ZHENGZHOU SHENGHONG HEAVY INDUSTRY TECHNOLOGY CO., LTD.

Project OverviewMixed Agriculture Operations — a diversified livestock and crop farm based in Southeast Asia commissioned a turnkey mixed animal waste and straw granulation plant to process combined chicken litter, pig manure and rice straw into uniform organic fertilizer pellets. The line was designed for an initial capacity of 3–5 tons per hour. Shenghong Heavy Industry supplied the complete production line including pre-treatment dewatering, formulation mixing, deep fermentation, disc pan granulation, drying, cooling, screening, coating and automatic packing.Key ChallengesThe client faced three core issues:Heterogeneous raw materials — combining chicken litter (high nitrogen), pig manure (high moisture) and rice straw (high fiber) required careful moisture balancing and ratio adjustment.Nitrogen loss control — fermented chicken litter can lose up to 40% nitrogen during aerobic composting if not managed properly.Labor-intensive traditional method — previously relied on manual turning and open-air composting, causing odor complaints from neighbors.Complete Plant Process FlowThe Shenghong turnkey line comprises the following stages:Pre-treatment: Chicken litter is separated by screw press (typically SHLX180 or SHLX280) to reduce moisture. Rice straw crushed separately. Pig manure collected via slurry system.Ratio-based batching: Three-stream material feeding via B500 belt conveyors feeds into a multi-material auto-batching system (B650) for precise ratio control—maintaining C/N ratio at 25-30:1 and moisture at 40-45%.Formulation mixing: Batched material enters a SH900x1500 spiral ribbon mixer where commercial microbes and mineral supplements are evenly distributed.Deep fermentation: Mixed material transferred to an in-vessel fermentation tank for controlled temperature 60-70°C over 7-10 days. Forced aeration ensures oxygen availability while minimizing ammonia volatilization.Disc pan granulation: Fermented material enters the Disc Pan Granulator (ZL series). Unlike drum granulators which work best with pure organics, the disc pan method excels at forming round balls from moderately moist mixtures. Powder rises along the rotating arc disc while water spray is added; particles adhere into seed cores, grow layer-by-layer into round balls, and overflow at the disc edge.Rotary drying: Wet granules (moisture ~30%) pass through a SHG8800 rotary dryer, reducing moisture below 15%.Rotary cooling: Hot dried granules cooled to ambient temperature.Sieving: Oversize granules crushed and returned; undersize fines recycled back to disc granulator inlet via 1.0x3.0 rotary screener.Coating and packing: Nutrient film applied in 1000x3000 drum coater, then bagged by BLD-K50/S packer.Main Equipment ConfigurationStageEquipmentModel RangeConveyingBelt ConveyorB500 / B600 / B800 / B1000BatchingMulti-Material Auto-Batching SystemB500 / B650 / B800DewateringScrew Press Dewatering MachineSHLX180 / SHLX280 / SHLX300MixingSpiral Ribbon MixerSH900x1500FermentationIn-Vessel Tank w/ Forced AerationCustom sizeGranulationDisc Pan GranulatorSH1.2x4 / SH1.5x6 / SH1.8x7 / SH2.0x8 / SH2.2x10 / SH2.4x10 / SH2.8x10DryingRotary DryerSHG8800 / SHG10100 / SHG12120CoolingRotary CoolerGL seriesSievingRotary Screener1.0x3.0CoatingDrum Coater1000x3000PackingAutomatic PackerBLD-K50/SWhy Disc Pan Granulation for Mixed Waste?For heterogeneous mixed animal waste + straw feedstock, the Disc Pan Granulator offers advantages:Tunable rolling path — disc angle adjustable 35-55° allows fine-tuning for different raw material combinations and target granule sizes.Binder-free granulation — natural binding properties of fermented chicken litter plus starch from straw create strong inter-particle adhesion without synthetic binders.Versatile sizing — produces uniform spherical pellets ideal for mechanized field application.Lower capital cost — simpler structure compared to drum granulators, making it attractive for mid-scale operations.Easy operation — minimal maintenance requirements with flexible belt drive and hardened main gear.Plant Specification SnapshotParameterSpecificationClient regionSoutheast AsiaRaw materialChicken litter + pig manure + rice strawTarget output3-5 t/hGranulation methodWet disc pan granulationGranule size2-6 mmOrganic contentUp to 100%Feed moisture20-40% (after dewatering)Power supply380V / 50Hz (customizable)CertificationBV, SGS, ISOWarranty1 year on all equipmentAbout This SolutionEvery Shenghong production line is engineered to the client's raw material, site layout and budget. Whether you work with mixed livestock waste, crop residues, food processing by-products or industrial organic waste, our engineering team will design a customized line from pre-treatment through packing.

Project OverviewMunicipal Wastewater Treatment — a municipal wastewater treatment authority in South China commissioned a turnkey sludge organic fertilizer plant to convert dewatered sewage sludge and yard waste into certified organic soil amendment. The line was designed for an initial capacity of 5–8 tons per hour. Shenghong Heavy Industry supplied the complete production line including thickening mixing, deep fermentation, stirring tooth-drum granulation, drying, cooling, screening, coating and automatic packing.Key ChallengesThe client faced three core issues:Heavy metal and pathogen concerns — regulatory requirement for complete pathogen elimination (temperature >60°C sustained 7+ days) and heavy metal immobilization.High fiber content — mixed sludge with yard trimmings creates fibrous feedstock that plugs conventional disc pan granulators.Acidic corrosion risk — decomposing organic acids from sludge can corrode standard equipment components.Complete Plant Process FlowThe Shenghong turnkey line comprises the following stages:Thickening and mixing: Dewatered sludge (moisture ~60%) is blended with yard waste, straw and wood chips by a B500 belt conveyor system. Ratio adjustment achieved via a B650 multi-material auto-batching system to reach 30-40% moisture for granulation.Formulation mixing: Pre-mixed material enters a SH1000x2000 spiral ribbon mixer where commercial microbes, bulking agents and mineral stabilizers are thoroughly blended.Deep fermentation (in-vessel): Material enters an in-vessel fermentation tank with forced aeration. Temperature reaches 65-75 °C over 5-7 days, achieving complete pasteurization and odor reduction meeting Class A biosolid standards.Drum granulation: Fermented material enters the Stirring Tooth-Drum Granulator (typically SH1.5x6 or SH1.8x7). The unique combination of mechanical stirring force and rotating drum action continuously mixes, granulates, forms balls, compacts and polishes powdery materials within the machine. Rubber-lined drum body prevents corrosion from acidic sludge decomposition products.Rotary drying: Wet granules pass through a SHG10100 rotary dryer, reducing moisture to below 15%.Rotary cooling: Hot dried granules cooled to ambient temperature by a GL series cooler drum.Sieving: Oversize granules crushed and returned; undersize fines recycled via a 1.2x4.0 rotary screener.Coating: Nutrient film applied in a 1000x3000 drum coater.Packing: Finished granules bagged by BLD-K50/S automatic packer (25 kg/bag).Main Equipment ConfigurationStageEquipmentModel RangeConveyingBelt ConveyorB500 / B600 / B800 / B1000BatchingMulti-Material Auto-Batching SystemB500 / B650 / B800MixingSpiral Ribbon MixerSH1000x2000FermentationIn-Vessel Tank w/ Forced AerationCustom sizeGranulationStirring Tooth-Drum GranulatorSH1.2x4 / SH1.5x6 / SH1.8x7 / SH2.0x8 / SH2.2x10 / SH2.4x10 / SH2.8x10DryingRotary DryerSHG8800 / SHG10100 / SHG12120CoolingRotary CoolerGL seriesSievingRotary Screener1.2x4.0CoatingDrum Coater1000x3000PackingAutomatic PackerBLD-K50/SWhy Drum Granulation for Sludge?For sewage sludge organic fertilizer, the Stirring Tooth-Drum Granulator offers distinct advantages:Rubber-lined drum body — prevents corrosion from acidic organic acids released during sludge decomposition, extending service life dramatically.Handles 100% pure organic content — no binder required — particles grow under controlled force to form dense spherical pellets.No blockage — continuous stirring action prevents fibrous sludge from plugging internal mechanisms.Class A compliance — granulation temperature combined with upstream fermentation ensures complete pathogen elimination.Plant Specification SnapshotParameterSpecificationClient regionSouth ChinaRaw materialSewage sludge + yard waste + strawTarget output5-8 t/hGranulation methodWet stirring tooth-drum granulationGranule size3-30 mm (adjustable)Organic contentUp to 100%Feed moisture20-40% (after dewatering)CertificationBV, SGS, ISOWarranty1 year on all equipmentAbout This SolutionEvery Shenghong production line is engineered to the client's raw material, site layout and budget. Whether you work with municipal sludge, pond dredging, food waste or agricultural residues, our engineering team will design a customized line from pre-treatment through packing.

Project OverviewAgriculture — a dairy farming cooperative based in Western Europe commissioned a turnkey cow dung organic fertilizer plant to convert daily manure production from over 200 head of cattle into high-quality granular fertilizer. The line was designed for an initial capacity of 3-5 tons per hour, with future expansion capability up to 10 t/h. Shenghong Heavy Industry supplied the complete production line including pre-treatment, deep fermentation, stirring tooth-drum granulation, drying, cooling, screening, coating and automatic packing.Key ChallengesThe client faced three core issues:High-volume raw material — daily manure output from 200+ cattle required a system capable of continuous processing without bottlenecks.Moisture variability — cow manure moisture content varies from 60% to 80% depending on bedding material and season, requiring flexible dewatering capabilities.EU environmental regulations — strict requirements on odor control, pathogen elimination and nutrient recovery from agricultural waste.Complete Plant Process FlowThe Shenghong turnkey line comprises the following stages:Pre-treatment stage: Fresh cow manure is collected by automated scraper or conveyor system and fed into an SHLX280 or SHLX300 screw press dewatering machine to reduce moisture from ~75% to 30-40%. Sawdust or straw added as bulking agent during collection.Formulation mixing: Dewatered manure, crop residues (straw/corn stalks), NPK supplements and commercial microbes are batched and thoroughly mixed in a SH900x1500 or SH1000x2000 spiral ribbon mixer to achieve the target formula.Deep fermentation (in-vessel): The mixed material enters an in-vessel fermentation tank where temperature reaches 60-70 °C over 7-10 days, completing pathogen elimination, weed seed destruction and odor reduction.Drum granulation: Fermented material enters the Drum Granulator (SH1.8x7 or SH2.0x8). The unique combination of mechanical stirring force and rotating drum action continuously mixes, granulates, forms balls, compacts and polishes powdery materials within the machine. No binder required — particles grow under controlled force to form dense spherical pellets.Rotary drying: Wet granules (moisture ~30%) pass through a SHG8800 rotary dryer, reducing moisture to below 15% and hardening the pellets.Rotary cooling: Hot dried granules are cooled to ambient temperature by counter-flow air in a GL series cooler drum.Sieving: Oversize granules are crushed and returned; undersize fines are recycled back to the drum granulator inlet via a 1.2x4.0 rotary screener.Coating: A thin anti-caking or nutrient film is applied in a 1000x3000 or 1200x4000 drum coater.Packing: Finished granules are weighed and bagged by a BLD-K50/S automatic packer (25 kg/bag).Main Equipment ConfigurationStageEquipmentModel RangeCapacity / PowerDewateringScrew Press Dewatering MachineSHLX180 / SHLX280 / SHLX300Input 4–8 / 10–15 / 15–25 t/h(Power: 4/2.2 / 4/4 / 7.5/2.2 kW)CrushingDouble-Shaft CrusherBSFS seriesmatching lineMixingSpiral Ribbon MixerSH600x1200 / SH700x1500 / SH900x1500 / SH1000x2000 / SH1500x30001.5–2 / 2–3 / 3–5 / 5–8 / 8–12 t/h(Power: 5.5 / 7.5 / 11 / 15 / 30 kW)FermentationIn-Vessel TankCustom sizeper tankGranulationDrum GranulatorSH1.2x4 / SH1.5x6 / SH1.8x7 / SH2.0x8 / SH2.2x10 / SH2.4x10 / SH2.8x103–10 t/hDryingRotary DryerSHG8800 / SHG10100 / SHG121203–10 t/hCoolingRotary CoolerGL series3–10 t/hSievingRotary Screener1.0x3.0 / 1.2x4.0 / 1.5x5.0 / 1.5x6.0 / 1.8x7.0 / 2.0x8.03–10 t/hCoatingDrum Coater1000x3000 / 1200x4000 / 1500x6000 / 1800x80003–10 t/hPackingAutomatic PackerBLD-K50/S1–5 bags/minWhy Drum Granulation for Cow Manure?For cow dung organic fertilizer, the Stirring Tooth-Drum Granulator offers distinct advantages:Handles 100% pure organic content — unlike disc pan granulators which work best at lower organic concentrations, the drum granulator can process nearly 100% organic material without binders.Adjustable granule diameter — granule size can be adjusted from 3mm to 30mm, suitable for different application scenarios (field spreading, soil amendment, specialty crops).Higher throughput per unit — individual units can produce 8-20 t/h, making them ideal for large-scale dairy operations.Rubber-lined drum body — prevents corrosion from acidic raw materials, extending equipment service life.Massy, uniform granules — particles can be sieved directly after granulation, reducing energy consumption compared to other methods.Project ResultsAfter installation and commissioning, the client achieved the following outcomes:Manure disposal eliminated: daily manure from 200+ head processed into marketable organic fertilizer.Finished product rate: stabilized at 85-90% (typical for drum granulation of cow manure).Granule quality: spherical, massy granules with adjustable diameter, excellent spreadability.EU compliance: fully meets EU organic fertilizer standards for nutrient content and pathogen elimination.Revenue diversification: converted previously costly manure management into a premium soil amendment product.Plant Specification SnapshotParameterSpecificationClient regionWestern EuropeRaw materialCow manure + sawdust/strawTarget output3-5 t/h (expandable to 10 t/h)Granulation methodWet stirring tooth-drum granulationGranule size3-30 mm (adjustable)Organic contentUp to 100%Feed moisture20-40% (after dewatering)Power supply380V / 50Hz (customizable)CertificationBV, SGS, ISO, CEWarranty1 year on all equipmentAbout This SolutionEvery Shenghong production line is engineered to the client's raw material, site layout and budget. Whether you work with cow manure, chicken litter, pig slurry, pond sludge, food waste or agricultural residues, our engineering team will design a customized line from pre-treatment through packing. Contact us with your target capacity and material profile, and we will prepare a detailed configuration proposal and quotation.

Project OverviewAgriculture — a pig farm operations group based in Southeast Asia commissioned a turnkey organic fertilizer plant to convert pig manure and rice husk into high-quality granular fertilizer. The line was designed for an initial capacity of 5–8 tons per hour, with future expansion capability up to 10 t/h. Shenghong Heavy Industry supplied the complete production line including pre-treatment, deep fermentation, disc pan granulation, drying, cooling, screening, coating and automatic packing.Key ChallengesThe client faced three core issues:Fibrous raw material — pig manure mixed with straw and rice husk contains high fiber content that makes conventional rotary drum granulators inefficient (low ball forming rate).Nitrogen-rich feedstock — fermented pig manure has nitrogen content above 8%, which causes wall-sticking problems on spiral-tooth granulators.Bio-hazardous wastewater — the pig farm needed a system that could handle wet manure directly without extensive pre-drying, reducing energy consumption and disease transmission risk.Complete Plant Process FlowThe Shenghong turnkey line comprises the following stages:Pre-treatment stage: Fresh pig manure is dewatered via an SHLX series screw press dewatering machine (typically SHLX280 or SHLX300) to reduce moisture from ~80% to 30-40%. Rice husks and straw are crushed separately and screened to uniform particle size.Formulation mixing: Dewatered manure, crushed rice husk, NPK additives and commercial microbes are batched and thoroughly mixed in a SH600x1200 or SH700x1500 horizontal mixer (spiral ribbon type) to achieve the target formula.Deep fermentation (in-vessel): The mixed material enters a fermentation tank where temperature reaches 60-70 °C over 7-10 days, completing pathogen elimination and odor reduction.Disc pan granulation: Fermented material enters the SHQ series Disc Pan Granulator (SHQ-20 or SHQ-25). Powder rises along the rotating arc disc while water is sprayed; particles adhere into seed cores, grow layer-by-layer into round balls, and overflow at the disc edge. Disc angle is set to 42° for optimal rolling path.Rotary drying: Wet granules (moisture ~35%) pass through a SHG8800 or SHG10100 rotary dryer, reducing moisture to below 15% and hardening the pellets.Rotary cooling: Hot dried granules are cooled to ambient temperature by counter-flow air in a cooler drum.Sieving: Oversize granules are crushed and returned; undersize fines are recycled back to the disc granulator inlet via a 1.2x4.0 or 1.5x5.0 rotary screener.Coating: A thin anti-caking or nutrient film is applied in a 1000x3000 or 1200x4000 drum coater.Packing: Finished granules are weighed and bagged by a BLD-K50/S automatic packer (25 kg/bag).Main Equipment ConfigurationStageEquipmentModel RangeCapacity / PowerDewateringScrew Press Dewatering MachineSHLX180 / SHLX280 / SHLX300Input 4–8 / 10–15 / 15–25 t/h(Power: 4/2.2 / 4/4 / 7.5/2.2 kW)CrushingDouble-Shaft CrusherBSFS seriesmatching lineMixingHorizontal Mixer (Spiral Ribbon)SH600x1200 / SH700x1500 / SH900x1500 / SH1000x2000 / SH1500x30001.5–2 / 2–3 / 3–5 / 5–8 / 8–12 t/h(Power: 5.5 / 7.5 / 11 / 15 / 30 kW)FermentationIn-Vessel TankCustom sizeper tankGranulationDisc Pan GranulatorSHQ-20 / SHQ-25 / SHQ-28 / SHQ-30 / SHQ-32 / SHQ-36 / SHQ-450.6–6 t/h eachDryingRotary DryerSHG8800 / SHG10100 / SHG121205–10 t/hCoolingRotary CoolerGL series5–10 t/hSievingRotary Screener1.0x3.0 / 1.2x4.0 / 1.5x5.0 / 1.5x6.0 / 1.8x7.0 / 2.0x8.05–10 t/hCoatingDrum Coater1000x3000 / 1200x4000 / 1500x6000 / 1800x80005–10 t/hPackingAutomatic PackerBLD-K50/S1–5 bags/minWhy the Disc Pan Granulator?For pig manure organic fertilizer, the disc pan granulator offers several advantages over alternatives:High finished-product rate — typically 93-97%, far above the ~60% of drum granulators for fibrous materials.No wall-sticking — unlike spiral-tooth machines, the smooth glass-fibre reinforced plastic disc lining resists adhesion of nitrogen-rich, moist material.Rounded, uniform granules — the tumbling action produces smooth spherical pellets 2-6 mm in diameter, ideal for mechanical spreading.Low energy cost — no pre-drying required; wet material feeds directly into the disc.Easy maintenance — simple structure with flexible belt drive and hardened main gear; base does not require anchor bolts.Project ResultsAfter installation and commissioning, the client achieved the following outcomes:Finished product rate: stabilized at 93-95% within the first week of operation.Granule quality: uniform round ball shape, diameter 2-5 mm, excellent spreadability in field trials.Odor reduction: deep fermentation eliminated >95% of original ammonia and methane odors.Revenue diversification: converted previously costly disposal of pig manure into a sellable organic fertilizer product at competitive price.Plant Specification SnapshotParameterSpecificationClient regionSoutheast AsiaRaw materialPig manure + rice husk + strawTarget output5-8 t/h (expandable to 10 t/h)Granulation methodWet disc pan granulationGranule size2-6 mmDisc diameter2.0-3.0 m (depending on model)Disc angle35-55 deg adjustableGranulation rate>=93%Power supply380V / 50Hz (customizable)CertificationBV, SGS, ISOWarranty1 year on all equipmentAbout This SolutionEvery Shenghong production line is engineered to the client's raw material, site layout and budget. Whether you work with pig manure, chicken litter, cow dung, crop residues or industrial organic waste, our engineering team will design a customized line from fermentation through packing. Contact us with your target capacity and material profile, and we will prepare a detailed configuration proposal and quotation.

Project Overview This case study explains how a South American (Brazil) agricultural input distributor commissioned a modular BB (bulk blending) fertilizer production line with a rated output of 10–15 T/H to serve sugarcane, soybean and maize growers. The client previously bought finished compound fertilizer from importers, which created high logistics costs, long lead times and very little control over N-P-K ratios. After comparing several suppliers, the client chose our PLC-controlled bulk blending plant because it can mix single fertilizers (urea, DAP, MAP, MOP, ammonium sulfate and others) into tailored formulas without any chemical reaction or granulation step. Why a Bulk Blending (BB) Line? Formula flexibility — nutrient concentration above 50%, with trace elements, pesticides and herbicides easily incorporated. Low operating cost — no drying, no granulation and no chemical reaction, saving energy and raw-material loss. Small footprint — a compact batching–mixing–packaging layout cuts land and civil-works investment. Fast market response — farmers receive blends matched to soil-test results and specific crop requirements. Project Scope & Configuration ItemSpecification Capacity10–15 T/H base; full range 1–50 T/H customizable Control systemPLC centralized control with automatic proportional batching MixingBB fertilizer mixer, blending uniformity above 95% BaggingQuantitative packaging 10–50 kg/bag with sewing conveyor Power supply380 V / 50 Hz (customizable), 15–30 kW MaterialsCarbon steel frame with stainless-steel contact parts Service12-month warranty, overseas engineer service available Production Process PLC computer control system Automatic proportional batching of raw materials (pit-style accumulative weighing) Slope scraper / belt lifting of materials BB fertilizer mixer blending into a homogeneous blend Transfer to weighing-machine storage silos Quantitative packaging (10–50 kg/bag) Conveying and sewing Finished-product palletizing and storage Equipment Included StageMachineFunction BatchingAutomatic batching machineRatio raw materials by formula MixingBB fertilizer mixerBlend uniformly above 95% PackagingQuantitative packaging machinePack fertilizer into 10–50 kg bags ConveyingBelt conveyorContinuous material transfer ControlPLC control cabinetCentralized automation and monitoring Technical Highlights Pit-style batching with accumulative weighing for fast, accurate raw-material handling. High-precision weighing controllers give a stable packaging tolerance of roughly ±0.5%. Sealed, cyclical dust-control design protects the working environment and operators. Modular skid layout allows capacity to be expanded later from 10–15 T/H up to 50 T/H. Uniform granule preservation — the blend keeps the original particle size of each material. Results & Customer Feedback After commissioning, the line reached a stable output of 12–14 T/H in single-shift operation and can scale with a second shift during the planting season. Blending uniformity exceeded 95%, and because the process needs no granulation or drying, the client cut energy and raw-material costs while responding to farmers' custom orders within days instead of weeks. “We now build the formula the customer asks for, the same week,” the plant manager reported. Only two operators are needed for normal running thanks to the centralized PLC cabinet. Conclusion This BB bulk blending project shows how a compact, PLC-controlled fertilizer blending line can help distributors replace imported finished fertilizer with local, on-demand NPK production — lowering cost, shortening lead time and unlocking flexible formulas for every crop. The same 1–50 T/H platform is easily adapted to other regions, capacities and raw materials.

NPK Fertilizer Production Line Success Case: Local Compound Fertilizer Manufacturing in East Africa Project Background As an East African agri-inputs company, our client supplies fertilizers to thousands of smallholder and commercial farms. Domestic NPK demand has been growing rapidly with agricultural modernization programs, yet most compound fertilizers were imported, exposing the business to long shipping lead times, currency pressure and supply chain disruptions. To secure stable supply and better serve local soil nutrient needs, the company decided to build its own NPK compound fertilizer production plant with an annual capacity of around 50,000 tons. Client Challenges High dependence on imported NPK compound fertilizer, with unpredictable costs and delivery schedules. Need for uniform, high-strength granules that withstand long-distance distribution and mechanical spreading. Limited local energy and water infrastructure - conventional wet granulation with a drying step was not economical. Requirement for a flexible line that can switch formulas (NPK, NP, DAP, MAP, CAN, SSP) to match regional crop and soil requirements. Shenghong Solution: Customized Double Roller Extrusion NPK Fertilizer Production Line Shenghong Heavy Industry provided a complete turnkey NPK fertilizer production line based on dry double roller extrusion granulation technology - a process that forms granules at normal temperature with no drying process, significantly reducing energy consumption and operating cost. The project line was configured at 6-8 t/h, and thanks to the modular design (each roller extrusion granulator unit delivers 1-4 t/h and multiple units can be combined), the plant can be expanded to 10-12 t/h or more as the market grows. In total, Shenghong lines support annual outputs from 5,000 to 200,000 tons. Complete Process Flow No.ProcessMain EquipmentFunction 1BatchingAutomatic batching machineProportion raw materials precisely according to formula 2GrindingGrinderGrind oversized granules and caking materials into powder 3MixingMixerBlend powder evenly and add micro-elements if required 4GranulatingFeeding machine & double roller extrusion granulatorExtrude mixed powder into firm granules at normal temperature 5ScreeningScreenerSeparate qualified granules; undersize returns for re-granulation 6CoatingCoating machineApply anti-caking agent, color or micro-elements 7PackagingPackaging machineWeigh and bag the finished fertilizer Key Technical Highlights Dry granulation at normal temperature - once forming, no drying process, saving fuel and electricity. High granule strength: unit crushed strength 10-25N, suitable for bulk handling and mechanized spreading. Ball formation rate up to 95% with uniform oval granules, 3-8mm (popular market size 2.8-4mm available). Customizable shapes: oval, irregular or wheat-shaped granules according to market preference. Raw material moisture requirement below 10%, compatible with urea, ammonium chloride, ammonium sulfate, superphosphate, potassium chloride, potassium sulfate and more. Low power consumption and simple structure - easy operation and maintenance, low spare parts cost. Factory trial production before delivery, plus on-site installation guidance and operator training. Project Results Production started on schedule with a stable output of 6-8 t/h, producing NPK 17-17-17, 20-10-10 and customized regional formulas. Landed cost per ton reduced significantly versus imported product, strengthening the client's competitiveness in the domestic market. No drying process cut energy consumption, lowering production cost and carbon footprint. Fast formula switching allows the client to respond quickly to seasonal crop demand across different regions. Client Feedback "We chose Shenghong because they offered a complete solution rather than just machines - from process design and equipment supply to installation supervision and training. The double roller extrusion technology gives us strong granules with low energy cost, and the line's flexible capacity lets us expand step by step." Why Shenghong Heavy Industry Established in 2003, Zhengzhou Shenghong Heavy Industry Technology Co., Ltd. (fertilizer-productionline.com) is a professional manufacturer and exporter of complete fertilizer production lines. With over 2,000 customers served and 80%-90% of products exported worldwide, Shenghong provides one-stop service from project consultation, process design and equipment manufacturing to installation, commissioning and after-sales support - helping fertilizer producers worldwide build reliable, profitable production capacity.

Project Overview This case study describes how a commercial poultry group in the Middle East built an 8 T/H chicken manure organic fertilizer production line to turn 60,000 tonnes of annual farm litter into saleable organic fertilizer. The farm previously paid contractors to remove the fresh dung, which created odor complaints and wasted a valuable nutrient resource. With rising fertilizer prices and strong regional demand for soil-friendly inputs, the client decided to process the manure on site into granulated organic fertilizer using a complete, turnkey line. The Challenge Fresh poultry manure carries high moisture and pathogens and cannot be stored or sold directly. Odor and dust had to be controlled to meet local environmental rules. The client needed uniform, market-ready granules — not raw powder — to sell to nearby farms and landscapers. The whole line had to fit a limited site footprint and run with a small crew. The Solution: A Complete Manure-to-Fertilizer Line The delivered turnkey plant integrates fermentation, crushing, mixing, granulating, drying, cooling, screening, coating and packaging. Raw manure is first harmlessly fermented with a compost turner and biological deodorant, then crushed to powder, blended with humic acid and trace elements, and granulated with a special organic granulator that needs no binder and reaches a granulation rate above 98%. ItemSpecification Capacity8 T/H base; 1–20 T/H / 10,000–200,000 tons per year customizable Raw materialChicken, cow, sheep and pig dung; straw; sludge; humic acid; bentonite Granule shapeBall shape, 2–8 mm adjustable, no binder required Granulation rateAbove 98% FermentationHigh-temperature aerobic fermentation with compost turner & deodorant Power supply380 V / 50 Hz (customizable), 37–120 kW Service12-month warranty, overseas engineers available Production Process Fermentation & harmless treatment (compost turner + biological deodorant) Crushing of fermented material to powder Batching and even mixing (add humic acid / trace elements) Granulation with organic fertilizer granulator (no binder) Drying with hot-air drum dryer Cooling to ambient temperature Screening — oversize returned to crusher, fines returned to mixer Coating and quantitative packaging (10–50 kg/bag) Key Equipment StageMachineFunction FermentationCompost turner & deodorizerHarmless, aerobic fermentation & odor control CrushingSemi-wet material crusherGrind compost to fine powder MixingHorizontal mixerBlend powder with additives evenly GranulationOrganic fertilizer granulatorForm uniform ball-shape granules Drying/CoolingRotary dryer & coolerLower moisture and stabilise granules ScreeningRotary screenerSort required particle size PackagingQuantitative packaging machineBag finished fertilizer 10–50 kg Technical Highlights One-step molding granulation with no binder, keeping the organic content intact. Above 98% granulation rate and round, dust-free granules that store well. Closed fermentation plus dust-removal and deodorization systems cut odor and dust drastically. Our own special organic fertilizer granulator handles high-moisture manure that conventional machines cannot. Modular design — the client can add a second shift or extend capacity later without rebuilding. Results & Customer Feedback After commissioning, the line reached a stable 8 T/H and converted the farm's annual litter into roughly 30,000–50,000 tonnes of granulated organic fertilizer. Odor complaints stopped, the farm hired only a handful of operators per shift, and the finished granules now sell both locally and to neighbouring markets, creating a new revenue stream instead of a disposal cost. “What used to be waste is now our most profitable product line,” the farm manager said. Conclusion This project shows how a complete chicken manure organic fertilizer production line — from fermentation to packaging — can turn a costly waste problem into a profitable, eco-friendly business. The same platform is easily adapted to other animal manure, capacities and regions.

Project Overview This case study details the design, manufacturing, and commissioning of a compound fertilizer rotary drum granulation production line for a leading agricultural enterprise in South Asia. The client required a high-capacity 20 tons per hour (TPH) production line capable of manufacturing NPK compound fertilizers with precise nutrient ratios, utilizing the rotary drum granulation process for superior granule uniformity and strength. Client Background The client is a major fertilizer manufacturer in South Asia with an annual distribution network covering over 500 retail outlets. Facing increasing regional demand for customized NPK blends, the company decided to invest in a new compound fertilizer production facility to expand capacity and improve product consistency. Their existing batch-mixing operation could no longer meet the quality standards demanded by large-scale agricultural buyers. Industry: Compound fertilizer manufacturing Region: South Asia Project Scale: Full production line, 20 TPH capacity Project Type: New factory expansion Client Requirements & Challenges Requirement Challenge Multiple NPK formulations (15-15-15, 20-10-10, 12-24-12) Rapid formula changeover without cross-contamination; each blend required different raw material ratios and process parameters. 20 TPH throughput with rotary drum granulation Achieving high throughput while maintaining granule roundness (sphericity > 90%) and crushing strength (> 25 N per granule) demanded precision drum engineering. Anti-caking treatment integration In-line coating system required to apply anti-caking agents during cooling phase to ensure product stability during long-term storage and transport. Environmental compliance Full dust collection and exhaust gas scrubbing system to meet local environmental regulations for chemical fertilizer production. Solution Delivered We supplied a complete rotary drum granulation production line with the following core configuration: Raw Material Batching System — Automated weighing and dosing for urea, DAP, MOP, ammonium sulfate, and micro-nutrients with precision to ±0.5%. Chain Crusher — Two-stage crushing to ensure uniform raw material particle size below 1 mm before mixing. Double-Shaft Horizontal Mixer — Continuous mixing with controlled residence time to achieve homogeneous NPK distribution. Rotary Drum Granulator (4.0m * 1.8m) — The core granulation unit featuring optimized lifter design, steam pre-conditioning, and variable-speed drive for precise control of granule size distribution (2–4 mm target). Rotary Dryer (2.8m * 24m) — Co-current hot air drying with multi-zone temperature control, reducing moisture from 12–15% to below 2%. Rotary Cooler (2.4m * 18m) — Counter-flow air cooling with integrated anti-caking agent spray system. Double-Deck Vibrating Screener — Separating on-spec granules (2–4 mm), oversize (returned to crusher), and undersize (returned to granulator) for closed-loop recycling. Rotary Drum Coating Machine — Surface treatment with colorant and anti-caking agents for enhanced product appearance and storability. Automatic Weighing & Packing System — 50 kg bag filling station with heat-sealing and palletizing conveyor. PLC Centralized Control System — Real-time process monitoring, automatic alarm handling, and production data logging for reliable line-wide automation. Project Execution Phase Timeline Key Activities Process Engineering 5 weeks Material balance calculation, P&ID development, 3D plant layout, equipment specification Manufacturing & FAT 10 weeks Fabrication of all major equipment, subsystem assembly, factory acceptance testing Logistics & Delivery 4 weeks 15 * 40HQ containers, full export packaging, customs clearance, inland transport to site Civil Works & Installation 8 weeks Foundation construction, steel structure erection, equipment positioning, piping, and electrical cabling Commissioning & Trial Run 4 weeks No-load testing, water trial, raw material trial, NPK 15-15-15 production run, parameter optimization Training & Handover 2 weeks 15 operators trained across 3 shifts, maintenance manual delivery, spare parts inventory setup Results & Key Metrics Following commissioning and a 30-day performance guarantee period, the following results were verified: Throughput: Stable production at 20.5 TPH, exceeding the contractual target of 20 TPH. Granule Sphericity: 93.2% of granules achieved spherical shape with roundness score > 90%, minimizing breakage during handling and transport. Granule Crushing Strength: Average 28.6 N per granule, well above the 25 N specification, ensuring product integrity from factory to field. Formula Flexibility: Successfully switched between 15-15-15, 20-10-10, and 12-24-12 NPK grades with cleanup and changeover completed in under 4 hours. Recycle Ratio: Closed-loop system maintained recycle ratio below 25%, maximizing first-pass yield and reducing energy consumption. Environmental Performance: Stack emissions met local PM2.5 standards; dust concentration at discharge point was below 30 mg/m³. Operator Certification: All 15 operators completed training and independently ran the full line within the 2-week handover period. Client Testimonial Highlights "The rotary drum granulation technology delivered exactly what we needed — consistent, spherical, and strong granules that our customers immediately noticed. The ability to switch between NPK formulations in a single shift has transformed our production flexibility. The PLC control system gives us stable and reliable operation, and our quality complaints have dropped to nearly zero since switching to this line." — Plant Manager, Client Company Conclusion This project underscores our expertise in delivering high-capacity compound fertilizer rotary drum granulation production lines that combine robust mechanical engineering with intelligent process control. From precision batching and steam-assisted granulation to anti-caking treatment and automated packing, every stage is optimized for throughput, quality, and operational efficiency. Whether you need a dedicated NPK compound fertilizer line or a multi-purpose rotary drum granulation system capable of handling diverse formulations, we offer complete turnkey solutions backed by on-site installation, training, and long-term technical support. For inquiries about our compound fertilizer equipment, please contact our engineering team for a customized proposal.