Organic Fertilizer Processing Line

With the deepening global transition toward ecological agriculture and resource recycling, converting livestock and poultry farming waste, agricultural straw, municipal sludge, and industrial organic solid waste into high-quality organic fertilizer has become a core pathway for achieving sustainable agricultural development. However, raw organic waste generally possesses complex physical characteristics such as high moisture content, strong viscosity, easy agglomeration, and mild acidic or alkaline corrosiveness. These characteristics impose stringent requirements on the stability, continuous operating capability, wear resistance, and corrosion resistance of processing equipment.

Zhengzhou Yizheng Heavy Machinery Equipment Co., Ltd., as a professional enterprise in the global fertilizer engineering and heavy equipment manufacturing industry, has long been committed to the research, development, and innovation of organic fertilizer processing technologies and equipment. With solid manufacturing capabilities and extensive engineering experience, the company provides global customers with complete organic fertilizer processing line solutions covering raw material pretreatment, biological fermentation, fine crushing, mixing and batching, granule forming, high-temperature dehydration, cooling and hardening, and automatic packaging, thereby promoting the organic fertilizer industry toward large-scale, automated, and intelligent development.

I. Product Overview

The complete organic fertilizer processing line manufactured by Zhengzhou Yizheng Heavy Machinery is a highly efficient industrial production system integrating modern biotechnology, automated control, and mechanical manufacturing technologies. The production line is specifically designed to process various organic wastes, transforming scattered, high-moisture, and polluting raw materials into high-value commercial organic fertilizers with uniform nutrients, high density, rounded appearance, and convenient storage and transportation through standardized industrial processes.

The complete production line offers a high degree of modular expandability, with annual production capacities ranging from 10,000 to 200,000 tons. The system can be custom-engineered according to the customer’s actual plant layout, investment scale, and raw material characteristics, such as chicken manure, cattle manure, pig manure, sheep manure, biogas residue, mushroom residue, bagasse, and municipal organic waste. The entire line integrates an intelligent PLC central control system to achieve dynamic equipment interlocking and real-time monitoring of material flow, effectively reducing labor costs and creating a modern green fertilizer plant with low dust emissions and low energy consumption.

Organic fertilizer processing production lines generally include raw material processing equipment, fermentation equipment, granulation equipment, drying equipment, screening equipment, and other equipment.

Raw material processing equipment is mainly used for crushing, mixing, and other treatment of organic waste, such as crushers and mixers.

Fermentation equipment is mainly used for fermenting raw materials, such as biogas slurry tanks and composting piles.

Granulation equipment is mainly used to process fermented organic materials into granular fertilizer, such as flat-die granulators and spherical granulators.

Drying equipment is mainly used to dry the produced fertilizer, such as rotary dryers and airflow dryers.

Screening equipment is mainly used to screen and classify dried fertilizer, such as vibrating screens and circular vibrating screens.

In addition to the above equipment, supporting conveying equipment, weighing and packaging equipment, and other systems can also be selected according to production requirements.

II. Working Principle

The operation of an organic fertilizer processing line is a continuous and highly coordinated physical and biological transformation process. The organic fertilizer processing technology developed by Zhengzhou Yizheng Heavy Machinery mainly includes the following seven core sections:

Raw Material Pretreatment and Biological Fermentation Section

After entering the plant, the moisture content of raw organic materials is first adjusted and maintained at 55%–65%, while the carbon-to-nitrogen ratio (C/N) is also adjusted. The prepared materials are conveyed into fermentation trenches or fermentation tanks, where groove-type compost turners or crawler-type compost turners perform regular turning and forced aeration. Under suitable conditions, aerobic microorganisms rapidly multiply and generate high temperatures of 55°C–70°C, which are maintained for 7–14 days to thoroughly eliminate pathogens, parasite eggs, and weed seeds, completing the harmless treatment and maturation of the material.

Fine Material Crushing Section

After fermentation, the organic material generally has a moisture content of 20%–40% and contains agglomerates and fibers of varying sizes. The material is conveyed into a semi-wet material crusher, which uses high-speed rotating dual-row wear-resistant rotors and blades to apply intensive impact, shearing, and tearing forces, rapidly reducing the material into fine powder suitable for granulation. This process effectively solves the industry problems of wall adhesion and blockage caused by high-moisture materials.

Dynamic Weighing and Precision Mixing Section

To ensure balanced nutrient content in the finished fertilizer, the crushed organic base material, inorganic nutrients (nitrogen, phosphorus, and potassium), and trace elements are fed into a multi-bin dynamic batching machine according to a predetermined formula. The batching machine performs precise metering through high-precision weighing sensors and variable-frequency feeding mechanisms. The materials are then discharged into a twin-shaft horizontal mixer. Driven by counter-rotating twin-shaft paddles, the materials undergo cross-convection and kneading, achieving highly uniform molecular-level mixing within a very short period.

Composite Shaping and Granule Forming Section

The uniformly mixed material enters the granulator, such as a new-type stirring-tooth granulator or rotary drum granulator. Under the combined action of high-speed rotating mechanical stirring teeth and centrifugal force generated by the drum, the fine powder rapidly aggregates into spherical granules under the influence of surface tension, achieving a granulation rate exceeding 95%, a dense internal structure, and a rounded appearance.

High-Temperature Dehydration and Cooling Solidification Section

Freshly granulated particles contain relatively high moisture and have a soft structure. The material is conveyed through the upper feed inlet at the front end of the dryer and enters the dryer. The drum is equipped with composite lifting flights designed through thermal engineering calculations. As the drum rotates slowly, the particles are continuously lifted to form a uniform material curtain and undergo thorough heat exchange with the high-temperature airflow supplied by the hot air furnace. After drying, the material is discharged through the lower outlet at the rear end onto the conveyor belt, significantly reducing particle moisture content.

The high-temperature particles are then conveyed through the upper feed inlet at the front end of the cooler and enter the cooler. Ambient cold air is forcibly introduced for rapid cooling. After cooling, the material is discharged through the lower outlet at the rear end onto the conveyor belt. This process rapidly hardens the granules, significantly improves their strength, and brings them to safe storage standards.

Multi-Stage Classification and Closed-Loop Recycling Section

The cooled granules are conveyed through the upper feed inlet into the rotary screening machine. High-strength screens with different aperture sizes accurately separate the material. Qualified finished granules proceed to the next process section. Oversized particles are discharged through the lower outlet and returned to the crusher for reprocessing. Undersized particles are returned to the granulator for secondary granulation, achieving zero-waste closed-loop production throughout the entire line.

Coating, Anti-Caking, and Quantitative Packaging Section

Qualified granules enter the rotary coating machine for surface powder coating or oil spraying, forming a dense protective film that enhances moisture resistance and compressive strength. Finally, the material enters the automatic quantitative packaging machine, where a computerized control system performs precision weighing, automatic discharging, bag clamping, sewing, and sealing to complete finished product packaging.

III. Product Applications

The organic fertilizer processing line manufactured by Zhengzhou Yizheng Heavy Machinery Equipment Co., Ltd. offers broad material adaptability and process flexibility and is widely used in the following fields:

- Livestock and Poultry Waste Resource Utilization Projects: Suitable for the harmless deep processing of manure from large chicken, pig, cattle, and sheep farms, converting harmful waste into high-quality commercial organic fertilizer.

- Comprehensive Utilization of Agricultural and Forestry Waste: Used for processing large quantities of agricultural and forestry residues such as crop straw, rice husks, peanut shells, mushroom residue, bagasse, and distiller’s grains.

- Urban Environmental Protection and Municipal Sludge Treatment: Applied in projects involving the reduction, harmless treatment, and resource utilization of sludge from municipal wastewater treatment plants, food waste, and organic solid waste.

- Bio-Organic Fertilizer and Compound Fertilizer Manufacturing: Specific functional microbial inoculants or inorganic nutrients are added during the mixing and granulation stages to produce premium bio-organic fertilizer and organic-inorganic compound fertilizer.

IV. Product Features

- Modular Design with High Layout Flexibility

The production line adopts a modular structure and can be flexibly designed as a straight-line, L-shaped, U-shaped, or multi-level layout according to the customer’s actual plant dimensions (length, width, and height) and terrain conditions, maximizing plant space utilization.

- Intelligent PLC Control and Automated Operation

The entire production line is equipped with an advanced PLC central control system and Human-Machine Interface. It includes individual machine current monitoring and interlocking protection functions. The upstream feeding speed can be automatically adjusted according to the downstream equipment load, effectively preventing material accumulation, blockage, and idle operation.

- Industrial-Grade Corrosion and Wear Resistance for Long Equipment Life

To withstand high-moisture, mildly acidic or alkaline materials and corrosive gases, critical components such as mixer liners, granulator stirring teeth, dryer and cooler lifting flights, and screening machine frames are manufactured from thickened wear-resistant alloys or lined with ultra-high molecular weight polyethylene anti-stick panels, significantly reducing equipment wear and corrosion.

- Energy-Efficient, Environmentally Friendly, and Dust-Free Workshop

The airflow systems of the dryer and cooler are optimized through thermal fluid dynamics, achieving high heat utilization efficiency and significantly reducing energy consumption. All material transfer points are equipped with enclosed covers and high-efficiency cyclone dust collection and water curtain dust suppression systems, ensuring that the workshop environment complies with environmental protection standards.

- Excellent Granule Quality and High Granulation Rate

The granulation and thermal processes are perfectly integrated, producing fertilizer granules with a granulation rate exceeding 95%, uniform particle size, smooth surfaces, and high physical compressive strength, effectively preventing moisture absorption and caking during transportation and storage.

V. Product Specifications

The following table provides standard technical reference data for complete organic fertilizer processing lines with different production capacities manufactured by Zhengzhou Yizheng Heavy Machinery:

 (Note: The above parameters are based on standard process configurations. Actual data can be adjusted and customized according to the customer’s raw material characteristics and specific process requirements.)

Building an efficient, stable, and durable organic fertilizer processing line is the foundation for fertilizer manufacturers to reduce costs, improve efficiency, and expand market share.

With years of R&D expertise in fertilizer equipment, a rigorous quality control system, and a comprehensive after-sales engineering service network, Zhengzhou Yizheng Heavy Machinery Equipment Co., Ltd. remains committed to providing global customers with complete organic fertilizer processing equipment of advanced technical standards and reliable quality. From individual equipment selection to complete Turnkey Projects, Zhengzhou Yizheng Heavy Machinery will continue to leverage its professional technical expertise to help customers transform organic waste into green value and promote the high-quality development of circular agriculture.

For more inquiries or more information, please contact:

Sales Department / Tina Tian
+86 – 15538237222
Zhengzhou Yizheng Heavy Machinery Equipment Co., Ltd
Email: tianyaqiong@yz-mac.cn
Website: www.yz-mac.com