The roller extrusion granulator represents a leap forward in organic fertilizer production technology, born from the integration of advanced German granulation expertise and localized innovation. Our company’s R&D team spent three years refining this equipment, conducting over 500 trials with diverse organic materials—from livestock manure to crop straws—to optimize its performance. Unlike traditional granulators that rely on high temperatures or binders, this machine uses mechanical pressure to compress powdered materials into dense granules, making it ideal for heat-sensitive additives like microbial inoculants and low-binder organic formulations. Its compact design (occupying just 15-20㎡ of floor space) and energy efficiency (consuming 80-100 kWh per ton of granules) have made it a cornerstone of small to medium-sized organic fertilizer plants worldwide.
Main Performance Characteristics: Engineering Excellence in Every Detail
1. Inclined Wheel Roller Design: Redefining Efficiency
The hallmark innovation of this granulator is its inclined wheel roller system, a departure from the flat die designs common in conventional equipment. The rollers are angled to ensure that the linear speed of both inner and outer rings of the die plate remains consistent (3.5-4.5 m/s), eliminating the "speed differential friction" that plagues flat die machines. This alignment reduces resistance by 30-40%, cutting energy consumption by 15-20% compared to similar models. Field data shows that the inclined wheel design extends die life from 500 tons (flat die) to 1,200-1,500 tons, as the uniform pressure distribution minimizes wear. A trial at a 5,000-ton/year organic fertilizer plant in Shandong Province found that this feature reduced mold replacement costs by $12,000 annually.
2. Uniform Roller Arrangement: Preventing Feeding Interruptions
Equipped with 2-4 symmetrically distributed rollers (depending on model), the granulator ensures steady material flow into the compression zone. Each roller is precision-balanced to within 0.05mm, eliminating the "material bridging" and uneven feeding that often halt production in single-roller or offset designs. This stability is particularly critical for fibrous materials like straw or wood chips, which tend to clump. In tests with 30% straw-amended manure, the machine maintained a consistent output of 1.5-2 tons/hour, compared to 0.8-1.2 tons/hour with conventional granulators prone to jamming.
3. Adjustable Pressure System: Versatility Across Materials
The medium-pressure adjustment structure allows operators to vary compression force from 50-120 bars, adapting to materials with different compressibility. For example, chicken manure (high in organic colloids) requires 60-80 bars to form dense granules, while wood chips (low cohesion) need 100-120 bars. The roller components are forged from high-chromium alloy steel (HRC 58-62), resisting abrasion even when processing gritty materials like composted municipal sludge. A farm in Brazil processing sugarcane bagasse reported that the rollers showed minimal wear after 800 hours of operation—three times the lifespan of standard carbon steel rollers.
4. Interchangeable Dies: Custom Granules for Every Need
The granulator supports a wide range of die apertures (2-30mm), enabling production of granules from fine 2mm pellets (ideal for seedling fertilizers) to coarse 30mm prills (used in orchards). Die changeover takes just 30-45 minutes with a quick-release system, allowing plants to switch between products without lengthy downtime. A Netherlands-based organic fertilizer manufacturer uses this flexibility to produce 12 different granule sizes for specialized crops, from 3mm for greenhouse vegetables to 10mm for vineyards.
Key Advantages: Built for Longevity and Profitability
1. Enlarged Pressure Wheels: Enhancing Durability
The pressure wheels are 30% larger in diameter (300-400mm) than standard designs, housing oversized bearings (6208-6212 series) that boost pressure capacity by 50%. This reinforcement allows the machine to handle sudden spikes in material density without component failure—a common issue in smaller rollers.
2. Heat Insulation: Protecting Critical Components
The enlarged wheel design creates a natural heat barrier, preventing frictional heat (generated during extrusion) from reaching the bearing chamber. Temperatures in the chamber remain below 60°C, preserving lubricating grease integrity and extending bearing life to 1,500-2,000 hours—double that of machines where heat transfers freely.
3. Repairable Rollers: Reducing Lifecycle Costs
The pressure wheels feature a wear-resistant surface that can be reconditioned 2-3 times via grinding, restoring their original dimensions. Each repair costs 30-40% less than replacing the roller, lowering annual maintenance expenses by $8,000-10,000 for a medium-sized plant.
4. Increased Pressing Area: Boosting Output
The multi-roller configuration expands the effective compression area by 40-60% compared to single-roller models, increasing production efficiency to 2-5 tons/hour (depending on material and granule size). A 10,000-ton/year facility in Australia upgraded from a single-roller machine and saw output rise by 35% while reducing energy use per ton.
Scope of Application: Versatility Across Challenging Materials
This granulator excels in low-temperature granulation, making it perfect for heat-sensitive biological fertilizers containing beneficial microbes (e.g., Bacillus subtilis), where temperatures above 60°C would kill the organisms. Its ability to process low-bonding materials is particularly valuable for:
● Agricultural Residues: Wood chips, rice husks, and crop straws (e.g., corn stalks, cotton stalks) with high fiber content (30-50%) and low natural cohesion.
● Organic Wastes: Municipal solid waste compost, food processing by-products (e.g., brewery spent grain), and livestock manure with moisture content 20-30%.
● Specialty Formulations: Low-nutrient organic fertilizers requiring minimal binders, such as those used in organic certification systems (e.g., EU Regulation 834/2007).
In a notable application, a Vietnamese facility uses the granulator to process 20 tons/day of coffee husks and pig manure, producing a 5mm organic fertilizer pellet that sells for a 20% premium over powdered alternatives. The machine’s ability to handle these diverse materials without additives has made it a linchpin of their circular agriculture model.
Conclusion: A Catalyst for Sustainable Fertilizer Production
The roller extrusion granulator embodies the principles of efficient, flexible, and cost-effective organic fertilizer manufacturing. Its innovative design addresses the key pain points of traditional granulation—high energy use, frequent downtime, and limited material compatibility—while meeting the growing demand for stable, easy-to-apply organic products. Whether for small-scale farms or large industrial plants, this equipment bridges the gap between raw organic waste and high-quality fertilizer, supporting the global shift toward sustainable agriculture. As organic farming continues to expand, the roller extrusion granulator stands ready to play a pivotal role in converting waste into wealth, one granule at a time.
