The challenge in organic fertilizer granulation lies not merely in converting powder into granules, but in ensuring that every granule can withstand the rigors of storage, transport, and application. The disc granulator, the new-type two-in-one organic fertilizer granulator, and the organic fertilizer ball-shaping machine correspond precisely to three progressive stages in the granulation process: pelletizing, consolidation, and refinement.
The disc granulator handles the initial step of transforming powder into pellets. Within the tilted, rotating disc, materials tumble repeatedly along a parabolic trajectory under the combined influence of gravity, centrifugal force, and friction. As a fine mist of water is sprayed, the fine powder accumulates in layers—much like a rolling snowball—and gradually grows in size. The disc’s tilt angle is typically maintained between 40° and 50°, with the rotational speed set at 50% to 60% of the critical speed; operators must make real-time adjustments based on the material’s stratification within the disc, aiming for an ideal distribution where larger granules reside in the inner layer and fine powder in the outer layer. While disc granulation achieves a pelletizing rate exceeding 93% and produces granules with good sphericity, the residence time of individual granules varies, leading to natural fluctuations in particle size distribution and necessitating the separation of a certain proportion of “return material” during subsequent screening.
The new-type two-in-one granulator takes a different approach by combining “crushing” and “granulation” into a single process. Upon entering the machine, high-speed rotating mixing teeth first shear and break down coarse fibers and large material clumps; subsequently, mechanical extrusion forces and the material’s inherent cohesiveness facilitate agglomeration and initial rounding. The entire process takes place continuously within a sealed cylinder, avoiding the heat loss and granule breakage associated with material transfer between separate granulation and rounding units. For high-moisture, high-fiber materials—such as chicken manure, crop stalks, and spent mushroom substrate—this two-in-one model maintains a stable pelletizing rate of 92% to 96% and offers greater tolerance for variations in material moisture content. Even after processing by a two-in-one granulator, the resulting granules still possess microscopic sharp edges and internal voids. The organic fertilizer ball shaping machine performs the final refining step: a high-speed rotating disc generates centrifugal force, causing the granules to tumble repeatedly and rub against one another within the shaping chamber. Instead of relying on external pressure, this process utilizes the granules’ own movement to achieve “self-polishing”—gradually rounding off sharp edges and compacting or smoothing out surface pits. The resulting granules exhibit significantly improved sphericity and enhanced compressive strength, making them less prone to breakage or moisture absorption during storage.