Fertilizer Machine

Bio-organic fertilizer, due to its dual functions of improving soil with organic matter and promoting the growth and disease resistance of functional bacteria, is becoming the fastest-growing sub-category in the fertilizer industry. The equipment configuration required for its production differs significantly from that of traditional organic fertilizer production lines. These differences are mainly reflected in key aspects such as sterilization, cooling, and the addition of microbial agents. The raw materials for bio-organic fertilizer must first undergo thorough aerobic fermentation using a compost turner, maintaining the compost temperature above 60℃ for at least 7 days to ensure the complete elimination of pathogens and weed seeds. After fermentation and maturation, the material enters the crushing and sieving process. At this stage, it is crucial that the sieving equipment adopts a closed design to prevent contamination by exogenous bacteria.

Fertilizer granules compaction technology is a mainstream physical forming process in dry granulation. It relies on pure mechanical pressure to form powdered fertilizer, eliminating the need for high-temperature and humid processes. It is a core technology for modern refined and low-carbon fertilizer production, widely applicable to the granulation of single-element fertilizers, inorganic compound fertilizers, and organic-inorganic compound fertilizers. The core of this technology is the principle of room-temperature dry forming, resulting in a simple and efficient production process. Uniformly proportioned powdered fertilizer raw materials are fed into the equipment, where stable mechanical pressure is applied through a roller press structure, causing the loose powder to compact and solidify. After screening and shaping, uniformly sized solid granules are formed. The entire process requires no water or chemical additives, eliminating cumbersome drying and cooling processes, significantly simplifying the production process.

Urea is a widely used, fast-acting nitrogen fertilizer in agriculture. Its unique physicochemical properties mean that the urea fertilizer granules compaction process differs significantly from that used for conventional compound fertilizers. Processing urea using an fertilizer granules compaction machine relies on pure physical pressure for shaping—eliminating the need for high-temperature drying or binders—and is precisely tailored to the material's characteristics, offering distinct advantages in terms of both fertilizer quality and production efficiency. First, forming at ambient temperature preserves nutrient efficacy and prevents loss. Urea has poor thermal stability; high temperatures cause decomposition, volatilization, and nitrogen loss. In contrast, the extrusion process operates entirely at ambient temperature without heating stages, fully retaining the original nitrogen content and ensuring the stability of the finished fertilizer's efficacy.

Recently, the installation work of the roller press granulator production line exported by our company to Padang, Indonesia, is progressing smoothly. Currently, all main equipment has been hoisted into place, and auxiliary equipment pipelines and electrical control systems are in the final assembly stage.

The overall progress is in line with the construction plan, and the project has been successfully implemented in Padang. Padang is located in a tropical rainforest climate zone with a long rainy season and high humidity. The project team developed a special construction plan: a waterproof and moisture-proof layer was added to the equipment base; all electrical components and precision parts were stored in sealed containers throughout the process; and rust prevention pretreatment was performed on equipment interfaces and welds during installation to mitigate the impact of high humidity on equipment lifespan from the installation stage. The core extrusion granulator main unit has completed horizontal calibration and initial roller gap adjustment. The supporting raw material lifting, finished product screening, and return systems are connected sequentially according to the process flow. Construction follows the sequence of "main unit first, then auxiliary equipment; mechanical first, then electrical control," with closed-loop handover between each process.

The fundamental difference between bio-fertilizers and conventional organic fertilizers lies in the survival of functional live microorganisms. This imposes equipment required for bio-fertilizer production selection; standard machinery is often unsuitable for the task.

The core requirements for bio-fertilizer equipment can be summarized by three principles: low-temperature operation, gentle processing, and cleanliness. Conventional high-temperature dryers (with inlet temperatures exceeding 300°C) would instantly kill the microbial strains, while the frictional heat generated by high-speed crushing and mixing would similarly reduce the activity of the microbial agents. Consequently, equipment selection must fundamentally avoid these issues. A typical configuration includes: a fermentation turner for oxygenation and decomposition; a crusher to break down materials; a low-speed mixer for the uniform incorporation of microbial agents; and a granulator for shaping, complemented by a low-temperature drying unit (maintaining temperatures below 60°C).

These units are seamlessly integrated to form a complete bio-organic fertilizer production line. A standard line encompasses systems for fermentation, crushing, proportioning, mixing, granulation, low-temperature drying, screening, and packaging, with each stage connected by conveyors and bucket elevators. The process begins with a turner decomposing raw materials over 15–25 days, followed by intermediate crushing, mixing, and granulation, and concludes with low-temperature drying, screening, and packaging. The level of automation across the line directly impacts batch consistency; fully automated lines can increase efficiency by approximately 30% compared to semi-automated ones.

Transforming chicken manure into commercial granular fertilizer involves three critical stages: fermentation, crushing, and granulation. The choice of poultry manure compost turner supplier, the processing value of the half-wet material crusher, and the operational suitability of the new type organic fertilizer granulator collectively determine the efficiency of the entire production line.

The first step in composting chicken manure is aerobic fermentation. Fresh chicken manure has high moisture content and high viscosity, requiring regular windrow turning to supply oxygen and dissipate heat. The choice of turner directly impacts the fermentation cycle: crawler-type models suit soft ground, while wheeled models are better for paved surfaces. A reliable supplier will assess factors such as manure source, processing volume, and site conditions before recommending a model—rather than simply quoting a price—while also providing essential system integration and after-sales support.

Fermented and decomposed material often contains clumps; attempting to granulate this directly makes it difficult to ensure consistent pellet formation and structural strength. A half-wet material crusher can process materials with 25%–55% moisture content without clogging; it breaks clumps into powder via high-speed impact and shearing, producing a fine output (adjustable to 40–80 mesh) that ensures a uniform feedstock for granulation.

After crushing, the material enters the granulation stage. The new type organic fertilizer granulator utilizes high-speed agitation to continuously mix, granulate, and spheroidize the fine powder. It accommodates moisture levels of 20%–50% and forms pellets without binders, achieving a granulation rate exceeding 90% and producing spherical granules, thereby significantly simplifying the process.

Oil palm empty fruit bunches (OPEFB) are characterized by high fiber content and a dense structure, placing specific demands on windrow turning equipment. When processing this material, large wheel compost turning machines, crawler-type compost production machines, and specialized palm tree waste compost making machines each offer distinct advantages; understanding these differences is essential for making the right choice.

Large wheel compost turning machines are common in palm composting facilities. They move along windrows on steel wheels, offering a turning width of over 3 meters and a depth of 1.5 to 3 meters, while effectively shearing and dispersing the fibrous material. With a simple design and readily available parts, they entail lower investment and maintenance costs, making them ideal for sites with hardened ground surfaces.

Crawler-type compost production machines effectively address the limitations of wheeled models. Moving on rubber tracks, they exert low ground pressure, allowing for stable operation on muddy plantation soil or slippery, wet composting sites without slipping or sinking. Their ability to turn in place makes them suitable for compact areas. They generally offer greater turning depth and power than comparable wheeled models, enabling them to penetrate the palm fiber pile in a single pass.

Specialized palm tree waste compost making machines are refined versions of general-purpose models. Typically equipped with heavy-duty cutter drums and forced-feeding mechanisms, they are designed to handle the tangling and jamming issues caused by highly resilient fibers, breaking large fiber chunks down to a size suitable for composting and accelerating decomposition.

In modern agriculture, a stable supply of high-quality compound fertilizer is fundamental to ensuring crop yields. A scientifically designed NPK fertilizer production line is essential for manufacturing fertilizer with uniform nutrient distribution and granules that are both strong and consistent in size. The operation of the entire line relies on the seamless coordination of sophisticated processes and high-performance fertilizer manufacturing equipment.

Among the various stages of the production line, raw material pretreatment often determines the quality ceiling of the final product. Production lines frequently encounter issues such as raw material caking and uneven ingredient mixing, which directly impact subsequent granulation results. The cage fertilizer crusher has emerged as a key solution to this challenge.

As a highly efficient fine-crushing device, it utilizes inner and outer steel cages rotating at high speeds in opposite directions to subject materials to powerful impact and shearing forces. Whether dealing with urea that has caked due to moisture absorption or hard ammonium phosphate, the crusher reduces materials to a fine, uniform powder while minimizing the risk of material sticking to the walls or causing blockages.

This high-quality material preparation paves the way for subsequent processing stages, enabling the entire production line to operate efficiently with tightly integrated steps. The crushed raw materials are precisely weighed by a computer-controlled automatic batching system before entering a double shaft paddle mixer. Uniform component distribution is a prerequisite for ensuring balanced nutrient content in every fertilizer granule.

In an organic fertilizer production line, the compatibility of equipment across stages—from initial fermentation to final shaping—directly determines efficiency and product quality. Compost turners decompose raw materials into uniform organic matter, while granulators transform this decomposed material into marketable granules. Large wheel compost turning machines and crawler-type compost making machines each have specific use cases; the choice depends primarily on site conditions.

Large wheel compost turning machines offer a turning width of up to 30 meters and a depth of 1.5–3 meters, with energy consumption approximately 70% lower than traditional equipment, making them ideal for large plants with annual capacities exceeding 100,000 tons. In contrast, crawler-type compost making machines utilize rubber tracks to prevent slipping or sinking on wet, soft ground and can execute 180-degree turns in place, making them suitable for sites with unpaved surfaces or high rainfall. Ultimately, selecting the right turning equipment is a matter of adapting to the operational environment.

The moisture content, fineness, and uniformity of the decomposed material—achieved after the turning process—directly impact the subsequent granulation results. Modern new type organic fertilizer granulators employ high-speed agitation and aerodynamic forces to continuously mix, granulate, and spheroidize the material within the machine. They accommodate moisture levels between 20% and 50%, enabling pellet formation without additional binders and achieving a granulation rate exceeding 90%. This eliminates the need for intensive drying after fermentation, significantly simplifying the production process.

Cow dung is a vital raw material for organic fertilizer; however, manure from large-scale farms typically has a moisture content of 60%–80%, making direct granulation nearly impossible. Consequently, selecting the right cow dung fertilizer machine is merely the starting point; the project’s ultimate success hinges on the equipment configuration of the entire production line and the supplier’s comprehensive capabilities.

Moisture management is the first hurdle in cow dung granulation. Fresh manure must undergo solid-liquid separation and fermentation (turning) to reduce its moisture content to approximately 30%–35% before granulation can begin. The fermentation stage requires a compost turner; the decomposed material is then fed into a crusher to break up clumps and fibers, blended in a mixer, and finally sent to the granulator for shaping. The complete equipment chain also encompasses screening, drying, and packaging—processes that are inextricably linked.

Choosing the right granulator is particularly critical. Cow dung has a high fiber content; for disc granulation, the material must be sufficiently fine to ensure a high pelletization rate. Stirring-tooth granulators offer greater adaptability to materials with high moisture and fiber content, whereas roller extrusion is better suited for dry-process methods involving lower moisture levels. Before selecting equipment, one must clearly define the raw material characteristics and the target product, as no single machine is suitable for every type of cow dung.

Beyond the equipment itself, selecting the right manufacturer is equally important. Responsible fertilizer machine manufacturers will inquire in detail about raw material sources, fermentation methods, and processing volumes—or even conduct small-scale pilot tests—rather than simply recommending a generic model. Suppliers capable of providing complete line configurations can offer comprehensive process advice covering everything from fermentation to the finished product, thereby preventing capacity mismatches between different stages of production.

In an organic fertilizer project, the organic fertilizer granulation machine is the core piece in the entire production line. However, many buyers focus solely on the machine itself, overlooking the reliability of the fertilizer machine manufacturers behind it—a factor that is crucial when integrating the complete set of organic fertilizer manufacturing machine.

When selecting a manufacturer, you should look beyond the price quote and consider three less obvious but vital dimensions.

First is the ability to match the equipment to the process. Determining whether a granulator suits your raw materials requires more than just looking at capacity specifications. For instance, the pelletizing performance of a disc granulator depends heavily on the raw material’s moisture content, fiber content, and degree of decomposition. A responsible manufacturer will ask detailed questions about raw material sources, fermentation methods, and processing volumes—or even conduct small-scale pilot tests—rather than simply recommending a generic model. If a supplier provides a quote based only on the desired output capacity, there is a significant risk of incompatibility later on.

Second is experience in designing the entire production line. Organic fertilizer production involves multiple stages, including crushing, mixing, granulating, drying, screening, and packaging. If a manufacturer specializes only in granulators without understanding the upstream and downstream processes, the line’s capacity may become unbalanced—for example, a granulator capable of producing 3 tons per hour might be starved if the crusher can only supply 1 ton, drastically reducing the line’s actual output. A manufacturer with full-line design expertise can recommend the optimal equipment configuration for each stage based on your site conditions and process requirements.

Third is the assurance of after-sales service and spare parts. Fertilizer equipment operates under high-wear conditions; components such as granulator discs, stirring teeth, and die plates require periodic replacement. A reliable manufacturer maintains an adequate inventory of spare parts and a responsive after-sales team to minimize equipment downtime. Before signing a contract, you should verify the lead times for wear parts and conduct an on-site visit to the manufacturing workshop; production scale and management standards are often reliable indicators of a company’s overall capabilities.