New type two in one organic fertilizer granulator

The new type of organic fertilizer granulator is a composite organic fertilizer granulation equipment that integrates crushing, mixing, and granulation. This equipment integrates the strong shearing and spheroidizing function of a wet-process stirring toothed granulator with the shaping and densifying function of a drum rounding machine into a single sealed casing, achieving highly efficient "one-time powder feeding, one-time spherical output" forming. The equipment is particularly suitable for projects requiring near-spherical appearance, high spheroidization rates, and the production of pure organic fertilizer without the addition of inert binders. With its outstanding advantages of multi-functionality, increased efficiency, low consumption, and resistance to material blockage, this equipment has become the preferred choice for lightweight and standardized organic fertilizer production.

Component composition and functional zoning

From a production process perspective, the new type of organic fertilizer granulator can be divided into the following functional units:

(I) Feeding Pre-treatment Unit: Includes a feeding hopper and a mixing device, used to receive and initially mix the fermented organic raw materials.

(II) Crushing and Refining Unit: Contains a high-speed rotating crushing rotor, with alloy hammers on the rotor violently striking the material at extremely high linear speeds. The fineness of the crushed material can reach 0.5-1mm.

(III) Granulation and Forming Unit: Includes a stirring tooth assembly or an extrusion assembly, which is the core station for granulation. The stirring teeth adopt a precise mechanical layout, forming a self-cleaning barrier during high-speed rotation.

(IV) Spheroidizing and Polishing Unit: Includes a rotating drum or disc system, used for rolling densification and surface polishing of the nascent granules.

(V) Screening and Return Unit: Contains a built-in screening device and return channel, realizing automatic separation of qualified and unqualified products.

Production line roles and processes

The new type of integrated organic fertilizer granulator plays a crucial role in the granulation stage of an organic fertilizer production line. The complete process flow is: aerobic fermentation of raw materials → crushing and screening → integrated granulation → drying → cooling → screening → packaging. This equipment combines the traditional "crusher + granulator" processes into one, eliminating the need for intermediate conveyor belts and elevators, significantly simplifying the production process.

For small and medium-sized organic fertilizer plants, the integrated granulator can serve as the core granulation equipment; in large-scale farms, it can directly process livestock and poultry manure without the need for transportation; in solid waste treatment centers, it can process municipal sludge, kitchen waste, and other waste. The equipment can operate independently or be combined with crushing and screening equipment to form a complete production line.

Granulation process and stages

The granulation process of the new organic fertilizer two-in-one granulator is a new wet continuous pusher granulation process. The entire process is divided into the following stages:

Crushing and refining stage: After the fermented semi-wet material (water content 25%-45%) enters the feed port, it first encounters the high-speed rotating crushing rotor. The alloy hammer on the rotor completely breaks up large pieces of hardened materials, incompletely decomposed straw fibers and agglomerated bacteria residue. Pre-pulverization eliminates the hidden danger of "material jamming" during the granulation process and refines the materials to an excellent granulation size.

Mixing and agglomeration stage: The crushed fine powder enters the granulation chamber and quickly agglomerates and nucleates under the combined action of the high-speed stirring of the stirring teeth and the liquid phase (water or bacterial agent). The material stays in the machine for a very short time, but it completes the qualitative change from "waste" to "commodity".

Spheroidization and densification stage: the primary particles enter the drum cavity or disc system, continuously roll and collide under the action of centrifugal force and friction, and are further densified and polished.

Screening and discharge stage: The formed particles are classified by the built-in screening device, qualified particles are directly discharged, and unqualified particles are sent back to the granulation area through the return channel for secondary granulation.

Pre-fermentation and material preparation
The new type of organic fertilizer granulator does not directly participate in fermentation, but it has specific requirements for the degree of fermentation of the feed materials. The feed materials must be fully decomposed, deodorized, and ground to the required fineness. Organic raw materials (livestock manure, straw, etc.) must first undergo aerobic fermentation and secondary aging, during which fermentation bacteria are added to decompose coarse fibers. The moisture content of the fermented material should be controlled between 22% and 38%. Direct feeding of fluidized wet materials with a moisture content >45% or completely dry powder with a moisture content <12% is strictly prohibited.

Operating procedures and key control points

The operating procedure for the new type of organic fertilizer granulator is as follows:

Pre-start preparation:Conduct a comprehensive inspection of the main body of the equipment, checking for deformation, cracks, or damage; check the tightness of the transmission components; check the surface of the mold for smoothness and blockage; lubricate all lubrication points according to the instruction manual; check the electrical system wiring for correctness and secureness; install a permanent magnet separator and a screen in the material feeding path.

No-load commissioning:Start the main motor and run it at low speed for 3-5 minutes, observing whether the equipment runs smoothly. Run it continuously without load for at least 20-30 minutes.

Load operation:Feed the material slowly, adjusting the speed (generally 10-20 rpm) and feed rate according to the material characteristics. Monitor the load using the ammeter on the panel.

Process monitoring:Check the granule quality every 15-30 minutes; listen for any metallic impact noises during the shift; immediately stop the machine if severe vibration or a burnt smell is detected.

Application effectiveness and industrial contribution
The new integrated organic fertilizer granulator has demonstrated outstanding application effects in small and medium-sized organic fertilizer production. Equipment investment is reduced by 40%-50% compared to the traditional separate production line; the floor space is reduced to 1/3-1/2 of the traditional production line; energy consumption per ton is reduced by 30%-40%; material loss rate is controlled within 3%; and only 1-2 operators are needed to complete the entire process. The equipment operates stably with a low failure rate, providing strong support for improving the quality and efficiency of organic fertilizer production.