New Type Organic Fertilizer Granulator

Agitator Granulator (new type organic fertilizer granulator)

The new organic fertilizer granulator—also known as an internal-rotor stirring-tooth granulator or wet-process granulator—is a technological product developed by agricultural machinery research institutes and related enterprises, drawing on years of experience in the design and manufacture of compound fertilizer processing equipment; it has been granted a national utility model patent. Primarily used for granulating various fermented organic materials, this equipment represents a breakthrough over conventional organic granulation processes.

This series of granulators utilizes a new wet-process continuous extrusion granulation design. Its key technical breakthrough is that raw materials require neither drying nor pulverization prior to granulation; fermented organic matter can be processed directly into spherical granules, resulting in significant energy savings. The equipment produces spherical granules with an organic content of up to 100%, enabling the production of purely organic granules. By leveraging the tendency of organic particles to interlock and grow under specific forces, the process eliminates the need for added binders; the resulting granules are robust and can be screened immediately, effectively reducing energy consumption during the drying stage.

The equipment is particularly well-suited for granulating coarse-fiber materials that are difficult to process with conventional machinery—such as crop stalks, distillery grains, spent mushroom substrate, and herbal residues—directly after fermentation. It also delivers excellent granulation results for materials like humic acid and municipal sludge. As the fermented organic matter does not require drying, the equipment accommodates a wide range of raw material moisture content, typically between 20% and 40%.

Structural Composition of the New Type Organic Fertilizer Granulator

The new organic fertilizer granulator consists of three core components:

1. Machine Body:The main load-bearing structure, welded from high-quality steel. The outer casing is primarily constructed from thickened seamless steel pipe, ensuring robustness, durability, and resistance to deformation. Inside, the body houses the granulation chamber, where the material undergoes the complete transformation from powder to granules. The compact, well-sealed design effectively prevents material leakage and dust pollution.

2. Granulation Rotor:The core working component responsible for granulation. The rotor is equipped with specially designed stirring teeth that forcefully mix, push, and compress the material through high-speed rotation. The layout and angle of these teeth are precisely calculated to ensure the material continuously undergoes mixing, granulation, spheronization, and densification within the machine. The tooth tips are made of wear-resistant alloy for a long service life and can be replaced individually as they wear down.

3. Drive System:Comprising a motor, a gearbox, and a drive shaft, this system powers the granulation rotor. The motor transmits power through the gearbox to the rotor, driving it at a set speed. Both the drive system and the machine body are mounted on a unified frame, ensuring a sturdy structure, stable operation, and easy installation. The equipment also features variable speed control, allowing users to flexibly adjust the main shaft speed based on material characteristics and granule size requirements.

The integrated design of the drive system and machine body not only ensures operational stability but also greatly simplifies installation and maintenance, making this a state-of-the-art, eco-friendly fertilizer production machine.

Working Principle of the New Type Organic Fertilizer Granulator
The working principle of the new organic fertilizer granulator is as follows: raw materials enter the machine through an inlet at one end and are continuously propelled by a granulating rotor; through mechanical interaction with the machine casing, granulation is achieved, and the finished granules are discharged from the other end. Specifically, the equipment utilizes high-speed mechanical agitation and the resulting aerodynamic forces to continuously subject fine powdery materials to processes such as mixing, granulation, spheronization, and densification. Granule size can be adjusted by varying the material feed rate and the rotational speed of the main shaft; generally, a lower feed rate and higher rotational speed result in smaller granules, and vice versa.
Applications and Raw Materials
This machine is particularly suitable for granulating lightweight, fine-powdered materials. The finer the primary particles of the material, the higher the sphericity and quality of the resulting granules; ideally, the material should have a particle size of less than 200 mesh prior to granulation. Typical materials include livestock and poultry manures (such as chicken, pig, and cattle manure) and mineral raw materials (such as carbon black, clay, and kaolin). It is also suitable for granulating organic fertilizers derived from fermented municipal waste, including livestock and poultry manure/urine, composted materials, green manure, seaweed fertilizer, oil-cake fertilizer, peat, mixed organic waste, industrial/agricultural by-products, and microbial fertilizers.

Key Points for Installation and Commissioning
Compared with other granulation equipment, the agitator granulator has the following advantages when producing fertilizers:
Good granulation effect
The fertilizer particles produced are highly round, uniform in size, smooth in surface, and have good fluidity. They are not easy to clump during storage and transportation, making fertilization operations easier.
Strong adaptability to materials
It can process fertilizer raw materials of various properties, especially organic raw materials with high viscosity and certain fiber content, and can achieve good granulation effect without complicated pretreatment.
Easy to operate
The equipment has a simple structure and an intuitive operation interface, and operators can become proficient in operation after simple training. During the granulation process, the granulation formation can be observed and relevant parameters can be easily adjusted to ensure granulation quality.
Lower energy consumption
Compared with some large-scale extrusion granulation equipment, the agitator granulator has lower power, lower energy consumption and relatively low operating cost, making it suitable for use by small and medium-sized fertilizer production enterprises.
Low equipment investment
The manufacturing cost of the agitator tooth granulator is low, the equipment price is relatively cheap, and the initial investment is small. For companies with limited funds, it is an economical and affordable choice.
Automated Control and Intelligent Monitoring

The machine comes standard with a PLC control cabinet and touchscreen, enabling real-time monitoring of the following:

Spindle current: Reflects load fluctuations; a sudden spike indicates excessive feed or an internal jam, triggering automatic frequency reduction for protection.

Bearing temperature: Dual PT100 sensors trigger an automatic audible and visual alarm if the temperature exceeds 70°C, prompting lubrication or a shutdown for inspection.

Rotational speed and output linkage: The main drive VFD is linked to the feed screw VFD, automatically matching speed with feed rate to ensure consistent pellet size.

Lubrication management: A built-in timer automatically signals when bearing lubricant needs changing after 300 hours of operation, preventing oversights due to human error.

This intelligent system allows a single operator to monitor the entire machine's operation, significantly reducing the risk of human error.

Environmental and Safety Characteristics

Dust Control: Inlet and outlet ports feature double-layer pneumatic sealing doors and negative-pressure dust extraction connections compatible with the workshop dust removal system, ensuring dust emission concentrations remain ≤10 mg/m³—well below national standards.

Noise Control: The drum is encased in polyurethane sound-insulating material, and the gearbox is fitted with vibration-damping pads; the overall machine noise level is ≤82 dB, meeting occupational health requirements.

Safety Protection: Includes protection against motor overload, phase loss, and overheating; fully enclosed guards for drive components; multiple emergency stop buttons across the machine; and maintenance doors equipped with limit switches that cut power immediately upon opening to ensure personnel safety.