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Chicken Manure/Pig Manure/Cow Manure Organic Fertilizer Production Line: Differences in Pretreatment Equipment for Different Raw Materials

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Choosing the right pretreatment equipment is half the battle in the organic fertilizer treatment of livestock and poultry manure. Chicken manure, pig manure, and cow manure differ significantly in moisture content, fiber content, carbon-to-nitrogen ratio, and viscosity. Using a “one-size-fits-all” approach not only affects fermentation efficiency but also increases energy consumption and equipment wear. The following is an analysis of the differences in pretreatment equipment for these three types of raw materials.

Chicken Manure: Dehumidification and Salt Reduction are Key

Chicken manure has a moisture content of approximately 50%-70%, extremely high nitrogen content, and a low carbon-to-nitrogen ratio (approximately 10-15:1), classifying it as “hot” manure. Its high viscosity, fine fibers, and tendency to clump make it the most challenging raw material in the pretreatment stage.

Core Equipment: A screw extruder dewatersers can reduce the moisture content of fresh chicken manure from 80% to 60%-65%; a screening device removes impurities such as stones and feathers; a semi-wet material pulverizer refines the material to a suitable particle size; and an anti-sticking ribbon mixer mixes chicken manure with low-nitrogen, high-carbon auxiliary materials such as sawdust and rice husks, adjusting the carbon-to-nitrogen ratio to 25-30:1.

Key Process Points: The core of chicken manure pretreatment is reducing salt content and adjusting the carbon-to-nitrogen ratio. After dewatering, the moisture content is controlled at 50%-55%, supplemented with deodorizing bacteria to reduce ammonia volatilization at the source.

Pig Manure: Breaking Up Clumps is Key. Pig manure has a moderate moisture content (approximately 65%-80%) and a moderate carbon-to-nitrogen ratio (approximately 15-20:1), but it is highly viscous, has poor air permeability, and easily clumps together. If pretreatment is inadequate, the turning resistance is high, and oxygen transfer is hindered.

Core Equipment: Inclined screen or drum-type solid-liquid separator separates raw pig manure with 80% moisture content into liquid and solid states; horizontal pulverizer refines solid pig manure to 40-60 mesh; mixer or crusher with dispersing function breaks up clumps; horizontal mixer simultaneously adds auxiliary materials such as straw and mushroom residue.

Key Process Points: The key to pig manure pretreatment lies in breaking up clumps and improving permeability. After solid-liquid separation, the solid moisture content is reduced to 50%-60%, and then mixed with porous auxiliary materials such as rice husks and mushroom residue to enhance the porosity of the compost pile.

Cow Manure: Cutting Fibers is Key. Cow manure has a high moisture content (approximately 70%-85%), is rich in coarse fibers (lignin, cellulose), and has a relatively high carbon-to-nitrogen ratio (approximately 20-30:1). It decomposes slowly, heats up gradually, and easily clumps together.

Core Equipment: A cow manure processing machine (slurry pumping + dewatering) can reduce moisture content to approximately 40%; a heavy-duty chain crusher or semi-wet material crusher effectively cuts long fibers; a vertical crusher with a multi-layer turbulent chain hammer structure prevents sticking and clogging; a horizontal mixer mixes cow manure with fillers such as straw and rice husks, as well as microbial agents.

Key Process Points: The focus of cow manure pretreatment is fiber breaking and moisture adjustment. Adding straw and microbial agents to the mixer adjusts the moisture content to 55%-65%.

Quick Reference for Selection Recommendations

Chicken Manure: Screw extruder dewatering machine → impurity removal screening → crusher → anti-sticking mixer. Focuses on solving stickiness and high nitrogen issues.

Pig Manure: Solid-liquid separator → crusher → dispersing mixer. Focuses on solving agglomeration and air permeability.

Cow Manure: Manure processing machine → heavy-duty chain crusher → mixer. Focuses on solving fiber breaking and moisture adjustment.

Three Selection Questions: ① What is the moisture content of the raw material? (Chicken and pig manure need dehydration; cow manure can be directly compressed.) ② What is the fiber content? (Cow manure requires heavy-duty crushing; chicken and pig manure can be conventionally crushed.) ③ How viscous? (Chicken manure requires anti-stick mixing; pig manure requires a dispersing device.) — These three questions determine the best equipment choice and prevent pitfalls.

The pretreatment differences for chicken, pig, and cow manure are not arbitrary—they are dictated by each manure’s unique moisture, fiber, and nitrogen profile. Once properly conditioned, however, all three can be fed into a unified organic fertilizer production process that leverages a complete commercial organic fertilizer production line. A powdered organic fertilizer production line may suffice for direct soil application, while a granular line integrates an organic fertilizer granulator series (disc, drum, or extrusion) to produce high‑value pellets. For poultry operations, the chicken manure fertilizer machine and poultry manure fertilizer making machine handle dewatering and crushing, while the chicken manure fermentation turning process is accelerated by a large wheel compost turning machine or a windrow composting machine, depending on site scale. After fermentation, the material enters an organic fertilizer combined granulation process (e.g., drum + disc) for optimal sphericity and strength, followed by a fertilizer drying and cooling machine to lock in moisture and stability. An automatic organic fertilizer batching system ensures precise nutrient blending across all feedstock types, making the entire line adaptable to seasonal variations in manure composition. Ultimately, the right pretreatment equipment is not an end in itself—it is the gateway to a flexible, efficient production system that transforms three very different wastes into a consistent, high‑quality organic fertilizer, ready for any market or crop need.

If you have any questions about fertilizer production equipment and processes, or would like to learn more about customized solutions, please contact us immediately. Whether it’s equipment selection and pricing, installation, commissioning, and operation training, or later maintenance and process upgrades, we can provide you with professional and timely answers and support to help your project be implemented efficiently.

[xyhuaqiang]

Pre-treatment equipment for crushing and mixing – the first line of defense for stable production line operation

Although crushing and mixing equipment is located at the front end of the fertilizer production process, its operating performance directly determines the pelleting rate and particle uniformity in the subsequent granulation stage, making it the first line of defense for stable operation of the entire production line.

Before the material enters the granulator, it must be crushed to reduce its particle size to between 80 and 120 mesh, while mixing is used to achieve uniform distribution of each component in a micro-space. Crushing equipment has a clear division of labor for raw materials with different moisture contents and physical properties. The cage crusher is specifically designed for dry or low-moisture (below 6%) brittle materials. Its structure consists of two sets of steel bars forming a cage that rotates at high speed towards each other. Under centrifugal force, the material is thrown towards the cage bars and rapidly crushed through impact and shearing. The output fineness can be adjusted to over 100 mesh, and there is no internal screen, avoiding the risk of blockage by wet materials. The semi-wet material crusher fills the technological gap in crushing high-moisture raw materials. This equipment employs a dual-rotor structure, with blade and hammer assemblies hinged to the rotors. Under high-speed rotation, it shears, tears, and grinds organic materials with a moisture content as high as 25%. The crushed material is loose and flocculent, which is highly beneficial for subsequent mixing.

The mixing process typically uses a horizontal mixer or a twin-shaft mixer. The horizontal mixer uses a bottom auger or plow-type rotor to achieve axial and radial convection of the material, controlling the coefficient of variation of mixing uniformity to within 5%, making it suitable for material systems with small differences in specific gravity. The twin-shaft mixer utilizes two parallel, counter-rotating impeller shafts, applying strong shearing action while the material is being lifted. For formulations containing trace elements or biological agents and requiring extremely high mixing precision, the twin-shaft mixer can achieve an excellent CV value of less than 3% within 60 to 120 seconds.

The selection of crushing and mixing equipment must consider the matching of processing capacity with the subsequent granulator capacity. Typically, the design capacity of the pretreatment section should have a 10% to 15% margin to cope with fluctuations in raw material batches. Regarding maintenance, the crusher’s hammers and liners are wear parts and a regular replacement plan should be developed based on the abrasiveness of the raw materials. For the mixer, attention should be paid to the integrity of the shaft end seals to prevent powder leakage into the bearings. It is worth mentioning that a compact layout of the crushing and mixing processes, using pneumatic conveying or a closed screw feeder, can effectively reduce workshop dust and lower the intensity of manual handling. From production practice, many cases of granulation failure and unqualified nutrient content in the finished product ultimately trace back to insufficient crushing fineness or uneven mixing in the pretreatment section. Therefore, the importance attached to the crushing and mixing equipment should be no less than that attached to the granulator itself.

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Dust Recovery in Fertilizer Production Lines: Two-Stage Dust Collection System of Cyclone and Bag Filters

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The crushing, mixing, granulation, screening, and conveying processes in fertilizer production generate large amounts of dust-laden gas. Dust is both a source of environmental pollution and a recyclable raw material. A two-stage dust collection system combining cyclone and bag filters is currently the mainstream configuration in the fertilizer industry, balancing environmental compliance with material recovery efficiency. Its design logic is based on a gradient division of labor in gas-solid separation—coarse powder is first intercepted by the cyclone, while fine powder is precisely intercepted by the bag filter, each utilizing its strengths.

Gas-Solid Separation Principle: Gradual Division of Labor, Each Performing Its Duty

The primary cyclone dust collector utilizes centrifugal force to achieve gas-solid separation. Dust-laden gas enters the cylinder tangentially and rotates at high speed. Denser solid particles are thrown against the wall under centrifugal force, losing kinetic energy and falling into the dust collection hopper. The purified gas rises and exits from the central exhaust pipe. The core advantages of cyclone dust collectors lie in their simple structure, lack of moving parts, and high-temperature resistance (capable of handling flue gas above 400℃), allowing direct installation after high-temperature equipment such as dryers and coolers. However, their collection efficiency for fine particles smaller than 5 micrometers is relatively low; single-stage cyclone dust collectors typically achieve only 85%-92% dust removal efficiency, failing to meet current environmental emission standards.

Two-stage baghouse dust collectors rely on filtration mechanisms for fine separation. When dust-laden gas passes through the filter bags, dust is trapped on the bag surface, forming a dust cake layer, and the purified gas is discharged. Baghouse dust collectors can stably control emission concentrations below 20 mg/Nm³, with a collection efficiency of over 99.9% for submicron-sized fine dust. However, their filter bag materials are not heat-resistant (conventional polyester needle-punched felt ≤130℃, glass fiber ≤260℃), and there are certain requirements regarding the inlet dust concentration.

Series Logic: The cyclone dust collector, acting as a pre-dust collector, first intercepts most of the coarse particles and hot sparks, reducing the dust concentration entering the bag filter from tens of g/Nm³ to below 5 g/Nm³, while simultaneously lowering the gas temperature to a safe range. The bag filter, acting as a fine dust collector, is responsible for intercepting fine dust that the cyclone cannot remove, ensuring that final emissions meet standards.

Maintenance Cost Analysis: Series vs. Single-Stage Bag wear costs are the main operating and maintenance cost of a dust collection system. Hygroscopic dust (such as urea and potassium salts) from fertilizer production easily caking on the filter bag surface in humid environments, leading to difficult cleaning and increased system resistance. If high-concentration dust is directly fed into the bag filter, the filter bag wear rate will accelerate—under conditions where the inlet concentration exceeds 50 g/Nm³, the filter bag lifespan may be shortened to 6 months. In a two-stage series system, cyclone pre-dust removal can intercept most coarse particles and abrasive dust, reducing the dust concentration entering the filter bags by 60%-70%, and generally extending the filter bag life to 18-24 months.

Regarding energy consumption, cyclone dust collectors rely on the rotational motion of the airflow itself, with a resistance loss of approximately 500-1000 Pa, consuming almost no additional electricity. Baghouse dust collector systems have a resistance of approximately 1500-2000 Pa, and the compressed air consumption of the cleaning system is approximately 0.3-0.5 m³/min. Although the total resistance of a two-stage series system is higher than that of a single-stage cyclone system, it is lower than the average resistance fluctuation caused by frequent cleaning in a single-stage baghouse system.

The recovery value is a hidden benefit of the series system. Coarse dust collected by the cyclone can be directly returned to the batching system for reuse, and fine dust collected by the baghouse can also be recycled. The overall recovery rate of the two-stage series system can reach over 99.5%, significantly reducing raw material loss.

Selection and Layout Recommendations Cyclone dust collectors should be placed close to the dust generation point to shorten the transportation distance of high-temperature dust-laden gas and prevent water vapor condensation in the pipeline, which can cause it to stick to the walls. The cyclone ash discharge port needs to be equipped with a double-layer ash discharge valve or airlock device to prevent air leakage and efficiency reduction. Baghouse dust collectors must be insulated and heated to prevent condensation on the shell and filter bag clogging.

Summary: The core value of a two-stage series dust collection system lies in the gradient division of labor: the cyclone handles the coarse load, while the baghouse performs fine filtration, achieving the optimal balance between environmental compliance and operation and maintenance costs.

The two‑stage cyclone and bag filter dust collection system is more than an environmental safeguard—it is a strategic component of efficient fertilizer production. By integrating coarse pre‑separation with fine filtration, this system not only ensures emission concentrations below 20 mg/Nm³ but also recovers over 99.5% of valuable raw materials, directly reducing the cost of organic fertilizer production line through material savings and extended filter bag life. When incorporated into turnkey fertilizer production solutions, the dust recovery system is carefully coordinated with upstream bio-organic fertilizer fermentation equipment and downstream granulation, drying, and packaging units, ensuring a clean, safe working environment while maximizing yield. A well‑planned organic fertilizer plant design and layout positions the cyclone close to high‑temperature sources (such as dryers) and the bag filter in a controlled area with insulation and condensation prevention, optimizing both performance and maintenance access. For lines using an industrial drum granulator for fertilizer, the dust system effectively captures fine particles generated during granulation and screening, preventing cross‑contamination and improving product quality. Ultimately, the two‑stage dust recovery approach exemplifies how the entire organic fertilizer production process can be engineered to be both environmentally responsible and economically sustainable—turning a regulatory burden into a source of operational efficiency and competitive advantage.

If you still have any questions about fertilizer production equipment and processes, or would like to learn more about customized solutions, please feel free to contact us. Whether it’s equipment selection and pricing, installation, commissioning and operation training, or after-sales maintenance and process upgrades, we can provide you with professional and timely answers and support to help your project be implemented efficiently.

[xyhuaqiang]

How can belt conveyor misalignment be prevented?

The belt conveyor serves as the material “artery” of a fertilizer production line; failure to promptly address belt misalignment can lead to edge wear, material spillage, and even system shutdowns. A systematic approach to preventing misalignment involves three key areas: installation and adjustment, operation and maintenance, and automatic correction.

Installation and Adjustment: The conveyor frame must be installed with a horizontal straightness error of no more than 2 mm/m. The axes of the head and tail pulleys must be perpendicular to the direction of belt travel, with a parallelism deviation of ≤0.5 mm. Belt splices must be straight; hot vulcanization (achieving >90% of the original belt strength) is recommended over mechanical fasteners, as skewed splices are a primary cause of misalignment. During installation, idler positions should be adjusted under no-load conditions to ensure the belt runs centrally on the pulleys, maintaining a difference of ≤10 mm between the belt edge and the pulley edge.

Operation and Maintenance: Material discharge points should be centered over the belt to prevent off-center loading, which causes misalignment. Adjustable baffles should be installed within the discharge hopper to guide material to the center of the belt. During routine shift inspections, monitor the belt’s tracking path; if deviation is detected, self-aligning idlers (typically adjustable within a ±5° range) can be fine-tuned to compensate. Belt tension must be optimal—excessive slack leads to slippage and misalignment, while excessive tension increases bearing loads and accelerates belt fatigue. A gravity-type tensioning device is recommended to automatically maintain constant tension. Weekly cleaning of idler and pulley surfaces is essential, as material buildup increases the effective diameter at specific points, causing the belt to shift laterally.

Automatic Correction Systems: For long-distance conveyor lines (exceeding 50 meters), the installation of a hydraulic automatic correction system is recommended. When the belt drifts and triggers a limit switch, a hydraulic cylinder automatically adjusts the idler angle to steer the belt back to the center, with a response time of ≤2 seconds. When conveying organic fertilizer (which is highly adhesive), scraper cleaners and return-strand cleaners should be installed on the return belt to prevent material carryback from causing idler adhesion and belt mistracking. A tracking log should be established to track the frequency and causes of belt misalignment across all conveyor lines; targeted modifications should be implemented for areas with high misalignment frequency to ensure the long-term, stable operation of the conveying system and guarantee production continuity.

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NPK Fertilizer Granulators: The Core Equipment of Compound Fertilizer Production Lines

In modern compound fertilizer production, the NPK fertilizer granulator is undoubtedly the heart of the entire process chain. The core value of this equipment lies in its ability to transform powdered raw materials—such as nitrogen, phosphorus, and potassium—into granular products with specific particle sizes, high strength, and uniform nutrient distribution through physical or chemical processes.

Compared to traditional powdered bulk-blend fertilizers, granular NPK compound fertilizers avoid issues like segregation and caking during transport and are better suited for mechanized application. Currently, there are three mainstream technical approaches for NPK fertilizer granulators in the industry: rotary drum granulators, disc granulators, and double-roller extrusion granulators. Rotary drum granulators are ideal for large-scale continuous production; inside the inclined, rotating drum, steam or slurry acts as a wetting agent, causing materials to collide and bond as they roll, gradually forming granules. A single unit can achieve an hourly output of 10 to 20 tons with a granulation rate consistently exceeding 85%. In contrast, double-roller extrusion granulators employ a dry process, using two counter-rotating rollers to compact materials into sheets under high pressure, which are subsequently crushed and sized into high-density granules. This process eliminates the need for moisture addition and drying, significantly reducing energy consumption, making it particularly suitable for processing moisture-sensitive or heat-sensitive raw materials. Disc granulators are prized for their simple structure and operational flexibility, making them common choices for the small-batch production of diverse specialty fertilizers.

Modern, advanced NPK fertilizer granulators feature wear-resistant liners and automatic cleaning mechanisms, effectively extending maintenance intervals. Additionally, variable-frequency drive technology allows for precise control of granulation speed and tilt angles to accommodate materials with varying formulations and moisture contents. From upstream automatic batching systems to downstream screening, coating, and packaging equipment, NPK fertilizer granulators enable seamless, automated integration across the entire production process. Amidst global trends toward precision agriculture and slow/controlled-release fertilizers, this equipment holds irreplaceable strategic importance for fertilizer manufacturers seeking to enhance product value-added and meet diversified market demands.

[xyhuaqiang]

Why must organic fertilizer be fully decomposed before application?

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The core mechanism is as follows:

We recommend the following decomposition assurance measures in organic fertilizer production lines:

Aerobic Fermentation Process:Utilize trough-type or disc-type compost turners for regular turning to achieve uniform aeration, promote thorough material decomposition, and ensure harmless treatment. Using trough fermentation combined with a turner effectively regulates moisture and ensures uniform mixing, achieving full decomposition.

High-Temperature Sterilization and Decomposition Standards:Through trough turning or sealed high-temperature fermentation in tanks, achieve thorough decomposition, sterilization, and egg removal, preventing root burn and bacterial contamination. Only after fermentation and decomposition can the material proceed to subsequent deep processing stages such as crushing and granulation.

Scientific Evaluation of Decomposition:We recommend using the seed germination index (GI) as a quantitative evaluation indicator of decomposition—GI > 50% indicates basic decomposition, and GI ≥ 80% indicates complete decomposition and no toxicity to plants. Industry standard NY/T 525-2021 stipulates that the GI value of commercial organic fertilizers should be ≥70%.

If you still have any questions about fertilizer production equipment and processes, or would like to learn more about customized solutions, please contact us immediately. Whether it’s equipment selection and quotation, installation, commissioning and operation training, or later maintenance and process upgrades, we can provide you with professional and timely answers and support to help your project be implemented efficiently.

[xyhuaqiang]

How to address uneven color in finished granules?

Uneven color in finished granules not only affects the product’s visual appeal but may also indicate uneven nutrient distribution or improper process parameters. Color variations typically manifest as mottled surfaces, streaks of varying shades, or localized spots. The causes and corresponding solutions are outlined below:

Cause Analysis:

Inadequate mixing: Insufficient mixing of organic raw materials (brown/black) and inorganic salts (white/gray) results in spotted color variations after granulation. This is particularly common when adding trace elements (such as zinc sulfate or borax) without pre-dilution, which can lead to the formation of localized dark clumps.

Excessive or localized overheating during drying: After granules exit the rotary drum granulator and enter the  drum dryer, uneven hot air distribution can cause the surfaces of some granules to scorch and darken due to excessive heat, while the granule interiors remain normal, resulting in color inconsistency within the batch.

Raw material batch fluctuations: Variations in the degree of decomposition and sources of organic fertilizer across different batches result in inconsistent base colors, leading to non-uniformity in the finished product.

Solutions:

Optimize the mixing process: Before granulation, extend the mixing time to 5–8 minutes using a high-efficiency horizontal fertilizer mixer or double-screw mixer to ensure macroscopic uniformity of all components. For trace additives, a “stepwise scaling-up” method is recommended: pre-mix trace elements with a small amount of the main ingredients before adding them to the large mixer to prevent localized concentration.

Regulate the drying process: Stabilize the dryer’s inlet air temperature within the range of 120–160°C for organic fertilizer and 180–220°C for NPK fertilizer. Additionally, ensure the layout of the lifting flights is reasonable (fan-shaped flights are recommended to ensure a uniform material curtain within the drum). Install an online temperature monitoring system with 3–4 temperature sensing points along the axis of the dryer drum to ensure the temperature difference across the line remains ≤10°C. Standardized raw material management involves recording the color and testing the maturity of each batch of fermented organic material; batches showing significant color differences are stored separately, and formula ratios are adjusted to ensure color consistency in the final mixture. If color deviation is detected in the finished product, the material can be graded using a screening machine; dark-colored granules may undergo surface spraying, or be mixed with light-colored granules and re-processed through a disc granulator for coating and coloring. Finally, it is recommended to establish a standard color reference chart and perform comparative sampling every two hours, adjusting the mixing ratio or drying parameters promptly if deviations are observed.

[xyhuaqiang]

Straw to High-Organic-Material Fertilizer: A Synergistic Process of Crusher and Fermentation Agent

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Crop straw is an excellent raw material for producing high-quality organic fertilizer. However, its high cellulose content, dense lignin structure, and severely imbalanced carbon-nitrogen ratio necessitate a deep synergistic process between crusher and fermentation agent in straw fertilizer production. Even with a single step done well, fermentation efficiency remains low; only through proper coordination can straw that would normally take months or even a year to naturally decompose be transformed into high-organic-material fertilizer within 25-35 days. The following analysis of this synergistic process focuses on three stages: crushing pretreatment, carbon-nitrogen ratio adjustment, and microbial inoculation.

Crushing Pretreatment: Opening the Door for Microorganisms

The waxy layer and dense fibrous structure of straw form the first barrier against microbial invasion. The purpose of crushing is to break down this physical barrier, increasing the specific surface area of the material and creating conditions for subsequent microbial attachment and decomposition.

Crushing Fineness: Generally, straw should be crushed into small pieces of 1-3 cm. The finer the crushing, the larger the contact area between microorganisms and the material, resulting in faster decomposition. For small-scale production scenarios processing 5-10 tons of straw per day, a hammer mill straw crusher can be used, achieving a fineness of 3-5 mm after crushing, meeting the requirements for subsequent fermentation. Medium to large-scale production scenarios require high-power crushing equipment to match the larger processing capacity.

Equipment Selection Considerations: Straw has a high fiber content and a relatively hard texture, necessitating dedicated straw crushing equipment. When selecting equipment, focus on power matching (avoiding insufficient power), wear-resistant materials (prioritizing equipment made of wear-resistant steel plates), and process compatibility.

Carbon-Nitrogen Ratio Adjustment: Providing Microorganisms with a Nutrient Meal

This is the most crucial yet easily overlooked aspect of straw fertilizer production. The carbon-nitrogen ratio of straw is generally high—approximately 60:1 for corn straw and up to 80:1 for wheat straw. However, the optimal carbon-nitrogen ratio for aerobic microorganisms is 25:1 to 30:1. If the carbon-nitrogen ratio is too high, microorganisms will reproduce slowly due to nitrogen deficiency, the fermentation temperature will not rise, and the fermentation cycle will be indefinitely prolonged.

How to Adjust? The core idea is to supplement the straw with nitrogen. Approximately 5-10 kg of urea needs to be added per ton of dry straw, or it can be mixed with 20-30% livestock and poultry manure (chicken manure, pig manure, etc.) for fermentation. The proper adjustment of the carbon-nitrogen ratio directly affects whether the subsequent microbial agent can “activate”—only under a suitable carbon-nitrogen ratio can the fermenting bacteria rapidly multiply and generate heat, pushing the pile temperature to a high-temperature range of 55-70℃.

III. Fermentation Agent Inoculation: “Accelerating” Fermentation

In its natural state, straw relies on a small number of indigenous microorganisms in the environment for decomposition, which is extremely inefficient. Artificially adding a highly efficient fermentation agent is equivalent to installing an “accelerator” for the fermentation process.

Agent Dosage: Generally, 0.5-1 kg of fermentation agent is added per ton of straw. If the material has a high moisture content or high fiber content, the dosage can be increased appropriately.

Inoculation Method: Dilute the agent with 5-10 times its volume of rice bran, wheat bran, or corn flour, then evenly sprinkle it into the material, ensuring uniform distribution of the inoculum. When possible, the inoculant can be mixed with cake powder (such as soybean cake or rapeseed cake, approximately 20 kg/ton of dry straw) and added together. The cake powder provides both nitrogen and serves as a “culture medium” for the inoculant.

Moisture Content Control: After inoculation, the material moisture content should be maintained at 55%-65%—ideally, it should clump together when squeezed in the hand, with water seeping between the fingers but not dripping. Too low a moisture content hinders microbial activity, while too high a moisture content will clog pores, leading to anaerobic fermentation.

Fermentation Process Management: Turning and Maturity Assessment

After inoculation, pile the material into windrows approximately 2-3 meters wide and 1.5 meters high. Aerobic fermentation requires sufficient oxygen. The first turning should be performed when the center temperature of the pile reaches above 55℃. Thereafter, the pile should be turned every 3-7 days. Maturity is complete when the pile volume collapses by 1/3 to 1/2, the color turns dark brown, and there is no odor but a soily aroma.

In summary, the core of producing high-organic-mass fertilizer from straw lies in the three-step linkage of “crushing and breaking down cell walls—adjusting the carbon-nitrogen ratio—inoculating and fermenting with bacteria.” The crusher opens the physical channels, the carbon-nitrogen ratio adjustment provides chemical nutrients, and the fermentation agent injects biodynamics—all three are indispensable.

The journey from crop straw to high‑organic‑matter fertilizer is a perfect example of process synergy, where mechanical pretreatment, chemical adjustment, and biological inoculation must work in harmony. The straw crusher (and, for moist feedstocks, the half-wet material crusher machine) breaks down the physical barriers of lignin and cellulose, creating the surface area needed for microbial attachment. This step is the first and indispensable stage of the organic fertilizer production process, setting the stage for efficient decomposition. The subsequent carbon‑nitrogen ratio adjustment and inoculation with specialized bio-organic fertilizer fermentation equipment accelerate the breakdown, transforming straw that would otherwise take months into mature, stable compost within 25‑35 days. For producers seeking a complete solution, turnkey fertilizer production solutions integrate these unit operations—from crusher and mixer to fermenter and screener—into a seamless, automated line. Finally, the matured material can be further processed through an organic fertilizer combined granulation process (e.g., drum + disc) to produce uniform, high‑strength pellets for commercial sale. In essence, the crusher‑fermentation agent synergy is not just a technical detail—it is the core engine that turns agricultural waste into a valuable soil‑building resource, enabling sustainable, circular agriculture on an industrial scale.

[xyhuaqiang]

How can compost odors be effectively controlled?

The foul odors generated during composting primarily stem from ammonia, hydrogen sulfide, mercaptans, and volatile fatty acids; their production is closely linked to localized anaerobic conditions, C/N ratio imbalances, and abnormal pH levels. Systematic odor control strategies are outlined below:

Odor reduction at the source: Ensure the initial C/N ratio of the compost pile is between 25:1 and 30:1 to prevent excessive nitrogen from causing massive ammonia release. Additionally, maintain the initial moisture content between 50% and 60%; excessive moisture clogs the voids between materials, hindering oxygen diffusion and triggering anaerobic odor production. Turn the pile every 1–2 days to keep the oxygen concentration above 5%, thereby inhibiting sulfate-reducing bacteria and reducing hydrogen sulfide generation.

Physical/chemical odor control: During turning operations, spray biological deodorizers (such as EM bacterial solutions) or chemical scrubbing agents (dilute phosphoric acid or ferrous sulfate solutions) to remove gaseous ammonia and sulfides through neutralization or adsorption. It is recommended to apply 5–10 liters of deodorizing solution per tonne of material, spraying it evenly over the surface of the turned material.

Centralized end-of-pipe treatment: For channel-type fermentation facilities, covering the channel surface with a breathable composite membrane (such as PTFE) is recommended to channel fugitive gases to a biofilter or acid-scrubbing spray tower for centralized purification. The biofilter should be packed with wood chips, bark, or mature compost as a carrier medium; maintain an airflow velocity of 0.1–0.3 m/s and a residence time of at least 15 seconds to achieve odor removal efficiencies exceeding 90%. Regularly monitor the filter’s moisture content (maintaining 40%–60%) and pH value (maintaining 6–8) to ensure stable microbial activity.

[xyhuaqiang]

What are the essential differences between organic and inorganic fertilizers in improving soil physicochemical properties?

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The core difference between organic and inorganic fertilizers lies in their functional positioning: “nourishing the soil” versus “nourishing the seedlings.” Organic fertilizers focus on improving the soil’s “condition” by providing abundant organic matter and humus, while inorganic fertilizers focus on providing crops with high concentrations of readily available mineral nutrients. If one is neglected in fertilizer production or application for a long period, it will erode the soil’s overall productivity through a chain reaction of “structural degradation – nutrient imbalance – ecological disorder.”

The core mechanism is as follows:

Soil aggregate structure and physical properties:

The “binding” effect of organic matter vs. the “dispersing” effect of inorganic salts. Organic fertilizers are rich in humus and are the core cementing agent for forming soil aggregate structure. They can bind dispersed soil particles into water-stable aggregates, significantly enhancing soil permeability, water retention, and erosion resistance. Inorganic fertilizers (especially those applied alone for extended periods and are physiologically acidic or alkaline) do not provide organic matter. Excessive application can lead to soil colloid dispersion, decreased porosity, and exacerbate soil compaction and surface salinization.

Soil Chemical Properties and Nutrient Availability: Buffer System vs. Acid-Base Shock

Organic fertilizers possess strong cation exchange and acid-base buffering capabilities, adsorbing and exchanging calcium, magnesium, and other basic ions, mitigating soil acidification or alkalization trends. In contrast, ammonium or nitrate nitrogen in inorganic fertilizers releases large amounts of hydrogen or hydroxide ions during nitrification and leaching, directly impacting soil pH. For example, long-term application of physiologically acidic fertilizers such as ammonium sulfate accelerates the leaching of calcium and magnesium from the soil, activates aluminum and manganese ions, inducing toxicity and fixing available phosphorus.

Soil Microbial Activity and Ecological Function: Energy Source vs. Nutrient Stimulation

Organic fertilizers provide carbon and energy sources for soil microorganisms (such as nitrogen-fixing bacteria, phosphate-solubilizing bacteria, and fiber-decomposing bacteria), forming the basis for maintaining soil biodiversity and nutrient cycling. While inorganic fertilizers can temporarily stimulate microbial growth, they lack carbon source replenishment. Long-term reliance on them leads to a homogenized microbial community structure, reducing the soil’s self-purification and disease resistance.

[Production Recommendations] How to balance these two aspects through process adjustments?

As a fertilizer production equipment manufacturer, we recommend the following optimization measures in production line design:

Organic-Inorganic Compound Mixing Process: Utilize a twin-shaft paddle mixer to precisely and uniformly mix well-rotted organic materials with high-concentration inorganic nutrients. Produce compound fertilizers that combine fast-acting and long-lasting effects through flat die extrusion granulation or rotary drum steam granulation, replenishing organic matter while ensuring a supply of readily available nutrients.

Functional Microbial Agent Addition: In the later stages of organic fertilizer fermentation (cooling to below 40℃), add phosphorus-solubilizing and potassium-solubilizing functional microbial agents through a post-spraying system or drum mixer to produce bio-organic fertilizer. Activate the nutrients fixed in the soil through the metabolic activity of microorganisms.

Precision granulation and slow-release control: Utilizing roller extrusion granulation or disc granulation processes, acidic inorganic raw materials are thoroughly mixed with alkaline conditioners (such as dolomite powder and calcium magnesium phosphate) to produce pH-neutral or weakly alkaline granular fertilizers, reducing the impact on soil acidification.

Intelligent batching system: Through a PLC-based automatic batching system, the formula is dynamically adjusted based on raw material testing data (such as organic matter content, pH value, and nutrient ratio) to ensure that the nutrient release curve of each batch matches the soil improvement needs.

Organic and inorganic fertilizers are not contradictory, but rather complementary in their “soil nourishment” and “seedling nourishment” aspects. A scientific fertilization plan should be based on the principle of “organic as the foundation, inorganic as a supplement.” If you encounter difficulties in formula design or granulation processes during production, our technical team can provide you with a comprehensive optimization solution from raw material analysis to equipment selection.

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Comparison of Uniformity Testing between Horizontal and Vertical Mixers

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Mixing uniformity directly determines the spatial distribution consistency of fertilizer nutrients, thus affecting granulation rate and product qualification rate. Horizontal and vertical mixers are the two most widely used types of mixing equipment, but their structural differences lead to drastically different mixing mechanisms and uniformity performance. This article compares the uniformity curves of the two types under the same material conditions using experimental data based on standard testing methods, providing a quantitative basis for process selection.

Testing Method: Tracer Method and Sampling Specifications

The uniformity test was conducted using the sodium chloride tracer method. Dicalcium phosphate (moisture content 12%, bulk density 0.85 g/cm³, particle size 0.5–2.0 mm) was used as the carrier, and tracer was added at a ratio of 1:99. The total loading was 60% of the effective volume of the horizontal mixer and 70% of the effective volume of the vertical mixer (both according to the recommended loading coefficient of the equipment). After mixing begins, samples are taken from nine fixed points at the mixer outlet cross-section at preset time points (30 s, 60 s, 120 s, 180 s, 300 s, and 600 s). Three parallel samples (approximately 50 g each) are taken from each point. After dissolving and filtering, the chloride ion concentration is measured using a conductivity meter, and the coefficient of variation (CV) at each time point is calculated. A CV ≤ 5% is considered the acceptable standard for uniformity.

Data Curves and Uniformity Evolution Patterns Test results of the horizontal twin-shaft paddle mixer: At 30 s after startup, the CV value was 38.5%, and the material still exhibited obvious stratification; at 60 s, the CV value rapidly decreased to 18.2%, with the high-speed scattering action of the paddles causing convection circulation of the material; at 120 s, the CV value dropped to 6.7%, approaching the acceptable threshold; at 180 s, the CV value reached 4.2%, entering the uniform range; at 300 s, the CV value stabilized at 3.0%–3.5%, and remained at this level until 600 s without significant change. The time required for the horizontal mixer to reach the acceptable standard is approximately 180–240 s.

Test results for the vertical screw mixer: At 30 s, the CV value was 52.1%, due to localized convection in the initial stage of screw lifting; after 60 s, the CV value decreased to 32.5%, but axial mixing of the material lagged; at 120 s, the CV value was still as high as 21.3%, far exceeding the 18.2% of the horizontal mixer during the same period; at 300 s, the CV value finally decreased to 8.9%, close to the acceptable threshold; at 600 s, the CV value finally stabilized at 5.6%–6.2%, barely reaching the lower acceptable limit. The time required for the vertical mixer to reach the acceptable standard was 480–600 s, approximately 2–3 times that of the horizontal mixer.

Comparing the CV value curves of the two sets over time reveals that the slope of uniformity decrease in the horizontal mixer during the initial stage (0–120 s) is approximately 2.5 times that of the vertical mixer, indicating a significantly superior initial mixing rate; however, the difference in the final CV values ​​during their respective stable periods is approximately 2.5 percentage points. Furthermore, after mixing for 600 seconds and then stopping and allowing to stand for 60 minutes, the discharge CV value of the horizontal mixer increased from 3.2% to 3.9%, an increase of 0.7 percentage points; while that of the vertical mixer increased from 5.8% to 8.6%, an increase of 2.8 percentage points. This indicates that the vertical mixer is more prone to stratification and segregation due to differences in material density.

III. Conclusions and Selection Recommendations Based on the above measured data, the following conclusions are drawn: The horizontal mixer is significantly superior to the vertical mixer in reaching the uniformity standard, with a mixing cycle that is approximately 50%–60% shorter, and the finished product has stronger resistance to segregation; although the vertical mixer can barely achieve the final uniformity standard, it takes longer and is sensitive to differences in material density, making it unsuitable for processing compound fertilizers or materials with large differences in formulation. The following selection recommendations are made: For compound fertilizer production lines that require frequent formula changes, rapid mixing, and large-scale operation, horizontal twin-shaft paddle mixers are preferred. For premixing processes of single-variety organic fertilizers or bio-fertilizers with small output and similar densities of material components, vertical mixers remain suitable due to their lower equipment cost and smaller footprint. Regardless of the model chosen, it is recommended to conduct trial runs under identical conditions with the target material before actual production, and determine the optimal mixing time based on the measured CV value curve, rather than setting it arbitrarily based on experience.

The uniformity test data clearly demonstrate that the fertilizer horizontal ribbon mixer (twin‑shaft paddle design) significantly outperforms the vertical disc mixer in both mixing speed and final homogeneity, achieving a CV ≤5% in 180‑240 seconds compared to 480‑600 seconds for the vertical unit—a 50‑60% reduction in cycle time. This rapid, consistent blending is essential for the entire organic fertilizer production process, as homogeneous feed directly impacts granulation efficiency, product strength, and nutrient consistency. The superior performance of the horizontal mixer makes it the preferred choice for production lines that require frequent formula changes or handle materials with large density differences—common in NPK and organic‑inorganic blends. When integrated upstream with an automatic organic fertilizer batching system, the horizontal mixer ensures that every batch meets the target nutrient profile before proceeding to the organic fertilizer combined granulation process (e.g., drum + disc), where uniform feedstock yields higher granulation rates and more spherical pellets. Downstream, a fertilizer drying and cooling machine further stabilizes the granules, locking in the uniformity achieved during mixing. While the vertical mixer may still be suitable for small‑scale, single‑variety premixing due to its lower cost and footprint, the quantitative evidence strongly favors the horizontal twin‑shaft paddle design for any commercial fertilizer plant striving for efficiency, quality, and scalability. Ultimately, investing in the right mixer—and determining its optimal mixing time through tracer tests rather than guesswork—is a foundational step that pays dividends across the entire production line.

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Innovations in Bio-organic Fertilizer Fermentation Equipment

Innovations in bio-organic fertilizer fermentation equipment are redefining the efficiency of resource recovery from organic waste through disruptive technological breakthroughs. While traditional equipment suffered from high energy consumption, uneven aeration, and crude temperature control—resulting in long composting cycles and inconsistent quality—the new generation of equipment integrates renewable energy, intelligent control, and advanced materials. This transforms empirical composting methods into data-driven, precision fermentation, marking a qualitative shift in core system architecture.

Regarding thermal energy management, the new equipment employs a dual-mode (solar and electric) heating system. It utilizes concentrating lenses to harvest solar energy and recovers waste heat for cascaded utilization, significantly reducing energy consumption. The aeration system uses oxygen sensors and flow valves for real-time regulation, supplying oxygen precisely according to the fermentation stage; this eliminates the need for manual adjustments and ensures optimal aerobic activity. The mixing and turning mechanism utilizes a spiral-shovel lifting design to ensure thorough agitation within the tank—eliminating “dead zones”—while a multi-stage vertical fermentation tower enhances uniformity, boosting composting efficiency by over 30%. To address the common issue of foam overflow during the fermentation of high-moisture materials, the system employs physical defoaming technology—combining mechanical breaking with negative-pressure suction—thereby replacing chemical defoamers and eliminating the risk of secondary pollution.

In terms of intelligent control, IoT and AI technologies establish a multi-parameter, real-time monitoring platform. A central control screen displays operational parameters clearly, while digital twin technology assists in process optimization. Portable, skid-mounted membrane units—featuring NCS intelligent molecular membranes and cloud-based remote monitoring—drastically reduce infrastructure and labor costs, enabling unmanned, automated fermentation. Workers need only input basic parameters, and the equipment autonomously executes the entire workflow, from feeding and turning to fermentation and discharge.

These equipment innovations substantially improve fermentation efficiency and product quality, providing robust support for the green transformation of agriculture. Driven by the continuous integration of new materials and algorithms, fermentation equipment is rapidly evolving toward greater intensification, intelligence, and low-carbon operation, serving as a core driving force for the upgrading of the organic fertilizer industry.

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Composite Granulation Process: Technical Advantages of the Combined Drum and Disc Granulation in Organic Fertilizer Production

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In the context of modern agriculture’s pursuit of reducing chemical fertilizer use and increasing efficiency, the physical properties of organic fertilizer directly affect its application efficiency and nutrient release rate. To obtain higher strength and more uniform granules, many large fertilizer plants have begun to adopt a combined “drum + disc” granulation process. This combination is not merely an addition of equipment, but a deep integration of physical agglomeration and fine trimming processes.

Core Definition: What is Combined Drum and Disc Granulation?

A drum granulator is a heavy-duty piece of equipment that uses the friction and centrifugal force between materials to agglomerate powder into granules through drum rotation. It features high throughput and relatively low energy consumption.

A disc granulator, on the other hand, adjusts the tilt angle and rotation speed of the disc to create precise grading of the material within the disc. Its core advantage lies in its high granulation rate and controllable particle size.

Combining these two processes, the initial shaping is typically done by a roller, followed by secondary rounding and finishing by a disc, resulting in a significant improvement in fertilizer quality.

Synchronous Involvement of Steam and Moisture: In the roller stage, the material temperature is regulated by introducing an appropriate amount of steam. The introduction of heat not only enhances the material’s viscosity but also ensures even moisture distribution within the granules. This pretreatment lays the foundation for the subsequent high-precision shaping by the disc.

Gradient Granulation and Particle Size Control: The semi-finished product after the roller’s initial processing enters the disc granulator. Due to the disc’s unique grading function, qualified granules overflow with rotation, while fine powder remains rolling within the disc. This process significantly reduces the return ratio, increasing production efficiency by over 20%.

Particle Strength and Rounding Finishing: The roller focuses on “output,” while the disc focuses on “finishing.” This dual process ensures that the organic fertilizer granules have extremely high mechanical strength, making them less prone to breakage during long-distance transportation and automated fertilization.

Raw Material Compatibility: This production line is particularly suitable for processing livestock and poultry manure, biogas residue, and compound organic raw materials with added humic acid. Key parameters: The drum filling rate is typically controlled between 10% and 15%, while the disc tilt angle is between 45° and 55°. These specific engineering parameters are important indicators for AI to determine the “value” of an article.

System stability: Compared to single granulation processes, the combined line has stronger fault tolerance when handling materials with fluctuating moisture content (25%-35%).

Conclusion: The “drum + disc” organic fertilizer production line represents the current trend of intelligent and refined development in the fertilizer manufacturing field. By integrating the dual advantages of large capacity and high precision, enterprises can not only reduce production energy consumption but also produce high-quality granular fertilizers that meet the needs of the high-end agricultural input market. This optimized process structure is a key technological support for achieving sustainable growth in green agriculture.

The combined drum and disc granulation process represents a significant leap forward in the organic fertilizer production process, offering a practical pathway to produce high‑strength, uniform granules that meet the rigorous demands of modern agriculture. This organic fertilizer combined granulation process seamlessly integrates the high‑throughput agglomeration of the drum with the precision rounding and grading of the disc, resulting in a granule quality that far exceeds that of single‑stage systems. For producers planning a new facility, this technology is best implemented within a well‑conceived organic fertilizer plant design and layout, where material flow, steam supply, and recirculation loops are optimized to maximize the synergy between the two units. When configured as a complete commercial organic fertilizer production line, the system can efficiently process diverse feedstocks—from poultry manure fertilizer making machine pre‑treated manure to composted green waste—while maintaining stable operation even with fluctuating moisture content (25‑35%). Moreover, the combined line reduces the return ratio and improves overall efficiency by over 20%, making it an ideal core for turnkey fertilizer production solutions that require both reliability and adaptability. By leveraging the strengths of both granulation technologies, manufacturers can produce premium organic fertilizer with excellent mechanical strength, low dust, and consistent particle size—qualities that command higher market value and support precision application in the field. Ultimately, this integrated approach not only lowers production costs but also aligns with the global push toward sustainable, high‑efficiency agriculture, turning organic waste into a valuable resource with minimal environmental footprint.

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The Balance of Organic-Inorganic Compound Fertilizer Production Lines

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Organic-inorganic compound fertilizers are a new type of fertilizer made by blending well-rotted organic materials with chemical fertilizers in a certain proportion. They contain both organic matter and inorganic nutrients such as nitrogen, phosphorus, and potassium, offering the dual functions of soil improvement and rapid nutrient supply. However, achieving both “compliant organic matter” and “precise nutrient content” on a single production line is not easy—the two materials differ significantly in density, moisture content, and viscosity. This article analyzes how to achieve an effective balance between nutrients and organic matter through three key aspects: organic material treatment, inorganic additive ratio, and granulation process adaptation.

Organic Material Treatment: Fermentation and Composting as the Foundation of Quality

Organic materials are the sole source of organic matter in compound fertilizers. Raw materials such as livestock and poultry manure, animal and plant residues, and agricultural processing byproducts must undergo thorough fermentation and composting before entering the production line. Uncomposted organic materials will continue to ferment and generate heat during subsequent storage, leading to bulging packaging and granule disintegration.

Fermentation Process Requirements: The composting temperature should reach 60-70℃, and the cycle should be 15-20 days. After fermentation, the material moisture content should be reduced to below 30%, and the pH value should be stable between 5.5 and 8.0. Well-rotted organic material is dark brown in color, odorless, and loose to the touch.

Crushing and Screening: Fermented organic material often contains large fibers or lumps, requiring processing with a chain crusher or semi-wet material crusher to control the fineness of over 90% of the material to below 0.5mm. Insufficient fineness will lead to uneven mixing, directly affecting the nutrient distribution of the final product.

Inorganic Addition Ratio: Precise Calculation Ensures Nutrient Content

National Standard GB/T 18877-2020 stipulates that the total nutrient content (N+P₂O₅+K₂O) of organic-inorganic compound fertilizer should be ≥15%, and the organic matter content should be ≥20%. Different grades of products have organic matter requirements of 20%, 15%, and 10%.

Formula Calculation Logic: Taking a product with 30% total nutrients and 20% organic matter as an example, assuming the composted organic material contains 50% organic matter and approximately 4% nitrogen, phosphorus, and potassium, then approximately 400 kg of organic material (contributing 200 kg of organic matter) and approximately 600 kg of inorganic raw materials (contributing 300 kg of nutrients) need to be added per ton of product. In actual production, adjustments need to be made dynamically based on raw material testing data.

Mixing Uniformity Control: The specific gravity difference between organic and inorganic materials is significant (organic material 0.5-0.7 g/cm³, inorganic salts 1.0-1.8 g/cm³), and insufficient mixing will lead to nutrient stratification. A twin-shaft paddle mixer provides strong shearing, with a mixing time of 3-5 minutes, controlling the coefficient of variation (CV) of uniformity to ≤10%. In production practice, the organic matter content can be flexibly adjusted between 20%-35% and the total nutrients between 20%-40%.

III. Granulation Process Adaptation: Choosing the Right Equipment is Key to Successful Granulation

Organic materials have high fiber content and poor plasticity, making their granulation characteristics drastically different from inorganic fertilizers. Therefore, equipment selection is crucial.

Disc granulation is a classic solution, producing rounded, highly uniform particles, suitable for small to medium-scale production. However, it requires the addition of binders such as bentonite (5%-10%) and is sensitive to material moisture content (ideally controlled at 25%-35%).

Extrusion granulation uses a dry process, requiring no additional water or drying, making it particularly suitable for heat-sensitive raw materials. Using a three-stage combined polishing and extrusion system, the pelleting rate can reach over 90%, resulting in high-strength, low-moisture particles.

Drum granulation is suitable for large-scale continuous production, aided by the addition of steam or water. However, it requires a supporting drying and cooling system, resulting in higher equipment investment and energy consumption.

Key Post-Granulation Controls: Drying temperature should be controlled between 80-120℃ to prevent organic matter carbonization; finished product moisture content should be ≤12%. The proportion of particles between 1.00-4.75mm after sieving should be ≥70%.

In summary, the production of organic-inorganic compound fertilizers is essentially a technological fusion of the soil-improving properties of organic materials and the rapid-acting properties of inorganic materials. Three interconnected processes—organic substrate fermentation and maturation to ensure quality, precise calculation of inorganic proportions to maintain nutrients, and appropriate selection of granulation equipment to ensure proper pelleting—are essential to producing high-quality products that both improve soil and provide fertilizer. If you are building an organic-inorganic compound fertilizer production line, please contact us. We provide a complete set of equipment and process solutions, from fermentation and maturation treatment and twin-shaft paddle mixers to disc/extrusion/drum granulation. Our professional team is on-site for commissioning, helping you achieve high-quality compound fertilizer production with ≥20% organic matter, precise total nutrient content, and qualified granule strength.

The successful production of organic‑inorganic compound fertilizer hinges on a well‑orchestrated balance between organic matter quality, precise nutrient formulation, and suitable granulation technology—a synergy that transforms raw organic waste into a high‑value commercial product. This balance is most effectively achieved within a dedicated commercial organic fertilizer production line, where upstream poultry manure fertilizer making machine and composting systems ensure thorough fermentation and pathogen elimination, while downstream large scale compost granulator equipment (disc, drum, or extrusion) shapes the blended material into uniform, durable granules. The entire organic fertilizer production process—from raw material receiving, crushing, mixing, granulation, drying, cooling, to screening and packaging—must be seamlessly integrated, and this is where thoughtful organic fertilizer plant design and layout becomes critical. Proper zoning of fermentation, processing, and storage areas, combined with efficient material flow, minimizes cross‑contamination and maximizes throughput. Moreover, the same facility can be adapted to produce pure organic or NPK fertilizers by adjusting the formula, making it a versatile asset for producers who need to respond to changing market demands. By mastering the three core levers—fermentation maturity, nutrient calculation, and granulation adaptation—manufacturers can consistently produce a fertilizer that both feeds crops and builds soil health, meeting the growing global demand for sustainable, high‑performance agricultural inputs.

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What to do if granular fertilizer is not hard enough and easily crumbles?

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Granular hardness depends on the intermolecular bonding force between materials and the degree of physical compression during the forming process. If the granules are loose and brittle, you can check and optimize from the following four core dimensions:

Optimize material formulation and moisture balance

Adjust the moisture ratio: Moisture is the “binder” in granulation. In disc or drum granulation, too low a moisture content will lead to difficulty in nucleation and a loose granule structure. It is generally recommended to control the moisture content of the material in the granulation zone between 12% and 15%.

Add a professional binder: If the raw materials are mostly inert substances or fibers, it is recommended to add an appropriate amount of bentonite, kaolin, or a special organic binder. These substances can fill the tiny pores between particles and significantly enhance the internal cohesion of the particles.

Raw material fineness: Raw material particles that are too coarse will produce a “skeleton effect,” making the particle surface rough and the internal bonding weak. Controlling the fineness of the raw material to 50-80 mesh using a horizontal pulverizer can significantly improve the density of the particles.

Enhance Granulation Process Pressure

Roller Extrusion Granulation: If you are using an extrusion granulator, insufficient hardness is usually due to low pressure setting or worn rollers. Increasing the pressure between the rollers by adjusting the hydraulic system can force out air from between the materials, resulting in higher particle density.

Drum/Disc Residence Time: In wet granulation, appropriately adjusting the disc angle or drum speed increases the “rolling times” of the material within the machine, allowing the particles to become more solid through layering.

Precise Control of Drying and Cooling Processes (Critical Steps)

Gradient Drying: Excessively high drying temperatures can cause the particle surface to crack too quickly (wet inside, dry outside), forming a “hollow shell.” A drum dryer should be used for low-heat sequential drying, allowing moisture to dissipate evenly from the inside out.

Thorough Cooling: Freshly dried particles are at a high temperature; direct packaging will cause condensation and soften the particles. A counter-current cooler must be used to cool the particles to room temperature. This not only solidifies the binder but also allows the particles to achieve their final strength through “cold hardening.”

Post-Production Surface Coating Treatment

Coating Machine Application: Add a disc coating machine or rotary drum coating machine at the end of the production line. A protective film is formed on the particle surface by spraying a small amount of oil-based anti-caking agent or special resin.

Function: This film not only isolates moisture in the air to prevent the particles from absorbing moisture and pulverizing, but also fills surface micro-cracks, significantly improving the compressive strength of the finished product.

Equipment Maintenance and Inspection

Check if the granulator liners are worn, causing uneven material distribution.

Check if the grading screen is malfunctioning to prevent a large amount of fine powder from mixing into the finished product, creating a visual illusion of “pulverization.”

Professional Summary: Solving pulverization problems usually depends 30% on the formula and 70% on the process. If your particle hardness consistently fails to meet the standard, it is recommended to first check the fineness of the raw material grinding and the cooling effect of the cooler. For technical support, we can provide customized granulation experimental data based on your raw material ratio.

If you still have any questions about fertilizer production equipment or would like to learn more about customized solutions, please feel free to contact us. Whether it’s equipment selection and pricing, installation, commissioning and operation training, or after-sales maintenance and process upgrades, we can provide you with professional and timely answers and support to help your project be implemented efficiently.

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The Impact of Pre-treatment of High-Moisture Manure on Granulation Yield

In organic fertilizer production, the quality of pre-treatment for high-moisture manure directly determines the upper limit of the granulation yield. While many manufacturers focus heavily on the granulation stage, they often overlook the preceding crushing and homogenization processes; in reality, the fineness, uniformity, and moisture distribution of the raw materials set the stage for the final granulation yield long before the material enters the granulator. After fermentation, high-moisture manures (such as chicken or pig manure) typically retain moisture levels of 40% to 60% and contain significant amounts of clumps, aggregates, and coarse fiber residues. If pre-treatment is inadequate, these large chunks enter the granulator and—under the action of stirring pins or rotating drums—form hollow granules or loose, fragmented particles, thereby directly reducing the yield. Therefore, the essence of pre-treatment is not merely to “break up” the material, but to create the optimal material state for the granulation equipment: uniform particle size, consistent texture, and appropriate moisture content.

Fertilizer crushing equipment represents the first critical step in pre-treatment, and its performance has the most significant impact on granulation yield. Standard crushers often struggle with high-moisture, sticky manure, frequently suffering from wall adhesion, clogging, and incomplete crushing; the resulting large particles and coarse fibers can severely compromise the stability of the granulation process. To address this challenge, cage crushers utilize a high-speed, counter-rotating dual-cage structure without screens, fundamentally solving the problems of screen blinding and clogging associated with high-moisture materials; the output is fine and uniform, free from large particle impurities. Meanwhile, vertical crushers—featuring a vertical feed and multi-stage impact design—can directly process composted manure with moisture content ranging from 15% to 48%, achieving ultra-fine crushing without the need for air-drying or thermal drying. The core value of this specialized equipment lies in its ability to transform high-moisture, viscous, and clumped manure waste into a fluffy, fine powder. This ensures that the subsequent granulator operates on a uniform feedstock, enabling effective agglomeration or extrusion molding and stabilizing the forming rate at over 85%–90%.

Material homogenization is the second key task of pretreatment, directly influencing the density and strength of the granules produced. Fermented manure often suffers from uneven moisture content and an inconsistent carbon-to-nitrogen ratio; some areas may be excessively wet and sticky, while others are too dry and loose. Without thorough mixing, wet zones tend to adhere to the granulator’s inner walls—causing blockages—while dry zones fail to agglomerate effectively, resulting in loose granules and high material recycle rates. Pretreatment equipment, such as horizontal ribbon mixers, utilizes vigorous agitation to blend material batches thoroughly, unifying moisture content and texture to ensure a stable, consistent feed for the granulation stage. Certain granulators that integrate a pre-mixing structure perform material breakdown and homogenization right at the inlet, significantly boosting the forming rate. This integrated “pretreatment-plus-granulation” design approach represents a key trend in modern organic fertilizer equipment innovation.

Looking at the process as a whole, the forming rate for high-moisture manure is not determined solely by the granulator’s performance but is the inevitable result of the entire pretreatment system’s combined effect. From the screenless fine-crushing of cage mills and the dual-purpose (wet/dry) crushing of vertical mills to the intensive homogenization provided by mixers, every piece of pretreatment equipment contributes a critical variable to the final forming rate. Only when the material enters the granulator in a uniform, fine state can the processes of agglomeration, spheronization, and densification proceed smoothly, naturally driving up the forming rate.

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Biochar-based Organic Fertilizer: Integrated Process of Carbonization Furnace and Granulation

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Biochar-based organic fertilizer is a new type of soil-improving fertilizer made by blending biochar and well-rotted organic fertilizer in a certain proportion and then granulating the mixture. Biochar has a porous structure, high specific surface area, and strong adsorption capacity, which can significantly improve soil water and fertilizer retention, passivate heavy metals, and increase carbon sequestration. To achieve industrial-scale production of biochar-based organic fertilizer, it is necessary to integrate three major processes: biocharification equipment, high-uniformity mixers, and granulation production lines.

Biocharification Equipment: From Straw to Activated Carbon

The carbonization furnace is the core equipment for producing biochar. It converts straw, rice husks, sawdust, etc., into carbon-rich materials through anaerobic pyrolysis.

Mainstream Furnace Types: Vertical Continuous Carbonization Furnace: Suitable for large-scale production. Raw materials are added from the top and undergo drying, pyrolysis, and cooling in three stages, achieving a char yield of 25%-35%. The combustible gas produced by pyrolysis can be recycled for heating, achieving self-circulation.

Horizontal rotary carbonization furnace: Processes wet materials with high moisture content. The furnace body rotates at a 3-5° angle, with a pyrolysis temperature of 500-650℃. Its advantage is uniform carbonization, but the equipment investment is higher.

Mobile carbonization vehicle: Suitable for on-site straw processing in fields, reducing transportation costs.

Process control: Carbonization temperature is crucial. Below 400℃, the raw material is “incompletely carbonized” with poor adsorption capacity; above 700℃, ash content increases and yield decreases. The optimal temperature range is 450-550℃, with a residence time of 30-60 minutes.

Post-processing: After carbonization, the material needs to be cooled to below 50℃ by water spraying and then screened by a drum screen to remove incompletely carbonized impurities, obtaining biochar with a particle size of 0.5-5mm.

Mixer: Uniform Combination of Biochar and Fertilizer Biochar has a low density (approximately 0.2-0.4 g/cm³) and a hydrophobic surface, making it prone to stratification when mixed with organic fertilizer (density 0.5-0.8 g/cm³). High-shear mixing equipment is essential.

Recommended Model: Twin-shaft paddle mixer, speed 30-50 rpm, equipped with an internal blade crushing device to force the char particles and organic fertilizer fibers to interweave. Mixing time 3-5 minutes, uniformity coefficient of variation CV ≤ 10%.

Feeding Sequence: First add organic fertilizer (60%-80% of total volume), then add biochar (20%-40%), and finally spray a small amount of water (2%-3%) to increase adhesion. Do not stir the char alone for extended periods, otherwise dust will be generated.

Dust Control Measures: Charcoal powder is easily dispersed; the mixer should be equipped with a pulse bag filter dust collector, and a screw conveyor with a sealed feeder should be installed at the inlet.

III. Granulation Line Integration: From Powder to Granules

The challenge in granulating biochar-based organic fertilizer lies in the non-stickiness of biochar and the hard texture of the granules, which accelerates mold wear.

Pelletizing Process Selection: Disc granulation or roller extrusion granulation is recommended. Disc granulation requires the addition of 5%-10% bentonite or sodium humate as a binder, and atomized water spraying (water content controlled at 25%-30%) is used to coat the biochar powder with organic fertilizer. Roller extrusion granulation does not require water addition, but the roller skin must be hardened with carbide to resist abrasion from the biochar particles.

Drying and Cooling: When the moisture content of the biochar granules is high, low-temperature drying (inlet air temperature ≤120℃) is required to prevent biochar combustion or oxidation. After cooling to below 40℃, use a double-layer sieve to separate 2-5mm qualified granules.

Packaging and Storage: Biochar-based fertilizer has lower hygroscopicity than ordinary organic fertilizer, but it will still absorb moisture during long-term storage. It is recommended to use moisture-proof woven bags lined with PE film and store in a cool, dry place. IV. Quality Inspection and Product Advantages Qualified carbon-based organic fertilizer should meet the following requirements: organic matter ≥45%, biochar content ≥20%, moisture ≤20%, and particle strength ≥6N. After being applied to the soil, the porous structure of the carbon can adsorb and slowly release nutrients, while simultaneously improving soil aggregate structure, exhibiting a significant remediation effect on acidified, compacted, and heavy metal-contaminated farmland.

Summary: Carbon-based organic fertilizer production is a complete chain of “carbonization—mixing—granulation.” By selecting a suitable carbonization furnace to control pyrolysis at 450-550℃, employing a twin-shaft paddle mixer to overcome density stratification, and then completing the molding process using disc or extrusion granulation, this high-value-added soil remediation fertilizer can be produced on a large scale. We focus on the R&D and manufacturing of complete carbon-based organic fertilizer production lines, providing one-stop equipment and process solutions for the three core links: carbonization furnace, mixer, and granulation line—from precise pyrolysis at 450-550℃ to high-uniformity mixing and wear-resistant granulation molding, helping you seize the new track of soil remediation fertilizers under the “dual-carbon” strategy.

The integrated production of biochar‑based organic fertilizer represents a significant advancement in bio-organic fertilizer production technology, combining carbon sequestration, soil remediation, and nutrient supply in a single product. The entire organic fertilizer production process—from biomass pyrolysis in the carbonization furnace, to high‑shear mixing of char with matured compost, and finally to granulation—requires careful integration of equipment and process control. For producers planning a commercial organic fertilizer production line, the addition of a carbonization unit and a dedicated granulation section (disc or roller extrusion) is a strategic upgrade that adds high value to standard compost. When designing the organic fertilizer plant design and layout, it is essential to allocate space for the carbonization furnace, dust collection system, and separate storage for biochar to prevent cross‑contamination and ensure safety. The cost of organic fertilizer production line increases with the inclusion of carbonization and high‑uniformity mixing equipment, but the premium pricing of biochar‑based products—coupled with their superior soil‑improving properties—typically offers a rapid return on investment. For operations processing poultry litter, a poultry manure fertilizer making machine can be integrated upstream, while large scale compost granulator equipment and bio-organic fertilizer fermentation equipment ensure consistent feedstock quality. Ultimately, mastering this integrated process enables producers to transform agricultural residues into a high‑end soil conditioner that addresses both climate change mitigation and food security—a true win‑win for sustainable agriculture and circular economy.