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.

The cost of establishing a urea manufacturing plant in 2026 exhibits significant variability, primarily shaped by three core factors: the adopted technology (conventional versus green), production capacity, and the level of automation. From large-scale industrial facilities catering to global agricultural demand to small-scale regional operations, the investment range spans from millions of dollars to as low as ten thousand dollars. Additionally, external factors such as feedstock prices, green technology premiums, and geopolitical influences further impact the overall cost landscape. A clear understanding of these cost components is essential for investors and industry players planning urea production projects.

Industrial-scale urea plants, designed for large-volume commercial production and international supply, require substantial capital investment. Among these, green urea plants, which adopt environmentally friendly technologies like electrolysis and renewable energy, represent a higher-cost option. A modern green urea plant with an annual capacity of approximately 220,000 tons is estimated to demand a total capital investment of around $510.79 million. For existing industrial facilities seeking expansion, the cost is relatively lower but still considerable. Expanding the daily capacity of an existing production line by 6–8% typically ranges between $80 million and $90 million. In terms of operational costs, the marginal production cost of urea post-construction is projected to be about $325 per ton, though this figure can surge to $400–$500 per ton depending on fluctuations in natural gas prices.

Small to medium-scale urea manufacturing plants, which focus on regional blending and granulation operations rather than full synthesis, feature significantly lower costs centered on equipment lines. Large-scale NPK/urea granulation lines with a production capacity of 18–25 tons per hour, capable of producing high-quality pellets, cost between $400,000 and $550,000. For new manufacturers with limited budgets, small to medium lines with a capacity of 1–6 tons per hour are more feasible, with setup costs ranging from $100,000 to $200,000. At the lowest end of the spectrum, basic mini turnkey urea or fertilizer blending units are available for $10,000 to $48,000, suitable for small-scale local agricultural needs.

Several key factors will drive urea plant costs in 2026. Feedstock, particularly natural gas, is the dominant cost component, accounting for 70% of total urea production costs. Despite some projections of a potential downward trend in global LNG prices due to increased supply, the original industry outlook anticipates rising natural gas prices in 2026 amid growing global LNG demand, which will push up baseline production costs. Green technology also carries a significant premium, with the levelized cost of green urea processes approximately 62% higher than conventional methods, mainly due to the high electricity demands of electrolysis and renewable energy systems. Geopolitical factors and import tariffs further exacerbate costs; certain chemicals and parts required for plant construction are expected to face 12–18% import tariffs in 2026, potentially increasing both construction and future repair expenses.

In summary, the cost of establishing a urea manufacturing plant in 2026 is highly context-dependent. Industrial-scale facilities, especially green ones, demand massive capital investment, while small to medium-scale operations offer more budget-friendly options. Meanwhile, natural gas prices, green technology premiums, and geopolitical tariffs will continue to be critical cost drivers. By carefully evaluating production scale, technology choices, and external cost factors, stakeholders can make more informed decisions to optimize investment returns and adapt to the evolving market environment.

Equipment Selection for Integrated Fertilizer Production

For investors considering a diversified fertilizer operation beyond urea, the selection of appropriate professional fertilizer manufacturing equipment is paramount. A comprehensive npk fertilizer production line often begins with a precise npk blending machine or npk bulk blending machine to create the base powder formulation. The subsequent granulation stage offers multiple technology paths. A traditional and versatile choice is the disc granulator, often deployed within a complete disc granulation production line where the disc granulator for shaping forms spherical granules through a tumbling action. For producing harder, more dense granules via compaction, a double roller press granulator or a complete roller press granulator production line is the optimal solution. The specific npk fertilizer production process dictates whether a fertilizer granulator based on agitation or extrusion is selected.

This equipment ecosystem extends into organic and bio-fertilizer manufacturing. A stand-alone organic fertilizer production line typically requires a windrow composting machine (or windrow machine) for efficient aerobic fermentation prior to granulation. To incorporate beneficial microbes, this evolves into a bio organic fertilizer production line. Here, the final granulation step might utilize a specialized npk fertilizer granulator machine equipment adapted for organic materials or, alternatively, an disc granulator machine known for its gentle shaping action that preserves microbial viability.

Ultimately, the capital and operational costs for these lines vary significantly based on capacity and technology sophistication. Integrating these granulation systems allows a single facility to produce a range of nitrogen-based, NPK compound, and organic fertilizers, providing strategic flexibility to adapt to regional market demands and raw material availability.

Organic fertilizer, as a key link connecting the resource utilization of agricultural waste and ecological farming, involves the scientific optimization and industrial scaling of natural microbial decomposition. Unlike the synthesis of chemical fertilizers, organic fertilizer production uses natural materials such as manure and plant waste as core raw materials. Through a series of standardized industrial processes, unstable organic waste is transformed into a stable product rich in humus, with balanced nutrients and soil-friendly properties.  Precise control of key parameters such as moisture, temperature, and carbon-nitrogen ratio is required throughout the process to ensure efficient microbial metabolic activity.

Raw material collection and pretreatment are fundamental steps in organic fertilizer production, directly determining the nutritional basis and safety of the product. Raw material sources must be strictly screened. Animal manure should primarily come from large-scale livestock farms, such as cattle, sheep, and chicken manure, and impurities such as stones and plastics must be removed beforehand. Plant waste includes crop straw, vegetable residues, oil palm empty fruit bunches, and oil cakes. Agricultural by-products such as oil palm empty fruit bunches require preliminary crushing to improve subsequent fermentation efficiency. The core task of the pretreatment stage is raw material ratio adjustment.  Materials are mixed according to their different carbon-nitrogen ratios; for example, high-carbon materials like straw need to be combined with high-nitrogen materials like manure to adjust the overall carbon-nitrogen ratio to the optimal range of 25:1-30:1.  Simultaneously, moisture content is adjusted to 55%-65% through drying or adding water to provide a suitable environment for microbial growth. For raw materials with a higher risk of contamination, a disinfection pretreatment step is also necessary to reduce the probability of pathogen residue.

Fermentation/composting is the core process of organic fertilizer production, divided into two main modes: aerobic fermentation and anaerobic fermentation.  Its essence is the decomposition and transformation of organic matter by microorganisms. Aerobic fermentation is suitable for large-scale production and requires regular turning of the compost pile using a turning machine to ensure sufficient oxygen supply. The temperature of the compost pile gradually rises to 50-60℃ due to microbial metabolic activity. This temperature range not only accelerates the decomposition of organic matter but also effectively kills pathogens such as E. coli and roundworm eggs in the manure.  Turning and fermentation typically continue for 20-30 days until the pile temperature drops and the material becomes dark brown and loose. Anaerobic fermentation is mostly used in small-scale production or for processing specific materials, such as the Bokashi fermentation system.  This process requires mixing raw materials with molasses and EM microbial agents, then sealing and covering the mixture to isolate it from air and promote the reproduction of anaerobic microorganisms. Although the fermentation cycle is relatively short (7-15 days), it requires appropriate turning of the mixture during the middle of the fermentation process to release accumulated harmful gases and replenish a small amount of oxygen, preventing incomplete fermentation. Parameter control during this stage is crucial. Moisture content is determined by a squeeze test; the ideal consistency is when the material forms a ball when squeezed but crumbles when released. Temperature needs to be monitored in real-time; if it falls below 50℃, the turning interval should be reduced, and if it exceeds 65℃, the turning intensity should be increased to lower the temperature and prevent the inhibition of microbial activity.

Subsequent processes of crushing, mixing, granulation, drying, cooling, and screening and packaging primarily serve to optimize the product’s form and storage stability. The crushing stage involves grinding the fermented and matured material into a powder of 80-100 mesh to ensure even distribution of nutrients. The mixing stage allows for the addition of appropriate trace element fertilizers and biological microbial agents, depending on the product’s intended use, to enhance the fertilizer’s targeted effects. A small amount of binder is also added to improve granulation performance. The granulation process uses a specialized granulator to produce uniform granules with a diameter of 2-4 mm, which facilitates field application and measurement while reducing dust pollution during transportation. The drying stage reduces the moisture content of the granules to below 12%, usually using low-temperature hot air drying to avoid high temperatures that could damage humus and other effective components. After cooling, screening equipment separates fine particles and impurities. Fine particles can be returned to the granulation process for recycling, while qualified granules are quantitatively packaged. Before packaging, the product’s organic matter content, pH value, and other indicators are tested to ensure compliance with national organic fertilizer standards. Throughout the entire process, quality control is essential, from raw material testing to finished product sampling, forming a complete quality traceability system to guarantee the safety and effectiveness of the organic fertilizer.

Advanced Systems for Modern Organic Fertilizer Production

The final stages of the organic fertilizer manufacturing system focus on transforming the cured compost into a consistent, marketable product. After crushing and mixing, the organic fertilizer production granulation phase is critical. Here, producers can choose from several technologies based on raw material characteristics and desired output. A traditional and effective method is the organic fertilizer disc granulation production line, where the moist powder is fed onto a rotating disc, forming spherical granules through a tumbling and layering mechanism. Alternatively, a flat die pelleting machine uses extrusion pressure to create cylindrical pellets, offering high density and strength. For facilities seeking space efficiency and process simplification, a new type two in one organic fertilizer granulator combines the mixing and granulation steps in a single machine, enhancing operational efficiency. An integrated organic fertilizer combined granulation production line may sequentially employ different granulators to achieve optimal particle structure.

This granulation flexibility is central to a complete organic fertilizer production line. When the process is designed to incorporate specific functional microbial consortia post-fermentation, it evolves into a sophisticated bio organic fertilizer production line. The entire system’s efficacy, however, is fundamentally reliant on the quality of the compost feedstock produced upstream by advanced fermentation composting turning technology, typically executed by robust equipment like a chain compost turning machine in windrow systems. Ultimately, selecting the right combination of an organic fertilizer disc granulation machine and supporting equipment defines the efficiency and product quality of the entire organic fertilizer manufacturing operation.

This integrated approach—from controlled aerobic fermentation to precision granulation—ensures that the final product is not only nutrient-rich but also possesses excellent physical properties for storage, transport, and soil application, meeting the demands of modern, sustainable agriculture.