Organic & Compound Fertilizer Granulation Production Line: 15 TPH Turnkey Export Project Case Study

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

Solution Delivered

We designed, manufactured, and shipped a complete fertilizer granulation production line comprising the following core equipment:

1. Chain Crusher — High-efficiency crushing of raw material lumps to uniform powder, suitable for both organic and inorganic inputs.
2. Horizontal Mixer — Twin-shaft paddle mixer ensuring thorough blending of raw materials with binders and additives.
3. 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).
4. Rotary Dryer & Cooler — High-efficiency drying and cooling units reducing moisture content to below 5%, ensuring long-term storage stability.
5. Vibrating Screener — Multi-deck screening system separating on-spec granules from oversize and undersize particles for recycling.
6. Automatic Packing Machine — Precision weighing and bagging system with dust collection to maintain a clean working environment.
7. Centralized PLC Control System — Enables single-machine independent operation or synchronized full-line automation with real-time monitoring and fault alerts.

Project Execution

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.