ZHENGZHOU SHENGHONG HEAVY INDUSTRY TECHNOLOGY CO., LTD.

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.

Project Overview This case study documents the successful export and deployment of a complete organic and compound fertilizer granulation production line for an international agricultural enterprise. The client required a turnkey solution capable of producing both organic and compound fertilizer granules at a throughput of 15 tons per hour (TPH), with flexibility to switch between single-machine operation and full-line automated production. Client Background The client, a well-established agricultural input distributor based in Southeast Asia, sought to expand its portfolio into fertilizer manufacturing to meet growing regional demand for high-quality organic and compound fertilizers. With over a decade of experience in agricultural distribution, the client identified a strategic opportunity to vertically integrate production and reduce dependence on imported finished fertilizers. Industry: Agricultural inputs & fertilizer distribution Region: Southeast Asia Project Scale: Full production line, 15 TPH capacity Project Type: Greenfield factory setup Client Requirements & Challenges Requirement Challenge Dual-purpose production (organic & compound fertilizer) Equipment must handle varying raw material properties — organic matter, chemical powders, and binders — without compromising granule quality. 15 TPH target throughput Balancing high capacity with uniform granule size (2–5 mm) required precise drum design and rotational speed calibration. Turnkey installation & training Remote site with limited local technical expertise demanded comprehensive on-site support, operator training, and detailed documentation. Single-machine or full-line operation Flexible control system needed to allow independent operation of individual machines (crusher, mixer, granulator, dryer, screener) or synchronized full-line automation. Solution Delivered We designed, manufactured, and shipped a complete fertilizer granulation production line comprising the following core equipment: Chain Crusher — High-efficiency crushing of raw material lumps to uniform powder, suitable for both organic and inorganic inputs. Horizontal Mixer — Twin-shaft paddle mixer ensuring thorough blending of raw materials with binders and additives. Rotary Drum Granulator — The heart of the line, featuring a steam-injection system for optimal moisture control during granulation. Capable of producing both organic and compound fertilizer granules with adjustable particle size (2–5 mm). Rotary Dryer & Cooler — High-efficiency drying and cooling units reducing moisture content to below 5%, ensuring long-term storage stability. Vibrating Screener — Multi-deck screening system separating on-spec granules from oversize and undersize particles for recycling. Automatic Packing Machine — Precision weighing and bagging system with dust collection to maintain a clean working environment. Centralized PLC Control System — Enables single-machine independent operation or synchronized full-line automation with real-time monitoring and fault alerts. Project Execution Phase Timeline Key Activities Engineering & Design 4 weeks Process flow design, 3D layout planning, equipment sizing, electrical schematics Manufacturing 8 weeks Fabrication, assembly, factory acceptance testing (FAT) before shipment Shipping & Logistics 3 weeks Containerized ocean freight with full export documentation Installation & Commissioning 5 weeks On-site civil foundation guidance, mechanical installation, electrical wiring, PLC configuration Training & Handover 2 weeks Operator training (3 shifts), maintenance SOP documentation, trial production runs Results & Key Metrics After commissioning and a one-month trial production period, the following results were achieved: Throughput: Consistently achieved 15.2 TPH, exceeding the target of 15 TPH. Granule Qualification Rate: 94.6% of output granules met the 2–5 mm specification, surpassing the industry benchmark of 90%. Production Flexibility: Successfully produced 5 different NPK compound fertilizer formulas and 3 organic fertilizer formulations during the trial period. Downtime: Less than 2% unplanned downtime during the first month of continuous operation. Energy Efficiency: Power consumption per ton of finished product was 18% lower than the client's initial budget estimate, thanks to optimized dryer heat recovery design. Operator Readiness: All 12 operators certified for independent operation within the 2-week training period. Client Testimonial Highlights "The production line has exceeded our expectations in both capacity and granule quality. We particularly appreciate the flexibility to run individual machines for maintenance or small-batch production, then switch to full automation for large orders. The on-site training was thorough, and our team was confident operating the line independently within two weeks." — Production Director, Client Company Conclusion This project demonstrates our capability to deliver complete fertilizer granulation production lines that meet rigorous international standards. Whether our clients need a single organic fertilizer granulator or a fully integrated compound fertilizer production line, we provide end-to-end support — from process engineering and equipment manufacturing to on-site installation, commissioning, and operator training. For more information about our fertilizer granulation machinery, including individual machines and custom production lines, please contact our engineering team.

Our technical team recently traveled to Indonesia to conduct field assessment and provide pre-installation guidance for a compound fertilizer production line combining both drum and disc granulation systems. The line is designed for efficient production of both standard and specialized fertilizer formulations. Before the formal installation began, our engineers completed comprehensive on-site inspections, covering factory layout, foundation planning, and material flow design. They worked directly with the client's team to optimize equipment placement and process coordination for the integrated drum and disc granulation setup. The production line features a well-arranged workflow where raw materials are first processed through the drum granulator for initial granule formation, followed by polishing and finishing in the disc granulator to achieve uniform particle size and smooth surface. This combined process is particularly suitable for producing various NPK compound fertilizers, especially those requiring both high production capacity and excellent product appearance. The system demonstrates strong adaptability for processing multiple raw material types, including ammonium phosphate, urea, potassium chloride, and various filler materials. This flexibility makes it ideal for fertilizer plants producing blends for different crops and soil conditions. This on-site technical support during the pre-installation phase ensured that all preparation work met the operational requirements of the dual granulation system. The combination of drum granulation (for high-volume production) and disc granulation (for product refinement) offers the client flexible and efficient production capacity. We are committed to providing professional technical support throughout the project cycle, helping international clients achieve successful installation and optimal operation of their fertilizer production systems.   Zhengzhou Shenghong Heavy Industry Technology Co., Ltd. Email: sales@gcfertilizergranulator.com WhatsApp: 0086 15286833220 Wechat: +86 15286833220

A compact organic fertilizer powder production line has been installed and commissioned in Paraguay, with an operating capacity of 1-2 tons per hour. The system is now running smoothly, efficiently converting organic materials into ready-to-use fine fertilizer powder. The production process begins with controlled fermentation of raw organic materials, followed by crushing, screening, and mixing to produce uniform, nutrient-rich powder. The line is designed for simplicity and reliability, making it particularly suitable for small to medium-scale operations seeking an efficient solution for organic waste valorization. This installation effectively addresses local needs for converting agricultural and livestock residues into valuable organic fertilizer. The system demonstrates stable performance in processing various organic inputs while maintaining consistent product quality. The successful implementation of this project supports Paraguay's growing organic agriculture sector and provides the client with a practical solution for sustainable fertilizer production. We remain committed to delivering appropriate technical solutions that meet regional requirements and contribute to circular agricultural practices.   Zhengzhou Shenghong Heavy Industry Technology Co., Ltd. Email: sales@gcfertilizergranulator.com WhatsApp: 0086 15286833220 Wechat: +86 15286833220

A medium-capacity compound fertilizer production line with a throughput of 3-7t/h has been successfully installed and commissioned in Mexico. The system is now operating stably, producing uniform, high-quality fertilizer granules to support the local agricultural market. The line is built around a robust drum granulator, which forms granules through continuous rolling and layering of raw materials in a rotating cylinder. The system is designed for flexibility, allowing adjustments in production parameters to accommodate different NPK formulations and meet varied crop nutrition requirements. This installation demonstrates effective adaptation to regional production needs, with the drum granulation method proving particularly suitable for mid-scale fertilizer operations. The successful commissioning and stable operation confirm the reliability and efficiency of the equipment under local working conditions. We are pleased to support fertilizer production development in Mexico and remain committed to providing practical, reliable solutions tailored to regional agricultural requirements.   Zhengzhou Shenghong Heavy Industry Technology Co., Ltd. Email: sales@gcfertilizergranulator.com WhatsApp: 0086 15286833220 Wechat: +86 15286833220