New type two in one organic fertilizer granulator

The new type of organic fertilizer granulator is a composite organic fertilizer granulation equipment that integrates wet stirring tooth granulation and drum rounding functions. By concentrating the two major processes of "crushing" and "granulation" into one machine, this equipment solves the industry problems of "wet material sticking to the walls, dry material failing to granulate, and coarse fibers being difficult to form" common in traditional granulation equipment. The equipment has a compact structure, is easy to operate, and can operate continuously for 24 hours, making it a core piece of equipment for improving quality and efficiency in the organic fertilizer production field.

Structural Disassembly and Component Description

From the perspective of operation and maintenance, the new organic fertilizer two-in-one granulator can be divided into the following modules:

(1) Crushing module: including crushing chamber, crushing rotor and alloy hammer. The inner walls of the crushing chamber and granulating chamber are lined with polymer polyethylene plates or stainless steel mirror panels. The crushing hammer is forged from high-chromium alloy steel with a hardness of over HRC60.

(2) Granulation module: including stirring tooth assembly or extrusion assembly. The stirring head is made of high chromium alloy or tungsten carbide surfacing. The stirring tooth assembly adopts a precise mechanical layout and can form a self-cleaning barrier when rotating at high speed.

(3) Transmission module: including main motor, reducer, belt transmission mechanism and bearing system. The spindle bearings need to be replenished with grease regularly.

(4) Screening and return material module: including built-in screening device and return material channel. Used for automatic separation of finished products and defective products.

(5) Intelligent control module: including PLC control system, ammeter and operation panel. Used for parameter adjustment and operation monitoring.

Application scenarios and applicable industries
The new type of organic fertilizer granulator is widely applicable to commercial organic fertilizer plants, bio-fertilizer enterprises, and large-scale livestock farm manure granulation workshops with an annual output of 10,000-80,000 tons. It is especially suitable for small to medium-sized continuous granular organic fertilizer production lines that require a streamlined layout and reduced equipment and workshop space. This equipment has a unique advantage in "one-time powder feeding and one-time round pellet forming" of high-moisture organic fermentation materials.

Common material types
The equipment can process a variety of organic raw materials, mainly including: composted livestock and poultry manure (chicken manure, pig manure, cow manure); fermentation powders of agricultural by-products such as straw powder, mushroom residue, distiller's grains, soybean residue, and traditional Chinese medicine residue; humic acid materials such as peat, lignite, and weathered coal; and municipal waste such as urban sludge. The materials need to be fully aerobic fermented and composted and then crushed through a 40-60 mesh sieve.

Working mechanism and operating logic
The core innovation of this equipment lies in its "crush-then-granulate" collaborative operation mode. When the fermented, semi-wet material enters the feed inlet, it is first thoroughly crushed by a high-speed rotating crushing rotor. The crushed fine powder directly enters the granulation chamber, where it rapidly agglomerates into granules under the combined action of high-speed stirring by the agitator teeth and the liquid phase. The granules then enter the rotating drum chamber or the spherical polishing zone, where they are further rounded, compacted, and polished under centrifugal force and friction. The entire process is completed in one continuous operation. Some high-end models are also equipped with a PLC intelligent control system, which can monitor parameters such as material moisture and rotation speed in real time.

Production capacity and equipment selection
The equipment is categorized into three sizes based on capacity: small, standard, and medium. Small models have a capacity of 0.5-1.5 t/h and a power of 7.5-15 kW; standard models have a capacity of 2-4 t/h and a power of 18.5-30 kW; and medium models have a capacity of 5-8 t/h and a power of 37-55 kW. Selection should be based on both capacity and material characteristics: small models are suitable for small-scale processing; standard or medium models are suitable for large-scale production. A 10%-20% capacity margin should also be reserved.
Target user profile
Primarily targeting bio-organic fertilizer plants and compound fertilizer plants with an annual output of 10,000-30,000 tons, as well as existing plants requiring technological upgrades. Suitable for users with high requirements for output, automation level, and product quality. The equipment offers high cost-effectiveness and is particularly suitable for small and medium-sized production entities with limited space and budgets.
Maintenance tips and schedule

The maintenance of the new type of organic fertilizer granulator should be carried out according to the following cycle:

Daily Maintenance: After each shift, open the quick-opening inspection door and thoroughly clean the cavity and polishing section with compressed air or a scraper to remove accumulated material; apply a Teflon anti-stick coating to the inner wall to reduce adhesion; do not rinse with water to prevent rust. Clean the machine body promptly after each use.

Regular Maintenance: Add #3 lithium grease to the main shaft bearing every 500 hours of operation until it reaches 1/2-2/3 of the cavity; clean and change the grease annually; change the reducer oil after the first 100 hours of operation; thereafter change the oil every six months. Conduct a comprehensive overhaul of the equipment every six months or one year.

Inspection System: Perform three checks before each shift—check the cleanliness of the magnetic separator, whether the anti-loosening marks on all connecting bolts are misaligned, the tension of the transmission belt, and the oil level of the reducer; during the shift, listen for any metallic impact noises or periodic friction sounds; observe the temperature rise of the bearing housing surface.

Summary of common faults

(I) Sudden drop in output or low pelleting rate: Often caused by material moisture content deviation (ideally 22%-35%), insufficient grinding fineness, belt slippage, or dulling of the agitator teeth.

(II) Abnormal vibration: Often caused by foreign objects entering the machine, detached agitator teeth, or loose anchor bolts. When one side of the agitator tooth head wears down to 1/3 of its original thickness, or the cutting edge shows curling or chipping, replacing only one tooth will disrupt the rotor's dynamic balance and cause severe vibration.

(III) Motor tripping: Often caused by excessive feed or seized bearings.

(IV) Excessive equipment vibration: Possible causes include loose anchor bolts, disrupted rotor dynamic balance, and damaged bearings.

Troubleshooting and Repair Solutions

Low pelletizing rate: Adjust process parameters sequentially, tighten the drive belt, or replace the agitator teeth. Check the material moisture content and adjust if it deviates.

Abnormal vibration: Open the cover to inspect and perform dynamic balancing. When replacing agitator teeth, the entire set must be replaced symmetrically; when the liner is worn down to 1/3 of its original thickness, the entire set should be replaced.

Motor tripping: Clear the blockage and reset the thermal relay. If the bearing is seized, replace the bearing.

Operation management: Establish an operation log, recording start-up and shutdown times, throughput, peak current, and replacement dates; implement a system of assigning specific personnel to specific machines.