25T/H Animal Manure Straw Organic Fertilizer Production Line in Argentina

Project Genesis and the Argentine Context

The Argentine Agribusiness Conundrum: Wealth and Waste

Argentina is a global agricultural titan, renowned for its beef, soybean, and wheat production. The vast Pampas region is the epicenter of this activity, supporting immense herds of cattle and endless fields of grain. However, this agricultural wealth generates a corresponding challenge: the management of millions of tons of livestock manure and crop residues. Traditionally, manure is stockpiled or spread raw on fields, leading to nutrient runoff, greenhouse gas emissions, and odor issues. Similarly, straw is often burned in the field, contributing to air pollution.

Concurrently, Argentine farmers are heavily reliant on imported synthetic fertilizers, the prices of which are volatile and subject to international market fluctuations and currency exchange rates. This creates a precarious economic situation for farmers and depletes the precious organic matter in the famed Pampas soils over the long term.

The Client's Vision: Closing the Nutrient Loop

Our client, a forward-thinking alliance of three major estancias (cattle ranches) and a large poultry operation, recognized that their waste problem was, in fact, a resource opportunity. Their vision was to establish a centralized processing facility that could aggregate manure and straw from their own operations and those of neighboring farms. The goal was twofold: to solve a pressing waste management issue and to produce a consistent, high-quality organic fertilizer that could reduce their dependence on chemical inputs, improve their soil health, and create a new revenue stream.

They needed a partner who could deliver a robust, high-capacity solution capable of handling the specific characteristics of Argentine manure and straw.

The RICHI Machinery Partnership: A Meeting of Vision and Engineering

After a global search, the client chose RICHI Machinery as their technology provider. The decision was driven by several key factors:

• Proven Scale: RICHI demonstrated a portfolio of successful projects of a similar or larger scale, proving their capability to handle 100,000 TPY production lines.
• Integrated Solution: The proposal included everything from the initial straw processing to the final bagged pellet, including advanced odor and dust control systems.
• Process Expertise: RICHI's deep understanding of the molecular membrane composting technique and granulation process for fibrous materials was critical.
• Value Engineering: The solution offered the perfect balance of automation, durability, and operational cost-effectiveness, ensuring a strong return on investment.

The project was initiated in Q1 2023, with commissioning completed in Q1 2024, and is now operating at full capacity.

Project Overview and Key Metrics

The facility was constructed on a greenfield site strategically located between the client's member farms to minimize raw material transport costs. The layout was meticulously planned by RICHI's engineering team to ensure an efficient, linear material flow.

In-Depth Analysis of Raw Materials

The foundation of this successful animal manure straw organic fertilizer production line in Argentina is the abundant and low-cost availability of its primary inputs. RICHI's agronomists and process engineers conducted a detailed analysis to create the optimal formulation.

Raw Material Sourcing and Characteristics

• Livestock Manure (66,800 TPY): Sourced from the consortium's own feedlots (cattle) and poultry houses. The manure is a rich source of nitrogen, phosphorus, and beneficial microorganisms. It is collected and delivered with a moisture content of ≤20%, which is ideal for the composting process, reducing the need for extensive pre-drying.
• Wheat Straw (25,390 TPY): Procured from the client's own grain operations and local wheat farms after harvest. The straw is a crucial carbon source. Its fibrous structure is essential for creating porosity in the compost pile, allowing oxygen to penetrate and facilitating aerobic decomposition. It also absorbs excess moisture from the manure.

The RICHI-Designed Composting Recipe

Creating a high-quality compost is a science. RICHI developed a precise recipe focusing on:

1. Carbon-to-Nitrogen (C/N) Balance: The manure is nitrogen-rich (low C/N ratio), while the straw is carbon-rich (high C/N ratio). Blending them at a calculated ratio brings the mixture to the ideal C/N range of 25:1 to 30:1, which is optimal for efficient microbial activity and minimizes nitrogen loss as ammonia gas.
2. Moisture Control: The target moisture for active composting is 50-60%. The combination of semi-dry manure and absorbent straw often achieves this naturally, with a built-in spray system in the mixer for fine-tuning.
3. Pile Structure: The chopped straw prevents the dense manure from compacting, ensuring a fluffy pile structure that allows for effective aeration, which is the key to odor-free, aerobic composting.

RICHI's Custom-Engineered Process and Technology

The production process is a masterclass in integrated organic waste management, designed by RICHI to be efficient, environmentally compliant, and highly automated. It consists of two parallel lines sharing initial and final stages but diverging in the fermentation and enrichment phases.

Stage 1: Raw Material Pre-processing

Incoming straw bales are first processed by the 2x RICHI Large Straw Crushers. These heavy-duty machines reduce the long straw into pieces of 2-5 cm, creating a uniform bulking agent. This process generates dust, which is immediately captured at the source by hoods and ducted to a high-efficiency RICHI Baghouse Dust Collector, with the cleaned air discharged through a 15m stack. The crushed straw is then mixed with the manure and microbial inoculant in a RICHI Large-Scale Mixing Unit to form a homogeneous blend.

Stage 2: Advanced Molecular Membrane Fermentation

This is the technological heart of the operation, where RICHI's advanced composting solution shines. The mixed material is formed into long windrows (static piles) and covered with a semi-permeable Molecular Membrane.

• The Membrane Technology: This specialized fabric is waterproof yet breathable. It allows carbon dioxide and water vapor to escape but traps odorous ammonia and hydrogen sulfide inside the pile. These trapped compounds are then re-assimilated by the microbes in the pile, effectively recycling nitrogen and eliminating foul odors.
• Forced Aeration: Beneath each windrow, a network of perforated pipes is connected to a blower. This system forces air into the pile, maintaining the aerobic conditions necessary for efficient and odor-free composting.
• Process Control: Probes within the pile monitor temperature, which rapidly rises to 60-75°C. This thermophilic phase is maintained for several weeks, ensuring thorough pathogen destruction and rapid organic matter stabilization.

The exhaust from the aeration system, which is primarily CO2 and water vapor with minimal odor, is treated via a RICHI UV Photolytic + Activated Carbon Adsorption System as a precautionary measure before being released through a 15m stack.

Stage 3: Secondary Fermentation and Bio-enrichment

The pre-composted material from under the membrane is then transferred to one of three RICHI Fermentation Tanks for a secondary, more controlled curing phase. For the Bio-Organic Fertilizer line, Calcium Magnesium Phosphate and an enhanced Microbial Consortia are added at this stage. A RICHI Turner periodically moves through the tanks, ensuring homogeneity and optimal conditions for the final maturation and bio-activation of the product.

Stage 4: Crushing, Screening, and Granulation

The cured and stable compost is passed through a RICHI Dual-Stage Crusher to break down any clumps into a fine, uniform powder. This powder is then screened by a RICHI Rotary Drum Screen to remove any oversized particles, which are recycled. The in-spec powder is fed into a RICHI Granulation Unit. In this organic fertilizer pellet machine, the fine material is agitated and pressed, forming dense, uniform granules. Water mist is added to assist in binding. Dust generated in crushing and screening is captured by a dedicated baghouse dust collector .

Stage 5: Packaging and Storage

The finished granules are cooled and then transported via conveyor to the RICHI Automatic Packaging Machines. These precision scales fill 25kg and 50kg bags, which are then sealed, palletized, and moved to the Finished Product Warehouse for storage and distribution.

Detailed Equipment List by RICHI Machinery

Environmental and Economic Impact

Environmental Stewardship

• Waste Valorization: Diverts over 92,000 tons of agricultural waste from harmful disposal practices like open burning and stockpiling.
• Climate Action: The controlled aerobic composting process drastically reduces methane emissions compared to anaerobic manure lagoons.
• Water Protection: Eliminates the risk of nutrient leaching from raw manure into groundwater and surface water.
• Soil Health Revolution: The final product returns vital organic matter and beneficial microbes to the Pampas soils, combating degradation and promoting long-term fertility.

Economic Viability

With a total investment of $1.5 million and an estimated average selling price of $120/ton for standard fertilizer and $150/ton for the bio-enriched product, the project achieves a gross annual revenue potential of approximately $13.2 million. After accounting for operational costs (labor, utilities, maintenance, packaging, and transport), the projected payback period is an impressive 1.5 to 2 years. This model not only creates a profitable enterprise but also provides member farms with a low-cost, high-quality soil amendment, insulating them from synthetic fertilizer price shocks.

Market Outlook and Conclusion

The Argentine Organic Fertilizer Opportunity

• Economic Imperative: The high cost and import-dependency of synthetic fertilizers make local organic production a strategic and economic necessity.
• Policy Shifts: Growing governmental and consumer pressure for sustainable agricultural practices is creating a favorable environment for organic inputs.
• Farmer Awareness: Leading Argentine producers are increasingly aware of soil health issues and are actively seeking solutions to maintain productivity.
• Export Potential: The "Made in Argentina" brand is strong in agriculture, opening doors for export to neighboring countries and beyond.

Why Partner with RICHI Machinery?

The resounding success of this Buenos Aires project is a direct result of RICHI Machinery's commitment to delivering not just equipment, but a comprehensive, profitable, and future-proof solution. Our expertise in handling the specific waste streams of the Argentine Pampas, combined with our advanced molecular membrane fermentation technology, positions us as the undisputed leader for such projects.

We don't just sell machines; we engineer success. From initial feasibility studies to ongoing operational support, RICHI Machinery is your dedicated partner in building a sustainable and highly profitable business from organic waste.

Ready to harness the power of the Pampas? Contact the RICHI organic fertilizer production project team today for a free, no-obligation preliminary design and quotation tailored to your specific resources and goals.