Double screws compost turning machines are high-frequency equipment for organic fertilizer fermentation. Proper routine maintenance directly impacts their service life and operational stability.
1.Precise Maintenance of Spiral Blades
After each operation, clean any sticky material from the blades (a high-pressure water jet can be used to prevent wear and tear from hardening). Check the blade fastening bolts weekly and tighten any loose bolts immediately to prevent vibration and increased wear. Derust the blades and apply a wear-resistant coating quarterly to extend double screws compost turning machine’s service life.
2.Transmission and Travel System Maintenance
Check the lubricating oil level in the motor and reducer monthly and add specialized lubricant to prevent wear and tear on gears and bearings due to lack of oil. Regularly clean debris from the travel tracks and crawler tracks to prevent jamming. If the double screws compost turning machine deviates, adjust the track parallelism or crawler track tension promptly to ensure smooth movement.
3.Electrical System Safety
Fermentation workshops are characterized by high humidity. Regularly check the seals of motors and control cabinets to prevent moisture-induced short circuits. Clean dust from electrical components, check for loose connections, and tighten terminal blocks. Perform a no-load test run monthly to test the operating status of motors and inverters. Detect and address any anomalies promptly to avoid prolonged downtime caused by electrical failures.
The fermentation process of large-scale organic fertilizer production (processing over 500 tons of raw materials daily) faces the challenges of high processing volume, tight fermentation cycles, and high labor costs. The double screws compost turning machine’s design features perfectly meet these requirements, making it a core piece of equipment for large-scale production.
1.Efficient and Continuous Operation
The double screws compost turning machine continuously moves along the fermentation tank, turning the compost without frequent downtime and adjustments. A single unit can process up to 100-200 tons per hour, meeting the continuous fermentation needs of large-scale production lines and ensuring timely composting.
2.Stable and Uniform Compost Turning Quality
Large-scale production requires high consistency in fertilizer quality. The double screws compost turning machine’s two spirals work in tandem, ensuring uniform mixing of the material, both vertically and horizontally, and ensuring even oxygen exposure. Fertilization temperature fluctuations are controlled within ±3°C, preventing uneven fermentation and causing uneven fertilizer quality.
3.Significantly Reduced Labor Costs
Traditional manual compost turning can only process 5-10 tons of material per person per day. A single double screws compost turning machine can replace 20-30 workers. The machine operates without human intervention (it supports automatic movement and compost turning), eliminating the efficiency fluctuations associated with manual operation.
With the large-scale development of the organic fertilizer industry, production lines are placing increasingly stringent demands on equipment adaptability. With its exceptional integration capabilities, large wheel compost turners have become core equipment for large-scale organic fertilizer production lines.
Within the production line process, they seamlessly connect pre-treatment and processing. During pre-treatment, raw materials such as livestock and poultry manure processed by a solid-liquid separator and pulverized straw from a pulverizer are piled into windrows 5-8 meters wide and 1.5-2 meters high. The large wheel compost turner slowly moves along the windrows, turning and fermenting the material. The fermented material is then conveyed by conveyor to equipment such as granulators, screens, and dryers, forming a complete production chain from pre-treatment to fermentation, enabling continuous production.
For large-scale production lines with an annual output of over 100,000 tons, the equipment rotates through multiple windrows: one receiving fresh raw material, one performing high-temperature fermentation, and one completing cool-down composting. This fixed cycle allows for a daily processing capacity of 800-1,500 tons, meeting the needs of large-scale production.
In addition, its electronic control system flexibly adjusts the turning and travel speeds, adjusting the fermentation progress based on the raw material supply and pelletizing capacity, ensuring a stable production line. Furthermore, compared to tank fermentation, it improves site utilization by over 30%, saving valuable land resources for large-scale production lines.
In organic fertilizer production, the quality of compost turning during the fermentation process directly determines fertilizer maturity and nutrient retention. The double screws compost turning machine, with its unique structural design, is a key device for addressing uneven compost turning and slow fermentation. Its dual helical operation ensures sufficient oxygen and uniform heat dissipation within the fermentation tank, significantly improving fermentation efficiency.
The core working components of the double screws compost turning machine are two sets of parallel spiral blades. As the device moves along the fermentation tank track, the blades rotate clockwise, tossing the bottom material upward while simultaneously dispersing it to the sides. This turning method creates a “rolling up and down, mixing left and right” motion pattern for the material.
During the fermentation process, turning the compost not only provides sufficient oxygen for microorganisms but also quickly dissipates heat generated by the fermentation process, preventing nutrient loss due to localized high temperatures. For different raw materials such as livestock and poultry manure, straw, etc., the spiral speed and double screws compost turning machine movement speed can be adjusted to control the turning depth (up to 1.5-3m) and frequency, ensuring that the materials are fully composted within 7-15 days. Compared with manual turning, the efficiency is increased by more than 10 times.
On the stage of modern agriculture, the new type stirring tooth organic fertilizer granulator performs like a master craftsman, transforming powdery raw materials into uniform, spherical fertilizer pellets. The new type of stirring tooth organic fertilizer granulator is also called “new type of two-in-one organic fertilizer granulator“, a title reflecting its dual-function efficiency. While alternatives like the disc granulator anchor a conventional disc granulation production line, this advanced fertilizer granulatoroffers remarkable versatility. It serves as a core component not just in a dedicated organic fertilizer production line, but can also be integrated into a standard npk fertilizer production line or a complete npk fertilizer line. This seemingly simple machine contains exquisite engineering design, with each component carefully calculated to complete the “raw material metamorphosis” with high efficiency and consistent quality, making it a valuable asset across different fertilizer manufacturing systems.
1. The “Internal Organs” of Granulator
An efficient new type of stirring tooth organic fertilizer granulator is like a precision Swiss watch, with each part performing its own role:
Feeding System – Like the machine’s “mouth,” composed of a hopper and screw feeder. This “smart oral cavity” can precisely control “food intake” according to production needs, ensuring materials enter the granulation cylinder evenly and steadily.
The granulation cylinder is the machine’s “stomach,” made of stainless steel with diameters ranging from 0.5-2 meters and lengths of 1-3 meters. Its smooth inner wall is like a non-stick coating, preventing material adhesion and making the granulation process smoother.
The stirring teeth are the machine’s “teeth,” with 4-8 high-strength alloy steel stirring teeth arranged symmetrically, rotating at 300-1000 rpm, mixing and kneading materials thoroughly like a blender.
Organic Fertilizer Materials
Require fermentation and composting first, crushed to 40-80 mesh, with moisture content controlled in the “golden range” of 20%-30%
Compound Fertilizers
Basic fertilizers like nitrogen, phosphorus, and potassium are mixed in precise proportions, requiring mixing uniformity of over 85%
2. The “Metamorphosis” of Fertilizer Production
From raw materials to finished fertilizer, a gorgeous transformation takes place:
After pre-processed materials enter the granulation cylinder, the water spray device evenly sprays water or binder like spring rain. The high-speed rotation of stirring teeth generates strong centrifugal force, causing materials to gradually agglomerate into 1-5 mm pellets through collisions.
Newly formed pellets must pass through the screening “quality checkpoint,” with unqualified pellets sent back for “reprocessing.” Qualified pellets then enter the drying and cooling stage, with moisture reduced to below 10% and temperature lowered to room temperature, finally dressed in the “clothing” of woven bags or plastic bags, ready to head to the fields.
Interestingly, the entire granulation process is like making meatballs – it requires the right “mince” (raw materials), appropriate “mixing intensity” (rotation speed), and proper “moisture” (binder) to produce uniformly sized “meatballs” (fertilizer pellets).
This seemingly simple machine is actually an important promoter of agricultural modernization. It not only improves fertilizer utilization and reduces resource waste but also saves farmers from the toil of manual fertilization. Next time you see neat, uniform fertilizer pellets, remember the “magician” working silently behind them.
Double screws compost turning machines operate frequently in organic fertilizer fermentation workshops. Improper operation or untimely maintenance can easily lead to problems such as uneven turning, insufficient power, and equipment jamming, impacting fermentation progress.
1. Dead corners remain after turning, and some areas remain uncomposted
The main cause is excessive clearance between the spiral blades and the sidewalls of the fermentation tank (over 10 cm), or the double screws compost turning machine is moving too fast, preventing material from being turned over the edges. To address this, adjust the position of the spiral blades to reduce the clearance to within 5 cm. Also, reduce the double screws compost turning machine’s speed to ensure that every area is thoroughly turned.
2. Motor overload and tripping, insufficient power
This is often caused by excessive moisture content (over 70%) in the raw materials, resulting in increased friction on the spiral blades due to high viscosity, or by large impurities in the raw materials that may be blocking the blades. To address this, adjust the moisture content of the raw materials to 60%-65% before clearing impurities from the fermentation tank. If the compost tank is frequently overloaded, check the tightness of the motor belt and tighten or replace it.
3. Rapid wear of spiral blades, reducing turning capacity
This is primarily due to the presence of hard impurities (such as sand and gravel) in the raw materials, or the blade material not being suitable for wear resistance. To address this, install a screen to filter out hard particles before the raw materials arrive. Regularly inspect the blades for wear. If the blade thickness has decreased by 1/3 or cracks appear, replace them promptly.
Drum fertilizer dryers account for 25%-30% of a fertilizer production line’s total energy consumption. Whether routine operation and maintenance are effective directly impacts a company’s operating costs.
Accurate Maintenance of Thermal Efficiency
Hot air is the core energy source of a drum fertilizer dryer. The pipes connecting the hot air furnace and the drum must be regularly inspected. Damaged pipe insulation can lead to heat loss (up to 10% or more) and require prompt repair or replacement. Clean accumulated slag in the hot air furnace to ensure complete fuel combustion, increase thermal efficiency to over 75%, and reduce fuel waste.
Dynamic Adjustment of Drum Operating Parameters
Adjusting operating parameters based on changes in raw material moisture content can avoid inefficient energy consumption. When the moisture content of the wet material is low, appropriately reduce the hot air temperature and increase the drum fertilizer dryer speed (shortening the dwell time). When the moisture content is high, adjust the opposite direction. This ensures that every unit of energy consumed is used for effective dehydration, avoiding the waste of high energy consumption processing low-moisture materials.
Preventive Replacement of Wear Parts
Worn drum seals (such as the seals at the feed and discharge ports) can cause cold air to infiltrate and hot air to leak, increasing the heating load. Check the seals monthly and replace any signs of aging or deformation. Also, regularly inspect the lift plate. If loose or worn, tighten or replace it promptly. Simple preventive maintenance can significantly reduce future failures and energy costs.
In the fertilizer industry, the drying requirements of organic and compound fertilizers differ significantly. Organic fertilizers require rapid dehydration and fiber clumping prevention, while compound fertilizers require gentle drying to prevent particle breakage.
For drying organic fertilizers, drum fertilizer dryers offer two key design advantages: First, they utilize a “high-speed + multiple lifter” combination. High speed combined with dense lifters effectively lifts fibrous materials, preventing entanglement and clumping. Hot air also directly penetrates the material layer, quickly removing moisture. Second, an anti-stick coating on the inner wall of the drum reduces wet organic fertilizer from sticking to the wall, reducing cleaning frequency and ensuring continuous production.
For drying compound fertilizers, the drum fertilizer dryer emphasizes “gentle temperature control + low speed”: steam heating is used, keeping the temperature between 120-150°C to avoid direct contact with high temperatures that could cause cracking on the particle surface. Furthermore, a reduced drum speed reduces particle friction within the drum, keeping the particle breakage rate below 3%.
Even when processing temperature-sensitive biofertilizers, the drum fertilizer dryer can adapt to these needs through a “low-temperature hot air modification.” This reduces the hot air temperature to 60-80°C, prolonging the material’s residence time. This allows for slow dehydration while maintaining a microbial survival rate above 85%, truly achieving “one device, multiple fertilizers.”
Breaking site limitations to make efficient composting achievable on any terrain
Intelligent Working Principle: Perfect Dialogue Between Nature and Technology
On vast composting grounds, the crawler compost turner moves steadily over organic material piles like a tireless gardener. This essential compost fertilizer machine is a cornerstone of modern bio organic fertilizer production. Its unique working method elevates traditional composting processes to unprecedented levels, forming a critical part of the equipments required for biofertilizer production. While a large wheel compost turning machine serves similar purposes in different setups, the crawler type excels in stability and efficiency. As a vital fertilizer production machine, it works in harmony with other components to create a complete organic production line. This integrated system, a sophisticated organic fertilizer manufacturing machine in its own right, ensures the efficient transformation of raw organic waste into high-quality, nutrient-rich fertilizer, paving the way for sustainable agriculture.
As the equipment moves across material piles via its crawler travel mechanism, the turning mechanism penetrates deep into the material core like skilled hands. Mixing arms, blades, or spiral devices work their magic through rotation—lifting bottom material to the surface while bringing surface material to the depths. This three-dimensional mixing approach ensures thorough oxygen contact, creating an ideal environment for microbial growth. Through regular turning under suitable conditions, organic materials undergo a remarkable aerobic fermentation journey, ultimately transforming into rich organic fertilizer.
The six core features of the crawler compost turner make it uniquely positioned in the field of organic waste treatment, representing an ideal choice for modern composting operations.
Exceptional Terrain Adaptability
Crawler design provides outstanding stability, easily handling various challenging ground conditions including uneven, soft, or slippery surfaces
Superior Turning Effect
Carefully designed turning mechanism penetrates material core, achieving efficient and uniform mixing while significantly improving fermentation efficiency
High Automation Level
Automated control of turning and travel functions significantly reduces manual intervention and enhances production efficiency
Flexible Operation
Moderate equipment size and flexible operation perfectly adapt to various site requirements, including confined or irregular spaces
Eco-Friendly and Energy Efficient
Promotes resource utilization of organic waste, reduces environmental pollution, and maintains economical operational energy consumption
Durable Construction
Crawler and turning mechanisms manufactured with durable materials, built to last and capable of handling long-term high-intensity operations
The true value of the crawler compost turner lies in its perfect integration of industrial-grade reliability with practical agricultural environment needs. Whether in large farms, organic fertilizer production bases, or complex field conditions, this “all-terrain warrior” demonstrates through its outstanding performance that quality composting shouldn’t be limited by any site conditions.
Pioneering a New Era in Composting
In today’s global push for sustainable agriculture, crawler compost turners are opening new pathways for organic waste resource utilization with their unique advantages. They not only solve the operational challenges traditional composting equipment faces in complex terrain but also serve as important forces driving green agricultural development through their efficient and eco-friendly characteristics. From livestock manure treatment to crop straw utilization, this innovative equipment is writing new chapters in the circular economy story worldwide.
Crawler Compost Turner – Making every piece of land fertile ground for efficient composting
When selecting a rotary drum granulator, companies should pay close attention to its core structure to ensure it precisely matches their production line requirements. A rotary drum granulator primarily consists of a rotating drum, transmission, support system, and spray system. The performance of each component directly impacts the overall performance of the equipment.
The rotating drum, as the core working component, is constructed from rolled steel plate. Lifting plates or spiral blades on the inner wall enhance the tumbling and collision effect of the material. When selecting a granulator, consider whether the steel plate thickness and blade design are compatible with the characteristics of the production material. The transmission provides power, and the power and quality of the motor and reducer affect the equipment’s operational stability and should be selected based on production capacity.
The support system bears the weight and rotation of the drum. The selection of rolling or sliding bearings should be considered based on the equipment load and operating environment. Furthermore, the atomization effect of the spray system determines the accuracy of humidity control, ensuring uniform spraying of water or adhesive. Only by comprehensively considering these structural details can you select a rotary drum granulator that is compatible with your production line and operates efficiently.
