In 2025, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. completed the full-process commissioning of a 10-unit extrusion granulation production line tailored for a customer in Guigang, Guangxi, officially entering a new stage of large-scale mass production. This production line focuses on the ultra-large-capacity production needs of compound fertilizers and organic fertilizers, integrating the entire chain of core processes including batching, crushing, mixing, granulation, screening, coating, and packaging. With its robust configuration of 10 granulation main units operating in parallel, highly automated process design, and stable and reliable operation, it has become a benchmark project for fertilizer production equipment in South China, injecting strong momentum into the upgrading of local agricultural industrialization.

Production Line Full-Chain Configuration and Core Equipment Analysis

The entire production line follows a closed-loop process of “precise batching – raw material pretreatment – efficient granulation – fine processing optimization – finished product output.” The equipment layout is compact and orderly, with seamless connections. Each unit works synergistically, ensuring both ultra-large capacity requirements and strict control over product quality stability.

Precision Batching and Raw Material Pretreatment Unit: Strengthening the Production Foundation

Multi-Compartment Collaborative Batching System: The production line starts with a 4-compartment automatic batching system. Each compartment is independently designed to store nitrogen, phosphorus, and potassium as main raw materials, as well as various additives. The total storage capacity meets the requirements of continuous 12-hour full-load production. Precision metering devices are installed at the bottom of the batching compartments. Combined with a PLC intelligent control system, the system automatically adjusts the amount of each raw material fed according to the preset formula, with a batching error of ≤1%, ensuring accurate fertilizer nutrient ratios.

High-Efficiency Crushing and Uniform Mixing: Raw materials are conveyed to a 90-type horizontal semi-wet material crusher via 2.9-meter and 11-meter belt conveyors. This equipment is specifically designed for high-moisture raw materials, employing wear-resistant alloy cutter discs and a graded crushing structure. It can crush large, agglomerated raw materials (particle size ≤80mm) into uniform fine materials ≤2mm, achieving a crushing efficiency of 15 tons/hour, meeting the stringent requirements for raw material fineness in subsequent granulation. The pulverized material is transferred via a Y-shaped tee and a 14-meter belt conveyor to two 2200-type precision mixers (presumably “precision mixers”). These machines feature a dual-shaft counter-rotating design with wear-resistant coatings on the impellers. During mixing, the material forms a strong convection circulation, ensuring thorough mixing of different components with a mixing uniformity error of ≤2%, laying the foundation for high-quality granulation.

Core Granulation Unit: 10 Main Units Create Super Capacity

The mixed material is then diverted via a tee and evenly fed by two 2200-type disc feeders to ten extrusion granulators. The feeders employ variable frequency speed control and automatic material level control technology, allowing real-time adjustment of the feed rate based on the granulator’s operating status, preventing granulation quality fluctuations or equipment overload caused by uneven feeding.

The core highlight of the entire production line is the parallel operation of 10 extrusion granulators. Each machine has an hourly output of 3 tons, and their combined operation achieves a total capacity of 30 tons/hour and a daily capacity of 720 tons, far exceeding the capacity of conventional production lines. The granulators employ a high-strength roller extrusion design, with roller skins made of high-chromium alloy. After quenching treatment, the hardness reaches HRC62 or higher, exhibiting extremely high wear resistance and extending the service life to over 10,000 hours. The equipment is equipped with a hydraulic pressure regulation system, allowing precise control of the extrusion pressure within the range of 6-18 MPa to adapt to the granulation needs of raw materials with different moisture content and compositions. The granulation rate remains consistently above 93%, with uniform particle size controlled at 3-5 mm and particle strength reaching 2.8 MPa. The particles are not easily pulverized, meeting the requirements for long-distance transportation and long-term storage.

Post-processing and Finished Product Output Unit: Enhancing Quality + Efficient Shipping

Screening and Coating Optimization: Granulated granules are transferred to a 15x60m drum screen (presumably a 1.5×6.0m standard size) via 7m and 11m belt conveyors. A double-layer screen design separates large, unqualified granules on the upper layer and selects qualified finished products on the lower layer, achieving a screening efficiency of 35 tons/hour. Unqualified granules are returned to the pre-processing unit via 8m and 5m return conveyors for reprocessing, achieving a material utilization rate of 99%. Qualified granules undergo anti-caking pre-treatment in a 16-type spiral duster, followed by a 1.5×6.0m coating machine. Atomized spraying technology evenly coats the granules with a coating agent, forming a dense protective film that effectively improves the fertilizer’s moisture resistance, stability, and slow-release nutrient effect.

Finished Product Storage and Automated Packaging: Wrapped finished products are conveyed to a finished product warehouse via a 12-meter belt conveyor for temporary storage. The warehouse is equipped with a material level monitoring system to provide real-time inventory status feedback. Finally, quantitative packaging is completed using an automatic packaging scale. The equipment supports rapid switching between multiple specifications such as 25kg, 40kg, and 50kg, with a measurement error ≤ ±0.2kg and a packaging speed of up to 200 bags/hour. Combined with a subsequent transfer system, it achieves rapid warehousing and shipment of finished products.

Core Advantages and Industry Value of the Production Line

Super Capacity Leading the Industry: The innovative configuration of 10 parallel granulation units breaks through the capacity bottleneck of conventional production lines, meeting the quantitative needs of large-scale fertilizer production enterprises and helping customers seize market share.

Intelligent, Efficient, Cost-Effective, and Inefficient: The entire process is integrated with a PLC intelligent control system, achieving automated control of batching, feeding, granulation, and screening, reducing manual intervention and labor intensity. The equipment’s energy consumption is 15% lower than that of conventional production lines with the same capacity, resulting in a significant reduction in overall production costs.

Stable, reliable, and highly adaptable: Core equipment adopts standardized and wear-resistant designs, key components are highly versatile, and maintenance is convenient. The production line can flexibly adapt to the production of various materials such as organic fertilizer, compound fertilizer, and bio-organic fertilizer, and supports product customization with different particle sizes and formulas, demonstrating extremely high adaptability.

The successful commissioning of 10 extrusion granulation production lines in Guigang, Guangxi, not only demonstrates Huaqiang Heavy Industry’s core strength in the R&D and integration of ultra-large capacity granulation equipment, but also provides efficient and stable equipment support for the modernization of agriculture in South China. In the future, Huaqiang Heavy Industry will continue to focus on customer needs, continuously optimize product performance and process solutions, and provide more competitive customized solutions for global fertilizer producers, contributing to the high-quality development of the agricultural industry.

Mastering High-Volume Dry Granulation

This groundbreaking 10-unit production line in Guangxi exemplifies the industrial-scale application of advanced fertilizer granulation technology. Its core innovation lies in the massive parallel deployment of extrusion granulators, a method that falls under the category of dry granulation processes.

The line is a prime example of a roller press granulator production line, where each fertilizer compaction machine (or fertilizer compactor) performs fertilizer granules compaction through high-pressure extrusion. This method of fertilizer compaction is a key fertilizer granulation processes used within the broader npk manufacturing process for specific product types. It stands in contrast to alternative fertilizer processing machine technologies, such as drum granulation using a rotary drum granulator for wet agglomeration. The successful scaling to ten parallel units demonstrates a mastery of this particular fertilizer granulation technology, enabling unprecedented production volumes of dense, low-moisture fertilizer granules.Therefore, this project is not just about capacity; it is a testament to the precision engineering and process control required to reliably scale up dry granulation, providing a model for high-output fertilizer manufacturing that prioritizes product density and energy efficiency.

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In material handling processes across numerous industries, including mining, building materials processing, chemical purification, food grading, and agricultural screening, precise and efficient screening is crucial for ensuring product quality and improving production efficiency. The drum vibrating screen, a high-efficiency screening device integrating the advantages of both drum screens and vibrating screens, breaks through the performance limitations of single screening equipment with its unique “drum rotation + vibration” dual-drive mode. It has become the preferred equipment for large-scale material screening in various industries, providing a reliable solution for the precise grading of materials of different particle sizes.

The stable and efficient operation of the drum vibrating screen stems from its scientifically designed structure, where core components work together to form a complete screening system. The drum body, the core of the equipment, consists of a screen, a support frame, and a drum shell. The screen aperture can be precisely customized according to specific screening needs, which is the foundation for separating materials of different particle sizes. The vibration device is key to improving screening efficiency. It typically consists of a motor, eccentric blocks, or vibration springs. By generating stable vibrations, it ensures uniform material distribution within the drum, preventing localized accumulation that could lead to insufficient screening. The drive unit, consisting of a motor and reducer, powers the drum’s rotation and precisely controls its speed to adapt to the screening rhythm of different materials. The support system, employing a combination of a support frame and bearings, stably supports the drum while reducing frictional losses during operation, ensuring smooth equipment operation. The inlet and outlet form an orderly material flow channel, with the outlet designed according to particle size classification to ensure accurate discharge of materials of different specifications. Furthermore, the sealing device effectively prevents dust leakage during screening, maintaining a clean working environment and meeting the requirements of modern green industrial production.

The core advantage of the drum vibrating screen stems from its unique working principle, achieving efficient screening through the synergistic effect of rotation and vibration. When material enters the drum through the inlet, the drive unit drives the drum to rotate at a uniform speed, while the vibrating device simultaneously generates vibration. Under the combined action of rotational and vibrational forces, the material continuously tumbles and spreads within the drum, ensuring full contact with the screen mesh. At this point, fine particles smaller than the screen mesh size pass smoothly through the mesh, completing the initial screening; while coarse particles larger than the mesh size move forward along the inner wall of the drum under the propulsion of rotation and vibration, eventually being discharged from the corresponding coarse material outlet. This dual-drive mode not only makes material screening more thorough but also significantly improves processing efficiency, meeting the continuous operation needs of large-scale production and avoiding the drawbacks of traditional single screening equipment, such as small processing capacity and low efficiency.

The unique structure and working principle endow the drum vibrating screen with many significant features, making it widely adaptable to various industries. High-efficiency screening is its core competitiveness; the dual action of rotation and vibration greatly improves screening efficiency while providing a large processing capacity, adapting to continuous production rhythms. Its application range is extremely wide, achieving stable screening of dry ore particles, building material raw materials, as well as food raw materials and agricultural waste with high moisture and viscosity, demonstrating good adaptability to material moisture and viscosity. The equipment structure is relatively simple, with a reasonable layout of core components, convenient subsequent maintenance, and strong operational stability, effectively reducing the company’s operation and maintenance costs. Furthermore, the equipment boasts excellent adjustability. By changing the screen mesh with different apertures or adjusting the vibration frequency, it can quickly adapt to the screening needs of different materials, offering exceptional flexibility. Simultaneously, the drum and screen are made of wear-resistant materials, ensuring a long service life and further reducing operating costs.

From ore grading in mines to aggregate screening in building material plants, from raw material purification in food factories to seed sorting in farms, the drum vibrating screen, with its core advantages of high efficiency, stability, and flexibility, provides strong support for screening operations across various industries. Against the backdrop of industrial production transitioning towards higher efficiency and greener practices, this equipment, integrating the advantages of dual-effect screening, not only improves enterprise production efficiency but also aligns with the development trend of environmentally friendly production, becoming an important piece of equipment driving the upgrading of material handling across various industries.

A Critical Quality Control Unit in Fertilizer Production

The drum vibrating screen exemplifies the critical role of precise material classification in industrial processes. In the fertilizer manufacturing industry, this type of efficient screening equipment is an indispensable component of professional fertilizer manufacturing equipment, ensuring the uniformity and quality of the final product.

Within a complete npk fertilizer production line, a screening machine is typically integrated at multiple stages of the npk fertilizer production process. For instance, after raw materials are precisely blended by an npk blending machine or npk bulk blending machine, screening may be used to ensure uniformity before granulation. Following granulation—whether using a disc granulation production line with a disc granulator for shaping or a roller press granulator production line—the hot, shaped granules are screened to separate on-spec product from undersized or oversized particles for recycling. This screening step is equally vital in an organic fertilizer production line, which begins with raw material processing using a windrow composting machine. The high-efficiency screening ensures that only granules of the correct size are packaged, directly impacting the marketability and performance of both standard NPK and specialized bio organic fertilizer production line outputs.Thus, the screening machine acts as a crucial quality gate, working in concert with blenders, granulators, and dryers to produce the consistent, high-quality fertilizer that modern agriculture requires.

With the rapid development of ecological agriculture, the market demand for organic fertilizers continues to rise, and the corresponding production methods are also becoming increasingly diversified. Based on differences in fermentation methods and production scale, the current mainstream organic fertilizer production methods mainly include the windrow composting method, the fermentation tank method, and the Bokashi method.  Each method has its own focus in terms of process design, equipment requirements, and applicable scenarios, respectively adapting to large-scale commercial production, precise customized production, and small-scale home/garden planting needs, collectively promoting the resource utilization of agricultural waste.

The windrow composting method is the mainstream choice for large-scale aerobic composting and is widely used in large organic fertilizer production enterprises, especially suitable for processing large quantities of agricultural waste such as crop straw and livestock manure from large-scale farms. The core advantage of this method lies in its strong large-scale processing capacity. Through dedicated windrow turning equipment (such as crawler-type windrow turners and trough-type windrow turners), automated turning of tens of thousands of tons of compost piles can be achieved, significantly improving labor efficiency and precisely controlling the aeration and temperature distribution of the compost pile. In the production process, the compost pile is usually stacked in windrows, with a height of 1.5-2 meters and a width of 3-5 meters. The windrow turner regularly turns the pile to maintain a stable temperature of 50-60℃, ensuring the killing of pathogens and the complete decomposition of organic matter. In addition, the equipment investment of the windrow composting method is relatively controllable, and the production process is mature, making it suitable for producing general-purpose organic fertilizers. The products are mainly supplied to large-scale planting bases and grain-producing areas, effectively reducing the reliance of large-scale agricultural production on chemical fertilizers and solving the problem of disposing of large quantities of agricultural waste. However, this method is subject to significant site limitations, requiring sufficient composting space, and the fermentation cycle is relatively long, usually requiring 25-35 days.

The fermentation tank method uses closed tank equipment as its core and is suitable for aerobic or anaerobic fermentation production requiring a highly controlled fermentation environment, especially widely used in the production of liquid organic fertilizers, such as amino acid liquid fertilizers and humic acid liquid fertilizers. The greatest advantage of this method lies in the precise and controllable fermentation process. The sealed tank effectively isolates the process from external environmental interference.  Through an intelligent control system, parameters such as temperature, oxygen content, and pH value are adjusted in real time, ensuring that microorganisms remain in their optimal metabolic state. This results in a fermentation efficiency increase of over 30% compared to traditional methods. In anaerobic fermentation mode, the fermentation tank can efficiently process high-concentration organic wastewater and livestock manure, producing organic fertilizer while simultaneously recovering biogas, achieving a dual output of energy and fertilizer. The aerobic fermentation mode can be used to produce high-quality powdered organic fertilizer. By precisely controlling the carbon-nitrogen ratio and fermentation time, the organic matter content and nutritional stability of the product are improved. The fermentation tank method is suitable for small and medium-sized fine fertilizer production enterprises. The products are mostly customized formulations, supplied to facilities such as greenhouse agriculture and fruit and vegetable planting bases that have high requirements for fertilizer quality. However, the initial investment in equipment is high, and the technical requirements for operators are also more stringent.

The Bokashi method is a small-scale anaerobic fermentation composting method.  With its advantages of simple operation and short fermentation cycle, it has become an ideal choice for home gardening, backyard vegetable gardens, and small farmers. This method uses specific functional microorganisms (such as EM bacteria) as the core. Kitchen waste, household plant residues, and a small amount of animal manure are mixed with molasses and EM bacterial agents and placed in a sealed container for anaerobic fermentation.  Composting is completed in only 7-15 days, shortening the composting cycle by more than half compared to traditional methods. The fermentation products of the Bokashi method are divided into solid fertilizer and fermentation liquid. The solid fertilizer can be directly applied to the soil or used as a seedling substrate, and the fermentation liquid can be diluted and sprayed as a foliar fertilizer, achieving full resource utilization. In addition, this method does not require large equipment, has a low operating threshold, and can effectively treat household organic waste, reducing the amount of household waste, thus possessing both economic value and environmental significance. However, the Bokashi method has a small processing scale and is not suitable for large-scale commercial production.  Furthermore, strict control of sealing conditions is required during the fermentation process; improper sealing can easily lead to fermentation failure and produce unpleasant odors. The differentiated development of different production methods allows organic fertilizer production to adapt to different needs, providing diversified technical support for green agricultural development.

From Fermentation to Finished Product: The Industrial Pathway

The diverse composting methods—windrow, tank, and Bokashi—each serve as the starting point for transforming organic waste into valuable amendments. To scale these processes for commercial markets, the compost produced must be integrated into a formal organic fertilizer manufacturing system, which standardizes and enhances the final product.

For large-scale operations utilizing windrow composting, the mature compost is processed through a complete organic fertilizer production line. The initial stage relies on advanced fermentation composting turning technology, often using equipment like a chain compost turning machine. To create a market-ready product, this compost undergoes organic fertilizer production granulation. Producers can choose specialized systems like an organic fertilizer disc granulation production line for uniform pellets or a more flexible organic fertilizer combined granulation production line. If microbial inoculants are added, this entire system becomes a sophisticated bio organic fertilizer production line, ensuring the survival and efficacy of beneficial microbes in the final product. This integration bridges the gap between raw composting and commercial-grade fertilizer.Ultimately, the choice of initial composting method defines the feedstock, while the subsequent industrial processing line defines the quality, consistency, and scalability of the fertilizer that reaches the farmer, enabling sustainable practices at every scale.