This innovative carbon-based fertilizer disc + drum granulation production line integrates two processes: “disc pre-granulation + drum finishing.” Specifically designed for the granulation needs of carbon-based raw materials (straw charcoal, bamboo charcoal, biochar, etc.), it solves the granulation pain points of lightweight and poor binding properties of carbon-based raw materials through a closed-loop process of “pre-forming + densification.” This enables large-scale, high-quality production of carbon-based fertilizer, suitable for green development scenarios such as ecological agriculture and organic farming.

Production Line Configuration and Core Details

Raw Material Pre-treatment Unit: Laying the Foundation for Granulation

(I) Raw Material Storage and Precision Batching

Multi-Compartment Storage System: Equipped with 5 raw material compartments (total volume 120m³), storing biochar, organic fertilizer fermentation material, nitrogen, phosphorus, and potassium inorganic fertilizer, binders (such as bentonite and starch), and trace elements respectively. The compartments are made of carbon steel with an anti-corrosion coating, and vibrators and star-shaped unloaders are installed at the bottom to prevent bridging and clogging of carbon-based raw materials.

Precision Batching Device: Employs a frequency-controlled screw feeder, with 5 batching systems operating synchronously, achieving a batching error of ≤±1%. The proportion of biochar can be flexibly adjusted (30%-60%), the ratio of inorganic to organic fertilizer is customized according to crop needs, and the binder addition is controlled at 3%-8% to ensure pellet formation rate.

(II) Raw Material Mixing and Moisture Adjustment

Twin-Shaft Mixer: A 50-type twin-shaft mixer is used. The impellers employ an anti-rotation design, driving strong convection and shearing of the materials to thoroughly mix the charcoal-based raw materials with other components, achieving a mixing uniformity error of ≤2%. The mixer is equipped with a spray humidification device to precisely adjust the raw material moisture content to 28%-35% (suitable humidity for the charcoal-based raw materials), preventing clumping due to excessive moisture or insufficient adhesion due to insufficient moisture.

Pulverization Pretreatment: If large lumps (particle size > 10mm) of biochar exist, they are first crushed to ≤3mm using a 400-type vertical pulverizer to ensure uniform raw material fineness and improve subsequent granulation results. The pulverizer is equipped with a cyclone dust collector to collect and reuse the crushed dust, achieving a material utilization rate of 99%. II. Core Dual Granulation Unit: Carbon-Based Particle Densification Forming

(I) Disc Pre-granulation: Key to Lightweight Material Pre-forming

Core Equipment Selection: Two Φ3.2×1.2 meter disc granulators (3-5 tons per hour per unit), with an adjustable inclination angle of 45°-55° and a rotation speed controlled at 20-30 r/min. The discs are lined with wear-resistant rubber plates to prevent wear from the carbon-based raw materials and enhance material adhesion.

Pre-granulation Process Details: The mixed raw materials are fed into the disc granulator. Through the centrifugal force and friction generated by the rotating disc, spherical wet particles with a diameter of 5-8 mm are formed (granulation rate ≥85%). A scraper is installed at the edge of the disc to promptly clean material adhering to the wall, and a spray device replenishes moisture in real time to ensure that the pre-formed particles are round and uniform, laying the foundation for drum finishing.

(II) Rotary Drum Granulation: Particle Densification Upgrade

Core Equipment Configuration: One Φ2.2×10 meter rotary drum granulator (6-10 tons per hour) is used, precisely matched with the capacity of the disc granulator. The inner wall of the drum is lined with wear-resistant ceramic plates, combined with a spiral layout of lifting plates, driving the material through a “tumbling-rolling-collision” motion to achieve particle densification.

Refinement Process Highlights: A spray device is installed inside the drum to replenish a small amount of binder solution, further rolling the pre-formed granules into dense granules of 3-6mm, increasing the particle strength from 1.2MPa to over 2.5MPa, solving the problem of easy pulverization of carbon-based granules. The drum speed is adjustable from 10-18 r/min, and the material residence time is 8-12 minutes to ensure dense and uniform particles.

III. Post-processing Unit: Quality Optimization and High-Efficiency Output

(I) Drying and Cooling Curing

Low-Temperature Dryer: Equipped with a Φ1.8×18 m drum dryer, using hot air circulation heating, the drying temperature is controlled at 70-90℃ (to avoid high temperature damage to carbon-based nutrients), reducing the particle moisture content from 30% to below 12%. The dryer has a built-in staggered lifting plate layout, ensuring uniform heating of the carbon-based particles, with a drying uniformity error ≤2%.

Dual-Stage Cooler: Employing a “first-stage counter-current cooling + second-stage co-current cooling” process, the particle temperature is first reduced from 70-80℃ to below 40℃ by a Φ1.6×15 m counter-current cooler, and then cooled to room temperature ±3℃ by a Φ1.2×12 m co-current cooler, further improving particle strength and moisture resistance. The cooler is equipped with a pulse dust collector to collect dust for recycling.

(II) Grading and Finished Product Processing

Grading and Screening Machine: A Φ1.5×6.0 meter drum screen with a double-layer screen design (upper layer aperture 6mm, lower layer aperture 3mm) is used to screen out qualified particles (3-6mm). Unqualified particles are returned to the disc granulator for reprocessing via a return conveyor belt, achieving a material utilization rate of 98%.

Anti-caking Treatment: When the screened finished particles are conveyed via conveyor belt, 0.1%-0.2% of an anti-caking agent (such as talc powder) is sprayed on them to ensure even mixing and prevent clumping during storage.

(III) Finished Product Storage and Packaging

Finished Product Silos: Two 100m³ sealed finished product silos are provided, equipped with dehumidification and ventilation devices to maintain a relative humidity of ≤60% to prevent the carbon-based fertilizer from absorbing moisture. A quantitative discharge device is installed at the bottom of the silo to achieve continuous and stable discharge.

Automated Packaging: Utilizing a dual-station automatic packaging scale, supporting rapid switching between 25kg and 50kg specifications, with a measurement error ≤ ±0.2kg and a packaging speed of 100 bags/hour. The packaging machine is equipped with a dust cover to reduce dust emissions, and the fully automated operation minimizes manual intervention.

Environmental Protection and Intelligent Control Unit: Stable Green Production

(I) Environmental Treatment System

Dust Treatment: Each dust-generating stage of the production line (crushing, screening, packaging) is equipped with a pulse dust collector, with a total processing air volume of 18000m³/h. Dust emission concentration ≤10mg/m³, meeting national environmental protection standards.

Wastewater Treatment: A small amount of cleaning wastewater during production is treated in a sedimentation tank and then recycled for raw material humidification, achieving zero wastewater discharge.

(II) Intelligent Control System

Integrated PLC central control system, real-time monitoring of key parameters such as ingredient ratio, moisture content, granulation speed, and drying temperature, supporting automatic fault alarms and data recording (storage period ≥90 days). The system supports manual and automatic mode switching and can dynamically adjust process parameters according to raw material characteristics to ensure stable production.

Core Advantages and Application Value of the Production Line

Breakthrough in Granulation Pain Points: The combined disc and drum granulation processes solve the problems of poor adhesion and low granulation rate of carbon-based raw materials. Granulation formation rate is consistently above 90%, with a strength exceeding 2.5 MPa, making it resistant to storage and transportation and less prone to pulverization.

Flexible Capacity: Hourly capacity covers 6-10 tons, with an annual capacity of 50,000-80,000 tons (based on 300 days of operation per year and 8 hours per day), adapting to the production needs of enterprises of different sizes.

Superior Product Quality: Carbon-based raw materials and nutrients are uniformly integrated, resulting in rounded granules with good flowability, facilitating mechanized fertilization. The slow-release characteristics of carbon-based components can improve fertilizer utilization by more than 30% and reduce nutrient loss.

Green, Environmentally Friendly, and Energy-Saving: High dust recovery and utilization rate; energy consumption is reduced by 12% compared to conventional single-process granulation production lines, meeting the requirements of green agricultural production.

A Specialized Link in a Broader Manufacturing Ecosystem

This carbon-based fertilizer granulation line represents a significant advancement in processing challenging, lightweight organic materials into high-quality, market-ready fertilizers. Its innovative dual-granulation approach sets a new standard for product quality and production efficiency in the niche of carbon-enriched soil amendments.

This specialized line is a prime example of professional fertilizer manufacturing equipment designed for a specific purpose. It exists within a larger ecosystem of fertilizer production technologies. For instance, the disc granulator used here is a key component in a disc granulation production line and can also serve as a disc granulator for shaping in other contexts. While this line produces organic-carbon blends, its principles complement other systems. A complete organic fertilizer production line might begin with a windrow composting machine to produce the base compost. For mineral-based production, an npk fertilizer production line would utilize an npk blending machine and different granulation technologies like a roller press granulator production line or a double roller press granulator as part of the npk fertilizer production process. Each type of fertilizer granulator serves a unique role in the diverse portfolio of modern fertilizer manufacturing.

Thus, this carbon-based line is not an isolated solution but an integral part of a comprehensive toolkit that allows manufacturers to meet the growing global demand for both specialized organic inputs and conventional high-analysis fertilizers.

Against the backdrop of agricultural green transformation, organic fertilizer, with its “waste-to-treasure” characteristic, has become crucial for protecting soil health and improving agricultural product quality. The creation of this green fertilizer relies on a complete and efficient organic fertilizer production line. From the fermentation and decomposition of organic materials to the application of core fermentation composting and turning technologies, and then to the precise processing of new granulation equipment, each step involves scientific ingenuity, collectively completing the magnificent transformation of agricultural waste into high-quality organic fertilizer.

The core prerequisite of an organic fertilizer production line is organic fertilizer fermentation, a key process in which microorganisms decompose organic materials. Whether it’s livestock manure, straw, or kitchen waste, all require suitable temperature, humidity, and aeration conditions to decompose and transform through the metabolic action of microorganisms, ultimately forming nutrient-rich, mature materials. Fermentation composting turning technology is the core support for ensuring smooth fermentation. Regularly turning the compost pile using specialized equipment replenishes oxygen, meeting the growth needs of aerobic microorganisms and preventing the production of foul odors from anaerobic fermentation. It also regulates the pile temperature, preventing high temperatures from killing beneficial microorganisms, and ensures more uniform material mixing, significantly improving fermentation efficiency and composting quality.

With technological upgrades, organic fertilizer production lines have evolved from traditional single-process systems to intelligent, integrated systems. Bio-organic fertilizer production lines, in particular, have become the mainstream of high-end organic fertilizer production due to their precise cultivation and preservation of beneficial microorganisms. The “finishing touch” of the production line is undoubtedly the core equipment in the granulation process—the organic fertilizer granulator. Traditional granulation equipment suffers from uneven particle size and high energy consumption, but the emergence of new-type organic fertilizer granulators has completely changed this situation.

Among many new granulation devices, the new two-in-one organic fertilizer granulator stands out due to its integrated design. This integrated granulator combines material mixing and granulation functions, simplifying the production process and precisely controlling particle size and hardness. The resulting organic fertilizer granules are uniform and round, facilitating storage, transportation, and field application. Compared to traditional equipment, the new granulator also boasts lower energy consumption and less pollution, aligning with green production principles and finding widespread application in large-scale organic fertilizer production enterprises.

A complete organic fertilizer production line involves interconnected steps, from raw material pretreatment and fermentation turning to granulation, drying, and screening. Fermentation composting technology lays the foundation for material maturation, while the new granulation equipment ensures product quality. Their synergistic effect significantly improves the resource utilization rate of agricultural waste. Today, with continuous technological advancements, organic fertilizer production lines are developing towards greater intelligence, efficiency, and environmental friendliness, not only solving the problem of organic waste pollution but also providing strong support for sustainable agricultural development. Understanding the scientific principles of organic fertilizer production lines allows for a clearer appreciation of the value of organic fertilizer and encourages greater attention to the circular economy in agriculture, injecting new momentum into the development of green agriculture.

 The powder + granular organic fertilizer production line is an integrated solution designed specifically for the diversified production needs of organic fertilizer enterprises. Through its core design of “shared raw materials, differentiated processes, and universal equipment,” it simultaneously achieves large-scale production of both powdered and granular organic fertilizers. One set of equipment meets different application scenarios (powder is suitable for fertigation and drip irrigation; granules are suitable for strip application and broadcasting), significantly improving capacity utilization and market adaptability, and is suitable for green agriculture scenarios such as ecological planting and facility agriculture.

Production Line Configuration and Core Details

I. Raw Material Pretreatment and Sharing Unit: Laying the Foundation for Dual Products

(I) Raw Material Storage and Fermentation Pretreatment

Raw Material Warehouse and Fermentation System: Equipped with 3 large-capacity 100m³ raw material warehouses to store organic raw materials such as livestock and poultry manure, straw, and mushroom residue; equipped with a 500m³ windrow-type fermentation turner (or trough-type turner) to ferment and decompose the raw materials (decomposition degree ≥85%), removing odors and pathogens. The fermentation cycle is 7-15 days. After fermentation, the moisture content of the raw materials is controlled at 35%-45%, laying the foundation for subsequent processing.

Crushing and Impurity Removal: The fermented raw materials are conveyed to a 90-type vertical crusher via a 6-meter belt conveyor, crushed to ≤3mm (granular fertilizer raw materials) or ≤1mm (powdered fertilizer raw materials). During the crushing process, impurities such as stones and plastics are removed by an impurity removal device. The crusher is equipped with a pulse dust collector, achieving a dust collection efficiency of 99% and a material utilization rate of 98%.

(II) Precise Batching and Mixing

Multi-Group Batching System: Equipped with a 4-compartment batching machine, storing fermented organic fertilizer, straw charcoal, trace elements, and functional microbial agents respectively. A variable frequency screw batching scale is used to precisely control the proportions (functional microbial agent addition amount 0.1%-0.5%), with a batching error ≤±1%. When producing powdered fertilizer, soluble additives such as humic acid and amino acids are added to improve the fertilizer’s water solubility; when producing granular fertilizer, 3%-5% binder (such as bentonite or starch) is added to ensure granulation effect.

Twin-shaft mixer: A 60-type twin-shaft mixer is used to thoroughly mix the multi-component raw materials, with a mixing uniformity error ≤2%. The mixer is equipped with a spray humidification/drying device to adjust the raw material moisture content according to the product type (powdered fertilizer: 20%-25%; granular fertilizer: 30%-35%).

II. Process branching unit: Parallel production of powdered and granular fertilizers

(I) Powdered organic fertilizer production line (branching branch 1)

Fine grinding and sieving: The mixed raw materials are further ground to 100-150 mesh using a 13-type ultrafine pulverizer to ensure uniform powder fineness and rapid dissolution. After grinding, the powder is graded using a 1.2×4.0 meter vibrating screen to remove substandard coarse particles, which are then returned to the pulverizer for reprocessing.

Finished Product Storage and Packaging: Qualified powder is conveyed via a sealed screw conveyor into two 50m³ finished product silos (dedicated to powder form). The silos are equipped with dehumidification and ventilation devices to prevent moisture absorption and clumping. The packaging process utilizes a dual-station automatic powder packaging scale with a screw feeder and dust cover design to prevent dust from flying. It supports switching between 20kg and 25kg specifications, with a measurement error ≤ ±0.2kg and a packaging speed of 80 bags/hour.

(II) Granular Organic Fertilizer Production Line (Branch 2) Core Granulation Process: The mixed raw materials are conveyed via an 8-meter belt conveyor to a Φ3.2×1.2-meter disc granulator (or rotary drum granulator). Through centrifugal force and the action of a binder, 3-5mm rounded granules are formed, with a granulation rate ≥90%. The granulator is equipped with a spray humidification device to adjust moisture in real time and ensure granule strength.

Drying and Cooling/Curing: Wet granules are conveyed via a 10-meter belt conveyor into a Φ1.8×15-meter drum dryer, where hot air circulation heating is used to control the drying temperature at 60-80℃ (to prevent inactivation of functional bacteria), reducing the moisture content to below 12%. They then enter a Φ1.5×12-meter counter-current cooler for rapid cooling to room temperature, increasing the granule strength to over 2.0MPa, making them more resistant to storage and transportation and less prone to pulverization.

Grading, Screening, and Packaging: The cooled granules are graded using a Φ1.5×6.0-meter drum screen (3-5mm sieve openings). Unqualified granules are returned to the granulator for reprocessing. Qualified granules are fed into two 80m³ finished product silos (dedicated to granules) and packaged using a dual-station automatic granule packaging scale, supporting 25kg and 50kg sizes at a packaging speed of 100 bags/hour.

III. Environmental Protection and Intelligent Control Unit: Green and Stable Production

(I) Environmental Protection System

Dust Treatment: Four MC-96 pulse dust collectors are installed in the crushing, screening, and packaging stages, with a total air volume of 18,000 m³/h. The dust concentration in the workshop is ≤10 mg/m³, meeting environmental standards.

Exhaust Gas Treatment: Odors generated during fermentation are purified by a biological filter before being discharged, with an ammonia concentration ≤15 mg/m³.

Wastewater Treatment: Production cleaning wastewater is treated by sedimentation and filtration tanks and then recycled for raw material fermentation humidification, achieving zero wastewater discharge.

(II) Intelligent Control System

An integrated PLC central control system is installed, with preset production modes for powder and granules. Process parameters (crushing fineness, ingredient ratio, drying temperature, etc.) can be switched with one click. Real-time monitoring of equipment operation status, raw material moisture content, and finished product output is provided. Automatic fault alarms and data recording (storage period ≥90 days) are supported, reducing manual intervention.

Core Advantages and Adaptability of the Production Line

Flexible Dual-Product Switching: One set of equipment enables simultaneous/switching production of powdered and granular organic fertilizers, with a conversion time of ≤2 hours. This adapts to different customer needs (growers, agricultural input dealers) and application scenarios, enhancing market competitiveness.

Highly Efficient and Stable Production Capacity: Hourly production capacity reaches 5-8 tons (powder) or 6-10 tons (granules), with an annual capacity of 40,000-80,000 tons, suitable for the production needs of small, medium, and large-scale organic fertilizer enterprises. Equipment sharing rate exceeds 70%, saving 30% in investment costs and 25% in floor space compared to two separate production lines.

Superior Product Quality: Powdered fertilizer has uniform fineness and good water solubility, suitable for fertigation and drip irrigation; granular fertilizer is round, dense, and high-strength, suitable for mechanized strip application and broadcasting, with a functional bacteria survival rate of over 90%, ensuring fertilizer efficacy.

Green and Environmentally Friendly: The entire process features a sealed design, dust recovery, and wastewater recycling, meeting national environmental protection requirements. The fermentation process also enables the resource utilization of agricultural waste, contributing to the development of green agriculture.

Suitable and Unsuitable Scenarios

Suitable Scenarios: Large-scale organic fertilizer production enterprises and agricultural waste resource utilization projects that require the supply of both powdered and granular organic fertilizers, suitable for diversified fertilization needs such as ecological planting, fruit and vegetable greenhouses, and grain crops.

Unsuitable Scenarios: Raw materials with a moisture content >50% and that are not fully fermented (easily leading to equipment blockage and product spoilage); pure functional microbial fertilizers (requiring low-temperature processing and additional low-temperature drying equipment).

A Flexible Solution for Diverse Market Needs

This integrated powder + granular organic fertilizer production line provides manufacturers with a highly adaptable and efficient foundation. It enables the flexible production of two major fertilizer forms from a shared raw material base, maximizing equipment utilization and market responsiveness.

While specialized for organic production, this line represents a category of advanced fertilizer production machine technology. Its drum granulation process using a rotary drum granulator is a common and effective fertilizer processing machine method. For operations looking to expand into mineral-based products, the principles of this line are complementary to an npk production line. The granulation stage could be adapted using alternative technologies, such as a roller press granulator production line for dry fertilizer granules compaction, or a disc granulation production line. These technologies are all part of modern npk fertilizer production technology, allowing manufacturers to build upon this organic foundation to create a comprehensive portfolio that serves both organic and conventional agricultural markets.

We warmly welcome people from all walks of life to visit, guide, and discuss business with us, and work hand in hand with Huaqiang Heavy Industry to promote the high-quality development of green agriculture!

Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. has successfully completed the installation and commissioning of a customized extrusion granulation production line for its Zambian clients, officially entering the stage of large-scale production. This production line focuses on the localized production needs of compound fertilizers and organic fertilizers, integrating the entire chain of processes including raw material pretreatment, precise mixing, efficient granulation, grading and screening, and finished product packaging. With its robust configuration of three granulation main units operating in tandem, stable design adapted to African conditions, and efficient and environmentally friendly operation, it has become a benchmark project for Chinese agricultural equipment in supporting the development of green agriculture in Africa, providing Zambian fertilizer producers with a one-stop mass production solution.

Production Line Configuration and Core Equipment Analysis

The entire production line follows a closed-loop logic of “refined raw material processing – uniform mixing – batch granulation – quality control – finished product output.” The equipment layout is scientific, the connections are tight, and the functions of each unit are complementary, ensuring both production efficiency and full adaptation to the characteristics of local raw materials and production conditions in Zambia.

Raw Material Pretreatment Unit: Laying a Solid Foundation for Granulation Quality

Raw Material Feeding and Crushing: The production line starts with a large-capacity feed hopper, adapting to the rapid feeding needs of bulk raw materials. The feed inlet is equipped with a spill-proof buffer device and an impurity filter grid, effectively reducing raw material loss and equipment failure risks. Raw materials are conveyed via an 11-meter belt conveyor to an 80-type vertical semi-wet crusher. This equipment is specifically designed for high-humidity agricultural waste and mineral raw materials in Africa, employing a “high-speed impact + shearing grinding” composite process. The cutter head is made of high-chromium wear-resistant alloy, achieving a hardness of HRC60 or higher after heat treatment. It can crush large, agglomerated raw materials (particle size ≤80mm) into uniform fine materials ≤3mm, with a crushing efficiency of 4 tons/hour, meeting the stringent fineness requirements of subsequent granulation. The crusher features a sealed casing design, coupled with a negative pressure dust removal interface, effectively controlling dust leakage and improving the production environment.

Grading, Screening, and Transfer: The crushed raw materials are transferred via a 9-meter belt conveyor to the first 2.0×4.0-meter drum screen, which uses a single-layer high-precision screen design to separate substandard coarse particles. These particles are then returned to the crusher for reprocessing via a subsequent return system, achieving a material utilization rate of 98%. Qualified fine materials are transferred systematically via 6-meter, 5-meter, and 8-meter belt conveyors. These conveyors use wear-resistant, non-slip conveyor belts with anti-slip textures, adapted to Zambia’s hot and dry climate, preventing slippage and spillage during transfer, ensuring stable and reliable transfer efficiency.

Raw Material Mixing and Feeding Unit: Precise Control Ensures Uniform Granulation

High-Efficiency Mixing Process: The transferred raw materials enter a 40-type twin-shaft mixer. This equipment uses an anti-rotating blade design with a wear-resistant coating on the blade surface. During mixing, the materials undergo strong convection, shearing, and tumbling motions, ensuring thorough mixing of the main nitrogen, phosphorus, and potassium raw materials with trace element additives, achieving a mixing uniformity error of ≤2%. The mixer is equipped with a variable frequency speed control system, which can flexibly adjust the mixing speed (15-30 r/min) according to the moisture content and ratio of the raw materials. It also supports automatic material level monitoring and automatic unloading to prevent material overflow or insufficient mixing, ensuring continuous production.

Stable feeding control: The mixed material is conveyed to a 2200-type disc feeder via 9-meter and 6-meter belt conveyors. This feeder uses variable frequency speed control and material level sensor linkage control technology to precisely control the feed rate (adjustment range 1-3 tons/hour), ensuring uniform feeding to the three granulation units and avoiding granulation quality fluctuations or equipment overload caused by uneven feeding. The feeder disc surface features an anti-slip design, adaptable to raw materials with different flowability, ensuring stable operation without material jamming, and guaranteeing efficient subsequent granulation.

Core Granulation Unit: Three Main Units Working Together for Production Capacity Advantage

The core highlight of the production line is the collaborative operation of three granulators, including two conventional extrusion granulators and one twin-shaft extrusion granulator, forming a “multi-machine complementary, high-efficiency mass production” production mode. The conventional extrusion granulators employ a high-strength roller extrusion design, with roller skins made of high-chromium alloy, achieving a hardness of HRC62 or higher after quenching treatment, exhibiting extremely high wear resistance and extending service life to over 8000 hours. The twin-shaft extrusion granulator is optimized for highly viscous raw materials, employing a twin-shaft synchronous extrusion structure to enhance material plasticization and molding effects, adapting to a wider range of raw material characteristics.

All three granulators are equipped with a hydraulic pressure regulation system, allowing precise control of the extrusion pressure within the range of 6-18MPa. The granulation rate remains consistently above 92%, with uniform particle size controlled at 3-5mm and a compressive strength of 2.5MPa, preventing pulverization and fully meeting the needs of field application and long-distance transportation in Zambia. The three machines operate in tandem, with each machine producing 2 tons per hour, resulting in a total capacity of 6 tons per hour and a daily capacity of 144 tons, fully meeting the local demand for large-scale fertilizer production. The granulator is installed on a dedicated granulator platform (4.5 x 3.2 x 3 meters), designed to meet equipment maintenance and operational safety requirements while optimizing plant space utilization.

Grading and Finished Product Output Unit: Strict Quality Control and Efficient Delivery

Secondary Screening and Recycled Material Utilization: Granulated particles are transferred via a 10-meter belt conveyor to a second 2.0 x 4.0-meter drum screen. This screen features a double-layer design; the upper screen separates large, unqualified particles, while the lower screen selects qualified finished products. The screening efficiency reaches 7 tons per hour, with a 98% pass rate for qualified particles. Unqualified particles are returned to the raw material pretreatment stage via a 7-meter return conveyor, re-entering the production process, achieving resource recycling and effectively reducing production costs. The screening machine is equipped with an automatic screen cleaning device, which can clean the material adhering to the screen surface in real time, preventing screen blockage and ensuring stable screening efficiency.

Finished product storage and automated packaging: Qualified granules are conveyed to the finished product silo via a 10-meter belt conveyor. The silo adopts a sealed design and is equipped with ventilation and moisture-proof devices 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 5 hours of full-load production. The packaging process is equipped with an automatic packaging scale, supporting rapid switching between multiple packaging specifications such as 25kg and 50kg. It adopts the gravity metering principle, combined with a high-precision sensor, with a metering error ≤ ±0.2kg and a packaging speed of up to 80 bags/hour, realizing rapid quantitative packaging of finished products. Combined with the subsequent transfer system, it efficiently completes the warehousing and shipping of finished products.

Core Advantages and Regional Adaptability of the Production Line

High Adaptability, Unaffected by Complex Operating Conditions: Core equipment utilizes high-temperature, wear-resistant, and corrosion-resistant materials, adapting to Zambia’s hot and dry climate. Crusheres, mixers, and other equipment have optimized parameters for local raw material characteristics, capable of processing various raw materials such as livestock manure, mineral powder, and straw, demonstrating exceptional adaptability.

Stable and Reliable, Low Maintenance Costs: Key components employ standardized designs, and easily replaceable wear parts are readily available locally. The equipment boasts a low failure rate and an overall operating rate exceeding 95%. Furthermore, the company provides comprehensive technical guidance and spare parts supply services, significantly reducing customers’ subsequent maintenance costs.

High Efficiency and Environmental Protection, Meeting Local Standards: The entire production line utilizes energy-saving motors and optimized process design, reducing energy consumption by 12% compared to conventional production lines of the same capacity. Sealed equipment design and dust collection devices effectively control dust pollution during production, meeting Zambia’s local environmental protection requirements.

A Keystone Project for Modern Fertilizer Production in Africa

This successful Zambian project highlights Huaqiang Heavy Industry’s capability to deliver complete, localized professional fertilizer manufacturing equipment solutions. The installed extrusion granulation line serves as a versatile core for producing compound fertilizers, fitting seamlessly into the broader spectrum of global fertilizer production technologies.

Specifically, this line represents a robust npk fertilizer production line capable of executing the complete npk fertilizer production process. While it utilizes extrusion granulators, the same client needs could be met with other granulation technologies within Huaqiang’s portfolio. For instance, a disc granulation production line using a disc granulator (or disc granulator for shaping) is ideal for different material properties, while a roller press granulator production line offers another efficient dry compaction option. For operations requiring organic inputs, this NPK line can be integrated with feedstock from an organic fertilizer production line that might begin with a windrow composting machine. Furthermore, an npk blending machine is a fundamental component for precise formulation in any blended fertilizer operation, showcasing the interconnected nature of these fertilizer granulator and processing systems.

The successful commissioning of the extrusion granulation production line in Zambia not only demonstrates Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd.’s comprehensive strength in the R&D of high-end granulation equipment and the implementation of overseas projects, but also provides efficient and stable equipment support for the modernization of agriculture in Africa. In the future, Huaqiang Heavy Industry will continue to focus on the production needs of different regions, optimize product performance and service solutions, and provide more competitive customized solutions for global customers, enabling “Made in China” to benefit the agricultural industries of more countries and regions.

In July 2025, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. successfully completed the installation and commissioning of a 30,000-ton-per-year organic fertilizer production line tailored for a client in Gao County, Sichuan Province, officially entering the large-scale production stage. This production line integrates the entire chain of core processes, including raw material pretreatment, crushing, screening, mixing, granulation, drying, coating, and packaging. It simultaneously covers both granular and powdered organic fertilizer product lines. With its highly automated configuration, environmentally friendly and energy-saving design, and optimized adaptability to the characteristics of raw materials in Southwest China, it has become a benchmark project for organic fertilizer production equipment in southern Sichuan, injecting strong momentum into the resource utilization of local agricultural waste and the development of green agriculture.

Production Line Configuration and Core Process Analysis: The entire production line follows a closed-loop design of “raw material resource utilization – fine processing – dual-product output – environmental compliance.” The equipment layout is scientific, the connections are tight, and the functions of each unit are complementary, ensuring a stable production capacity of 30,000 tons/year while achieving a dual improvement in product quality and environmental benefits.

Raw Material Pretreatment Unit: The Foundation of Waste-to-Treasure Process

Raw Material Feeding and Crushing: The production line starts at the loader-loaded hopper, adaptable to the rapid feeding needs of bulk agricultural waste such as livestock manure, straw, and mushroom residue. The feed inlet is equipped with spill prevention and impurity filtration devices to prevent large hard objects from entering. The raw materials are conveyed via a 6-meter belt conveyor to a 90-type vertical crusher. This equipment uses a high-speed impact crushing principle, with a high-chromium wear-resistant alloy cutter disc that can crush large raw materials (particle size ≤100mm) into uniform particles ≤3mm, achieving a crushing efficiency of 6 tons/hour, meeting the fineness requirements of subsequent processing. The crushing stage is equipped with a pulse dust collector and induced draft fan to effectively collect dust, with dust emission concentration ≤10mg/m³, meeting environmental standards.

Grading and Screening & Recycling: The crushed raw materials are transferred via a 9-meter belt conveyor to a 10×30-meter drum screen (presumably a 1.0×3.0 meter standard size). A single-layer screen design separates substandard coarse particles, which are then returned to the crusher for reprocessing via a 10-meter recycling belt conveyor, achieving a material utilization rate of 98%. Qualified fine materials are conveyed to the subsequent mixing stage via 5-meter and 7-meter belt conveyors, achieving a screening efficiency of 5.5 tons/hour, ensuring the purity and uniformity of the raw materials.

Dual-Production Line Core Processing Unit: Parallel Production of Granules and Powders

(I) Granular Organic Fertilizer Production Line

Precise Batching and Mixing: Raw materials are vertically conveyed to the automatic raw material batching silos (3 silos) via a 350-type bucket elevator (8 meters high). Each silo can store main materials, additives, and functional auxiliary materials separately, equipped with high-precision metering devices, ensuring a batching error of ≤1%. After batching, the materials are fed into a 50-type twin-shaft mixer via 7-meter and 26-meter belt conveyors. The mixer employs an anti-rotating blade design, ensuring a mixing uniformity error of ≤2%, laying the foundation for high-quality granulation.

Granulation, Drying, and Cooling: The mixed materials are transferred to the granulation stage via 4-meter forward/reverse belt conveyors and 12-meter belt conveyors (based on capacity estimates, this involves multiple flat-die granulators operating in parallel). The granulators utilize a hydraulic pressurization system, achieving a stable granulation rate of over 92% and particle size control of 3-5mm. After granulation, the wet granules are conveyed via a 10-meter belt conveyor to a 1.5×15-meter dryer, where a hot air furnace provides a stable heat source. The drying temperature is precisely controlled between 60-80℃, reducing the granule moisture content from 30% to below 12%. Subsequently, the granules are conveyed via an 8-meter belt conveyor to a 1.2×12-meter cooler, where a counter-current cooling process rapidly lowers the granule temperature to room temperature, increasing the granule strength to over 2.5MPa.

Coating and Finished Product Output: The cooled granules are conveyed via 11-meter and 18-meter belt conveyors to a 1.2×4.0-meter coating machine. Atomized spraying technology evenly coats the granules with a coating agent, improving their moisture resistance and slow-release nutrient effect. The coated granules undergo a second screening using a 1.8×6.0-meter drum screen. Qualified products enter the finished granule silo, and finally, quantitative packaging is completed using an automatic granule packaging scale, supporting 25kg and 50kg specifications with a packaging error ≤±0.2kg.

(II) Powdered Organic Fertilizer Production Line

Fine Grinding and Screening: After some raw materials are crushed and screened, they are fed into a 50-type twin-shaft mixer via 13.7m and 14m belt conveyors for formula mixing. They are then transferred to a 13-type pulverizer for secondary fine grinding, reducing the material to a fine powder of 100-150 mesh (0.1-0.15mm) to ensure the powder’s dissolution rate and absorption efficiency. The ground powder is then screened by a dedicated screening device, with qualified fine powder entering the finished powder silo.

Automated Packaging: The finished powder is quantitatively packaged using an automatic powder packaging scale. The equipment employs spiral feeding and weighing feedback control technology to prevent powder from flying. The packaging speed reaches 80 bags/hour, with high metering accuracy, ensuring standardized product output.

Environmental Protection and Auxiliary Units: Comprehensive Guarantee for Green Production

Waste Gas Treatment System: The production line is equipped with Y5-47-6c induced draft fans (for dryers), Y5-47-5 induced draft fans (for coolers), and dedicated dust removal fans. These are linked to pulse dust collectors, dust collection chambers, water washing towers, and scrubbers to provide multi-stage purification of dust and waste gas generated during production. Waste gas is washed in a water tank before being discharged through the chimney, ensuring that all emission indicators meet national environmental standards for the organic fertilizer industry.

Intelligent Control and Auxiliary Configuration: The production line integrates a PLC intelligent control system to monitor the operating parameters of each piece of equipment (temperature, speed, material level, etc.) in real time. It supports automatic fault alarms and data recording for refined management. Electric heating devices ensure production stability in low-temperature environments. All belt conveyors and bucket elevators adopt a sealed design to reduce material loss and dust pollution.

Core Advantages and Regional Adaptability of the Production Line

Dual Production Lines for Flexible Adaptation: Simultaneous production of granular and powdered organic fertilizers allows for flexible adjustment of capacity ratios based on market demand, achieving an annual capacity of 30,000 tons to meet the diverse fertilization needs of Southwest China.

Precise Matching to Regional Characteristics: Optimized crusher and mixer parameters to suit the characteristics of agricultural waste raw materials in Gao County, Sichuan Province, adapting to the processing requirements of high-humidity, high-fiber raw materials; the equipment features corrosion-resistant and moisture-proof designs, adapting to the rainy and humid climate of southern Sichuan.

Significant Environmental and Energy-Saving Benefits: Equipped with a complete dust removal and exhaust gas treatment system, achieving green production; the drying and cooling processes utilize energy-saving motors and heat recovery designs, reducing energy consumption by 15% compared to conventional production lines of the same capacity, helping customers reduce costs and increase efficiency.

Building a Complete System from Waste to Product

This successful 30,000-ton-per-year project demonstrates a holistic approach to organic fertilizer manufacturing. The entire organic fertilizer production line is a sophisticated system that bridges the gap between raw agricultural waste and high-value fertilizer products. While this configuration focuses on the post-fermentation processing stages, its success is built upon a foundation of high-quality raw compost.

The initial stage of efficient organic fertilizer fermentation is critical, typically achieved through advanced fermentation composting turning technology to produce mature, stable organic matter. Huaqiang Heavy Industry’s solution seamlessly integrates this pre-processed material into the automated granulation and powder production lines, creating a complete, value-adding system that supports both economic and environmental sustainability for local agriculture.

The successful commissioning of the 30,000-ton-per-year organic fertilizer production line in Gao County, Sichuan Province, not only demonstrates Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd.’s professional strength in the R&D of complete sets of organic fertilizer equipment and multi-product line integrated design, but also provides an efficient solution for the resource utilization of agricultural waste in Southwest China. In the future, Huaqiang Heavy Industry will continue to focus on the needs of green agricultural development, optimize product performance and process solutions, provide more customers with customized and environmentally friendly organic fertilizer production equipment, and help the agricultural industry achieve high-quality and sustainable development.