Organic fertilizer is a natural fertilizer, but also an important part of sustainable development of human agriculture, so people pay more and more attention to the production of organic fertilizer. The following introduces the main production process of organic fertilizer production equipment and the relevant situation of organic fertilizer fermentation equipment.

Organic fertilizer production process is generally divided into: fermentation, crushing, ingredients, mixing, molding, drying, cooling, screening, packaging. Of course, some high-end fertilizers will add slurry to make the fertilizer look more beautiful.

1. The first is the fermentation equipment. Most organic fertilizer manufacturers will use the composting fermentation. The key point of composting fermentation is the strain. Only when there are good strains can we get high-quality organic fertilizer. Then there is the crushing equipment. The more commonly used crushing equipment in the organic fertilizer industry is the chain crusher. 

2. Then there is the batching equipment. The batching equipment is divided into manual batching scale and computer batching scale. As the name implies, it is manual weighing equipment and computer automatic weighing equipment. According to the size of the manufacturer and the difficulty of ingredients, the equipment suitable for them will be selected. Here we mainly talk about the computer batching scale. The computer batching scale can evenly configure several or more kinds of different raw materials and trace elements. It can also be seen that the development of electronic products in China is very rapid. Followed by mixing equipment, organic fertilizer industry in the more commonly used mixing equipment is the disc mixer.

3. Focus on the granulation equipment, which is divided into disc granulator machine, rotary drum granulator, flat die pellet mill, ring die pelleting machine and organic fertilizer granulator. According to the characteristics of different raw materials, different granulation methods should be selected. Screening machines and packaging machines are general equipment and do not need to be discussed. These are the components of the organic fertilizer production line equipment.

The organic fertilizer production line with an annual output of 20000 tons, taking poultry and livestock manure as an example, can process up to 80000 cubic meters of manure annually. Fertilizer made from cow manure and straw through high-temperature fermentation is very effective for soil improvement and promoting fertilizer absorption.

Process description of the production line for 20000 tons of cow manure straw powder organic fertilizer annually:

It mainly consists of equipment such as a stacker, crusher, mixer, granulator, dryer, cooling machine, screening machine, wrapping machine, automatic packaging machine, etc.

Working principle of an annual production line for 20000 tons of cow manure, straw, and powdered organic fertilizer:

1. Composting fermentation

The fermentation of bio organic raw materials plays a very important role in the entire organic fertilizer production process. Adequate fermentation is the foundation for producing high-quality organic fertilizers.

The organic fertilizer turner achieves complete fermentation composting and can achieve high stacking and fermentation, improving the speed of aerobic fermentation.

2. Crushing treatment

The semi wet material crusher is an efficient crusher with strong adaptability to organic raw materials with high water content. The semi wet material crusher is widely used in the production process of organic fertilizers, and has a good crushing effect on wet raw materials such as chicken manure and sludge. This crusher greatly shortens the production cycle of organic fertilizer and saves production costs.

3. Mixing treatment

After the raw materials are crushed, they are mixed with other auxiliary materials and stirred evenly before granulation. The dual axis mixer is mainly used for pre adding water and mixing powdered materials. Its spiral blades have multiple angles and can quickly and uniformly mix raw materials regardless of their shape, size, and density.

4. Screening

After cooling, there are still powdery substances in the finished product particles. All powdered materials and unqualified particles can be screened out through a drum screening machine. Then, it is transported by a belt conveyor to a mixer for mixing and granulation. Unqualified large particles need to be crushed before granulation. The semi-finished products are transported to the organic fertilizer coating machine.

5. Packaging

This is the final production process. The fully automatic quantitative packaging machine is an automated packaging machine designed and manufactured specifically for particles of different shapes. The weighing control system meets the requirements of dust and water prevention, and the material box can also be configured according to customer requirements. Suitable for batch packaging of bulk materials, it can automatically weigh, transport, and seal bags.

 Whether it is organic fertilizer production line, npk production line or bio-organic fertilizer production line, the basic organic fertilizer complete set of equipment includes fermentation equipment, crushing equipment, mixing equipment, granulation equipment, drying and cooling equipment, screening equipment, coating equipment and packaging equipment Wait. In order to improve the production quality of fertilizers, screening machines are required for classification. Rotary drum screening machin is a commonly used equipment in npk fertilizer production line and organic fertilizer production. It is mainly used for the separation of finished products and returned materials to achieve product classification and finished product classification. The combined screen is easy to maintain and replace, and has a simple structure. It is an ideal equipment for fertilizer production lines.

So what problems should be paid attention to in the work of rotary drum screening machine?

  1. When the screening machine runs smoothly, the trommel screen starts the feeding and discharging equipment for trial operation.

  2. Close the sealing isolation cover after normal discharge (during normal operation, the sealing isolation cover should always be in the closed position).

  3. Check the discharge particle size, whether there is leakage and dust.

  4. Run for half an hour, carefully check all parts, and deal with any problems in time.

  5. When working, the operation should be checked frequently. If abnormal operation or abnormal sound is found, it should be stopped in time to check, find out the reason and eliminate the fault.

  6. Installation of the screen body of the trommel screening machine. Determine the position of the discharge port according to the feeding port of the equipment, and determine the installation position of the screen body.

  7. Pre-embedded steel plate. Before installation, the steel plate should be embedded according to the requirements of the equipment installation drawing, and the upper plane of the embedded steel plate should be on the same plane. Pre-embedded steel plates required for installation. Foot bolts shall be prepared by the installation unit.

  8. Install the base bracket. Hoist both ends of the screen body on the base bracket, adjust the installation angle of the screen body to the design angle, and finally fix and weld.

1. It is necessary to determine the output of fertilizer production machine, such as the annual output of tens of thousands of tons, or the number of tons produced per hour, so as to determine the price.

2. It is necessary to determine the shape of the particles, whether they are powdery, columnar, oblate or standard round. Generally, the commonly used granulating equipment for organic fertilizer are: disc granulator, drum granulator, wet granulator, roller extrusion granulator, flat die granulator and ring die granulator. The selection of fertilizer granulator machine should be decided according to the local fertilizer market. The process of organic fertilizer equipment is different due to different particle shape, and the price of organic fertilizer equipment is also different.

3. It is necessary to determine the configuration level of fertilizer production machine. The configuration level is different, the price of organic fertilizer equipment is different, the number of labor is different, and the stable yield and high yield of organic fertilizer equipment are also different: generally, the equipment with high configuration should be added with automatic batching device, automatic packaging device, automatic quantitative feeding device, cyclone dust removal and ink dust removal.
4. It is necessary to determine the type of fertilizer production line, which is compound fertilizer organic fertilizer equipment or organic fertilizer organic fertilizer equipment. For the same yield, organic fertilizer and organic fertilizer equipment generally consider high water content, bacteria species are not resistant to high temperature, and the model is generally larger than that of compound fertilizer. There are four types of organic fertilizer, including pure organic fertilizer, organic-inorganic compound fertilizer, bio organic fertilizer and compound microbial fertilizer. There are different varieties of organic fertilizer and different equipment of organic fertilizer.

5. It is necessary to select the type of fermentor. The general fermentation forms are: stack fermentation, shallow tank fermentation, deep tank fermentation, tower fermentation and rotary cylinder fermentation. The fermentation methods are different, and the equipment for organic fertilizer fermentation is also different. Generally, the shallow tank tipper is most suitable for the principle of aerobic fermentation (advantages of shallow tank tipper: it is most in line with the principle of aerobic fermentation, not easy to form anaerobic, full and complete fermentation, and fast fermentation speed).

6. It is necessary to determine the level of environmental protection requirements. The places with low environmental protection requirements generally choose heavy-duty dust removal, and the investment of organic fertilizer equipment is less; for places with high environmental protection requirements, heavy-duty dust removal and ink dust removal are generally selected, which can meet the national air emission quality standards.

In the organic fertilizer production line, the granulator plays a crucial role, and its main functions include:

Forming: The fertilizer granulator processes powdered or liquid organic fertilizer raw materials into granules for subsequent drying, screening, packaging, and application.

Improving physical properties: Granular organic fertilizers have better physical properties, such as fluidity, anti caking, and storage stability.

Improving application efficiency: Granular fertilizers can be directly applied to the soil through mechanical fertilization equipment, improving the efficiency and uniformity of fertilization.

Controlled release: The dissolution and nutrient release rate of granular fertilizers are usually slower than that of powdered fertilizers, which helps plants absorb nutrients more evenly.

Easy to store and transport: Granular fertilizers have a small volume, large weight, and are not easily scattered, making them easy to transport and store over long distances.

Improving market value: Granular organic fertilizers have a cleaner appearance, are easier to measure and sell, and enhance the product’s market competitiveness.

Reducing environmental pollution: Through granulation, the loss of fertilizers during storage and transportation can be reduced, reducing environmental pollution.

Adjusting moisture content: During the granulation process, the humidity of the finished product can be controlled by adjusting the moisture content of the raw materials to meet the requirements of subsequent processes.

Adding slow-release materials: During the granulation process, slow-release materials such as sulfur coatings can be added to organic fertilizers to control the rate of nutrient release.

Improving the consistency and uniformity of fertilizers: The granulator ensures consistency in the size and shape of fertilizer particles for each batch, improving the uniformity of fertilizers.

Enhancing the functionality of fertilizers: During the granulation process, other functional substances such as microbial agents, growth regulators, etc. can be added to organic fertilizers to enhance their functionality.

Meeting specific application requirements: Some specific agricultural applications may require granular fertilizers of specific sizes or shapes, and the granulator can be adjusted according to these requirements.

The role of fertilizer granulator in organic fertilizer production line is not limited to changes in physical form, but also includes improvement of fertilizer performance and expansion of fertilizer function. It is an indispensable key equipment in the organic fertilizer production process.

Process flow of organic fertilizer production line for manure treatment in livestock and poultry farms

In livestock and poultry farms, manure treatment is a crucial step, and the production of organic fertilizer is one of the important methods for converting these manure into valuable resources. The process flow is mainly divided into four steps: collection, separation, composting, and fermentation.

The first stage is the collection phase, where livestock and poultry manure is effectively collected and preliminarily separated. It is possible to separate livestock and poultry manure from urine through a centralized collection and separation system to reduce the generation of ammonia and odor, and improve subsequent treatment efficiency.

Then comes the composting stage, where the separated animal manure is sealed and stored, and organic waste is properly organized and stacked, supplemented by ventilation equipment to control temperature, humidity, and oxygen supply, accelerating the decomposition process of organic matter. During this process, it is important to maintain appropriate humidity and ventilation to avoid the generation of odors and harmful gases.

Finally, in the fermentation stage, after the completion of composting, the compost is subjected to secondary composting fermentation to further enhance the stability and efficiency of the fertilizer. This process requires attention to reasonable moisture control and temperature regulation to ensure the full decomposition of organic matter and the killing of harmful microorganisms.

Organic fertilizer provides organic matter to the soil, thereby providing the necessary nutrients for plants and helping to establish a healthy soil system, rather than destroying it. Therefore, organic fertilizers contain huge business opportunities, and with the gradual restrictions and prohibitions on the use of fertilizers by most countries and relevant departments, the production of organic fertilizers will become a huge business opportunity.

Most organic raw materials can be fermented into organic compost. In fact, after crushing and screening, organic fertilizer compost becomes high-quality and saleable powdered organic fertilizer.

Whether building an organic fertilizer production line, an npk fertilizer production line or a bio-organic fertilizer production line, the following suggestions are worth a look.

1. Precautions for administrative handling of factory construction.

First, the feasibility study and demonstration of ecological organic fertilizer enterprises

Prepare a feasibility study report for an organic fertilizer production enterprise and submit it to the local Bureau of Industry and Information Technology (the Industrial Information Committee for project approval)

2, environmental pollution assessment.

Find companies with environmental qualifications to conduct environmental pollution assessments. Submit to the local Development and Reform Commission for formal project approval.

3, apply for an industrial and commercial business license

To set up a company, the business scope must include “organic fertilizer”, “bio-organic fertilizer”, “organic and inorganic compound fertilizer”, “microbial fertilizer” and other formal fertilizer names. After obtaining the business license, it is necessary to complete all the procedures required by the company, including tax registration, company code determination, and company account processing.

4, planning and construction of organic fertilizer factories

Contact the organic fertilizer production equipment enterprise, and with the assistance of the manufacturer, the construction should be carried out reasonably with the permission of the local land planning department. Arrange the relevant equipment reasonably, wait for the acceptance of the provincial and municipal agricultural departments, and prepare for the relevant production registration procedures.

5, buy organic fertilizer production equipment.

Look for a powerful organic fertilizer manufacturer, pay attention to product quality, after-sales service and other factors, and purchase equipment and put it into production. The main equipment of the organic fertilizer granulation production line includes: automatic batching system, disc mixer, double roller granulator, dryer, chain pulverizer, trommel screen, coating machine, packaging scale, cyclone dust collector, conveyor.

6, apply for organic fertilizer trademark

A company that intends to develop for a long time must apply for its own trademark and make its own brand. The normal operation of the enterprise and the application for national registration procedures.

The roller squeezing granulator is an efficient granulation equipment, mainly composed of the following key components:

Pressure roller: The main component of a roll extrusion granulator, usually composed of two relatively rotating pressure rollers, with specific groove designs on the surface of the pressure rollers, used for extrusion molding of materials.

Feeding device: responsible for evenly feeding raw materials between pressure rollers to ensure continuous and stable feeding.

Transmission system: including motor, reducer, coupling, etc., used to drive the rotation of the pressure roller.

Adjustment mechanism: used to adjust the gap between the pressure rollers to control the size and shape of particles.

Cutting device: located behind the pressure roller, used to cut the extruded strip material into particles of the required length. It can be a fixed blade or a rotating blade.

Drying system: Newly formed wet particles need to be reduced in moisture content through the drying system, usually including a dryer and heat source equipment.

Screening and grading device: used to separate particles that meet the standards and unqualified particles that require rework.

Cooling system: The dried particles need to be cooled to ensure their stability during storage and transportation.

Packaging system: including automatic weighing and packaging equipment, used to package finished granular fertilizers.

Control system: Modern roller extrusion granulators are usually equipped with PLC or microcomputer control systems to achieve automatic control of the entire granulation process.

Support and framework: The supporting structure of the entire machine ensures its stability and durability.

Dust removal system: Dust may be generated during the granulation process, and the dust removal system is used to collect dust and reduce environmental pollution.

Lubrication system: Ensure lubrication of pressure rollers and other moving parts, reduce wear, and extend equipment life.

Safety protection devices, such as emergency stop buttons, protective covers, etc., ensure the safety of operators.

The collaborative work of these components of the roller extrusion granulator ensures the efficiency and stability of the granulation process. According to different production needs, the specific configuration of roller extrusion granulators may vary, but the above listed are the basic components common to most roller extrusion granulators.

In general, organic fertilizer mainly includes granular and powder fertilizers, pure organic fertilizers, bio organic fertilizers, and organic-inorganic compound fertilizers. The organic fertilizer production line is a complete set of equipment and processes for fertilizer production, including manure maturation and fermentation, raw material mixing, particle processing, drying, packaging, etc. It includes all equipment for producing organic fertilizer using animal manure as raw material, adding wood chips, mushroom residue, sugarcane bagasse and other accessories for stacking fermentation.

The organic fertilizer production line includes fermentation equipment, granulation equipment, crushing equipment, stirring equipment, screening equipment, cooling equipment, drying equipment, coating equipment, automatic packaging equipment and other process flows.

Introduction to the technology scheme and process for producing organic fertilizer from livestock and poultry manure:

The main method is to ferment and decompose the organic matter mixture, add trace elements such as nitrogen, phosphorus, and potassium according to the formula requirements, crush them, and stir them in a mixer. After thorough stirring, the material is granulated, dried, cooled, and screened, and the finished particles are sent to the finished product silo. The packaged organic fertilizer is made into brown or grayish brown granular form, without mechanical impurities and odor.

1. Disc granulation production line

The disc granulation production line has a high granulation rate, low maintenance rate, smooth operation, sturdy and durable equipment, long service life, and low investment, making it the equipment of choice for many users.

2. Stock conversion and granulation production line

Large production capacity, low maintenance rate, and low energy consumption. We can design organic fertilizer production line equipment with a production capacity of 1-3 million tons according to customer requirements and provide a complete set of organic fertilizer production equipment.

3. Roller granulation production line

Easy to operate, low technical requirements, relatively simple process flow, low investment, strong adaptability to environmental conditions, stable operation, and low noise.

4. BB fertilizer production line

The BB fertilizer production line is designed and manufactured according to the requirements of compound fertilizer factories and fertilizer distributors, with a production capacity of 1-20000 tons. It adopts the process of directly feeding into the lifting tank and discharging from the mixer.

The raw material route of extrusion granulation to produce compound fertilizer is relatively wide, which can be used in npk compound fertilizer production line and npk production line. At present, there are more than 20 kinds of materials that have been successfully used in extrusion granulation: nitrate in nitrogen fertilizer Ammonium, urea, ammonium chloride, calcium nitrate, etc. Phosphate fertilizers include ammonium phosphate, common calcium, heavy calcium, phosphate rock powder, etc. Potash fertilizers include potassium chloride, potassium sulfate, etc., and trace elements such as boron, iron, copper, etc. can be added. Zinc, manganese, etc. Extrusion granulation has no special requirements on the particle size of raw materials. Both 1-4mm granular materials and fine powder materials can be used. Powder materials and powder products with unqualified particle size are better to use. Can reduce costs.

The main equipment included in the double roller granulator production line: automatic batching system, roll extrusion granulator, disc mixer, trommel screening machine, belt conveyor, packaging scale, etc.

Extrusion granulation production process:

1. storage, metering

Mixed fertilizer raw materials such as urea, ammonium phosphate, potassium chloride, etc. are transported to the storage silo by bucket elevator and belt. The number of storage bins, the complexity of metering and mixing techniques, is related to the number of components in the product formulation.

2. extrusion

The mixed fertilizer mixture is extruded by a roller extruder, the principle of which is to shape the material by extrusion. The mixed material is fed into the gap between the two oppositely rotating roller shafts through a vertical screw feeder. During the extrusion process, the pressure of the material gradually increases. When the gap between the two shafts is small, The material is relatively compressed, and then gradually decreases until it reaches 0.

3. Crushing and grading

The slabs formed in the double roller granulator  are further broken up and classified to the desired particle size.

4. Polishing and finishing

Typically, the final product undergoes one or two steps of polishing.