The new type two-in-one organic fertilizer granulator/new type stirring tooth-drum granulator is a composite wet continuous granulation equipment that integrates the core advantages of both traditional stirring tooth granulators and drum granulators. It is a core forming equipment in organic fertilizer production lines. This equipment overcomes the limitations of single granulation equipment, employing an innovative wet continuous pusher granulation process. It combines the dual characteristics of forced granulation by mechanical stirring with the rolling polishing forming of the drum, perfectly solving the industry pain point that conventional granulation equipment cannot handle coarse fibrous and high-moisture organic materials.
The new type two-in-one organic fertilizer granulator is currently high-end forming equipment in the organic fertilizer production field. It cleverly combines the high pelletizing rate of "stirring tooth granulation" with the high density of "drum granulation," solving the problems of difficult forming and low particle strength when processing coarse fibrous materials with traditional equipment.
This equipment is suitable for large-scale production of organic fertilizers and organic-inorganic compound fertilizers. It can directly granulate fermented and decomposed organic materials without deep drying or the addition of binders. It boasts a high granulation rate, excellent granule quality, stable operation, and lower energy consumption, making it mainstream upgraded equipment in the ecological organic fertilizer production industry. The whole machine adopts a thickened seamless steel pipe shell and an integrated stable base, featuring strong structural rigidity, wear resistance, durability and long service life. Multiple specifications are available to fit various organic fertilizer production projects of different scales.
This equipment is widely used in the production of organic fertilizer, bio-organic fertilizer, and organic-inorganic compound fertilizer. It fits small & medium processing factories, large organic fertilizer manufacturers, livestock farm supporting fertilizer production lines and agricultural ecological fertilizer bases. Specific application scenarios include:
1. Granulation of various livestock and poultry manure to realize resource utilization of breeding waste;
2. Granulation treatment of composted agricultural and forestry waste such as straw, mushroom residue and herb residue;
3. Harmless and resource-based granulation treatment of municipal sludge and fermented organic waste;
4. Mass production of high, medium and low concentration organic-inorganic compound fertilizers by hot and cold granulation processes;
5. Precision granulation of microbial organic fertilizer, ecological organic fertilizer and green agricultural fertilizer.
Compared with single disc granulators and rotary drum granulators, this machine has better adaptability to hard-to-granulate coarse fiber materials. The finished particles feature uniform appearance and high compressive strength, with far stronger versatility and practicability than traditional equipment.
The new type two-in-one organic fertilizer granulator features compact and scientific overall structure, mainly composed of the following assemblies:
1. Feeding System: Uniform feeding section to guarantee continuous and stable material delivery into the granulation chamber.
2. Primary Granulation Section (Stirring Tooth Granulation Section): Equipped with forged high-chromium alloy steel stirring teeth with special heat treatment, hardness reaches HRC60 or above. Raw materials are mixed and preliminarily granulated by high-speed rotating stirring teeth here.
3. Secondary Granulation Section (Rotary Drum Granulation Section): Adopts internal stirring tooth + external rotating drum design for secondary shaping and spheroidizing of semi-finished particles.
4. Transmission System: Consists of motor and reducer, driving continuous operation of granulation rotor. The transmission unit and machine body are fixed on the same frame for reasonable layout and stable running.
5. Discharge System: Finished particles are discharged from the other end of the machine.
6. Frame and Housing: The housing is welded by thickened seamless steel pipe or high-carbon steel plate, installed with casters and transmission components. Stable base design ensures smooth operation.
7. Intelligent Control System: Optional for partial models to realize automatic operation.
The core working assembly — granulation agitator — is manufactured from wear-resistant high-chromium alloy steel. It supports long-term stable operation even when processing livestock manure mixed with sand, gravel and shell powder.
The new two-in-one organic fertilizer granulator relies on powerful mechanical force for material granulation. High-speed rotating stirring teeth apply shearing, extrusion and kneading force on raw materials, prompting fine powder to agglomerate into solid particles.
Four-stage workflow:
Feeding and pushing → Mixing and stirring → Extrusion and nucleation → Rolling polishing and growth → Screening and discharge
1. Feeding and pushing: Raw materials are fed from inlet and forcibly transported into granulation chamber by screw conveyor. Material moisture content is generally controlled within 20%–40%.
2. Mixing and stirring: Pretreated raw materials enter the rotary cylinder. Rotating stirring teeth conduct intensive stirring, shearing and mixing to realize even material distribution and initial agglomeration.
3. Extrusion and nucleation: Under mechanical force from stirring teeth, wet materials are extruded and kneaded to form tiny particle nuclei. Materials repeatedly collide and rub between stirring teeth and cylinder wall; fine powder gradually condenses into small particles.
4. Rolling Polishing and Growth: As the cylinder rotates, particles roll along the cylinder wall under centrifugal force. Fine powder continuously adheres to particle surface, and particles gradually grow to 2–8mm. Intermittent stirring prevents particle adhesion and guarantees uniform particle size.
5. Screening and Discharge: Formed particles are separated via the screen at the discharge port. Oversized and undersized particles are screened out and returned for re-granulation.
Rotary drum granulator adopts wet granulation technology. Appropriate water or steam is added to moisten base fertilizer inside the cylinder to promote sufficient chemical reaction. Under certain liquid phase conditions, cylinder rotation drives material particles to aggregate into spherical pellets under extrusion force.
The new two-in-one granulator combines the compression granulation advantages of stirring tooth granulation and rotary drum granulation:
1. Stirring Tooth Section: High-speed mechanical stirring force and aerodynamic effect enable continuous mixing, granulation, balling and densification of powder materials inside the machine. Produced particles are spherical with sphericity ≥0.7, particle size 0.3–3 mm, granulation rate ≥90%.
2. Rotary Drum Section: The drum is lined with special rubber plates or acid-resistant stainless steel plates, realizing automatic descaling and nodule removal without traditional scraper devices. Particles are rolled and polished under centrifugal force to obtain smooth and round surfaces.
3. Synergistic Effect: The combination of two granulation technologies achieves higher balling rate, better particle appearance, energy saving and higher efficiency.
1. Pre-fermentation Preparation
Raw Material Ratio: Livestock manure : straw = 3:1 ~ 4:1
C/N Ratio Adjustment: C/N ratio controlled at 25:1 ~ 30:1
Moisture Adjustment: Initial moisture 50–60%
Inoculum Addition: Add fermentation bacteria including EM bacteria and lactic acid bacteria
2. Fermentation Process Flow
Raw Material Mixing → Stacking Fermentation → Turning and Aeration → Heating and Deodorization → Maturation and Decomposition → Post-Maturation and Aging → Crushing and Sieving
3. Key Control Points in Fermentation
| Parameter | Control Standard | Monitoring Method |
|---|---|---|
| Pile Temperature | 55–65°C (High-temperature stage) | Insert thermometer for measurement |
| Turning Frequency | Turn over once every 2–3 days | Adjust according to temperature changes |
| Fermentation Cycle | 10–15 days (Main fermentation) | Observe material color and odor |
| Moisture Content | Reduce to 30%–40% (Optimal for granulation) | Hand squeeze method / Moisture tester |
| pH Value | 6.5–8.5 | pH test paper / Electrode measurement |
| Decomposition Standard | Dark brown, odorless, temperature drops to ambient temperature | Sensory inspection + instrument detection |
4. Advantages of Direct Granulation After Fermentation
One core advantage of the new two-in-one organic fertilizer granulator: fermented organic materials do not require drying treatment. Raw materials with moisture of 20%–40% can be directly granulated.
This greatly cuts energy costs. Traditional granulation equipment needs drying below 15% before granulation. The discharged particle moisture is about 30%, lowering the load of subsequent drying procedures.
1. Granulation Process Flow
Raw material preparation (moisture 20–40%) → Feeding and mixing → High-speed stirring and nucleation → Rolling polishing and growth → Sieving and discharging
2. Key Process Parameters
| Parameter | Control Range | Influence |
|---|---|---|
| Raw Material Moisture | 20%–40% (Optimal: 35%–40%) | Too low causes loose pellets; too high leads to sticking and blockage |
| Raw Material Fineness | ＜50 mesh (＜300 mesh preferred) | Finer materials achieve higher pellet sphericity |
| Main Shaft Rotation Speed | Adjustable | Higher speed produces smaller pellets; lower speed produces larger pellets |
| Feeding Rate | Adjust according to production capacity | Affects pellet size and uniformity |
| Gap Between Stirring Teeth & Drum Wall | 5–8mm | Excessively large gap reduces pelleting rate; too small gap causes frequent collision |
| Pelleting Rate | ≥90% (Max up to 98%) | Core index evaluating granulation performance |
| Pellet Sphericity | ≥0.7 | Indicator for pellet roundness |
| Pellet Diameter | 0.3–3mm (Adjustable) | Adjusted according to finished product requirements |
| Pellet Strength | 10–30N | Affects transportation and storage performance |
| Oversize Pellet Ratio | ＜15% | Proportion of unqualified large particles |
3. Granulation Key Points for Different Materials
| Material Type | Moisture Control Range | Speed Adjustment | Special Requirements |
|---|---|---|---|
| Livestock & Poultry Manure | 35%–40% | Medium rotation speed | Complete fermentation and decomposition in advance |
| Crop Straw | 30%–35% | Relatively high rotation speed | Long fiber material, must be fully crushed |
| Organic-Inorganic Compound Fertilizer | Adjust according to formula | Medium rotation speed | Pay attention to chemical reactions of raw materials |
| Municipal Sludge | 30%–40% | Medium rotation speed | Mix with straw to adjust C/N ratio |
| Carbon Black / Clay | 25%–35% | Relatively high rotation speed | Fine powder material with high pellet sphericity |
1. Daily Inspection: Professional staff shall inspect equipment regularly, check component wear and lubricating oil supply. Inspect bolt tightness; ensure rollers, supporting rollers and gears are fully greased.
2. Cleaning and Maintenance: Regularly clean equipment to avoid dust and residual materials affecting operation. After shutdown, clear residual materials thoroughly, especially hardened deposits between stirring teeth. Remove entangled impurities and bonded materials timely.
3. Lubrication Management: Lubricate all points following operation manual. Check lubrication system for oil leakage.
4. Wear Inspection: Monitor wear of vulnerable spare parts and replace components on schedule. New wheel rims tend to get loose and require frequent inspection.
5. Operation Records: Establish operation log, record startup & shutdown time, hourly output, operating current and parts replacement date.
| Fault Phenomenon | Possible Causes | Solutions |
|---|---|---|
| Oversized pellets / Mass caking | Excessively high material moisture or too low rotation speed | Reduce material moisture and increase main shaft rotation speed |
| Excessive powder / Low spheronization rate | Insufficient moisture or uneven feeding | Spray appropriate water for adjustment and maintain continuous & uniform feeding |
| Severe machine vibration | Foreign impurities mixed in materials or unlevel base frame | Stop machine to clear foreign objects and recalibrate unit horizontal level |
| Sudden sharp rise of power load | Severe material sticking on inner wall or excessive feeding rate | Clean residual materials adhered to inner wall and reduce feeding volume |
Raw Material Collection → Pretreatment → Fermentation → Crushing → Batching → Mixing → Granulation → Drying → Cooling → Screening → Packaging
| Process Section | Main Equipment | Function Description |
|---|---|---|
| Fermentation System | Compost Turner, Mixing Blender, Biological Deodorizer | Material decomposition and harmless treatment (10–15 days) |
| Crushing System | Semi-wet Material Crusher, Chain Crusher | Crush fermented materials to below 50 mesh |
| Batching System | Electronic Batching System, Disc Feeder | Proportion multiple raw materials according to production formula |
| Mixing System | Horizontal Mixer / Pan Mixer | Mix all raw materials evenly |
| Granulation System | Two-In-One Granulator (Core Equipment) | Wet granulation, pelleting rate over 90% |
| Drying System | Rotary Dryer, Hot Air Furnace | Reduce pellet moisture below 10% |
| Cooling System | Cooler | Rapid cooling to prevent pellet caking |
| Screening System | Rotary Screening Machine | Classified screening to remove unqualified pellets |
| Packaging System | Automatic Packaging Scale | Quantitative packaging, 20–50kg per bag |
| Dust Removal System | Cyclone Dust Collector / Pulse Dust Collector | Dust emission ≤10mg/m³ |
Compared with traditional production lines, the new two-in-one granulator brings the following integrated advantages:
1. High Integration: Combine mixing and granulation into one machine. Cancel intermediate conveying equipment between separate mixers and granulators. Material loss rate drops from traditional 5%–8% to 1%–2%; floor space saved by 30%–50%.
2. High Production Efficiency: Integrated operation shortens production cycle. Single machine hourly output: 1–5 tons, efficiency increased by 20%–40% versus separate traditional equipment.
3. Superior Granulation Effect: Optimized design for organic fertilizer raw materials. Suitable for high-fiber & high-moisture organic materials; particle sphericity＞85%, particle strength 10–30N.
4. Low energy consumption & low operation cost: Integrated layout reduces the quantity of driving motors. Unit energy consumption reduced by 15%–25%; fewer maintenance points and required operators.
| Annual Production Capacity | Granulator Model | Matching Power | Main Production Line Equipment |
|---|---|---|---|
| 10,000 tons per year | Model RT-60 | 37kW | Compost turner, crusher, mixer, granulator, dryer, screening machine |
| 30,000 tons per year | Model RT-80/100 | 55–75kW | The above equipment with upgraded specifications |
| 50,000–100,000 tons per year | Model RT-120/150 | 90–110kW | Automatic batching system, PLC control system |
| Over 200,000 tons per year | Multiple units in parallel | Combined power of multiple units | Fully automatic production line equipped with DCS control system |
1. Dual-process integration & wide material adaptability: Granulation modes can be flexibly adjusted according to raw material humidity, viscosity and fiber content without complicated pretreatment.
2. High pelletizing rate and beautiful particles: Granulation rate reaches 90%–99%. Spherical particles with smooth round surface, no sharp corners and low pulverization rate.
3. High organic content support: Realize 100% pure organic granulation without binders.
4. Energy saving & consumption reduction: Raw materials with moisture 20%–40% can be directly granulated, no pre-drying required. Floor space reduced by around 2/3, equipment investment cost cut by 30%–50% compared with traditional lines.
5. Concentrated particle size & easy adjustment: Narrower particle size distribution than disc granulators and traditional rotary drum granulators.
6. Sturdy and durable: Core spare parts adopt high-manganese wear-resistant steel, service life extended over 50% compared with conventional granulators.
The new type two-in-one organic fertilizer granulator (stirring tooth rotary drum granulator) organically combines forced stirring granulation of stirring tooth granulator and rolling polishing mechanism of rotary drum granulator, achieving technological breakthrough in organic fertilizer granulation. It features granulation rate of 90%–98%, capable of processing high-moisture materials (20%–40%) and coarse fibrous raw materials difficult for conventional equipment. Pure organic granulation can be realized without binders, making it ideal forming equipment for organic fertilizer and organic-inorganic compound fertilizer production.
If you have inquiries on fertilizer equipment and production technology or need customized solutions, please contact us anytime. We provide full service including equipment selection & quotation, installation, commissioning, operation training, after-sales maintenance and process technical upgrades.
| Model | Capacity (t/h) |
Output Granules Size (mm) |
Motor Power (Kw) |
Outside Dimension (mm) |
| YSL2-80/120 | 4-8 | 1-5 | 37+18.5+5.5 | 7500*2300*1950 |
| YSL2-100/150 | 6-10 | 1-5 | 55+18.5+11 | 7700*2550*2260 |
| YSL2-120/180 | 8-15 | 1-5 | 75+22+15 | 9600*3000*2750 |
