无标题

The first overseas shipment of fermentation compost turning machine for 2026 has successfully departed; our custom-made large wheel compost turning machines have been loaded and are en route to a major manure resource utilization facility in Laos. As the local livestock and fruit/vegetable industries in Laos continue to expand, the challenge of managing accumulated livestock manure has become acute. After comparing various options—such as trough-style and windrow compost turning machines—the client selected the large-scale rotary-disc model. This equipment features a wide operating span and high-volume turning capacity, making it compatible with wide fermentation troughs; it aerates materials by throwing them high into the air, facilitating rapid dehydration and cooling—ideal for the region’s rainy tropical climate—and effectively preventing anaerobic odor and incomplete decomposition. The equipment is constructed using thickened, corrosion-resistant steel plates and wear-resistant alloy tines, with upgraded sealing and protection designed for Southeast Asia’s humid environment to ensure a long service life. The shipment includes comprehensive operation manuals and spare parts, with direct logistics transport to the Mohan border crossing for export. In recent years, the company has steadily expanded its presence in the ASEAN agricultural equipment market, seeing consistent growth in export orders for complete sets of organic fertilizer fermentation and granulation equipment. By offering cost-effective machinery and one-stop overseas technical services, the company has secured long-term repeat business from clients across multiple countries. Moving forward, the enterprise will continue to refine its fermentation equipment to better suit Southeast Asian operating conditions, thereby supporting the standardized development of the region’s organic fertilizer industry.

The primary causes of granule adhesion in roller press granulator production lines include excessive raw material moisture, material buildup in the roll die holes, improper extrusion pressure, and moisture re-absorption during post-discharge stacking. Addressing this requires simultaneous, multi-dimensional control across raw material pretreatment, main machine adjustment, discharge conveyance, and auxiliary processes.

Precise control of raw material moisture is fundamental. For organic fertilizer, the optimal moisture content is 22%–28%; excessive moisture makes the material too plastic, resulting in soft granules that stick together upon stacking, while low moisture makes granules brittle. Small amounts of bentonite or humic acid can be added to enhance toughness, avoiding the need for excessive water supplementation. Wet raw materials should be evenly mixed in a twin-shaft mixer and pre-dried to remove wet clumps. Materials must be covered to prevent moisture absorption on rainy days and screened before storage to remove large, damp chunks, thereby preventing localized moisture imbalances that cause sticking to the rolls or granule adhesion.

Optimize the operating parameters of the fertilizer roller press granulator. Increase the gap between the two pressure rolls to reduce extrusion density and internal granule moisture content. For hydraulic models, moderately lower the extrusion pressure to prevent the material from being compressed into thin, sticky flakes. Regularly clean the roll die holes; fertilizer buildup on the inner walls makes demolding difficult and causes granules to stick together in strips. Use a steel wire brush to clear accumulated material from the die holes after shutdown, and apply an anti-stick coating to the roll surface to reduce material adhesion. Reduce the speed of the variable-frequency feed screw to ensure a uniform, low-volume feed; moderate die-hole filling prevents granules from sticking together due to overfilling.

Improve the discharge, conveying, and cooling processes. Freshly formed wet granules are hot and sticky and should not be stacked directly; minimize the discharge drop height and install buffer deflectors to reduce granule compression and stacking. Immediately transfer discharged granules to a rotary cooling and screening machine; low-temperature airflow rapidly removes surface moisture and reduces surface tackiness. Moderate screen vibration helps separate stuck granules, while fine powder is recycled for re-extrusion. Install belt scrapers on the conveyor system to prevent material buildup and adhesion of fresh granules to the belt.

Implement supporting controls for daily operation and maintenance. Clear out residual wet material from the equipment at the end of each shift to prevent hardening or clumping that could disrupt the next day’s production. During production breaks, periodically purge material adhering to the roller surfaces and feed hoppers. Incorporate appropriate amounts of talc or light calcium carbonate into the formula as anti-sticking agents to reduce inter-granular adhesion. Avoid continuous, long-term processing of wet materials with high salt or organic content; instead, schedule intermittent shutdowns to clean the roller surfaces, thereby eliminating the root causes of sheet-like adhesion and elongated, fused defective granules.

The large wheel compost turning machine is specialized equipment designed for large-scale channel-type fermentation. It operates by traveling longitudinally along rails on both sides while using a rotary disc for transverse turning and aeration. Consequently, the civil engineering of the fermentation channels, rails, ground surface, spatial clearance, and drainage systems must meet standardized, rigorous specifications; these factors directly determine the fermentation compost turning machine‘s operational stability and the effectiveness of the composting process.

Fermentation channel dimensions must align with the equipment’s span. Mainstream models accommodate channel widths of 8–30 meters, wall heights of 2–3 meters, and material pile heights of 1.5–2.5 meters. A single channel must be at least 30 meters long, with large-scale projects typically featuring lengths of 50–200 meters. Channel partition walls must meet load-bearing standards and stand perfectly vertical (without leaning) to prevent the equipment from shifting laterally and scraping against the walls. The channel floor must be fully paved with reinforced concrete at least 15 cm thick, with surface flatness controlled to within ±3 mm. A slight longitudinal slope of 1‰–2‰ is required, accompanied by leachate collection drains, to prevent water and sludge accumulation that could trigger anaerobic fermentation or corrode the rails.

The rail system serves as the core foundation. Specialized steel rails are laid along both sides of the channels; the rail gauge must strictly match the equipment’s wheel assembly, horizontal deviation must not exceed ±3 mm, and anchor bolts must be securely embedded without looseness. Maintenance walkways (0.8–1.2 meters wide) must be reserved on both sides of the rails to facilitate equipment maintenance and personnel access. Multi-channel layouts require space for equipment transfer to enable a single machine to operate across multiple channels.

There are specific limits regarding site load-bearing capacity and slope. The rail foundation requires a bearing capacity of at least 2 t/m²; soft soil foundations necessitate an additional steel reinforcement layer. The overall site slope must not exceed 3°; excessive slope can cause the equipment to drift off-track and result in uneven turning depths. For outdoor sites, the construction of a rain shelter is recommended to prevent rainwater from increasing the material’s moisture content and causing rust on the travel drive components. Regarding spatial requirements, the workshop’s clear height must exceed the equipment’s highest point by at least one meter to facilitate the lifting and maintenance of the rotating disc. The site layout must designate specific zones for raw material storage, fermentation tanks, and finished product discharge, while also reserving access lanes for forklift transport. Obstructions such as protruding pipelines or stones are prohibited within the area to prevent damage caused by high-speed rotating disc blades; additionally, provisions must be made for embedding ventilation and aeration piping to meet aerobic fermentation oxygen requirements. Once the site construction is complete, the track level must be calibrated before equipment installation and commissioning can proceed.

The windrow compost turning machine utilizes a track-based, self-propelled chassis that requires no rails. Mainstream models feature a fully hydraulic, independent drive system suitable for open-air windrow composting, offering superior mobility on soft surfaces such as manure or sludge piles. Powered by a diesel engine, the machine splits power to simultaneously drive the turning drum and the hydraulic pumps for the travel system; independent hydraulic motors and planetary gear reducers on each track control their respective speeds. The chassis assembly includes drive sprockets, track rollers, carrier rollers, idlers, and track tensioners. The large ground contact area and low ground pressure prevent slipping or sinking on muddy, wet, or soft composting surfaces. While economy models may use mechanical transmission—resulting in linked track power and reduced steering flexibility—large-scale equipment employs a fully hydraulic structure.

This fermentation compost turning machine is controlled via dual operating levers, executing various maneuvers by utilizing the speed differential between the left and right tracks. For straight-line travel, both tracks operate synchronously at the same speed, with continuously variable control over forward and reverse velocities. Differential steering is achieved by slowing or stopping one track while the other continues to move; this results in a tight turning radius, making the machine suitable for windrows spaced closely together. A key feature is its ability to perform zero-radius turns—by driving one track forward while reversing the other, the machine can pivot on the spot, eliminating the need for a large turning area and thereby saving space at the fermentation site.

The travel system offers two operating modes: a low-speed working mode and a high-speed transfer mode. In the low-speed working mode, the turning drum lowers into the material pile, advancing slowly and steadily to simultaneously perform turning, aeration, and material discharge. In the high-speed transfer mode, the drum is lifted off the ground, allowing for rapid relocation to new piles and improving site turnover efficiency. Compared to wheeled turners, the crawler system offers superior shock absorption for smoother travel on uneven terrain and stronger hill-climbing capability under load. It avoids compacting the underlying composting material, making it suitable for windrow composting of various organic feedstocks, including livestock manure, straw, and spent mushroom substrate.

NPK blending fertilizer production lines do not require fermentation, granulation, or drying stages, resulting in lower civil engineering requirements; however, they are subject to specific site constraints regarding equipment installation, raw material storage, environmental compliance, and safe operation and maintenance, all of which directly impact production stability and environmental impact assessment (EIA) approval.

There are strict standards regarding spatial dimensions and ceiling height. Factory buildings for small-scale lines require a ceiling height of at least 3.2 meters, while medium-scale lines require no less than 4 meters to ensure the proper installation of vertical batching silos and conveying equipment, as well as to provide clearance for overhead maintenance and material loading. The workshop layout must be orderly and open, with access aisles at least 3 meters wide to accommodate forklifts and trucks; cramped conditions can lead to material spillage and hinder NPK bulk blending machine maintenance, making continuous automated production impossible.

The flooring must be hardened to high standards with impermeable surfacing and a load-bearing capacity exceeding 3 tons/m². Foundations for batching silos, mixers, and packaging machines require reinforcement and leveling to ensure a flat surface free from subsidence. Constructing the plant on soft ground or in low-lying, water-prone areas is strictly prohibited; such conditions can cause weighing sensor inaccuracies—leading to batching errors and nutrient content deviations—and allow accumulated water to dissolve fertilizer and erode the floor, creating risks of caking and dust generation.

The site environment must meet moisture-proofing and ventilation requirements. Since urea and potash fertilizers are highly hygroscopic and prone to caking, the plant must avoid low-lying, damp, or groundwater-seepage areas and be equipped with ventilation and dehumidification systems to keep the workshop dry. Additionally, as production generates minor amounts of dust, the site should not be immediately adjacent to residential areas or schools; space must be reserved for dust extraction ductwork, and airtight dust-control measures implemented to mitigate the risk of environmental complaints and mandatory rectification orders.

Utility infrastructure must meet standards; the plant requires a stable 380V industrial power supply, with waterproof and grounding measures in the electrical control area to ensure the stable operation of automated batching systems. Drainage channels must be installed to collect wastewater from equipment cleaning and floor washing, preventing water accumulation and dampness. Furthermore, the site must be clearly divided into raw material, production, and finished product zones with segregated layouts to prevent cross-contamination, thereby ensuring formula precision and stable, compliant production.

The root cause of fertilizer segregation in BB fertilizer production lines lies in significant differences in specific gravity and particle size among raw materials; factors such as inadequate mixing, large vertical drops during conveying, and excessive discharge speeds exacerbate this issue. Adjustments across three areas—raw material pretreatment, equipment modification, and operational practices—can effectively mitigate segregation.

Screening raw materials to ensure uniform specifications is fundamental. When sourcing, select NPK granules with similar sizes—avoiding combinations like small-particle monoammonium phosphate (MAP) with large-particle urea—and screen or crush any clumped fertilizer to eliminate extreme size disparities. Coated raw materials can be used; their higher surface friction makes them less likely to separate after mixing. Strictly control raw material moisture content; while excessively dry granules flow too freely and segregate easily, retaining a small amount of moisture promotes slight inter-particle adhesion, thereby reducing the likelihood of separation.

Optimize conveying and discharge processes. Minimize the vertical drop from the mixer to the packaging scale, keeping it within 80 cm; if the drop is too high, install buffer chutes or flow deflectors to reduce the impact force of falling material. Operate conveyor belts at low speeds and install flow-splitting baffles above the belt to prevent material from bouncing and segregating. Eliminate intermediate storage hoppers; convey the mixture directly to packaging after mixing to reduce static holding time, as segregation becomes more pronounced the longer the material sits undisturbed.

Standardize daily production operations. Empty residual material from hoppers whenever changing formulas, and separately pre-disperse fertilizers with significantly different specific gravities. Ensure synchronized and uniform feeding of ingredients to prevent a single raw material from surging into the mixer. Maintain moderate humidity in the workshop to reduce segregation caused by the rolling of dry materials; handle finished bags gently and prohibit dropping them from heights. Regularly calibrate mixer rotation speeds to prevent centrifugal segregation caused by excessive mixing speeds.

Implementing this comprehensive strategy keeps nutrient segregation deviations within acceptable limits, ensuring uniform nutrient distribution throughout each bag. This prevents uneven crop growth caused by segregation and helps maintain a stable product reputation among farmers.

Connection plates for windrow compost turning machines fall into two categories: frame connections and track link connections. Selection is based on four core standards: material thickness, operational load, site environment, and assembly dimensions. Choosing the right components minimizes failures such as cracking, de-tracking, and deformation, thereby extending the chassis’s service life.

Material hardness is the primary selection criterion. For heavy-duty fermentation operations, frame connection plates should be made of thickened Q355 steel, while track link connection plates must be forged from high-manganese steel. Ordinary thin iron plates lack toughness and are prone to tearing under the long-term impact of the turning roller; in contrast, forged and heat-treated high-manganese steel offers superior wear and impact resistance, minimizing friction-induced wear from sand, gravel, and sludge. For sites handling highly corrosive manure or sludge, plates require a dual-layer anti-corrosion and wear-resistant coating to delay rusting and thinning, preventing a rapid loss of structural strength.

Plate thickness is determined by equipment tonnage and windrow height. For small crawler turners (under 3 meters), frame connection plates should be at least 14mm thick, with a standard track link plate thickness of 10mm. For medium-sized models (4–5 meters), frame connection plates should be 16–18mm thick with reinforcing ribs, and track link plates thickened to 12mm. For large, heavy-duty equipment (windrow height >2 meters, daily processing >500 tons), frame connection plates should be thickened to 20mm with added reinforcing ribs, and track link plates should be wider, thicker, and wear-resistant to distribute the torque generated during travel and turning, preventing frame distortion.

Strictly verify OEM assembly dimensions to ensure a perfect match for bolt hole spacing, plate dimensions (length and width), and pin hole diameters. Deviations in hole diameter can lead to insecure bolt fastening, rapid loosening due to operational vibration, and cracking caused by uneven stress on the plate. Mixing new and old connection plates is prohibited; inconsistencies in thickness or width can cause unbalanced track tension, steering drift, and frequent de-tracking or downtime. Prioritize OEM standard parts during procurement; for custom parts, provide the exact equipment model to ensure precise mold fabrication.

The service life of roller shells in double roller press granulators depends primarily on the shell material, the raw materials being processed, and daily maintenance; significant differences exist depending on operating conditions. Wear rates vary drastically between processing dry inorganic NPK fertilizers and high-moisture organic fertilizers.

When processing dry inorganic materials such as urea, ammonium phosphate, and potash, the low moisture and low viscosity mean materials do not easily adhere to the roller grooves, resulting in a gradual wear rate. Standard high-manganese steel shells can last 8 to 12 months in continuous production. Opting for thickened shells made of high-chromium alloy with wear-resistant surface hard-facing significantly enhances durability; under normal conditions, these can last 2 to 3 years, processing tens of thousands of tons of fertilizer without extensive wear, while maintaining consistent granulation quality.

Conversely, processing decomposed organic fertilizer or organic-inorganic compound fertilizer accelerates shell wear manifold. These materials have high moisture content, high coarse fiber levels, and strong adhesion, causing them to stick persistently to the roller grooves; the cleaning process causes constant friction against the roller surface, and raw materials often contain abrasive impurities like sand, stones, or hard lumps. Standard high-manganese steel shells last only 3 to 6 months; even upgraded, thickened, wear-resistant shells last a maximum of only 8 to 12 months, often developing surface pitting, loose granules, and increased material recycling rates midway through their service life.

Several factors can drastically shorten shell lifespan: failure to remove impurities from raw materials, allowing stones or iron fragments to impact the surface and create dents; uneven feeding, causing one-sided wear; setting the roller gap too narrow, leading to direct dry friction between the shells; and failing to clear adhered material during daily shutdowns, allowing hard lumps to continuously grind against the roller pockets. Diligent daily practices—such as removing iron and impurities, ensuring uniform feeding, properly adjusting the roller gap, and promptly clearing adhered material—can extend the shell’s service life by approximately 30%. Once wear on the roller grooves exceeds one-third and granulation quality deteriorates, the shells require hard-facing repair or complete replacement. Considering overall operation and maintenance costs, double-roller extrusion granulation equipment is not the ideal choice for organic fertilizer production.

With the widespread adoption of soil testing and formula fertilization and the standardized management of the fertilizer industry, traditional manually operated NPK bulk blending machine can no longer meet the requirements of production, quality inspection, environmental protection, and traceability. Intelligent transformation of NPK blending fertilizer production lines has become a multi-dimensional necessity, covering the entire process of ingredient mixing, production control, environmental protection, operation and maintenance, and data management.

Precise automatic ingredient mixing is a core intelligentization requirement. Traditional manual feeding and weighing has large errors, easily leading to insufficient nitrogen, phosphorus, and potassium nutrients. The equipment needs to be equipped with a high-precision weighing module and a PLC intelligent control system. Each raw material silo should have independent frequency conversion feeding to dynamically compensate for weight deviations caused by material bridging and uneven feeding, controlling the mixing ratio error within 0.5%. The system can store hundreds of formulas, allowing for switching without manual recalculation. It can also automatically add micronutrients such as calcium, magnesium, and boron to achieve customized fertilizer blending to suit the soil needs of different regions.

Full-process automated linkage control reduces reliance on manual labor. The entire production line features one-button start/stop for batching, conveying, mixing, screening, and packaging. All equipment is interlocked and operates in tandem; if any stage experiences blockage or material shortage, the entire line automatically issues warnings and slows down to prevent material accumulation and waste.

Intelligent operation and maintenance, along with remote control, are essential for cost reduction. Equipment is connected to an IoT platform, allowing managers to remotely view production capacity, energy consumption, and fault records via mobile phones and computers. The system predicts potential problems such as belt wear and sensor drift, sending early maintenance reminders to reduce unexpected downtime. It automatically calculates power consumption and raw material loss per ton of fertilizer, generating energy consumption reports to assist factories in optimizing production scheduling and controlling operating costs. This comprehensive intelligent transformation, balancing production efficiency, product quality, environmental compliance, and refined management, is an inevitable trend for the upgrading of the blended fertilizer industry.

Replacing the water bucket of a windrow compost turning machine requires strict adherence to safety regulations and close attention to installation details to avoid leaks, pipe blockages, equipment damage, and other problems, ensuring the normal operation of the equipment.

Before replacement, ensure proper safety preparation. Park the fermentation compost turning machine on a level surface, completely stop the machine, disconnect the power, and lock the safety devices. Open the drain outlet to empty the water in the bucket. Depressurize pressurized water tanks beforehand to prevent residual water pressure from causing injury. Clean up debris around the bucket and prepare a new bucket of the same specifications, sealing gaskets, wrenches, and other tools and accessories. Take precautions throughout the process.

When removing the old bucket, first disconnect the inlet and outlet pipes and overflow pipe in sequence, and seal the pipe openings with a cloth to prevent soil and weeds from entering the pipes and water pump, causing subsequent blockages. Then slowly remove the fixing bolts and clamps. If the parts are rusted, use a rust remover. Do not forcibly pry them open to avoid damaging the bucket. Gently remove the old bucket and place it in the designated location.

Before installing the new bucket, verify the model, size, and interface location to ensure a perfect match, and thoroughly rinse the inside of the bucket. All sealing gaskets at the interfaces must be replaced with brand new ones; never use old, worn gaskets to prevent leaks. Connect the pipes in sequence, ensuring they are straight and free of twists or bends, and tighten the pipe clamps securely. Place the bucket correctly and tighten the fixing bolts evenly diagonally, ensuring even force distribution and preventing cracking of the bucket wall due to compression.

After installation, conduct a water test. Add water to the bucket to the normal water level, let it stand for a moment, and carefully check the bucket body and all interfaces for leaks. Then start the sprinkler system to check if the water flow is smooth and if the nozzles are clogged. During operation, observe whether the bucket shakes or shifts. Finally, tidy up the wiring, keep electrical connections away from water sources, take waterproofing precautions, clean up water stains and tools, and complete the replacement work.

Poor discharge, bridging, and blockage in the batching silo are common problems in NPK blending fertilizer production lines. These are often caused by material characteristics, silo structure, auxiliary devices, and improper operation and maintenance. Troubleshooting can be done step-by-step, starting with the most difficult issues.

First, address the material itself. Moisture-induced clumping, mixed particles, and excessive dust are the main causes of blockage. Clumped materials need to be screened and crushed beforehand to control the moisture content and prevent wet material from entering the silo. Different particle sizes should be stored separately to reduce fine powder accumulation. Regularly clean the material adhering to the silo walls to prevent material buildup and narrowing of the discharge opening.

Second, optimize the silo and discharge structure. A small silo cone angle and insufficient discharge opening size can easily create dead zones. The discharge opening can be widened appropriately, and fluidizing air cushions, anti-bridging rods, or vibrators can be installed inside the silo to break up material bridging. Inspect gate valves, butterfly valves, and screw feeders, removing any stuck particles and debris from the valve bodies, repairing any deformed or jammed valve cores, and ensuring smooth valve opening and closing.

Then, debug the auxiliary conveying equipment. If the screw conveyor stalls or feeds slowly, reduce the speed and check for blade deformation or wear; replace severely worn blades promptly. If the belt feeder slips or accumulates material, adjust the belt tension and clean any accumulated material from the rollers. Properly control the silo level, maintaining a low to medium level to avoid overloading and compaction, which can exacerbate bridging.

Finally, ensure proper daily management and maintenance of the NPK bulk blending machine. Establish an inspection system, cleaning the silos, valves, and conveyor channels every shift; during the rainy season, ensure the raw materials and silos are sealed against moisture. Adjust the start/stop duration and frequency of the vibrator according to the different flowability of the raw materials to achieve automatic arch breaking. For aging silos that have been in use for a long time, the inner walls can be modified to a smooth material and guide plates can be installed to fundamentally improve the feeding conditions and ensure continuous and stable batching.

Windrow compost turning machine walking system faults often manifest as deviation, derailment, slippage, weak walking, and track damage. By combining these fault symptoms with corresponding inspections and routine maintenance, quick troubleshooting and solutions can be achieved.

For track deviation and derailment, first stop the machine and clean the inside of the tracks, idlers, and guide wheels to remove accumulated mud, sand, and material to prevent obstruction. Then adjust the tension of both tracks to ensure consistent tension. The standard is that the middle of the track should sag 2-3 cm when pressed down. Too loose a tension will easily cause derailment, while too tight a tension will accelerate wear. Check the guide wheels and idlers for uneven wear or deformation; replace severely worn ones directly. Frame deformation can cause track misalignment; the frame fixing bolts need to be corrected. During operation, avoid compacting material piles on one side or traveling at an angle for extended periods.

For slippage and insufficient power, first check the rubber treads of the track plates; replace them promptly if worn smooth. In muddy or slippery areas, reduce the travel speed and avoid sudden acceleration and sharp turns. Inspect the travel reducer and drive wheel teeth. Worn or missing teeth can cause power transmission failure, requiring repair or replacement. Also check the travel motor for overheating or poor wiring connections; tighten terminals and clean dust from the motor’s cooling system.

Cracked track shoes and detached rubber are often caused by aging or impacts from hard objects. Damaged track shoes can be replaced individually. Avoid running the equipment over stones or metal debris to minimize impacts. Rubber is prone to aging from prolonged exposure to sun and rain; cover it if storing outdoors.

Daily maintenance is key to preventing malfunctions: Clean debris from track gaps after each shift; regularly lubricate travel bearings and rollers; during the rainy season, waterproof the travel mechanism to prevent water ingress and corrosion of bearings. Before long-term storage, loosen the tracks slightly to prevent prolonged pressure and deformation of the rubber.

The large wheel compost turning machine is specifically designed for trough-type aerobic fermentation. The matching fermentation tank is the core area for organic fertilizer composting. It is typically constructed of reinforced concrete, ensuring durability, uniformity, and adaptability for reciprocating operation. The length of a single fermentation tank is commonly 30–80 meters, and the tank width, depending on the disc turner model, is available in mainstream specifications of 3 meters, 4 meters, and 5 meters. The tank depth is uniformly controlled at 1.6–2 meters, and the pile height does not exceed 1.5 meters to ensure sufficient oxygen supply for fermentation.

Forced ventilation pipes are pre-embedded at the bottom of the tank, along with an aeration fan. Air is delivered to the bottom of the pile through these pipes, working in conjunction with the turner’s agitation to form a three-dimensional oxygen supply system, accelerating organic matter decomposition and shortening the composting cycle. Straight tracks are cast on both sides of the tank for the large-disc compost turner to move and position itself. The flatness of the tracks directly affects the stability of the equipment’s operation, preventing deviation and abnormal wheel wear.

The entire fermentation tank is treated with waterproofing, seepage prevention, and corrosion resistance. The inner walls are coated with anti-corrosion mortar or a special coating to resist corrosion from manure and biogas slurry, while preventing leachate leakage and environmental pollution. Operating channels and collection ditches are provided between the tanks to collect leachate for recycling, achieving environmentally friendly production in the organic fertilizer fermentation line.

Compared to open-air windrow fermentation, tank fermentation offers stronger sealing, less odor and dust diffusion, and is less affected by rain and snow, allowing for continuous production year-round. Multiple fermentation tanks can be used in separate areas, enabling the efficient flow of raw material feeding, fermentation, and discharging, with seamless process coordination. Regular cleaning of the ventilation holes at the bottom of the tanks is necessary to prevent material blockage affecting aeration, and the tracks should be checked for settlement or deformation to ensure the normal operation of the turning machine.

The water tank of the windrow compost turning machine, equipped with a high-pressure water pump and atomizing spray nozzles above the drum, is a standard component of windrow fermentation. It serves four core functions, including fermentation control, dust control, equipment protection, and microbial agent spraying.

First, it precisely regulates the moisture content of the compost pile to ensure aerobic fermentation. When the moisture content of raw materials such as chicken manure, straw, and dry sludge is low (below 25%), water is added simultaneously with turning to adjust the moisture content of the pile to the optimal fermentation range of 30%–38%. In summer, high temperatures cause rapid water loss and localized drying and suffocation. Water is sprayed while turning the pile, ensuring even drying and preventing localized dryness and anaerobic foul odors, significantly shortening the composting cycle. The water tank can also be used to add composting bacteria liquid and liquid nutrients, which are evenly mixed into the materials with the water mist during turning, eliminating the need for manual sprinkling of microbial agents and resulting in more even mixing and improved fermentation efficiency.

Second, it suppresses dust and ash at the work site. Dry material turning and turning easily generates dust. The spray nozzles synchronize with the drum to spray water mist, suppressing dust the moment the material is thrown up, improving the working environment, reducing dust inhalation and raw material loss, and preventing dust from adhering to tracks, bearings, and oil seals, thus reducing the probability of dust-induced wear on parts.

Third, it cleans material adhering to the blades and protects vulnerable parts. Straw and biogas residue are highly sticky and easily clog the turning and turning blades. Water from the water tank can be sprayed on the drum blade shaft during intermittent operation to wash away clumps of sticky fertilizer, preventing overload of the blades, motor stalling, and reducing abnormal wear of the agitator teeth and drum blockage.

Fourth, it provides emergency equipment cooling. In high-temperature summer operations, water stored in the water tank can be used to spray the engine and hydraulic oil pipes to assist in heat dissipation; in the field where there is no external water source, water can be stored on the vehicle and sprayed as needed, eliminating the need for separate water pipes, allowing for flexible operation on irregularly stacked outdoor piles.

Standard models have a water tank capacity of 500-1000L, and a single water storage can meet the water replenishment needs of 2-3 piles of raw materials.

First, they offer greater adaptability to different terrains. Wheeled compost turners rely on tires for movement, making them prone to slipping and sinking in muddy, manure-saturated, or soft soil conditions, hindering their ability to reach the compost pile. Windrow compost turners, with their larger contact area and lower pressure, can operate even on damp, muddy ground around the manure pile. They can also operate in wet greenhouses or after rain without needing to be dried out, making them more practical for small to medium-sized open-air fermentation sites.

Second, they offer better compatibility in terms of turning depth and material selection. Wheeled compost turners typically have a maximum turning depth of less than 1 meter, making it difficult to thoroughly turn highly moist chicken or pig manure, which tends to stick to the rake teeth. Tracked compost turners, on the other hand, can reach depths of 1.2–1.8 meters, effectively breaking up sticky, well-rotted manure and sludge mixtures. This results in more even oxygen supply to the pile, a more stable fermentation cycle, and flexible adjustments for both wide and narrow piles.

Thirdly, tracked machines offer high operational stability. The lateral thrust generated during the turning and dumping of large material piles makes wheeled machines prone to being pushed off course and veering off course. Tracked machines provide strong grip, preventing the machine from swaying under heavy loads, ensuring uniform turning and minimizing variations in the finished product’s decomposition. Most tracked models are equipped with hydraulic lifting and remote control, allowing for quick and easy adjustment of the rake tooth height, and can be operated remotely by a single person.

Fourthly, tracked machines offer higher site utilization. Wheeled machines require a wide aisle, while tracked machines have a smaller turning radius, allowing for narrower stacking distances and enabling the storage of more raw materials in the same space. The only drawback is that tracked machines experience wear and tear over time, but their overall adaptability to various working conditions far surpasses that of wheeled machines.

Customers with damp raw materials, simple open-air sites, or those who produce chicken and duck manure year-round should prioritize tracked machines; those with dry and loose raw materials, hardened and level sites, and lower budgets should consider wheeled models.

Reducing production costs of NPK blending fertilizer production lines requires meticulous management in four areas: raw material control, equipment operation and maintenance, production management, and energy and consumable consumption, while balancing efficiency and losses.

Prioritizing raw material management is the core of cost reduction. Centralize bulk procurement of raw materials to lower procurement and logistics unit prices; strictly inspect raw materials, controlling moisture content to ≤5% and particle uniformity to reduce agglomeration, segregation, and screening losses from the source. Plan the production sequence, concentrating similar formulas for continuous production to reduce material change frequency and minimize equipment waste and cleaning time. Classify and recycle screened agglomerates and waste materials, crush them, and reuse them to improve raw material utilization.

Strengthen the maintenance of NPK bulk blending machine to reduce failure losses. Develop a regular maintenance plan, calibrate batching scales on time, and inspect vulnerable parts such as conveyor belts and bearings to avoid capacity losses due to accuracy deviations and sudden shutdowns. Daily cleaning of residual materials in equipment prevents mixing and scrapping; timely maintenance of sealing and dust removal components prevents dust leakage. Optimize equipment operating parameters to match the capacity of each unit in batching, mixing, and packaging, avoiding idle or overload operation.

Optimize production and labor patterns. Increase the automation utilization rate of the production line, stabilize continuous full-load production, and reduce unit product energy consumption and fixed costs. Implement reasonable shift scheduling, streamlining redundant personnel by allowing one person to perform multiple roles, thus improving labor efficiency. Standardize work processes to reduce rework and waste caused by operational errors.

Strictly control auxiliary consumables and energy consumption. Select high-performance packaging bags and sealing accessories, and use them only as needed to avoid waste; optimize the use of auxiliary equipment such as dust removal and lighting, and shut them down promptly during non-operational periods. Plan the storage of raw materials and finished products rationally to improve space utilization and reduce warehousing and transportation costs. Multi-stage collaborative management can steadily reduce overall production costs.

Insufficient uniformity in compost turning with windrow compost turning machines can easily lead to localized anaerobic digestion, uneven fermentation, and incomplete deodorization. Improvement can be achieved through optimization in four aspects: equipment debugging, operational standards, material pretreatment, and daily maintenance.

First, optimize equipment parameters and structural debugging. Adjust the lifting height of the turning drum according to the height and width of the material pile, ensuring the teeth penetrate the bottom of the pile to prevent surface turning and bottom stagnation. Set the travel speed appropriately; too high a speed will result in insufficient material dispersion, while too slow a speed will cause accumulation. A standard speed is 4–8 meters per minute. Adjust the drum speed; too low a speed will result in poor mixing, while too high a speed will cause dust generation. Match the speed to the material moisture content. Inspect the spiral blades and teeth to ensure they are intact, without deformation, and with consistent spacing. Replace any severely worn parts promptly to ensure smooth material gathering, dispersing, and scattering.

Second, standardize on-site operations. Maintain a regular pile shape with uniform width and height, avoiding excessive differences in width and height. A staggered, reciprocating operation is employed, with slight overlap between adjacent work areas to eliminate blind spots in the turning process. Each turning operation is thorough, avoiding simplification of procedures. During the high-temperature fermentation stage, the frequency of turning can be increased to further break up clumps of material.

Proper pre-treatment of materials is fundamental. Long-fiber materials such as straw and vines should be crushed in advance to prevent them from entangled in the drums and hindering turning. The material ratio should be uniform, with a moisture content controlled between 55% and 65%. Excessive moisture content results in sticky, clumpy materials that are difficult to break up; insufficient moisture content leads to loose materials and reduced mixing efficiency.

Finally, routine maintenance is crucial. After each operation, clean the drums and blades of any sticky material and entangled debris to prevent accumulation from altering the turning trajectory. Regularly inspect the tracks and hydraulic system to ensure smooth, stable, and vibration-free movement, preventing machine swaying that could cause turning deviation. After long-term use, calibrate the drum coaxiality to ensure stable operation and maintain consistently high turning uniformity.