Working Principle of the Equipment

The working principle of the windrow compost turner is based on the biological requirements of aerobic fermentation, revolving around three core aspects: power transmission, material turning, and aeration fermentation:
Step 1 – Equipment Mounting and Positioning
The entire vehicle mounts a pre-piled, elongated compost base during operation. The equipment moves across the material pile via its tracked walking mechanism.
Step 2 – Power Distribution and Transmission
The diesel engine power is divided into two paths: one part is the main output, driving the turning drum rotation via a belt pulley reduction drive; the other part is output through a diesel engine power distribution box, driving the hydraulic pump to provide power to the hydraulic system.
Step 3 – Turning and Crushing
The auger blades under the frame turn the compost base material. The turning shaft rotates at high speed, and the turning blades turn, break up, and throw the material from the bottom to the rear. The blade shaft effectively crushes clumps formed during the raw material fermentation process. During the turning process, the material is fully stirred and loosened, achieving uniform mixing.
Step 4 – Oxygen Supply and Aeration
While turning the material, the compost turner introduces air (oxygen) into the pile. Turning the compost pile allows for ample exchange of temperature, humidity, and oxygen between the pile and the outside environment. Aerobic microorganisms accelerate the decomposition of organic matter under sufficient oxygen conditions, maintaining a high-temperature fermentation environment of 60-70℃.
Step 5 – Compost Reshaping: After the turner operates, new windrows are formed, eliminating the need for manual manpower to maintain the compost pile. As the turner continues to move forward, the material is turned, broken, and repositioned, forming new windrows.
The core value of the turner for aerobic fermentation lies in: achieving the exchange of temperature, humidity, and oxygen between the internal structure of the compost pile and the outside environment through turning, accelerating the organic fertilizer fermentation process and shortening the production cycle.

Equipment Operation Method

Break-in Period: New machines require 5-6 hours of no-load or light-load break-in (moving, reversing, turning).
Before Start-up: Check the electrical circuit, belt tension, engine oil, and coolant.
Start-up Operation: Depress the clutch fully, ignite, and idle for 10 minutes. During operation, engage first gear and move at low speed. The turning shaft speed should be stabilized at approximately 2400 rpm. Adjust the travel speed according to the dryness of the material.
Stopping: First stop the turning shaft, then disconnect the power.

Equipment Maintenance Methods

1. Routine Maintenance (Daily/Per Shift): Perform maintenance weekly when operation is infrequent; perform maintenance daily when operation is frequent.

2. Periodic Maintenance (Quarterly/Every 500–2000 Working Hours)

Application of Equipment in Organic Fertilizer Production Lines

The windrow compost turner is the core fermentation unit in a windrow organic fertilizer production line. It is equipped with front-end raw material pretreatment and rear-end crushing, screening, hydraulic roller granulation, and packaging equipment. There are two production line configurations:
1. Small-scale organic fertilizer production line (10,000-30,000 tons/year)
Process flow: Mixing livestock and poultry manure and straw → Windrow stacking → Periodic turning and composting by tracked compost turner → Crushing of composted organic fertilizer → Screening → Hydraulic roller dry granulation → Packaging of finished granules
2. Large-scale organic fertilizer production line (50,000-100,000 tons/year)
Process flow: Solid-liquid separation of manure and sludge → Automatic batching and mixing of raw materials → Large windrow composting yard → Circulating turning by multiple tracked compost turners → Secondary composting and aging → Fine crushing → Screening and impurity removal → Hydraulic roller granulation / disc wet granulation → Coating and cooling → Automatic weighing and packaging
3. Standalone independent operation mode: For farms without a fixed production line, a tracked compost turner can be purchased separately, and a manual loader can be used to assist in stacking. After fermentation and decomposition, the powdered organic fertilizer can be sold directly without the need for granulation equipment.

Equipment Fermentation Process

The windrow compost turner serves the aerobic composting fermentation process and is the core equipment in the fermentation section of organic fertilizer production.
(I) Windrow Composting Process
Windrow composting technology refers to the aerobic fermentation process where materials are piled into long, narrow stacks and mechanically aerated using a specialized turner. Tracked turners are used in ground-based windrow composting fermentation processes. Materials need to be piled into long windrows, and the turner periodically stirs and breaks up the materials, allowing organic matter to decompose under aerobic conditions.
(II) Aerobic Fermentation Stage
Aerobic composting fermentation typically involves the following stages:
1. Pre-mixing: Livestock manure, fillers, etc., are mixed evenly in a specific ratio.
2. Heating Stage: The pile temperature gradually rises from ambient temperature to approximately 45°C. The dominant microorganisms are primarily mesophilic microorganisms (fungi, bacteria, and actinomycetes), and the decomposed substrates are mainly sugars and starches. 3. High-Temperature Stage: The turner introduces air into the compost pile through turning, providing oxygen for aerobic microorganisms. The compost temperature can reach 55-70℃. Maintain a high temperature of 60-70℃ for 3-4 days. High temperatures kill pathogens and weed seeds.
4. Maturation Stage: As easily decomposable organic matter is depleted, the temperature gradually decreases, and the material becomes mature and stable.
(III) The Role of Turning in Fermentation
Turning is an important measure to improve composting efficiency and product quality. The core value of the turner for aerobic fermentation lies in:
Oxygen Supply: Turning introduces air (oxygen) into the compost pile, meeting the metabolic needs of aerobic microorganisms.
Temperature Regulation: Turning dissipates heat, preventing excessively high pile temperatures that inhibit microbial activity.
Humidity Regulation: Turning promotes moisture evaporation, regulating pile humidity.
Crushing: The cutter shaft effectively crushes clumps formed during raw material fermentation.
Homogeneity: Ensures uniform mixing of materials within the pile, preventing localized anaerobic conditions.
The turning process typically involves 4-5 cycles. The compost turner also functions as a crusher, eliminating the need for an additional crusher during production, thus significantly improving work efficiency and reducing costs.
(IV) Fermentation Effect Through continuous turning, the compost turner effectively breaks down clumps formed during the fermentation process. The fermented organic matter is fully decomposed and can be directly fed into the granulation stage. Aerobic composting not only solves environmental pollution problems but also provides a source of organic fertilizer for agriculture.

Core Target Audience:

1. Large-scale livestock and poultry farms: Large-scale pig, chicken, cattle, and sheep farms requiring environmentally friendly and resource-based manure treatment to address environmental regulations regarding manure discharge and reduce fertilizer procurement costs by producing their own organic fertilizer.
2. Organic fertilizer production plants: Plants producing 10,000-100,000 tons of powdered/granular organic fertilizer annually require low-cost windrow fermentation equipment to replace high-infrastructure trough-type compost turners.
3. Environmental solid waste treatment companies: Environmental engineering contractors undertaking harmless composting projects for municipal sludge, kitchen waste, and garden waste.
4. Agricultural planting bases and family farms: Thousands of acres of orchards and vegetable bases requiring self-made fermented organic fertilizer for fruit and vegetable cultivation.
5. Organic fertilizer equipment dealers and production line contractors: Procurement of complete organic fertilizer fermentation + granulation production lines, selling complete machines to end-user farms and fertilizer plants.
6. Agricultural and forestry waste recycling and processing enterprises: Recycling and composting straw and mushroom residue into organic fertilizer for export.

Core Advantages of the Equipment

Compared to wheeled models,windrow compost turners offer better maneuverability and higher stability. Their “dual stepless speed control” technology automatically adjusts according to material resistance, ensuring fermentation quality (sufficient oxygen intake) and significantly extending machine lifespan, making them a core tool for the industrialization of windrow composting.

Equipment Safety Prohibitions and Important Supplementary Instructions

1. Unauthorized modification of the machine structure or addition of external equipment is prohibited. The manufacturer will not be liable for after-sales service for damage caused by modifications.
2. Operation on sloping ground or areas with unevenness exceeding 20cm is strictly prohibited to prevent track rollover and chassis damage.
3. This equipment is a site-specific fermentation machine and is prohibited from long-distance road travel. Cross-site transport must be carried by flatbed trailer.
4. When the equipment is running, no one is allowed to stand around the rollers or tracks. Personnel are prohibited from staying in front of or behind the operating area to prevent injury from falling materials.
5. In damp, sewage-filled working environments, the circuit insulation must be checked regularly to prevent short circuits that could burn out the electrical control system.
6. Overloading, exceeding width limits, and exceeding height limits are strictly prohibited. Long-term overloading will damage the reducer and hydraulic system.

Windrow compost turners, as core equipment in the fermentation section of organic fertilizer production lines, have become the preferred choice for large-scale organic fertilizer plants, large-scale livestock farms, and sludge treatment centers due to their advantages such as full hydraulic drive, tracked movement, on-the-spot turning, and high-power turning. Their aerobic fermentation technology can transform livestock manure, agricultural waste, and other organic raw materials into high-quality organic fertilizer within 15-20 days, achieving the dual goals of resource utilization and environmental protection.
Whether you are building a new organic fertilizer/compound fertilizer/feed production line and need a complete equipment solution, upgrading an existing production line and need equipment selection advice, or encountering difficulties in granulating high-moisture, sticky, or coarse-fiber materials and need technical support—we are always ready to provide you with professional and sincere service.