At the end of August 2025, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd.’s customized 8-ton/hour extrusion granulation production line for a Malaysian client completed full-process commissioning and officially entered the mass production stage. With its core advantages of high capacity, high precision, and low energy consumption, this production line perfectly adapts to local raw material characteristics and environmental standards. Its modular design and intelligent configuration have become a typical model for high-end extrusion granulation equipment exported overseas.

Production Line Core Configuration and Process Link

The entire production line follows a closed-loop process design of “pre-treatment – mixing – granulation – post-treatment – finished product packaging.” Each unit of equipment is precisely matched and works in synergy for high efficiency, achieving an automation level of over 90%.

Raw Material Pre-treatment and Mixing Unit

The raw material conveying system uses three belt conveyors of different specifications, respectively responsible for raw material transfer, intermediate material connection, and return material conveying. The conveyor belt width is adapted to the 8-ton/hour capacity requirement, ensuring smooth operation without material spillage, and improving conveying efficiency by 15% compared to conventional equipment.

The core mixing equipment uses two 1.2×3.0 meter twin-shaft horizontal mixers with counter-rotating blades, ensuring a mixing uniformity error of ≤3%. The equipment is equipped with a variable frequency speed control system, allowing for flexible speed adjustment based on raw material moisture content and proportions, ensuring the moisture content of the mixed materials is stably controlled within the optimal granulation range of 28%-32%.

The core granulation unit utilizes four 2.5-type double-roller extruders operating in parallel. Each machine has a capacity of 2.2 tons per hour, achieving a total designed capacity of 8 tons per hour when operating together. The rollers are made of high-chromium alloy, achieving a hardness of HRC60 or higher after quenching treatment, resulting in three times the wear resistance of ordinary materials and extending the service life to over 8000 hours.

The granulators employ a hydraulic pressure regulation system, allowing for precise control of the extrusion pressure within the range of 5-15 MPa, suitable for granulating various materials such as organic fertilizers and compound fertilizers. The roller surface features a customized serrated design, effectively enhancing material gripping force and maintaining a stable granulation rate above 92%. Particle size is uniformly controlled within 3-5mm, meeting customers’ standardized production requirements.

Post-processing and Environmental Protection Unit: The screening stage is equipped with one 1.8×6.0 meter double-layer drum screen. It employs a grading design; the upper screen separates large pieces of material, while the lower screen filters qualified particles. Unqualified material is directly returned to the mixer for regranulation via a return conveyor belt, achieving a material utilization rate of 98%.

The environmental protection system integrates a pulse-jet dust collector and exhaust gas treatment device. Through a negative pressure dust collection design, dust generated during production is collected and treated centrally, with dust emission concentration ≤10mg/m³, fully complying with local Malaysian environmental regulations. Equipment operating noise is controlled below 75dB, achieving green and low-carbon production.

Finished Product Storage and Packaging Unit:

The finished product silo has a capacity of 20 cubic meters and is equipped with a material level monitoring system to provide real-time feedback on material levels, preventing spills or shortages.

The packaging process utilizes a fully automated quantitative packaging machine. Packaging specifications can be flexibly adjusted within the range of 25-50 kg/bag, with a packaging error of ≤±0.2 kg and a packaging speed of 120 bags/hour, meeting the needs of large-scale shipments.

Core Technological Advantages of the Production Line:

Modular design is used throughout the entire process. Each equipment unit can be independently disassembled and maintained, significantly reducing downtime for maintenance and achieving an overall equipment uptime of over 95%.

An intelligent control system is adopted, integrating a PLC touchscreen operating interface. This allows for real-time monitoring of the operating parameters of each piece of equipment (speed, pressure, temperature, etc.), supports automatic fault alarms and data logging, facilitating remote management and process optimization for customers.

The overall layout of the production line is compact, requiring only 800 square meters of space, saving 20% ​​of space compared to conventional production lines with the same capacity. Simultaneously, optimized material conveying paths shorten transfer distances, and energy consumption is reduced by 12% compared to the industry average.

The successful commissioning of this 8-ton-per-hour extrusion granulation production line once again demonstrates Huaqiang Heavy Industry’s technological strength in the field of high-end fertilizer equipment manufacturing. In the future, the company will continue to focus on equipment performance upgrades and process optimization to provide global customers with more competitive customized production line solutions.

Comparative Granulation Technologies in Fertilizer Manufacturing

This Malaysian project highlights the efficacy of extrusion-based fertilizer compaction technology. The roller press granulator production line operates on the principle of dry fertilizer granules compaction, where the fertilizer compactor applies high pressure to form dense granules. This method is a key part of modern npk fertilizer manufacturing process and organic fertilizer manufacturing process when dealing with dry powders. In contrast, the npk manufacturing process often employs alternative technologies like the rotary drum granulator, which uses a wet agglomeration method with a liquid binder. For organic systems, a dedicated organic fertilizer disc granulation production line is common, where the disc granulator for shaping forms granules through a tumbling and layering action.

The choice of fertilizer production machine technology—be it a fertilizer compaction machine for dry compaction or a drum/disc for wet agglomeration—fundamentally shapes the entire organic fertilizer manufacturing system. Extrusion offers advantages in energy efficiency (no drying needed) and granule hardness, while rotary methods often provide higher capacity and spherical shape. The optimal selection depends on raw material properties, desired product characteristics, and overall production economics.

Therefore, a comprehensive fertilizer equipment supplier must master these diverse granulation technologies to provide truly customized solutions, matching the precise mechanical, chemical, and economic requirements of each client’s operation, whether for NPK or organic fertilizer production.

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In modern fertilizer production, screening and packaging are crucial steps before the finished product leaves the factory. A professional screening and packaging production line, through its integrated design of “grading and screening – impurity removal – precision packaging,” not only improves product appearance and quality but also directly impacts storage, transportation, and final usage effectiveness. This system is suitable for the large-scale production of various granular and powdered fertilizers and is core equipment for achieving fertilizer commercialization and standardization.

How the Production Line Works: Process and Core Equipment

A typical screening and packaging line begins with the receipt of granulated or dried fertilizer. The material first enters a grading and screening machine via a closed conveyor system. For common granular fertilizers (such as compound fertilizers), a drum screen is typically used. Its multi-layered replaceable screens accurately separate qualified particles (e.g., 2-5 mm) and remove oversized pieces, fragments, and impurities. For powdered fertilizers, vibrating screens are more commonly used, effectively controlling dust while performing fine screening.

The screened qualified fertilizer is then conveyed to an automatic quantitative packaging scale. Modern packaging scales offer high precision, with an error controllable within ±0.2 kg. They support rapid packaging of various sizes from 10 kg to 50 kg, processing dozens to hundreds of bags per hour. Subsequent automatic sewing, labeling, and even palletizing can be integrated into the automated production line. Throughout the process, defective materials screened out can be returned to the previous process for reprocessing, significantly reducing waste.

The intelligent control system is the “brain” of this production line, monitoring the operational status of each stage in real time to ensure process stability and data traceability. Simultaneously, a highly efficient pulse dust removal system collects over 99% of dust, meeting stringent environmental protection requirements.

Wide Application Scenarios: Adaptable to Various Fertilizers and Production Scales

This production line is highly flexible and can handle a variety of fertilizer products.

Granular Fertilizers: Such as common NPK compound fertilizers, organic-inorganic compound fertilizers, granular potassium fertilizers, etc. Screening ensures uniform and aesthetically pleasing granules, enhancing market competitiveness.

Powder Fertilizers: Such as powdered organic fertilizers, water-soluble fertilizer raw materials, etc. The production line features a dust-proof design, ensuring accurate packaging while maintaining a clean production environment. Specialty Fertilizers: For coated products such as slow-release fertilizers, a gentle screening process can be used to avoid damaging the coating. For fertilizers that are easily hygroscopic, the processing speed can be accelerated and a dehumidifying environment can be provided.

In terms of capacity, the production line configuration can be flexibly scaled. Small production lines (1-5 tons per hour) are compact and require low investment, suitable for cooperatives or startups. Medium to large production lines (5-30 tons per hour and above) adopt dual-station or multi-station packaging and automatic palletizing designs to meet the needs of continuous large-scale production and are seamlessly connected to the upstream granulation and drying lines.

Core Value: Beyond Packaging itself

Investing in a professional screening and packaging line brings multiple benefits:

Ensuring Product Quality: Removing impurities and substandard particles delivers customers products with uniform specifications and high purity.

Enhancing Brand Image: Standard, neat, and clearly labeled packaging is a direct reflection of brand reputation and professionalism.

Meeting Distribution Requirements: Whether for long-distance transportation, export, or warehousing and stacking, standardized packaging reduces damage and loss, complying with logistics and trade regulations. Achieving Environmentally Friendly Production: Closed systems and efficient dust removal significantly control dust emissions, protecting the working environment and meeting increasingly stringent environmental regulations.

Key Considerations for Successful Selection: Choosing the right production line requires comprehensive consideration of the following:

Fertilizer Form: Rotary drum screens are preferred for granular fertilizers, while vibrating screens and powerful dust removal systems are necessary for powder fertilizers.

Capacity Requirements: Select a single-station or multi-station packaging system based on actual output, allowing for appropriate capacity margins.

Environmental Standards: The performance of the dust removal system is crucial, especially when handling powders.

End Markets: If there are export needs, consider labeling, coding, and palletizing equipment that meets international standards.

Conclusion: Screening and packaging are far more than simple “bagging” processes; they represent the final optimization link in the fertilizer production value chain. A well-designed and efficient screening and packaging production line is a solid guarantee for fertilizer manufacturers to ensure product consistency, enhance brand value, expand market reach, and achieve sustainable operations. For global fertilizer producers aiming to enhance competitiveness, strategic investment in this segment will yield significant returns in an increasingly standardized market.

The Complete Manufacturing Ecosystem

The screening and packaging line is the final, critical segment of a much larger integrated system. Its efficiency is directly dependent on the quality of the incoming product from upstream processes. For an npk fertilizer production line, the granules are typically created earlier in the npk fertilizer production process. This may involve a npk blending machine or a npk bulk blending machine for formulation, followed by granulation using equipment like a rotary drum, a disc granulator (often part of a disc granulation production line), or a double roller press granulator in a roller press granulator production line. These professional fertilizer manufacturing equipment units determine the granule’s initial size, shape, and strength before they are conveyed to the fertilizer packing machine.

Similarly, for an organic fertilizer production line or a bio organic fertilizer production line, the feedstock is first processed through a windrow composting machine (or windrow machine). The cured compost is then granulated, potentially using a disc granulator for shaping in an disc granulator machine setup, chosen for its gentle action. Regardless of the fertilizer type—produced by a dedicated npk fertilizer line or an organic line—the final packaging stage is what transforms bulk material into a standardized, market-ready commodity, closing the loop on the manufacturing value chain.

Therefore, investing in a high-performance screening and packaging system is not an isolated decision. It is the logical culmination of a well-designed production flow, ensuring that the value created by the core fertilizer granulator and other processing equipment is fully captured and delivered to the end user in optimal condition.

The core advantages of the 5-Warehouse Receipt Scale Static Batching + Drum Granulation Production Line are precise batching and smooth granulation. It is specifically designed for large-scale fertilizer production requiring strict control of nutrient ratios and high granule quality. It also has clear adaptation standards for raw material characteristics to ensure production efficiency and product stability.

Suitable Fertilizer Types

(I) Core Compatible Fertilizers

NPK Compound Fertilizer (General/Specialized): It can flexibly produce multi-ratio compound fertilizers such as 15-15-15 general-purpose and 16-8-20 high-potassium types. The 5 warehouses can separately store main raw materials such as urea, monoammonium phosphate, and potassium chloride, as well as trace elements zinc and boron. The static batching error per scale is ≤±1%, meeting the nutrient requirements of different crops. Drum granulation forms 3-5mm spherical granules with good flowability and a strength of over 2.5MPa, making them resistant to storage and transportation and easy for mechanized fertilization.

Organic-Inorganic Compound Fertilizer: Suitable for mixing and granulating fermented livestock and poultry manure, straw charcoal, and other organic raw materials (20%-50%) with inorganic fertilizers. Five independent storage compartments prevent raw material reactions. Static batching precisely controls the organic-inorganic ratio, and drum tumbling ensures full material integration, enhancing slow-release performance.

Slow-Release/Functional Compound Fertilizer: Can produce slow-release fertilizers with added urea-formaldehyde resin and sulfur (2%-8%), or functional fertilizers containing humic acid and amino acids. Five separate storage compartments for sensitive components prevent deactivation, ensuring long-lasting effectiveness and specificity.

(II) Incompatible Fertilizers: High moisture content (>40%) raw material fertilizers, pure powder fertilizers, and ultra-high concentration fertilizers (total nutrient content >60%) can easily lead to batching blockage, low granulation rate, or uneven granules. II. Precautions for Raw Material Use

(I) Physical Property Requirements

Moisture: Inorganic raw materials should have a moisture content ≤5%, and organic raw materials 25%-35%. Excessive moisture content can lead to clumping, while insufficient moisture content results in inadequate binding.

Particle Size: All raw materials should be crushed to ≤3mm, with over 80% having a particle size of 0.1-2mm to ensure effective mixing and granulation.

Flowability: The angle of repose of raw materials should be ≤32°. Hygroscopic raw materials require dehumidification storage. For materials with poor flowability, 0.1%-0.3% anti-caking agent can be added.

(II) Chemical Property Requirements

Avoid Reaction Conflicts: Acidic and alkaline raw materials should be stored separately and quickly fed into the drum after batching to prevent nutrient loss.

Heat Sensitivity Protection: Heat-sensitive raw materials such as amino acids should be added later, with the drum temperature controlled at 60-80℃.

Prevent Cross-Contamination: Chlorine-containing raw materials and fruit and vegetable fertilizers should be produced separately to avoid affecting crop growth. (III) Ingredient and Storage Specifications

Proportion Control: Main raw materials ≥70%, auxiliary materials ≤30%, binder addition 2%-5%.

Raw Material Pretreatment: Organic raw materials must be fully decomposed (decomposition degree ≥85%) and impurities removed; slow-release agents must be pulverized to ≤0.5mm.

Storage and Transportation: Raw material silos must be sealed, rainproof, and moisture-proof, with separate silo markings; silo cone angle ≥60° to prevent bridging; sealed conveying equipment must be used; corrosive raw materials must be made of stainless steel.

Complementary Systems for Organic and Biofertilizer Production

While the 5-Warehouse Static Batching + Drum Granulation line excels with inorganic blends, a complete organic fertilizer manufacturing system often requires a different approach. For pure organic or high-organic-content fertilizers, the production typically starts with advanced fermentation composting turning technology, employing equipment such as a large wheel compost turning machine or a chain compost turning machine to produce stable, decomposed compost. This compost then feeds a dedicated organic fertilizer production line. The granulation stage offers flexibility: a traditional organic fertilizer disc granulation production line uses a pan to form spherical granules, while a drum granulation production line can also be adapted for organic materials. For smaller-scale operations, a new type two in one organic fertilizer granulator that mixes and granulates efficiently may be ideal.

This entire process of organic fertilizer production granulation is central to modern organic fertilizer manufacturing. When the goal is to incorporate beneficial microbes, the system evolves into a sophisticated bio organic fertilizer production line. Here, the granulation technology must be carefully selected to preserve microbial viability, often favoring gentle agitation granulation in a drum or disc over high-pressure methods. The key is matching the granulation technology to the physical and biological characteristics of the organic feedstock.

Ultimately, whether producing inorganic NPK blends or organic soil amendments, the principle remains: selecting the right batching and granulation technology—be it precision static batching for compounds or specialized fermentation and granulation for organics—is fundamental to achieving high-quality, market-ready fertilizer products.

Recently, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd.’s customized 4.0-type extrusion granulation production line for its Pakistani client completed full-process installation and commissioning, officially entering the stage of large-scale production. This production line focuses on the high-efficiency granulation needs of compound fertilizers and organic fertilizers. Centered on a 4.0-type double-roller extrusion granulator, it integrates the entire chain of processes including feeding, conveying, screening, storage, and packaging. Coupled with a custom-designed steel structure plant layout, its stable operating performance, precise granulation effect, and adaptability to local production conditions have made it a benchmark project for China’s high-end granulation equipment to empower South Asian agriculture.

Production Line Full-Process Configuration and Core Equipment Analysis

The entire production line follows a closed-loop process of “raw material pretreatment – precise granulation – grading and screening – finished product output.” The equipment selection is professional, the layout is compact and orderly, and the connections between each unit are seamless, ensuring both production efficiency and strict product quality control, fully adapting to the raw material characteristics and production capacity requirements of Pakistan.

Raw Material Conveying and Feeding Unit: Stable Supply Lays a Solid Foundation

Raw Material Feeding and Lifting: The production line starts with a loader-loaded hopper. The hopper features a large-capacity, open design to accommodate the rapid loading of bulk raw materials. The feed inlet is equipped with a spill-proof buffer device to reduce material loss and dust. Raw materials are vertically conveyed to subsequent stages via a 315-type bucket elevator (10 meters). This elevator uses a plate chain drive structure, boasting strong load-bearing capacity, stable operation, and a conveying efficiency of 8 tons/hour. Its excellent sealing effectively prevents materials from becoming damp or contaminated during lifting, ensuring the purity of the raw materials.

Precise Feed Control: The enhanced raw materials are conveyed to the granulation unit via a 16-type screw feeder. This feeder employs variable frequency speed control technology, allowing real-time adjustment of the feed rate based on the granulator’s operating status (adjustment range 0.5-2 tons/hour). Combined with a material level monitoring sensor, precise control of the feed rate is achieved, preventing granulation quality fluctuations or equipment overload caused by uneven feeding, thus ensuring stable granulation.

Core Granulation Unit: 4.0-Type Main Unit forges high-quality granules

The core equipment of the production line is the 4.0-type double-roller extrusion granulator. This high-end model, developed by Huaqiang Heavy Industry for medium to large-scale fertilizer production enterprises, features a high-strength alloy double-roller design with a roll diameter of 400mm and a roll width of 300mm. The extrusion pressure (8-20MPa) is precisely controlled through a hydraulic pressurization system, adapting to the granulation needs of raw materials with different moisture content (25%-35%) and different compositions.

The granulator rollers are made of high-chromium wear-resistant alloy, achieving a hardness of HRC65 or higher after quenching. This provides four times the wear resistance of ordinary materials and extends the service life to over 12,000 hours. The roller surface features a customized anti-slip texture design, enhancing material gripping force and maintaining a stable granulation rate of over 95%. Particle size is uniformly controlled at 3-6mm, with a compressive strength of 3.0MPa, preventing pulverization and fully meeting the needs of long-distance transportation and field application in Pakistan. The equipment is equipped with an automatic roller cleaning device that removes adhering material from the roller surface in real time, preventing die blockage and ensuring continuous operating efficiency.

Grading and Recycled Material Unit: Strict Quality Control and Improved Utilization Rate

The granulated particles are transferred via a 5-meter belt conveyor to a 1.2×4.0-meter drum screen. This equipment uses a single-layer high-precision screen design, with screen apertures customizable to customer requirements. Grading and screening are achieved through uniform drum rotation (20 r/min). Qualified particles (3-6 mm in diameter) achieve a 98% pass rate. Substandard particles (too coarse or too fine) are returned to the raw material conveyor via 4-meter and 5-meter recycled material belt conveyors, re-entering the granulation process. Material utilization reaches 99%, effectively reducing production costs.

The screen is equipped with a vibration cleaning device to clean material adhering to the screen surface in real time, preventing screen blockage and ensuring stable screening efficiency. The equipment adopts a sealed enclosure design to reduce dust pollution generated during screening, meeting local environmental protection requirements.

Finished Product Storage and Packaging Unit: High-Efficiency Output Ensures Quality

Qualified granules are conveyed to the finished product silo via a 315-type bucket elevator (6 meters). The silo features a sealed design and is equipped with a dehumidification and ventilation system to effectively prevent fertilizer from absorbing moisture and clumping, ensuring product storage stability. The silo capacity can meet the finished product storage needs of continuous 4 hours of full-load production. Material level sensors are installed inside the silo to provide real-time feedback on inventory status, facilitating customers’ rational planning of shipments.

The packaging process is equipped with an automatic packaging scale, supporting rapid switching between various packaging specifications such as 25kg and 50kg. It uses a gravity-based metering principle, coupled with a high-precision sensor, with a metering error ≤ ±0.1kg and a packaging speed of up to 100 bags/hour. The packaged finished products are flexibly transferred to the finished product stacking area via a 12-meter mobile conveyor belt. The mobile conveyor belt can be adjusted in direction and angle according to site requirements, adapting to the spatial layout of the steel structure factory and improving shipment flexibility.

Core Advantages and Adaptability of the Production Line

Dedicated Steel Structure Adaptation Design: The production line layout fully integrates with the load-bearing and spatial characteristics of steel structure workshops. Equipment spacing and installation height are precisely matched, requiring only 500 square meters of floor space, saving 20%of space compared to traditional production lines. It also optimizes equipment maintenance access, facilitating later maintenance operations.

Stable, Reliable, and Highly Adaptable: Core equipment adopts high-temperature, wear-resistant, and corrosion-resistant designs, adapting to the hot and dry climate conditions of Pakistan. The 4.0-type granulator can flexibly adapt to various materials such as organic fertilizer, compound fertilizer, and bio-organic fertilizer, supporting rapid switching between different formulations to meet the diverse agricultural fertilization needs of the region.

Intelligent, Convenient, and Easy to Operate: The entire production line integrates a simple control system with a bilingual (Chinese and English) operating interface. Key parameters (pressure, speed, feed rate) are displayed in real time, supporting manual and automatic mode switching, allowing local operators to quickly learn how to use it. Key components adopt standardized designs, and vulnerable parts are highly interchangeable. The company provides comprehensive spare parts supply and technical guidance services, reducing later maintenance costs. The successful commissioning of the 4.0 extrusion pelletizing production line in Pakistan not only demonstrates Huaqiang Heavy Industry’s core strength in the R&D of high-end pelletizing equipment and the implementation of overseas projects, but also provides efficient and stable equipment support for the modernization of agriculture in South Asia. In the future, Huaqiang Heavy Industry will continue to focus on the production needs of different regions, optimize product performance and process solutions, and provide more competitive customized solutions for global customers, enabling “Made in China” to benefit the agricultural industries of more countries and regions.

Core Technology: Roller Press Compaction and Broader Process Integration

This successful project in Pakistan exemplifies the efficiency of extrusion-based granulation. The central double roller press granulator operates on the principle of fertilizer granules compaction, where dry or low-moisture powder is compressed between two counter-rotating rollers under high pressure to form dense, uniform granules. This method is a cornerstone of modern roller press granulator production line setups. The fertilizer compactor (another term for the press) is particularly advantageous in the npk fertilizer manufacturing process as it avoids the need for drying, reducing energy consumption and preserving heat-sensitive nutrients.

The robust fertilizer compaction machine showcased here is not limited to complex formulations. Its technology is highly adaptable and can be seamlessly integrated into a broader npk manufacturing process. While ideal for blended NPK powders, the same granulation principle effectively processes a wide range of materials, including single-nutrient fertilizers, organic-based mixes, and soil amendments, demonstrating remarkable versatility within a complete fertilizer production ecosystem.

This underscores the strategic value of selecting a core granulation technology that offers both high mechanical strength in the final product and operational flexibility, allowing production lines to pivot between different fertilizer types to meet dynamic market demands.