The granulation stage is the most sensitive to formula changes. New-type organic fertilizer granulators and two-in-one granulators rely on the material's inherent stickiness and moisture content to roll into granules. If a new formula has high fiber content and low stickiness, the granulation rate drops and the volume of recycled material (fines/oversize) increases, causing effective output to shrink. Bio-organic fertilizer granulation involves an additional constraint: temperature. When the proportion of functional bacteria in the formula changes, the drying temperature must be adjusted accordingly; this often forces a slower drying speed, meaning output is limited by drying capacity rather than granulation capacity.

The double-roller extrusion process is similarly affected by formulas. Double-roller press granulators and fertilizer roller presses compress powdered material into sheets, which are then crushed into granules. If the new formula results in high material hardness or brittleness, the proportion of fine powder after crushing increases, leading to more recycled material and a lower yield of finished product. Double-roller press technology requires stable feed fineness and moisture content; if roller gaps and pressure are not adjusted in sync with formula changes, output fluctuations are inevitable.

The BB (Bulk Blend) fertilizer process may appear simple, but it is also affected. BB fertilizer production lines and mixers rely on physical blending, with output primarily determined by batching speed and mixing time. However, changes in the proportions of urea, ammonium phosphate, and potash in the formula alter the mixture's bulk density. For formulas with low bulk density, the same weight of material occupies a larger volume, requiring more time for the packaging machine to fill bags and causing an involuntary drop in overall line output. In the BB fertilizer mixing process, significant differences in raw material particle sizes may also necessitate longer mixing times to ensure uniformity, further reducing hourly output.

The closed-loop recycling system of the entire roller press granulation line also changes in response to formula adjustments. When the recycle ratio increases from 30% to 50%, the actual processing capacity of the extruder and screening machine is consumed by the recycled material; consequently, the capacity for processing fresh material drops, and overall output naturally decreases.

Therefore, switching formulations is not merely a matter of adjusting the settings on the ingredient scales; it requires recalibrating parameters such as granulator speed, roll gap pressure, drying temperature, mixing time, and screen aperture size. Only by understanding this can one accurately estimate the production line's true capacity.