ZHENGZHOU SHENGHONG HEAVY INDUSTRY TECHNOLOGY CO., LTD.

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

A complete organic fertilizer production line integrating flat die granulation with drying technology has been installed and commissioned. The line is now fully operational with a capacity of 3.5t/h, producing uniform and high-quality granular organic fertilizer ready for packaging and distribution. The system features a flat die granulator as the core forming unit, efficiently compacting fermented organic materials into solid granules through mechanical pressure. An integrated belt-type dryer is directly connected to the granulator, providing continuous and uniform drying to stabilize the granules and reduce moisture content to commercial standards. This installation demonstrates efficient coordination between granulation and drying stages, ensuring smooth material flow and stable production output. The flat die granulator proves particularly effective in processing fibrous organic materials, while the belt dryer offers adjustable temperature and speed control for different material characteristics. The successful implementation of this project highlights our ability to provide integrated solutions that combine specialized granulation technology with appropriate drying systems. The line supports the client in producing durable, high-value organic fertilizer granules suitable for storage, transportation, and agricultural use.     Zhengzhou Shenghong Heavy Industry Technology Co., Ltd. Email: sales@gcfertilizergranulator.com WhatsApp: 0086 15286833220 Wechat: +86 15286833220

A complete dual-purpose organic fertilizer production system with an annual capacity of 50,000 tons has been installed and put into full operation. The line efficiently produces both powdered and granular organic fertilizers from the same integrated processing system, supporting flexible market supply. The production system operates through a continuous process that begins with raw material fermentation and progresses through crushing, mixing, and drying to produce high-quality fertilizer powder. A parallel granulation line enables the conversion of the same base materials into uniform, commercially-ready granules, providing complete production flexibility. Designed for efficiency and versatility, this installation allows the client to adjust production output between powder and granules based on seasonal demand and customer requirements. The system maintains consistent quality across both product forms while operating at its designed capacity. This project demonstrates our capability to deliver large-scale, multi-format organic fertilizer solutions, supporting producers in maximizing their operational flexibility and market responsiveness.   Zhengzhou Shenghong Heavy Industry Technology Co., Ltd. Email: sales@gcfertilizergranulator.com WhatsApp: 0086 15286833220 Wechat: +86 15286833220

A complete Bulk Blending (BB) fertilizer production line has been installed and put into operation for our client. The line is now running smoothly, delivering precisely blended fertilizer formulations with high efficiency and consistency. The system includes key components such as automatic batching units, mixing equipment, and packaging machinery. Designed for flexibility, it enables quick formulation changes and accurate nutrient ratio control, allowing the production of customized fertilizer blends to meet specific crop and soil requirements. This installation demonstrates our expertise in providing practical and reliable solutions for the BB fertilizer sector. The line operates with minimal waste and high repeatability, supporting the client in serving diverse agricultural markets with tailored fertilizer products. We remain committed to delivering quality equipment and technical support to help fertilizer producers enhance their blending capabilities and respond effectively to market demands.       Zhengzhou Shenghong Heavy Industry Technology Co., Ltd. Email: sales@gcfertilizergranulator.com WhatsApp: 0086 15286833220 Wechat: +86 15286833220