New Type Stirring Tooth-Drum Granulator

The new type two in one organic fertilizer granulator integrates material wetting, mixing, and spherical granulation into a single continuous process, breaking away from the traditional two-stage layout of "mixing followed by granulation." Its core design philosophy focuses on streamlining workflows, reducing equipment requirements, and simplifying operations, thereby enabling a more direct transformation of organic fertilizer from powder to granules. The new type two in one organic fertilizer granulator features an inclined rotating drum equipped with internal zoning structures and a spray system; as material moves through the drum, it naturally transitions from dry powder to a moistened state and finally into spherical granules. For small- to medium-sized organic fertilizer processing operations looking to streamline production lines, lower investment costs, and reduce daily maintenance, this integrated unit offers an efficient and easy-to-manage solution.

Granulation Process

Stage 1: Wetting and Pre-mixing. Powdered organic fertilizer raw materials are fed into the front of the drum via a quantitative feeder. Internal guide plates and mixing blades repeatedly lift and scatter the material, creating a loose "curtain" of particles. A spray system injects atomized water or liquid binder into this zone, allowing the suspended, tumbling powder to rapidly absorb moisture. As water evenly permeates the material, it shifts from a dry powder to a moist state capable of clumping when squeezed, laying the groundwork for subsequent granulation.

Stage 2: Kneading and Nucleation (Seed Pellet Formation). As the drum rotates, the material advances while mixing intensity gradually decreases, entering a transition zone dominated by kneading and compression. Under the drum's rotation, the moistened powder is compacted and kneaded, expelling internal air; driven by liquid bridge forces, fine powder particles aggregate to form tiny "seed pellets" (nuclei). The uniformity and density of these nuclei at this stage directly determine the quality of the final granules.

Stage 3: Rolling Growth and Spherical Shaping. In the smooth-walled rear section of the drum, friction carries the material to a high point before it rolls back down, creating a continuous tumbling flow. As the seed pellets repeatedly roll and tumble, they adhere to surrounding moist powder, gradually increasing in size, while collisions and friction smooth and round their surfaces. Once the granules reach the set size, they overflow from the discharge outlet and proceed to the subsequent drying, cooling, and screening stages.

Process Advantages

The process flow is compact with fewer intermediate steps. Powdered material does not require a separate mixer, eliminating the need for transfer equipment and chutes between the mixer and the new type two in one organic fertilizer granulator; this reduces the total number of machines in the line, thereby lowering both power consumption and material loss. Performing two processes in a single machine reduces potential points of failure and enhances process stability.

Seamless integration of mixing and granulation. Materials enter the pelletization stage immediately after wetting, avoiding fluctuations in moisture and temperature. This ensures consistent environmental conditions for the formation and growth of seed granules, resulting in more stable granule uniformity and strength.

Centralized adjustment of operating parameters. Operators need only monitor three key variables—drum rotation speed, water spray rate, and feed rate—to simultaneously influence mixing effectiveness and pellet quality. This allows for shorter commissioning periods and rapid recipe switching. This centralized control model offers greater flexibility for organic fertilizer production that requires frequent adjustments to particle size or formulations in response to market changes.

Application in Fertilizer Production Lines

Regarding the upstream process, fermented and pulverized organic fertilizer powder is conveyed by a bucket elevator into the new type two in one organic fertilizer granulator's integrated feed hopper or fed directly into the drum inlet via a metered screw feeder. Since the integrated unit performs mixing functions, multi-component raw materials can be fed directly after simple pre-mixing following pulverization; this eliminates the need for a twin-shaft mixer and simplifies the downstream equipment chain.

Regarding the downstream process, wet granules overflowing from the granulator pass through a discharge chute onto a belt conveyor, which transports them to a dryer for moisture removal. The granules exhibit high sphericity and a narrow size distribution, facilitating uniform airflow penetration within the dryer and improving thermal efficiency. After drying and cooling, the granules pass through a grading screen; undersized fines are returned to the granulator inlet to be mixed with fresh material and re-granulated, creating a closed-loop cycle.

In terms of automation, the integrated granulator can be connected to the plant-wide control system, enabling interlocked regulation of feed rate, water spray rate, and drum rotation speed. For workshops handling multi-product production, process parameters for various formulations can be stored and recalled with a single click, thereby reducing the setup workload during product changeovers.

Applications Fields

In the field of pure organic fertilizer production, this equipment enables the mixing and granulation of fermented livestock and poultry manures (such as chicken, pig, sheep, cattle, and duck manure) and agricultural organic wastes (such as straw powder, rice husk powder, sawdust, spent mushroom substrate, and biogas residue) into spherical organic fertilizer granules.

In the field of bio-organic and functional fertilizers, functional microbial agents are pre-mixed into the fermented material before undergoing a room-temperature "two-in-one" granulation process; this prevents the inactivation of the microbial agents caused by high temperatures, resulting in granules with high biological activity.

In the field of soil conditioners and specialty fertilizers, materials such as humic acid, peat, and silicon-calcium compounds are moistened, mixed, and granulated using this equipment to produce easy-to-apply spherical granules suitable for soil improvement and the mitigation of continuous cropping obstacles.