In the organic fertilizer market, granular fertilizer is gaining increasing favor among farmers due to its unique advantages—easy mechanized application, dust-free storage and transportation, and a more gradual release of fertilizer effects. Among the many granular fertilizer products, pure organic spherical granules have become a favorite in the high-end market due to their good appearance and pure fertilizer efficacy. Disc granulation production lines are specifically designed for this product, utilizing the material’s own viscosity to form granules without adding any chemical binders, resulting in a finished product with nearly 100% organic matter content. This article will detail the equipment, process key points, and advantages of this production line.

Core Production Line Equipment: Tailor-made for Pure Organic Fertilizer

A complete pure organic disc granulation production line requires close coordination between upstream and downstream processes. Huaqiang Heavy Industry provides a complete set of equipment from raw material crushing to finished product packaging, optimized for the characteristics of pure organic fertilizer.

Chain Crusher: Fermented organic materials often have hardened lumps, requiring prior crushing. Huaqiang chain crusher can pulverize composted materials to an ideal fineness of 20-40 mesh, laying the foundation for subsequent granulation.

Wind stack turning machine: The core equipment in the fermentation process, ensuring that the raw materials are fully composted and free of pests and eggs. The Huaqiang wind stack turning machine moves flexibly and turns the material evenly, providing high-quality fermentation raw materials for granulation.

Large disc granulator: The core of the production line. Disc diameters are selectable from 2.5 meters to 4.5 meters, disc inclination angles are adjustable from 35° to 55°, and rotation speed can be flexibly set according to material characteristics. The inner wall of the equipment is lined with high-strength wear-resistant rubber, extending service life and preventing material from sticking to the wall.

Vibrating screener: Classifies and screens the granulated material. Qualified granules enter the packaging stage, oversized granules are crushed and reused, and fine powder is returned to the granulator for re-granulation.

Semi-automatic packaging machine: Designed specifically for granular fertilizer characteristics, it offers precise weighing and rapid filling, perfectly matching the upstream production capacity.

Core Process Points: The Transformation from Powder to Granules

Raw Material Preparation: Fermented and decomposed pure organic fertilizer (such as chicken manure, cow manure, mushroom residue, etc.) needs to be crushed twice to ensure uniform fineness and absence of lumps. The moisture content should be controlled at 25%-30%—ideally, it should be able to form a ball when squeezed but crumble easily when released.

Disc Granulation: The crushed material is conveyed into a disc granulator via a conveyor belt. Under the combined action of centrifugal force and friction, the material continuously rolls and agglomerates within the disc, gradually growing into granules. Operators can control the particle size by adjusting three key parameters:

Disc Inclination Angle:A larger inclination angle results in a shorter residence time and smaller particles; a smaller inclination angle results in a longer residence time and larger particles. Generally, it is controlled between 35° and 55°.

Disc Rotation Speed:A faster rotation speed results in greater centrifugal force, a longer material throwing distance, and a faster granulation speed. It is typically controlled at 10-20 rpm.

Water Spraying: Appropriate water spraying enhances material viscosity and promotes granulation. Excessive moisture content leads to sticking to the granulator walls, while insufficient moisture reduces the granulation rate. Huaqiang equipment is equipped with an adjustable water spraying device for precise control.

Under suitable parameters, the granulation rate can reach over 95%, and the particle diameter can be flexibly controlled between 2-8 mm to meet the needs of different crops and application scenarios.

Drying Method: A major advantage of pure organic granules is that drying is unnecessary. Under sunny and well-ventilated conditions, spreading out the wet granules to air dry for 1-2 days will reduce the moisture content to a safe storage standard (below 15%). This saves a significant amount of energy compared to drying processes, truly achieving “green production.”

Screening and Packaging: After drying, the granules are graded by a vibrating screen. Qualified granules are bagged in a packaging machine, while oversized granules or fine powder are returned to the granulator for reuse, achieving zero waste of raw materials.

III. Finished Product Advantages: Excellent Appearance and Superior Fertilizer Efficacy

Pure organic granular fertilizer produced using disc granulation technology boasts multiple competitive advantages in the market:

Perfectly spherical granules with excellent appearance:The disc granulator forms granules through rolling and agglomeration, resulting in smooth, round, and full granules with uniform color. Such products immediately attract farmers’ attention on agricultural supply store shelves. One organic fertilizer factory, after adopting the Huaqiang disc granulation production line, saw its product price increase by 20%, yet demand still exceeds supply.

No binders added, high organic matter content:Pure organic raw materials rely on their own viscosity to form granules, eliminating the need for any chemical binders such as bentonite or starch. The finished product has an organic matter content close to 100%. This means that every granule is pure organic matter, leaving no impurities after application to the soil.

Long-lasting effect, no seedling burn:Compared to powdered fertilizer, granular fertilizer releases nutrients more gradually, resulting in a longer-lasting effect. Simultaneously, the granular shape avoids dust generation and does not damage crop leaves during application, making it particularly suitable for high-value-added scenarios such as seedling cultivation and greenhouse cultivation.

Moderate hardness, convenient for storage and transportation: The granules produced by disc granulation have moderate strength, making them less prone to breakage during packaging and transportation, while also being able to absorb water and disintegrate in the soil, releasing nutrients. Huaqiang’s production line can control the granule hardness by adjusting parameters according to customer needs, meeting different market requirements.

Case Study: Upgrading from “Soil Fertilizer” to “Commodity” A certain organic fertilizer factory in Shandong used to only produce powdered fertilizer, resulting in low prices, thin profits, and frequent complaints from farmers due to dust issues. After introducing the Huaqiang disc granulation production line, the factory granulates fermented chicken manure fertilizer, resulting in a completely new product appearance: The granules are round and uniform, neatly stacked after packaging, and displayed alongside branded compound fertilizers without being inferior. The price has increased from 800 yuan/ton for powdered fertilizer to 1200 yuan/ton, yet demand still exceeds supply. Surrounding high-end orchards and vegetable bases have become stable customers, with annual sales exceeding 5000 tons. One fruit farmer commented, “Before, using powdered fertilizer left me covered in dirt; now, using granular fertilizer is convenient, clean, and the effect is just as good.” V. Customized Services: Adapting the Production Line to Your Needs Every organic fertilizer factory has different raw material characteristics and market positioning. Huaqiang Heavy Industry’s disc granulation production line offers a variety of customization options:

Disc Specifications: Diameters of 2.5m, 3m, 3.6m, 4.5m, etc., with hourly outputs ranging from 1 ton to 10 tons to match different production capacity needs.

Particle Diameter: By changing the scraper position and adjusting parameters, it can produce small particles of 2-5mm or large particles of 5-8mm.

Material Selection: Parts in contact with materials can be made of carbon steel lined with wear-resistant rubber or stainless steel to meet different hygiene requirements.

Automation Level: From single-machine manual to fully automatic PLC control, flexible configuration is available according to budget.

From perfectly spherical particles to near 100% organic matter content, from energy-saving processes that do not require drying to a flexible and adjustable diameter range—Huaqiang’s disc granulation production line provides pure organic fertilizer producers with an upgrade path from “soil fertilizer” to “commercial product.” When your product wins market favor with its rounded shape and excellent appearance, you will understand: choosing the right granulation equipment is choosing the right shortcut to the high-end market.

The journey to premium spherical organic granules begins with proper raw material preparation within a comprehensive organic fertilizer manufacturing system. Fermented, composted organic matter requires size reduction before granulation. For materials with typical moisture content (25-55%), a half-wet material crusher machine is the ideal choice, efficiently breaking down clumps without clogging. For drier or more fibrous materials, a robust chain crusher provides powerful crushing, while a cage crusher delivers an exceptionally fine and uniform grind, essential for creating a smooth, consistent feed for the granulator. These machines form a key part of the organic fertilizer granulator series. The prepared powder then enters the heart of the organic fertilizer disc granulation production line. As an innovative alternative, a new type two in one organic fertilizer granulator combines final crushing and initial granulation, offering a compact, efficient solution for producing the high-purity, perfectly spherical granules that command a premium in the market.