With the global transition toward green, low-carbon agriculture and soil restoration, the harmless treatment and resource utilization of livestock manure, crop straw, and municipal organic waste have become central to modern agricultural industrialization. Organic fertilizers not only effectively increase soil organic matter and improve soil aggregate structure but also significantly enhance crop quality and yield. However, organic waste materials generally possess characteristics such as high moisture content, high viscosity, corrosiveness, and complex compositions, placing stringent demands on the continuity, stability, wear resistance, and corrosion resistance of industrial production equipment.
As a leading enterprise in international fertilizer engineering and heavy equipment manufacturing, Zhengzhou Yizheng Heavy Machinery Equipment Co., Ltd. has been dedicated to the research, development, and manufacturing of organic fertilizer production technologies and equipment for decades. Leveraging extensive engineering expertise and advanced manufacturing capabilities, the company provides complete organic fertilizer production line solutions covering process planning, equipment selection, manufacturing, installation, commissioning, and operational support for customers worldwide.
I. Product Overview
The complete organic fertilizer production line manufactured by Zhengzhou Yizheng Heavy Machinery is a highly efficient industrial production system specifically designed for large-scale, automated, and environmentally friendly fertilizer manufacturing enterprises. The complete production line covers the entire process from raw organic waste collection and pretreatment, biological fermentation, material size reduction, precision batching, granulation, thermal drying, cooling and hardening, precision screening, to automatic finished-product packaging.
The production line features outstanding modular expandability and excellent adaptability to different raw materials, with annual production capacities ranging from 10,000 to 200,000 tons. The system can be flexibly customized according to the customer’s plant layout, investment budget, and raw material characteristics, including chicken manure, cattle manure, pig manure, sheep manure, biogas residue, mushroom substrate waste, sugar mill filter cake, municipal sludge, and other organic materials.
The entire system integrates an intelligent PLC centralized control architecture, enabling continuous material conveying, automatic weighing, and dynamic interlocking throughout the production line. This significantly reduces labor intensity while effectively eliminating dust emissions and odor leakage commonly associated with conventional fertilizer production facilities.
Organic fertilizer production equipment generally consists of material processing equipment, fermentation equipment, drying equipment, screening equipment, and packaging equipment.
- Material Processing Equipment includes crushers, grinding mills, and mixers, which prepare raw materials for subsequent fermentation, drying, and other processing stages.
- Fermentation Equipment mainly includes compost turners, fermentation tanks, and biogas slurry storage tanks, which convert organic materials into mature organic fertilizer through biological fermentation.
- Drying Equipment includes rotary dryers, airflow dryers, and continuous dryers used to reduce the moisture content of fermented organic fertilizer.
- Screening Equipment mainly includes vibrating screeners, circular vibrating screeners, and linear vibrating screeners used to classify dried fertilizer into different particle sizes.
- Packaging Equipment mainly includes automatic packaging machines and bagging equipment for packaging screened fertilizer products for storage and transportation.
Each of these machines plays a critical role in the organic fertilizer manufacturing process. Different equipment performs different functions, and all equipment within the production line must operate in coordination to produce high-quality organic fertilizer.
II. Working Principle
Industrial organic fertilizer manufacturing is a comprehensive conversion process involving biology, thermodynamics, fluid mechanics, and mechanical engineering. The organic fertilizer production process developed by Zhengzhou Yizheng Heavy Machinery consists of the following seven major process sections, with all equipment operating in close coordination.
1. Aerobic Biological Fermentation
Fresh organic waste materials, such as livestock manure, are first adjusted to the proper carbon-to-nitrogen (C/N) ratio and moisture content, maintaining moisture between 55% and 65%, which is considered the optimal fermentation range.
The material is transferred into fermentation trenches or fermentation tanks, where groove compost turners, crawler-type compost turners, or vertical high-temperature aerobic fermentation tanks manufactured by Zhengzhou Yizheng perform regular turning and forced aeration.
Under suitable conditions, aerobic microorganisms multiply rapidly, generating temperatures of 55°C–70°C for 7–14 days, effectively eliminating pathogens, parasite eggs, and weed seeds while completing deodorization, harmless treatment, and organic matter stabilization.
2. Material Size Reduction and Crushing
The matured compost usually contains agglomerates and coarse fibers of varying sizes.
The material is conveyed into a semi-wet material crusher, which utilizes high-speed dual-row wear-resistant blades and rotors to apply intensive shearing, impact, and tearing forces to fermented materials containing 20%–40% moisture.
The material is rapidly reduced to a fine powder smaller than 0.5 mm while preventing wall adhesion and material blockage during operation.
3. Dynamic Precision Batching and Mixing
To satisfy the nutritional requirements of different crops, the processed organic base material, inorganic nutrients (nitrogen, phosphorus, and potassium), and trace elements are fed into a multi-bin dynamic batching system according to predetermined formulations.
The batching system employs continuous variable-frequency feeding combined with high-precision weighing sensors to accurately meter each component before discharging them into a twin-shaft horizontal mixer.
Driven by counter-rotating twin-shaft paddles, the materials undergo complex convection, shearing, and cross-flow mixing, achieving highly uniform molecular-level blending within a short period.
4. Core Granule Formation
The uniformly mixed powder enters the granulation stage.
Depending on the raw material characteristics, customers may select a new stirring-tooth granulator, rotary drum granulator, or double-roll extrusion granulator.
Taking the new stirring-tooth granulator as an example, fine particles aggregate into spherical granules under the combined action of high-speed rotating stirring teeth, centrifugal force, surface tension, and mechanical force, producing fertilizer granules with a granulation rate exceeding 95%, uniform density, and excellent sphericity.
5. Rotary Drying and Forced Cooling
Freshly granulated fertilizer particles contain relatively high moisture and insufficient structural strength.
The material is conveyed through the upper feed inlet into the rotary dryer. Inside the rotating drum, specially engineered lifting flights continuously raise the granules to form a uniform material curtain, allowing efficient heat exchange with the high-temperature airflow supplied by the hot air furnace.
After drying, the material exits through the lower discharge outlet onto the conveyor belt, where moisture content is substantially reduced.
The hot granules are then conveyed into the upper feed inlet of the rotary cooler, where ambient cooling air is introduced to rapidly reduce the product temperature.
After cooling, the material is discharged through the lower outlet onto the conveyor belt.
This process rapidly hardens the granules, significantly increases crystallization strength, and brings the product to a safe storage condition.
6. Precision Screening and Closed-Loop Recycling
The cooled granules are conveyed through the upper feed inlet into the rotary screening machine.
Using high-strength screens with different mesh sizes, the material is accurately classified into three fractions:
- Qualified finished granules proceed directly to the packaging section.
- Oversized particles are discharged through the lower outlet, crushed by a chain crusher, and returned to the granulation section.
- Undersized particles are recycled directly back into the granulator as seed material for secondary granulation.
This process achieves 100% waste-free closed-loop recycling throughout the production line.
7. Automatic Packaging and Anti-Caking Treatment
Qualified granules first enter a rotary coating machine where oil spraying or powder coating forms a protective surface layer that enhances compression resistance and moisture resistance.
The coated material is then transferred to the automatic weighing and packaging machine.
Using a computerized pneumatic weighing system, the equipment performs accurate weighing, automatic filling, bag clamping, sewing, and sealing to complete commercial packaging.
III. Product Applications
The complete organic fertilizer production line manufactured by Zhengzhou Yizheng Heavy Machinery Equipment Co., Ltd. offers excellent industrial adaptability and is widely applied in the following industries:
- Large-scale Livestock Farm Waste Treatment: Suitable for chicken, pig, cattle, and sheep farms, converting livestock manure into high-value commercial organic fertilizer.
- Agricultural Waste and Biomass Recycling: Processing crop straw, rice husks, peanut shells, mushroom residue, bagasse, distillery residue, and other agricultural organic wastes.
- Municipal Environmental Engineering: Treating municipal wastewater sludge, food waste, and urban organic solid waste through harmless treatment, volume reduction, and resource recovery.
- Compound Fertilizer and Bio-Fertilizer Manufacturing: Supporting the production of high-activity bio-organic fertilizers and organic-inorganic compound fertilizers through the precise addition of functional microbial inoculants.
IV. Product Features
- Modular Process Design with Flexible Layout
The entire production line adopts a modular structural design and can be configured as straight-line, L-shaped, U-shaped, or multi-level layouts according to the customer’s building dimensions and site conditions, maximizing land utilization while reducing construction costs.
- Intelligent Electrical Interlocking with High Automation
The production line is equipped with an advanced PLC centralized control system and touchscreen Human-Machine Interface (HMI). Each machine features motor current monitoring and electrical interlock protection.
Material flow in upstream equipment is automatically synchronized with downstream processing capacity, effectively preventing material accumulation, blockage, and idle equipment operation.
- Industrial-Grade Corrosion and Wear Resistance
To withstand the harsh operating environment associated with high-moisture organic materials and corrosive gases, critical components—including 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 (UHMW-PE) anti-adhesion panels, effectively eliminating scaling, corrosion, and excessive wear.
- Low Energy Consumption and Environmentally Friendly Dust-Free Operation
The airflow systems of the dryer and cooler are optimized using advanced thermal and fluid dynamic engineering, achieving exceptionally high thermal efficiency while reducing energy consumption by 15%–20% compared with conventional equipment.
All material transfer points are enclosed and equipped with high-efficiency cyclone dust collectors and water curtain dust suppression systems to ensure that workshop dust concentrations fully comply with stringent environmental regulations.
- High Granulation Rate and International-Standard Product Quality
Through optimized granulation and thermal processing technologies, the production line achieves a granulation rate exceeding 95% while producing fertilizer granules with uniform particle size, smooth surfaces, and excellent compressive strength.
These characteristics effectively prevent moisture absorption and caking during storage and transportation.
V. Product Specifications
The following table presents the standard technical specifications for Zhengzhou Yizheng Heavy Machinery’s complete organic fertilizer production lines with different production capacities.
|
Technical Parameter |
YZ-10K (10,000 t/year) |
YZ-30K (30,000 t/year) |
YZ-50K (50,000 t/year) |
YZ-100K (100,000 t/year) |
YZ-200K (200,000 t/year) |
|
Production Capacity (t/h) |
1.5–2.0 |
4.0–5.0 |
7.0–8.0 |
14.0–16.0 |
28.0–30.0 |
|
Applicable Raw Material Moisture (%) |
30–40% (after fermentation) |
30–40% (after fermentation) |
30–40% (after fermentation) |
30–40% (after fermentation) |
30–40% (after fermentation) |
|
Granulation Rate (%) |
≥95% |
≥95% |
≥96% |
≥98% |
≥98% |
|
Finished Granule Size (mm) |
Φ2.5–4.5 |
Φ2.5–4.5 |
Φ2.5–4.5 |
Φ2.5–4.5 |
Φ2.5–4.5 |
|
Finished Product Moisture (%) |
≤14% |
≤14% |
≤14% |
≤14% |
≤14% |
|
Total Installed Power (kW) |
120–160 |
280–350 |
450–580 |
850–1100 |
1600–2100 |
|
Recommended Plant Area (m²) |
800–1200 |
2000–3000 |
3500–5000 |
7000–10000 |
15000–20000 |
|
Control System |
Central Push-Button Control / PLC |
PLC + Touchscreen HMI |
Distributed PLC Control System |
DCS Industrial Automation Control |
Fully Automatic Intelligent DCS Control |
Note: The above specifications are based on standard process configurations. Actual parameters may be customized according to the customer’s raw material characteristics and specific process requirements.
Modern organic fertilizer production is a comprehensive industrial project that emphasizes systematic engineering, operational stability, and long-term return on investment. Selecting a production line with well-designed processes, advanced equipment, and reliable performance is the fundamental key for fertilizer manufacturers to reduce operating costs, improve efficiency, and expand into high-value markets.
With decades of manufacturing experience in fertilizer equipment, a rigorous quality management system, and a global engineering service network, Zhengzhou Yizheng Heavy Machinery Equipment Co., Ltd. remains committed to providing technologically advanced, high-quality complete organic fertilizer production systems. From individual equipment manufacturing to complete Turnkey Projects, Zhengzhou Yizheng leverages its strong brand reputation and engineering expertise to help customers convert various organic wastes into high-value green fertilizers while jointly promoting the sustainable development of the global circular agriculture and environmental protection industries.
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
Post time: Jul-28-2026