Organic fertilizer equipment forms the backbone of modern agricultural waste recycling systems, transforming diverse organic materials into standardized, nutrient-rich fertilizers. These mechanical systems streamline complex biological and physical processes, ensuring efficiency, safety, and consistency in fertilizer production. By categorizing equipment based on its role in the production chain, we can better understand how each component contributes to converting raw waste into valuable agricultural inputs.
1. Fermentation Equipment: The Foundation of Decomposition
Fermentation equipment initiates the critical process of stabilizing organic matter, breaking down complex compounds into simpler nutrients while eliminating pathogens. Two primary types dominate industrial applications:
● Compost Turning Machines
These are essential for aerobic fermentation, where oxygen supply is vital to microbial activity. Self-propelled hydraulic turners, suitable for large open-air compost piles (100-500 tons), feature rotating blades that lift and aerate materials, reducing compaction and homogenizing temperature. For smaller operations, 槽式翻抛机 (trough turners) with chain-driven paddles handle 10-50 ton batches, operating within enclosed troughs to control odor and retain heat. Both types maintain pile temperatures at 55-65°C—ideal for thermophilic bacteria—accelerating decomposition from 3-6 months (natural composting) to 20-30 days. A 200-ton capacity hydraulic turner, for example, can process a 100-meter-long pile in 2-3 hours, ensuring each section is turned every 2-3 days to prevent anaerobic zones.
● Fermentation Tanks
These closed systems offer precise control over temperature, moisture, and oxygen, making them suitable for high-moisture materials like food waste (70-80% moisture) and poultry manure. Horizontal cylindrical tanks, equipped with internal agitators and aeration pipes, process 5-50 tons per batch. They maintain a consistent 60-70°C using jacketed heating or recirculated hot air, achieving pathogen kill rates exceeding 99% (including Salmonella and E. coli). Some advanced models integrate biofilters to neutralize ammonia emissions, addressing environmental concerns. A 20-ton tank can complete fermentation in 7-10 days, compared to 15-20 days for open systems, making it ideal for facilities near urban areas or strict odor regulations.
2. Crushing and Mixing Equipment: Homogenizing Raw Materials
After fermentation, materials require processing to achieve uniform particle size and nutrient distribution—key for consistent fertilizer quality.
● Organic Fertilizer Crushers
Hammer mills with adjustable screens (1-5mm) are widely used to break down hardened compost clumps, reducing particle size to ensure even nutrient release. For fibrous materials like straw-amended manure, vertical shaft crushers with rotating blades shred tough cellulose into fine fragments. Specialized semi-wet material crushers, featuring anti-blocking reverse scrapers, handle high-moisture (60-70%) materials without clogging—critical for processing pig manure or kitchen waste. A 5-ton/hour crusher can reduce 30mm clumps to 2mm particles, increasing surface area for better mixing with additives.
● Mixers
Double-shaft paddle mixers dominate this category, blending fermented materials with nitrogen supplements (e.g., urea) or trace elements (zinc, boron) to adjust nutrient ratios. These machines, with capacities of 1-10 tons/batch, use counter-rotating paddles to create turbulent flow, achieving 95% uniformity in 3-5 minutes. For granular additive integration, ribbon mixers with outer helical blades gently fold powders into the material stream, preventing segregation. A 3-ton mixer, for instance, can blend 2.5 tons of fermented manure with 500kg of straw powder and 20kg of trace elements, ensuring the final C/N ratio stays within the optimal 25:1-30:1 range.
3. Granulation Equipment: Shaping Fertilizer for Utility
Granulation converts powdered materials into free-flowing particles, enhancing handling, storage, and application efficiency. Three main technologies cater to different material properties:
● Disc Granulators
Rotating discs (1.5-5 meters in diameter) tilted at 30-45° create spherical granules by agglomeration. As material is fed onto the disc, spray nozzles add binder solutions (e.g., molasses or clay slurries) to form nuclei, which grow into 2-5mm granules as they tumble. Suitable for low-moisture (25-35%) materials like cattle manure, disc granulators operate at 10-15 tons/hour with 80% granule uniformity. They excel at producing small to medium granules ideal for greenhouse crops.
● Extrusion Granulators
These machines force material through die holes (1-8mm) using rotating screws, producing cylindrical pellets. High-pressure models (50-80 bars) handle high-fiber materials, while low-pressure versions suit sticky substrates like poultry manure. Extrusion avoids drying before granulation, working with 30-40% moisture content—advantageous for energy savings. A 5-ton/hour extrusion line can produce 3mm pellets with minimal dust, favored for organic rice and wheat cultivation.
● Double-Roller Granulators
Two counter-rotating rollers with concave pockets compress powdered material into dense flakes, which are then crushed and screened into 2-6mm granules. This dry granulation process requires no binders, making it ideal for heat-sensitive additives like microbial inoculants. With capacities up to 20 tons/hour, they’re used in large-scale operations producing fertilizer for export or industrial agriculture.
4. Drying and Cooling Equipment: Stabilizing Granules
Post-granulation, moisture control ensures shelf stability and prevents caking.
● Drying Machines
Rotary drum dryers, inclined at 3-5°, use hot air (80-120°C) to reduce granule moisture from 30-35% to <15%. Material tumbles through the drum as hot air flows countercurrently, achieving uniform drying. For heat-sensitive products (e.g., those with beneficial microbes), low-temperature belt dryers (50-60°C) use forced air, preserving microbial activity. A 10-ton/hour rotary dryer can process 12-ton batches of granules in 45 minutes, with energy consumption of 80-100 kWh/ton.
● Cooling Machines
Counterflow coolers rapidly reduce dried granules from 60-80°C to ambient temperature, preventing moisture reabsorption. Ambient air is drawn through the granule bed, exchanging heat to cool them to within 5°C of room temperature. A 10-ton/hour cooler ensures granules reach stable moisture levels (<12%), critical for storage—uncooled granules can develop mold within weeks, ruining entire batches.
5. Packaging Equipment: Finalizing for Market
Automatic packaging systems ensure accurate, efficient, and hygienic final processing.
● Weighting and Sealing Machines
Belt-type weighing scales (5-50kg/bag) use load cells for precision (±0.2%), filling woven polypropylene or paper bags. Sewing machines or heat sealers close bags, with options for automatic palletizing. High-speed lines (30-50 bags/minute) integrate metal detectors to ensure product safety, meeting export standards. Smaller facilities use semi-automatic systems (5-10 bags/minute), balancing cost and efficiency.
Each equipment category plays a synergistic role: fermentation breaks down waste, crushing and mixing ensure uniformity, granulation adds utility, drying and cooling stabilize the product, and packaging readies it for market. Together, they enable the transformation of 100 tons of agricultural waste into 60-70 tons of high-quality organic fertilizer—closing the loop in sustainable agriculture.
