At the final critical stage of organic fertilizer production, granulation technology directly determines the product’s market competitiveness. The organic fertilizer disc granulator (Disc Granulator), with its unique granulation method and excellent forming capability, has become a shining star in the fertilizer industry, miraculously transforming fine powders into uniform “fertilizer pearls.”
Working Principle: The Magic of the Inclined Disc
The core of the organic fertilizer disc granulator is a rotating disc with an adjustable inclination angle. When fully fermented organic material enters the disc along with an appropriate amount of binder, the material begins to “dance” under the triple effects of centrifugal force, gravity, and friction: fine powder continuously rolls, collides, and adheres along the inner wall of the disc, gradually increasing like a snowball, eventually forming uniform spherical granules.
The subtlety of this process lies in its “natural pelletizing” principle—no strong extrusion is needed; instead, granulation is achieved through the material’s own characteristics and physical effects. Operators can precisely control particle diameter (typically 2-8 mm) by adjusting disc inclination, rotation speed, and water addition, meeting the needs of different crops and markets.
Unique Advantages: Why Choose Disc Granulation?
Compared to traditional double roller press granulator or drum granulation, disc granulators demonstrate multiple advantages:
Excellent Particle Uniformity: Naturally rolled granules are complete spheres with smooth surfaces and consistent particle sizes, which not only enhances product appearance but also ensures even fertilization.
Significantly Reduced Energy Consumption: Compared to extrusion granulation requiring high pressure, disc granulators only need to drive disc rotation, reducing energy consumption by 30%-50%.
Simple Operation and Maintenance: Simple structure, low failure rate, and easy cleaning, especially suitable for continuous production environments.
Strong Adaptability: Can process various organic materials, including livestock manure, fermented straw, sludge, etc., with relatively lenient requirements for material moisture content (20%-40%).
Moderate Particle Strength: The formed granules are strong enough to resist breakage during transportation yet disintegrate appropriately in soil to release nutrients.
Key Role in Production Lines
In a complete organic fertilizer production line, the disc granulator plays the role of “forming specialist.” It is typically positioned after fermentation, crushing, and mixing processes, and before drying, screening, and packaging:
Receiving Preceding Processes: Receives uniformly sized raw materials from the half-wet material crusher and fully mixed formula materials from the melting pot.
Achieving Morphological Transformation: Converts loose powder into regular granules, greatly enhancing product commercial value and application convenience.
Preparing for Subsequent Processes: Granulated materials entering the dryer benefit from regular spherical shapes that promote airflow, improving drying efficiency; uniform particle sizes also make screening more efficient.
Innovation Evolution: Intelligent Disc Granulation Technology
Modern disc granulators are no longer simple mechanical devices. The latest models are equipped with sensor systems and automatic control devices that monitor particle growth in real-time, automatically adjusting inclination, rotation speed, and water spraying. Some advanced models even integrate visual recognition systems to ensure consistent granule quality.
Market Prospects: Driving Green Agriculture
With global emphasis on organic agriculture and rapidly growing demand for organic fertilizers, the market prospects for disc granulators are vast. Especially in developing countries, this granulation equipment with moderate investment costs, simple operation, and easy maintenance has become the first choice for small and medium-sized organic fertilizer plants.
Looking ahead, with the development of precision agriculture, disc granulators are expected to deeply integrate with intelligent formulation systems, producing “customized” granular fertilizers based on soil testing data—granules with different nutrient ratios and release rates can be produced in the same batch, truly achieving “site-specific fertilization, demand-based nutrient supply.”
