Scale: Small, Medium, Large
Daily Production Capacity: 5-10 tons, 10-50 tons, 50-100 tons
Lot Size: 500-800㎡, 1000-2000㎡, 2500㎡
Main equipment configuration: fermenter/compost turner + feeder + crusher + drum screen + packaging machine
Processed Raw Materials: Livestock and poultry manure, straw, rice husks, sawdust, mushroom residue, kitchen waste, distiller's grains, vinegar grains, etc.
The production process of powdered organic fertilizer can be divided into four major steps: pretreatment → fermentation and composting → further processing → finished product packaging. The core equipment for each step is as follows:
1. Pretreatment: Adjusts the raw material moisture and carbon-nitrogen ratio (C/N) and removes impurities in preparation for fermentation.
●Pulverizer: Grinds crude fiber materials such as straw and branches to a 20-50 mesh size for easier mixing and fermentation.
●Screener: Removes impurities such as stones, metal, and plastic from the raw materials.
●Mixer: Mixes manure with crushed straw and other auxiliary materials in appropriate proportions, adjusting the moisture content to 50%-60% and the carbon-nitrogen ratio to 25:1-30:1.
2. Fermentation and composting: Microorganisms decompose organic matter, killing pathogens, insect eggs, and weed seeds, rendering it harmless and stabilizing.
Fermentation Equipment:
●Small-scale production lines utilize windrow fermentation with a turner (tracked or wheeled). Turning provides oxygen and dissipates heat, accelerating composting. The cycle is approximately 15-20 days. Medium-to-large production lines: Use tank fermentation with a tank turner or sealed fermentation tanks.
●Deodorization Equipment: Ammonia and other odors are generated during the fermentation process, requiring deodorization systems such as spray towers and biofilters to meet environmental emission standards.
3. Further Processing: Process the composted material into a uniform, dry powdered product.
●Dryer: If the moisture content of the composted material is too high, it must be dried to below 20% to prevent clumping and mold. Drum dryers or fluidized bed dryers are commonly used.
●Secondary Grinding: Composted material may clump, requiring re-grinding using a vertical grinder or cage grinder to ensure the required fineness.
●Screening Machine: Secondary screening removes impurities from incomplete composting and ensures uniformity of the finished product.
●Replication Equipment: If producing functional organic fertilizer, precise addition is required using a metering and mixing system, followed by mixing in a mixer.
4. Finished Product Packaging: The powdered organic fertilizer is packaged in fixed quantities for easy storage and transportation. Automatic packaging machine: Weighing packaging machine can realize automatic metering and sealing, and supporting conveying equipment to connect the production line.
Powdered organic fertilizer production line process flow:
1. Raw material collection and pretreatment
Raw material selection: The main raw materials are livestock and poultry manure, agricultural waste, and industrial organic waste. The carbon-nitrogen ratio and moisture content of the raw materials must be maintained. If the ratio is too high, dry materials should be added to adjust it; if it is too low, water should be added.
Crushing and mixing: Crude fiber materials such as straw are crushed and mixed with manure to adjust the moisture and carbon-nitrogen ratio in preparation for fermentation.
2. Aerobic fermentation
Waste management: The mixed raw materials are stacked into windrows or placed in fermentation tanks.
Turning and fermentation: A tiller is used to regularly turn the pile and maintain a temperature of 55-75°C to kill pathogens, insect eggs, and weed seeds. The fermentation cycle typically lasts 10-15 days, until the material is mature, dark brown, odorless, and loose to the touch.
3. Pulverization and screening
Pulverization: The matured material is crushed in a grinder to break up lumps and refine the particles. Screening: Impurities and large lumps are removed through a screening machine to obtain a semi-finished product with uniform particle size.
4. Ingredient Mixing
Based on the product's nutritional profile, the screened organic fertilizer, inorganic fertilizer, and functional additives (such as humic acid and microbial agents) are mixed in a mixer in appropriate proportions and thoroughly mixed.
5. Drying (Optional)
Reducing the moisture content of the material to prevent mold during storage.
6. Finished Product Packaging
The dried powdered material is conveyed via a conveyor belt to a quantitative packaging machine, which automatically measures, bags, and seals the product for final storage or shipment.
Advantages of the Powdered Organic Fertilizer Production Line:
1. Comprehensive Nutrition:
Rich in organic matter, nitrogen, phosphorus, potassium, and trace elements, combined with active substances such as humic acid and beneficial bacteria, the fertilizer has a long-lasting effect improving soil and promoting crop growth.
2. Environmentally Friendly:
Using organic waste as raw material, it reduces pollution and is a low-carbon production method. Long-term use improves soil quality, meeting the needs of ecological agriculture.
3. Wide Application:
Suitable for a variety of crops and soils, it can be used as a base fertilizer or topdressing, with flexible application methods and compatibility with other fertilizers.
4. Cost-Effective:
Low raw material costs, simplified production processes, low equipment investment and energy consumption, affordable prices, and strong market demand.
5. Safe and Stable:
High-temperature composting kills pathogens, bacteria, and insect eggs. Standardized production ensures uniform particle size and nutrient content, meeting national standards.
Comparison Dimension | Small production line | Medium-sized production line | Large production line |
Hourly output | 1-5 tons | 5-20 tons | 20+ tons |
Applicable Scenarios | Family farms, small breeding farms, small workshops | Small and medium-sized fertilizer plants, agricultural cooperatives, and medium-sized farms | Large fertilizer enterprises and large-scale breeding bases |
Degree of automation | Low, mainly dependent on manual operation | In the process, key links (turning and packaging) are automated, while some links require manual labor. | High, full-process PLC control system, capable of remote monitoring and automatic adjustment |
Fermentation method | Strand fermentation (open air stacking, cycle 15-20 days) | Mainly tank fermentation, some with small fermentation tanks | Closed fermentation tanks / large tank fermentation, which can precisely control temperature and humidity |
What raw materials can a powdered organic fertilizer production line process? What are the raw material requirements?
It can process organic waste such as livestock and poultry manure, crop straw, mushroom residue, distiller's grains, and food waste. The raw material moisture content must be controlled between 50% and 60% . It must be free of large metal pieces, rocks, and other impurities. Furthermore, the food waste must be free of grease and salt to prevent fermentation from interfering.
Does the fermentation process produce foul odors? How are environmental issues addressed?
The fermentation process produces odors such as ammonia, which require environmental protection equipment. Small production lines can use simple covering or spraying for deodorization; medium- and large-scale production lines require systems such as spray towers and biofilters to absorb and decompose odors. Furthermore, wastewater from equipment cleaning must be collected and treated to avoid direct discharge and ensure compliance with local environmental approval standards.
Is the investment cost significantly different for production lines of different sizes? How long does it take to recoup the investment?
The difference is significant. Equipment investment for a small-scale line is 100,000-300,000 yuan, for a medium-sized line 500,000-1.5 million yuan, and for a large-scale line several million to ten million yuan. The payback period is affected by raw material costs, capacity utilization, and market price. Generally, it takes 1-2 years for a small-scale line and 2-3 years for a medium- to large-scale line.
What is the production cycle for powdered organic fertilizer? How many days does it take from raw materials to finished product?
The total cycle is approximately 15-30 days, depending on the fermentation method: windrow fermentation takes 15-20 days, tank fermentation takes 7-10 days, and closed fermentation tanks take 5-7 days. Subsequent processing (drying, crushing, and packaging) takes approximately 1-3 days. Medium- to large-scale production lines have a shorter overall cycle due to their high degree of automation.
What is the storage and shelf life of finished powdered organic fertilizer?
Store in a ventilated, dry place, away from rain, and avoid direct sunlight and moisture. Packaged in moisture-proof woven bags, the unopened product has a shelf life of 6-12 months. Once opened, it should be used as soon as possible, preferably within 1 month.
Can the production line flexibly adjust the product fineness? Can other nutrients be added?
Yes. By changing the pulverizer screen (20-60 mesh), the fineness can be adjusted to meet the needs of different crops . If functional organic fertilizer is to be produced, trace elements, humic acid, probiotics, etc. can be added through the metering and mixing system, and the final product remains in powder form.
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