Applying organic fertilizer production lines have become a world-widely popular choice among farmers, investors, and fertilizer producers. As it can adopt different production methods to process kinds of organic raw materials, people can get many types of organic fertilizer products for the crops and plants according to special project requests. This has brought organic fertilizer production to a global business trend.
Located in Zhengzhou city, China, Shunxin machinery has been a leading supplier of organic manure processing machines for almost two for decades. With help from our powerful technical team and thoughtful service team, our customers have established and benefited from hundreds of organic fertilizer production plants over 50 countries.
How to make organic fertilizer from manure processing plant
Generally, the final finished products in organic fertilizer production plants are of two types: the Powdery and the Granular. Let’s see how these two different production systems perform for the final finished organic fertilizer products.
For most commercial organic fertilizer manufacturers, the operation flow of organic waste to fertilizer production line has two parts: the raw organic material composting, and the powder / granular organic fertilizer processing. Both parts are separately designed in case of contamination from raw material to the semi processing or the finished fertilizer products.
1. Preparing for the composting area and raw materials for organic fertilizer production
One reference of 3D diagram design for the raw organic material composting part
For the raw materials collected from different breeding farms, the water content is normally low enough for the composting process. Channel / Groove composting is a better way for middle or large scale of raw organic materials. The following two types of composting machines are the most suitable machines to process such a scale of raw materials. We can design the size of the composting area according to your budget and material amount to be processed.
Shunxin Wheel Composting Machine in Colombia
Shunxin Groove Composting Turner in Myanmar
Many owners of farms or slaughterhouses use a lot of water to clean and collect animal manure. For the raw material like this, the water content is too high to proceed with the composting. In this condition, most of the customers select our Shunxin Animal Manure Solid-liquid Separating Equipment to dehydrate the material then to compost.
Shunxin Solid-liquid Separator in Malaysia
2. During the composting process in the organic fertilizer production factory, many customers take our suggestions to improve the compost nutrition and quality, for example:
A. Adjusting the Carbon-Nitrogen Ratio of the raw organic materials to about (25~35):1 for a better composting. If the ratio is too high, the organic material mixture starts to ferment slow and late; meanwhile nitrogen gas gets released with the bad smell if the ratio’s too low. You can mix the animal manure with the crop waste in the composting area. Our studies and customers’ practice have proven that the output compost will be much more nutritious than that from a single material.
B. To ensure the Moisture of the organic material mixture to be at about 60~70% at the beginning of composting. It should be noted that the organic material won’t start to ferment if the moisture is too low; while it ferments extremely slow and breeds bad bacteria if with too high moisture. You can add water into the material mixture as the moisture will drop down while turning in the composting process.
C. Paying attention to the mixture Temperature and turning the material in time for complete composting. Organic matters get burned and decreased at a higher temperature while no fermenting at a lower temperature. Thermometers can help you monitor the temperature change during the composting period. You can flip the organic materials every time it rises to about 60℃.
After the composting process, the organic material will be ready for fertilizer making. According to the different organic fertilizer standards from our customers, we can design a corresponding processing plan for the organic fertilizer production factory.
3. How to make powder fertilizer in a Powder Organic Fertilizer Production Plant?
Reference of Equipment Models in Shunxin Powder Organic Fertilizer Production Line design
Many customers have the idea to get into the fertilizer business for the first time. We usually suggest the powder organic fertilizer production line as a start. In such a plant, we just need to deal with the raw organic material to the final powder fertilizer products. As the fundamental processes in a powder fertilizer plant are simply as Screening, Crushing, and Packing, the project will be very easy to manage and cost low.
a. The Screening machine is designed to sieve out the small number of large particles in the material compost for crushing, while most of the material compost will be powdery after the turning and composting process. According to the customer’s requirement for the fertilizer project, the working capacity of the Screener ranges from 1ton/hour to 20tons/hour, which decides the machine length, width and height; the Sieve net up there can be customized to the designated mesh size for special screening processing.
Shunxin Rotary Screening Machine at fertilizer plant site
b. The Crushing device is used to crush the big clumps or blocks into a powder so that all the compost can be finely powdery for packing. We have designed 9 types of crushing machines to process different kinds of raw materials and more than 20 models for different handling capacities. They can be applied in different positions in the organic fertilizer production line to process different targeted materials.
Shunxin Semi-wet Material Crushing Machine for high-moisture raw materials
Shunxin Vertical Type Crushing Machine with powerful working capacities
Shunxin Chain Type Crushing Machine to process the unqualified granules after the granulation
c. The Packing equipment is set up to package the powdery compost into bags by designated weight as needed. The packing speed is 240~360 bags / hour with the bag weight 5~50 kgs, and the allowable error does not exceed 0.1%. For powdery and granular products at different packing capacities, we have several packer types and models for your choices to process in the fertilizer production plant.
Shunxin Semi-automatic Packing Machine for final powder organic fertilizer plant site
4. How to make granular fertilizer in a Granular Organic Fertilizer Production Plant
Some customers prefer granular fertilizer products, or they have already owned a fertilizer producing project and they want to expand the production scale. Then we can design a suitable granulation plan for your fertilizer plant.
Normally, a granular organic fertilizer plant will apply the Wet granulation method for a better granulation efficiency for the final granular products. And the moisture is a key factor during the whole granulation process. After the Screening and Crushing processes as the same as in a powder fertilizer plant with the same handling capacity, the other main processes in a granular Fertilizer Production Plant are as the following: Granulating, Drying, Cooling, Screening, and Packing.
Reference of Equipment Models in Shunxin Granular Organic Fertilizer Production Line design
a. The Granulating equipment most used in the organic fertilizer granulation plant is the Stirring granulator and the Drum granulator. The Stirring granulator processes powder materials to granules products from 1 ton / hour to 8 tons / hour, with a beautiful appearance for good-looking products; The Drum granulator handles capacities from 1 ton / hour to 25 tons / hour, automatically operating with perfect granulation. After the composting process, the material humidity is about 30%. It can make the granulation effect at the best stage.
Shunxin Organic Material Stirring Granulating Machine with a high popularity and more compact granulation
Shunxin Organic Material Rotary Drum Granulating Machine for scales of granulation projects
b. The Drying machine in the organic granulator fertilizer production plant is applied for dehydrating the new-born granules from the previous process. To heat the air through the drum body, you can choose the electricity, fuel, or petrol as the heat source according to the actual situation at the project site. During this process, the inlet air temperature as required is over 300℃, and the pellets discharged from the outlet is about 50~60℃; The moisture will be dried out from the 30% in the raw powder materials to below 10% in the pellet products, just suitable for the later packing process.
Shunxin Rotary Drying + Cooling Machines ready for delivery to process granular organic fertilizer products
c. The Cooling machine body is similar to the drying machine, with working capacities of 1~20 tons / hour. The pellet temperature gets cooled down to about 20~30℃ after the cooling process, right OK for packing. Matching with the Drying machine, they can greatly and automatically improve the working efficiency to process the targeted products on the moisture and temperature. Structure simple and performing stable, Shunxin Drying + Cooling systems for organic fertilizer production plants are highly reliable in the process.
d. The same Screening process here is for separating the qualified granular products for packing and unqualified semi-granules or powder for re-crushing and re-granulating.
e. Similar as it in the powder organic fertilizer production plant, the Packing equipment is for packing the granular fertilizer products into bags as needed.
Large-capacity models of the equipment as mentioned above can be used in the middle-large scale fertilizer projects. To keep the production line running steady and smoothly in the plant, we can adjust the order of the line processes, or apply some more machines for like the Buffering and Feeding operations, or add some new equipment as the Mixing and Coating processes, etc. Every single special request on the fertilizer project will be fully considered, and we will make our proposal at its best for your organic fertilizer production plant.
5. How to start a small scale organic fertilizer production plant
For those customers with an idea of small scale organic fertilizer production line, we can design a unique equipment configuration for you according to the kinds of your raw materials and handling capacities.
Small machine types and models can help make sure the scale is small for such fertilizer plants. For example, we can use the following Compost Turner types instead of the large scale ones in the Composting process:
With the same working principle, our Moving Compost Turner is the minimum model for composting and it operates easily as long as the worker can drive; During the composting, it can evenly mix the raw material, and turn the mixture up side down completely. Thus it is one of our most popular and best-selling turners among customers.
Shunxin Moving Type Organic Manure Compost Turning Machine for fertilizer processing in India
We have four models of the Crawler Compost Turner with a working capacity of 700~1500m³/hour. It is more powerful for composting on its bigger diesel engine. When driving it for the composting, you can turn the organic materials up side down completely. Thus it is one of our most popular and best-selling turners among customers.
Shunxin Crawler Type Organic Manure Compost Turning Machine for fertilizer processing in India
For the Granulating process, we also have more than 10 models of the Disc granulator type. It operates easily and automatically with a very small space and a small power consumption, with the processing capacities covering from an experimental scale to 5 tons / hour. You will find it very flexible and suitable for your granulating process as needed.
Shunxin Disc / Pan Granulating Machine with multiple models for your choice
Besides, controlling the fertilizer equipment involved in the production plant is another way. For example, we can save some of those processes designed for large scale production, such as the Batcher and Mixer for blending different kinds of materials evenly and continuously, Polisher and Coator for specific process on the final pellet products, and so on.
How much money is needed to start organic fertilizer production plant?
As seen above, for the same line handling capacity, the powder fertilizer line is usually included in the granulator fertilizer production line. So for different final fertilizer products, different machine models are correspondingly applied in the project configuration. This makes the equipment cost in the financial tabulation very different in setting up organic fertilizer production plants.
For example, for the handling capacity of the fertilizer project from 1 ton/hour to 20 tons/hour, the machine price of a powder organic fertilizer production line is from about US$18,000 to US$150,000, and it’s about US$38,000 to US$800,000 for a granulator organic fertilizer production line.
We will design the necessary plant and equipment for organic fertilizer production according to the key factors of your fertilizer production project: your raw material type, the processing capacity, and your project budget. Welcome to share your project information and details with us. Let’s work on a perfect plan to open your organic fertilizer production plant.
Project sites of organic fertilizer production lines all over the world
Every customer has his own material situation and special requests on the final fertilizer products. We will design a unique plan for your fertilizer project according to your material type and handling capacity. Here are some examples of our organic fertilizer production lines at the site for your reference.
1. Shunxin 2~3 tons / hour Powder bio-organic fertilizer production line in USA
In the commercial project of the bio-organic waste to fertilizer production line, the final products are mainly made from fresh chicken and pig manure without any chemical composition. The customer mixes the powdery material compost with other ingredients like organic fertilizer fungus and humic acid, etc. to get powder fertilizer products according to different fertilizer formulas.
2. Shunxin 6~8 tons / hour Powder Vermicompost organic fertilizer manufacturing plant in India
During the production of organic fertilizer from plant residues and sheep manure, the customer gets final powder organic fertilizer products by processing the vermicompost manually and mixing it into the raw organic materials.
3. Shunxin 4~6 tons / hour Stirring Granulator plant and equipment for organic fertilizer production in Uzbekistan
With the cow dung processing plant to make organic fertilizer, the customer adds crop waste into the composting part for better and more balanced nutrients in the final granular fertilizer products.
4. Shunxin 50,000 tons / year granular organic fertilizer processing plant in Thailand
It’s a large scale industrial use of organic waste to fertilizer production line. Our customer has connected all the breeding farms in his city and sets up the organic manure production system to cope with the granular fertilizer processing.