Category: organic fertilizer equipment

organic fertilizer equipment

Flat die pelleting machine: Protecting the activity of microbial agents in low-temperature granulation

by organic fertilizer production line

The core challenge in biofertilizer production lies in ensuring that the granulation process does not destroy the activity of the microbial agent. Most functional bacteria (such as Bacillus subtilis and Trichoderma harzianum) are significantly inactivated at temperatures above 45°C. The flat die pelleting machine, with its low-temperature granulation capabilities, is a suitable choice for biofertilizer production. Its core advantage lies in its low-friction, no-additional-heat granulation process.

The flat die pelleting machine utilizes a vertical extrusion process, with the rollers and the die in contact with each other over a surface area rather than at points. This results in more uniform force per unit area, less frictional heat generation, and a temperature within the granulation chamber typically maintained at 35-40°C, well below the inactivation threshold of the microbial agent.

Furthermore, the machine does not rely on high-temperature conditioning or hot air conditioning; instead, it achieves granulation solely through the viscosity of the raw material and moderate extrusion, eliminating the need for additional heat input.

Furthermore, the flat die granulator’s speed is adjustable (typically 30-50 rpm). For biofertilizer raw materials with high microbial content, the speed can be reduced to below 30 rpm to further reduce frictional heat generation and ensure a microbial survival rate above 85%.

In practical applications, it is even more effective when used with a “room-temperature binder.” This eliminates the need for heating and dissolving the pellets, while also improving the pelletizing efficiency and complementing the flat die pelleting machine‘s low-temperature characteristics. This ensures the biofertilizer’s core function (microbial activity) while producing uniform pellets, meeting the dual requirements of “functionality” and “commerciality.”

organic fertilizer equipment

Operational adjustment tips for ring die granulators in low-temperature environments

by organic fertilizer production line

During winter in northern China or in low-temperature workshops (temperatures below 5°C), ring die granulators are prone to low pelletizing efficiency and poor pellet formation due to decreased raw material viscosity and insufficient lubrication of equipment components. Targeted adjustments are required to ensure proper operation.

During raw material processing, an electric heater can be added to the conditioner to preheat the raw materials to 15-20°C. This increases raw material molecular activity and viscosity, preventing low-temperature conditions that can lead to agglomeration and difficulty in extrusion.

Also, the steam saturation can be appropriately increased (from 80% to over 90%) to utilize steam heat to assist in heating the raw materials and prevent moisture from freezing at low temperatures, which can affect pelletizing. During raw material storage, insulation should be installed in the silo to prevent the raw materials from cooling too low during storage and avoid wasted energy from secondary heating.

Before operating the ring die granulator, preheat the ring die and rollers for 30 minutes. This can be done by running the machine at no load to allow frictional heating, or by wrapping the outer ring die with an electric heat tracer. The temperature should be set between 25-30°C to prevent the raw material from solidifying and clogging the die bore due to low temperatures. The lubricant should also be replaced with a low-temperature-specific lubricant (viscosity grade 46#) to prevent freezing and potentially blocking transmission components. The lubricant fluidity should be checked every two hours to ensure proper lubrication.

These adjustments can effectively mitigate the effects of low temperatures on the ring die granulator, ensuring a pellet formation rate above 95% and preventing material waste due to low temperatures.

organic fertilizer equipment

Organic fertilizer production line processing chicken manure: A comprehensive analysis of key considerations

by organic fertilizer production line

Chicken manure, rich in nutrients and widely available, is a high-quality raw material for organic fertilizer production. However, due to its high moisture content, susceptibility to fermentation and spoilage, and the presence of impurities, key processes must be carefully controlled to ensure product quality and smooth production.

Pretreatment is fundamental. Fresh chicken manure typically has a moisture content of 70%-80%. It needs to be reduced to 55%-60% using organic fertilizer production equipment to prevent anaerobic putrefaction during fermentation. Simultaneously, impurities such as stones, plastics, and feathers must be removed manually or mechanically to prevent damage to subsequent equipment. If the chicken manure is severely clumped, it needs to be crushed to ensure uniform particle size, laying the foundation for fermentation.

The fermentation stage is crucial. Chicken manure has a high nitrogen content and needs to be mixed with straw, sawdust, and other carbon source materials in a specific ratio to adjust the carbon-to-nitrogen ratio to 25-30:1, promoting microbial activity. During fermentation, the compost pile needs to be turned regularly using a compost turning machine to ensure aeration and maintain a high temperature of 55-65℃ for 7-15 days to achieve sterilization, insect control, and decomposition.

Subsequent processing must be standardized. The decomposed chicken manure needs to be crushed and screened again to ensure there are no large pieces of uncomposted material, with a particle size controlled within 2 mm for easy granulation. During granulation, the material moisture content must be controlled at 20%-30% to avoid clogging the die holes; the drying temperature should not exceed 80℃ to prevent damage to organic matter and beneficial microorganisms. Simultaneously, the entire organic fertilizer production line must be properly sealed and deodorized to reduce odor diffusion and meet environmental protection requirements.

organic fertilizer equipment

Complete Guide to Organic Fertilizer Fermentation

by organic fertilizer production line

Basic Principles of Fermentation

Organic fertilizer fermentation is a complex biochemical process that primarily involves the decomposition and transformation of organic matter through microbial activity. This process can be divided into two main stages:

High-temperature Stage: Temperature rises to 60-70°C, eliminating harmful pathogens and weed seeds.

Maturation Stage: Temperature gradually decreases to around 40°C, while beneficial microorganisms continue decomposing organic matter.

Key Fermentation Steps

1. Raw Material Preparation and Ratio

Select appropriate raw material combinations, typically including: livestock manure (60-70%), plant straw (20-30%), and auxiliary materials (about 10%). The ideal carbon to nitrogen ratio should be maintained at 25-30:1.

2. Pile Construction

Form mixed materials into windrows 2-3 meters wide and 1.5-2 meters high. Proper pile size helps retain heat and promote ventilation.

3. Temperature Control

Control temperature through regular turning and ventilation:

  • Initial stage: Temperature rapidly rises to 55-65°C
  • Middle stage: Maintain at 50-60°C
  • Final stage: Gradually decreases to ambient temperature

4. Moisture Management

Maintain moisture content between 50-60%. Excessive moisture creates anaerobic conditions, while insufficient moisture inhibits microbial activity.

5. Turning Operation

Regular turning based on temperature changes:

  • High-temperature period: Turn every 2-3 days
  • Cooling period: Turn weekly
  • Maturation period: Turn every two weeks

Modern Fermentation Technologies

Trough Fermentation

Conducted in concrete troughs equipped with turners and aeration systems, with a fermentation cycle of 15-20 days.

Reactor Fermentation

Conducted in sealed containers with complete control over temperature, humidity, and ventilation, reducing fermentation cycle to 7-10 days.

Signs of Completed Fermentation

  • Temperature stabilizes at ambient level
  • Material turns dark brown with no foul odor
  • Texture becomes loose with moisture content below 30%
  • pH value stabilizes between 6.5-8.5

Quality Control Essentials

Successful organic fertilizer fermentation requires strict control of the following factors: appropriate raw material ratios, adequate oxygen supply, suitable temperature and humidity, and sufficient fermentation time. Through these controls, high-quality organic fertilizers can be produced, providing strong support for sustainable agriculture.

Successful organic fertilizer fermentation requires strict control of the following factors: appropriate raw material ratios, adequate oxygen supply, suitable temperature and humidity, and sufficient fermentation time. Through these controls, high-quality organic fertilizers can be produced, providing strong support for sustainable agriculture.

The efficiency of organic fertilizer fermentation largely depends on the proper selection and operation of specialized equipment. Modern fertilizer production machine systems are designed to optimize these critical parameters throughout the entire organic fertilizer production line. For large-scale operations, a large wheel compost turner provides efficient aeration and mixing, while smaller facilities might utilize a chain compost turner for similar purposes.

In a comprehensive bio organic fertilizer production line, the compost fertilizer machine plays a pivotal role in maintaining optimal fermentation conditions. The complete suite of equipments required for biofertilizer production includes not only turning machines but also crushers, mixers, granulators, dryers, and screening equipment. These integrated systems ensure consistent quality and accelerate the decomposition process, transforming organic waste into valuable nutrients for crops while maintaining environmental sustainability.

organic fertilizer equipment

Core features of bio-organic fertilizer equipment: Focusing on activity protection and high-efficiency adaptation

by organic fertilizer production line

As a key carrier for ensuring product quality, bio-organic fertilizer equipment is designed and functions around the core needs of bio-organic fertilizer: “preserving activity, promoting composting, and ease of application.”

1.Strong Activity Protection Orientation

The core value of bio-organic fertilizer lies in the activity of beneficial microorganisms. The equipment avoids high-temperature damage throughout the entire process. In the fermentation stage, precise temperature control through a compost turning machine and fermentation tank satisfies both sterilization and composting requirements while preventing microbial inactivation. Granulation employs a low-temperature extrusion process, and cooling equipment quickly lowers the material to room temperature, reducing damage to the microbial community from high temperatures.

2.Controllable Composting Process

The equipment achieves precise control of fermentation conditions through mechanical design: the compost turning machine can adjust the turning frequency to ensure sufficient oxygen in the pile; the fermentation tank adopts a closed design, monitoring and adjusting temperature, humidity, and oxygen content in real time, shortening the composting cycle while ensuring uniform material composting and reducing odor emissions.

3.Wide Range of Raw Material Compatibility

The bio-organic fertilizer equipment is highly adaptable to various organic raw materials such as poultry and livestock manure, straw, mushroom residue, and distiller’s grains. The crushing equipment can adjust the particle size according to the hardness of the raw materials; the mixing equipment can evenly blend raw materials with different moisture content and specific gravity to ensure precise carbon-to-nitrogen ratio.

4.High Modularity and Flexibility

The equipment adopts a modular design, allowing for flexible combinations based on production scale. Small production lines can be equipped with simple compost turners and manual packaging equipment to reduce investment costs; large-scale production can be configured with automated fermenters and continuous granulation units to improve production efficiency.

organic fertilizer equipment

Maintaining key components in fertilizer coating machines

by organic fertilizer production line

Proper routine maintenance of fertilizer coating machines can reduce downtime and extend the coating machine life, with particular attention paid to key components.

First, maintain the conveyor belt. Fertilizer pellets easily accumulate. After daily downtime, clean the conveyor belt surface with a soft-bristled brush, especially around the edges to prevent residual pellets from clumping and scratching the belt coating. Check the conveyor belt tension weekly. If slippage occurs, adjust the tensioner immediately. Also, check the conveyor belt joints for cracks. Repair any cracks promptly to prevent uneven conveying and film shifting. For coating machines that frequently handles high-humidity pellets, apply anti-rust lubricant to the conveyor belt bearings monthly to prevent rust and seizure.

Second, clean the heat seal assembly. The heating tubes in the heat-sealing tunnel are prone to film residue. Wipe them every three days with a heat-resistant cloth. If the residue is hard, gently clean it with a small amount of alcohol. Be careful not to scratch the surface of the heating tube with hard objects to prevent damage to the temperature control sensor. Check the sealing performance of the heat-sealing tunnel weekly. If the tunnel door seal strips are deteriorating, replace them promptly to prevent heat loss that affects the heat seal and reduce energy waste.

Third, inspect the cutting blade. Check the cutting blade for sharpness weekly. If burrs appear, sharpen them with a whetstone at a 45° angle to ensure a smooth cutting edge. Also, clean the cutting blade holder to prevent film debris from getting stuck and causing deviations in cutting dimensions, which could affect packaging consistency. Check the cutting blade’s fixing screws monthly for looseness. Tighten them immediately if loose to prevent blade deviation during cutting, which could pose a safety hazard.

organic fertilizer equipment

Precise proportioning in NPK blending fertilizer production lines

by organic fertilizer production line

NPK blended fertilizers, due to their ability to flexibly adjust the proportions of nitrogen, phosphorus, potassium, and micronutrients according to crop needs, have become an important choice for modern agricultural fertilization. The standardized operation of NPK blending fertilizer production lines directly determines product quality and application effectiveness.

Raw material pretreatment is a fundamental step. The production line must select single-nutrient raw materials with qualified purity and stable moisture content. First, the lumpy raw materials are crushed to a uniform particle size using crushing equipment to avoid large particles affecting mixing uniformity. Simultaneously, stones and impurities in the raw materials must be removed to prevent damage to subsequent equipment. The moisture content of the raw materials must be controlled below 5%.

The batching stage is crucial. The amount of each raw material is precisely weighed according to the preset formula using metering equipment. The proportions of nitrogen, phosphorus, and potassium, the main nutrients, can be flexibly adjusted according to crop type and soil fertility. Some production lines also add micronutrients such as calcium, magnesium, and sulfur to achieve comprehensive and balanced nutrient distribution. Metering errors must be controlled within acceptable limits.

Standardized mixing and subsequent processing are essential. The weighed raw materials are fed into a fertilizer mixer machine, where mechanical mixing ensures uniform blending of all components. Strict control of the mixing time is crucial to prevent localized material agglomeration. If the mixed material is in powder form, it can be processed into granules using granulation equipment to improve transportation convenience and application uniformity. Finally, unqualified granules are removed by sieving, and the mixture is then quantitatively packaged using packaging equipment. Storage requires moisture protection to prevent clumping and spoilage.

The entire NPK blending fertilizer production line is simple and efficient, with its core strengths lying in the control of raw material purity, precise proportioning, and uniform mixing.

organic fertilizer equipment

The connecting process of flat die granulator in organic fertilizer production line

by organic fertilizer production line

In the overall process of an organic fertilizer production line, the flat die granulator plays a crucial “bridging” role. It receives the organic fertilizer raw materials from the preceding processes, after fermentation, crushing, and mixing, transforming the loose, powdery material into structurally stable granules, laying the foundation for subsequent drying, cooling, and packaging stages.

From a working principle perspective, the flat die granulator uses a motor-driven transmission mechanism to rotate the pressure rollers. When the raw material enters the machine, the pressure rollers exert extrusion force on the material, forcing it through pre-set die holes on the flat die, ultimately forming cylindrical or other shaped granules. This process requires minimal binders, relying primarily on the material’s own viscosity and extrusion force to achieve shaping, thus preserving the nutritional components of the organic fertilizer while avoiding the potential impact of chemicals on the soil.

For organic fertilizer production, the flat die granulator not only solves the problems of dust and caking during raw material transportation, but also controls the diameter and hardness of the granules by adjusting the die size and pressure roller pressure, meeting the needs of different crops and different fertilization scenarios. It is one of the indispensable core equipment in the production line.

organic fertilizer equipment

Rotary Screener: Master of Precision?

by organic fertilizer production line

In modern industrial production, the rotary drum screening machine stands as a master sorter, bringing revolutionary breakthroughs to material classification through its unique dual-motion mode—the perfect combination of drum rotation and mechanical vibration. This equipment represents not only technological achievement but also the perfect embodiment of efficiency and precision across multiple production contexts.

Within comprehensive fertilizer manufacturing systems, this screening technology integrates seamlessly with both organic fertilizer production line and npk fertilizer production line operations. Following the fertilizer granulator process—whether utilizing a disc granulator in a specialized disc granulation production line or other granulation methods—the screening machine ensures consistent product quality. For compound fertilizers, it works in concert with the npk blending machine to deliver precisely graded products, making it an indispensable component in any complete npk fertilizer line.

Exquisite Structure: Every Component Matters

Drum Body

As the core of the equipment, the drum body consists of screen mesh, support frame, and drum shell. The screen aperture is meticulously designed according to classification requirements, ensuring precise separation of materials with different particle sizes.

Vibration Device

High-frequency vibration generated by motors, eccentric blocks, or vibration springs ensures even material distribution within the drum, significantly improving screening efficiency and preventing material accumulation.

Drive System

Powerful motors combined with precision reducers provide smooth and reliable rotational power for the drum, ensuring long-term continuous stable operation.

Sealing Design

Advanced sealing devices effectively prevent dust leakage, maintaining a clean working environment while meeting modern industrial environmental requirements.

Wide Applications: Versatile Assistant Across Industries

Compound Fertilizer

Precisely separates return materials from finished products, achieving fine product classification

Mining Industry

Efficiently screens various ores, enhancing resource utilization

Building Materials

Accurately classifies sand and gravel aggregates, ensuring product quality

Food Processing

Hygienically and safely screens food raw materials, guaranteeing product quality

The most remarkable feature of the rotary vibrating screen is its unique working principle. It ingeniously combines the continuous operation capability of drum screens with the efficient screening characteristics of vibrating screens. Through drum rotation, materials are fully tumbled while vibration facilitates rapid passage of fine particles through the screen mesh, achieving a “1+1>2” screening effect.

Intelligent Design: Guarantee of Efficiency and Stability

The support device employs heavy-duty frames and precision bearings to ensure absolute stability during high-speed operation; carefully designed inlet and outlet ports facilitate smooth material flow and precise classification; intelligent control systems monitor equipment operation in real-time, enabling automated production. Every detail reflects the engineers’ ingenious craftsmanship.

The rotary screener represents not only significant progress in industrial screening technology but also an important manifestation of modern intelligent manufacturing. With its outstanding performance, wide applicability, and reliable operational stability, it plays an indispensable role in global industrial production. From mines to farms, from chemical plants to food workshops, this equipment continues to quietly drive various industries toward higher quality and greater efficiency through its precise and effective working methods.

organic fertilizer equipment

The “Core Support” in the fermentation of oil palm empty fruit bunch organic fertilizer

by organic fertilizer production line

Oil palm empty fruit bunch(OPEFB), rich in crude fiber and with a loose structure, are a high-quality raw material for organic fertilizer processing. However, these materials are prone to problems such as accumulation and oxygen deficiency, and uneven temperature during fermentation. The application of a compost turning machine provides crucial support for solving these problems, significantly improving the decomposition efficiency and quality of the oil palm empty fruit bunch.

In the fermentation stage of processing oil palm empty fruit bunch organic fertilizer, the crushed oil palm empty fruit bunch are first mixed with livestock and poultry manure, microbial agents, etc., in a certain proportion to form fermentation material. Because of the low density of oil palm empty fruit bunches, if left to stand for a long time after mixing, a closed space easily forms inside the material, leading to a decrease in the activity of aerobic microorganisms. This not only prolongs the decomposition period but may also produce unpleasant odors.

At this stage, the oil palm empty fruit bunch compost turning machine can periodically turn the fermentation pile, breaking up material clumps with mechanical force and introducing air into the pile to provide sufficient oxygen for microbial reproduction. Simultaneously, the turning process allows for thorough exchange of material throughout the pile, preventing localized overheating or underheating and maintaining the pile at a suitable composting temperature of 55-65℃, thus accelerating the decomposition and transformation of coarse fibers in the oil palm empty fruit bunch.

Furthermore, the compost turning machine can flexibly adjust the turning frequency according to the moisture content of the fermentation material. If the material is too moist due to the high hygroscopicity of the oil palm empty fruit bunch, increasing the number of turns can promote moisture evaporation; if the material is too dry, it can be turned simultaneously with the water replenishment process to ensure uniform moisture content.

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