by the centrifugal force generated by the disc's rotation. These two forces work continuously, causing the material to tumble, roll, and rub against each other. Fine powder initially binds with a small amount of moisture and organic matter as binding points, forming tiny mother spheres. These mother spheres continuously absorb surrounding powder during tumbling, gradually growing larger and eventually forming uniformly sized granules.

The machine's internal fixed scraper is in close contact with the disc surface and edge. On one hand, it scrapes away wet material adhering to the disc surface, preventing material accumulation and caking; on the other hand, it breaks up excessively large clumps, guides the material layer, ensures material circulation and tumbling, and avoids uneven forming. Some models are equipped with a misting spray system, allowing for the addition of water or liquid binder as needed to increase material viscosity and improve pelleting rate.

The disc tilt angle and rotation speed are flexibly adjustable to control material residence time, thereby altering particle size. A larger tilt angle and faster rotation speed result in shorter material residence time and smaller particles; conversely, smaller particles are produced at lower angles.

This fertilizer produciton machine uses physical forming throughout the entire process, preserving the nutrient structure of the material and making it suitable for well-rotted organic fertilizer raw materials. By controlling the moisture content and fineness of the raw materials during production, and coordinating with proper scraper operation, stable granulation results can be achieved, producing round and compact organic fertilizer granules.

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What is an NPK Bulk Blending Machine?

NPK bulk blending machine, relies on physical proportioning and mixing to produce nitrogen, phosphorus, and potassium blended fertilizers. The process is simple, and the formula can be changed flexibly, making it the mainstream choice for small and medium-sized fertilizer plants. The entire process involves no chemical reactions and requires no granulation or drying.

The complete NPK blending fertilizer produciton lines consists of a feeding and conveying system, automatic batching, mixing, screening, packaging, and dust removal system. Raw materials are fed into a multi-bin batching station via a closed bucket elevator. The equipment is equipped with a high-precision weighing module that automatically measures the weight according to the preset formula, with a weighing error controlled within ±0.3%, ensuring that the nutrient ratio meets the standards. The core equipment is a twin-shaft paddle mixer or a rotary drum mixer, where materials are fully tumbled and collided inside the drum. Mixing a single batch takes only 3–5 minutes, achieving a mixing uniformity of over 95%, effectively preventing nutrient separation.

The mixed material is then screened by a drum screen to remove lumps and oversized particles. Qualified particles are sent to a fully automatic packaging machine for quantitative bagging, sealing, and coding. The entire production line is equipped with a pulse dust collector to reduce dust pollution. Combined with a PLC control system, it can store multiple formulas, and formula switching takes only about ten minutes, demonstrating a high degree of automation.

This equipment is suitable for various granular nitrogen fertilizers, phosphate fertilizers, potash fertilizers, and trace element raw materials. It requires the raw material moisture content to be ≤5% to prevent agglomeration and blockage. The equipment has a compact structure, small footprint, and low energy consumption, resulting in low initial investment and maintenance costs. Production capacity ranges from 1 to 15 tons per hour. Daily production requires controlling the feed rate, and thoroughly cleaning residual materials from the equipment when changing formulas to avoid component mixing, thereby stabilizing product quality and production efficiency.

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What is a Bio-Organic Fertilizer Production Line?

 A bio-organic fertilizer production line is a complete set of mechanized bio-organic fertilizer equipment. It utilizes organic waste such as livestock and poultry manure, straw, mushroom residue, and agricultural by-products as raw materials. Through composting, fermentation, the addition of microbial agents, and molding, it produces bio-organic fertilizer that meets industry standards, balancing organic matter, nutrients, and beneficial live bacteria. It is a mainstream complete set of equipment for resource-based organic fertilizer utilization.

The entire production line is divided into four main modules: raw material processing, high-temperature fermentation, deep processing, and finished product packaging. First, raw material pretreatment involves sorting, crushing, and mixing to adjust the moisture content and carbon-to-nitrogen ratio of the materials. Specialized fermentation agents are added to create conditions conducive to fermentation. The core process is aerobic fermentation, relying on a turning device to continuously supply oxygen, allowing the materials to fully decompose at temperatures above 55℃, killing insect eggs, pathogens, and weed seeds, while simultaneously decomposing large organic molecules.

The fermented material is then subjected to secondary crushing and sieving to remove lumps and impurities. For granular products, granulation equipment such as discs and stirring teeth will be used to produce uniform granules. These granules are then dried and cooled at low temperatures with strict temperature control to protect the beneficial bacteria within the product from inactivation. Finally, the product is screened, graded, and automatically packaged in quantitative quantities to produce powder or granular bio-organic fertilizer.

The entire production line can be customized in large, medium, and small sizes based on production capacity, ranging from simple semi-automatic to fully automated configurations. It is widely used in livestock farms, agricultural cooperatives, and specialized fertilizer plants. It achieves both harmless and resource-based treatment of waste and mass production of high-quality fertilizer that improves soil, promotes growth, and prevents disease, thus combining environmental benefits with economic value.

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Applications of Fertilizer Roller Press Granulator Production Line

This fertilizer roller press granulator production line utilizes a dry extrusion molding process, eliminating the need for water addition and drying. Its wide range of applications allows it to be adapted to the production of various fertilizer types, catering to different plant sizes and raw material types.

Regarding fertilizer types, this production line primarily produces organic fertilizers and organic-inorganic compound fertilizers. It can also produce pure nitrogen-phosphorus-potassium compound fertilizers, bio-fertilizers, humic acid fertilizers, and micronutrient fertilizers. It is particularly suitable for heat-sensitive materials, operating at ambient temperature throughout the process. This effectively protects the microorganisms, organic matter, and active ingredients, preventing high-temperature degradation—an advantage not found in traditional wet granulation equipment.

In terms of raw material compatibility, it can process well-rotted organic raw materials such as livestock and poultry manure, straw, mushroom residue, and distiller's grains. It can also be used with granular and powdered fertilizers such as urea, potassium chloride, and monoammonium phosphate. It can process dry powder, loose materials, and slightly agglomerated materials normally, requiring only a moisture content control of 5%–8% for production.

In terms of production scale and site requirements, fertilizer production machines feature a flexible modular design. Small, simple lines are suitable for township processing plants, planting bases, and small to medium-sized farms for producing fertilizers for self-use and regional retail. Fully automated production lines can meet the large-scale mass production needs of medium and large-sized fertilizer enterprises, supporting continuous operation and adapting to bulk export orders.

Furthermore, this process is also suitable for deep processing of fertilizers and waste recycling. Fine powder and scraps generated during granulation can be recycled and re-granulated, resulting in high raw material utilization. The overall equipment has a moderate footprint and is easy to operate and maintain, making it suitable for both new fertilizer projects and the renovation of old production lines. It is a mainstream granulation solution that balances versatility and economy.