15T/H Cattle Manure Fertilizer Production Line in Morocco

Project Background

National Context

Morocco is widely known as one of the world’s major phosphate exporters and possesses significant natural fertilizer resources. However, the country faces ongoing challenges in agricultural sustainability, particularly with soil degradation, low organic matter content, and increasing demand for food crops. While phosphate-based fertilizers are readily available domestically, the organic matter needed to restore soil fertility must often be supplemented.

At the same time, Morocco’s agricultural and livestock sectors generate vast amounts of organic residues, including cattle and poultry manure, crop straws, olive pomace, and sawdust from forestry operations. Historically, much of this biomass was underutilized or improperly managed, leading to waste, pollution, and greenhouse gas emissions.

Against this backdrop, the Moroccan government has encouraged private-sector investments in green industries, especially in waste-to-value projects that align with its environmental and economic development strategies. The introduction of a large-scale organic fertilizer pellet production line fit perfectly into this vision.

Client Profile

The client is a mid-sized agricultural cooperative located near Meknes, in the heart of Morocco’s fertile agricultural region. The cooperative consists of around 200 local farmers, primarily focused on cereal crops, olive plantations, and dairy farming. Facing rising costs of chemical fertilizers and an urgent need to improve soil quality, the cooperative decided to diversify its business model by investing in fertilizer processing.

The cooperative’s primary motivation for the cattle manure fertilizer production line in Morocco project included:

• Reducing fertilizer costs by producing organic alternatives internally
• Enhancing soil fertility through the application of bio-organic fertilizer rich in organic matter
• Utilizing agricultural and livestock waste to create value-added products
• Supporting Morocco’s sustainability goals while opening new revenue streams by selling surplus pellets to surrounding agricultural regions

The choice of Morocco as a location was logical given the abundance of raw materials, the supportive regulatory environment, and the high domestic demand for organic fertilizers.

Project Scale and Objectives

The cattle manure fertilizer production line in Morocco project was designed as a 15 tons per hour production line, with 100,000 tons of finished organic fertilizer pellets annually. The plant operates on a single-shift basis, 300 days per year, 22 hours daily, ensuring stable output while maintaining flexibility.

The primary objectives of the cattle manure fertilizer production line in Morocco project were:

• To establish a fully automated fertilizer production line capable of handling mixed raw materials
• To achieve sustainable waste management for local agricultural and livestock residues
• To provide affordable, high-quality organic fertilizer pellets for the cooperative and surrounding farmers
• To create new jobs for the local community and stimulate rural economic growth

Raw Materials

In Morocco, the availability of raw materials for organic fertilizer production is abundant and diverse. The project design specifically targeted resources that are both sustainable and locally available, minimizing transportation costs and ensuring long-term supply security.

Raw Material Types and Characteristics

The raw materials are mixed according to specific formulations developed by agronomists to ensure that the final fertilizer pellets contain balanced nutrients, adequate organic matter, and appropriate moisture content for pelletization.

Process Flow and Technology

The cattle manure fertilizer production line in Morocco employs a fully integrated process flow tailored to the high moisture content of livestock manure and the fibrous nature of straw and crop residues.

Main Process Steps

1. Raw Material Collection and Transportation

   Raw materials are transported to the facility using tractors and trucks. Dedicated storage zones are established for different types of biomass to prevent cross-contamination.

2. Pre-treatment and Mixing

   Manure is partially dried using a solid-liquid separator, reducing initial moisture. Crop residues (straw, stalks) are crushed with a hammer mill to achieve uniform particle size. Olive pomace and sawdust are introduced to balance the C/N ratio. A horizontal fertilizer mixer ensures even blending of raw materials.

3. Fermentation

   The mixed biomass undergoes aerobic fermentation in dedicated composting halls. Temperature, oxygen, and humidity are closely monitored to promote pathogen reduction and nutrient stabilization. Fermentation typically lasts 15–20 days, depending on raw material composition.

4. Crushing and Screening

   After fermentation, the semi-finished material is crushed again to ensure fine texture. Screening removes oversized particles, ensuring uniform feedstock for pelletization.

5. Pelletization

   The prepared material is fed into RICHI’s ring die organic fertilizer pellet machine, designed specifically for high-moisture organic materials. Conditioning with steam ensures proper binding, reducing dust and improving pellet durability. Pellets are extruded to 3–5 mm diameter, optimal for soil application.

6. Drying and Cooling

   A rotary drum manure dryer equipment reduces moisture content to below 15%. Cooling systems stabilize pellets, preventing caking during storage.

7. Screening and Packaging

   Pellets pass through a vibrating screen to remove fines. Finished pellets are packaged in 25 kg bags or 1-ton jumbo bags for distribution.

Equipment Configuration

The cattle manure fertilizer production line in Morocco was equipped with state-of-the-art machinery supplied and installed by RICHI Machinery. The configuration included:

• Solid-liquid separator (manure dewatering)
• High-capacity hammer mill for straw and crop residues
• Horizontal organic fertilizer mixer machines with moisture control
• Aerobic fermentation system with turning machines
• Fine crusher and vibrating screen
• Ring die cow dung pellet making machine (main unit)
• Rotary drum dryer with heat recovery system
• Pellet cooler and final screening system
• Automatic bagging and palletizing system

The total investment for equipment was approximately USD 1.25 million, falling within the reasonable range for a 12–15 t/h fertilizer pellet production line.

Investment and Economic Analysis

The cattle manure fertilizer production line in Morocco project required a total capital investment of USD 1.8 million, including equipment, civil construction, electrical systems, and working capital.

Breakdown of Investment

Operating Costs

Annual operating costs were estimated at around USD 1.8 million, including labor, maintenance, energy, raw material transport, and packaging.

Revenue Potential

• Average selling price of organic fertilizer pellets: USD 120/ton
• Annual output: 100,000 tons
• Gross annual revenue: USD 12 million
• Net profit margin: estimated at 20–25%, ensuring a payback period of under 4 years

Environmental and Social Benefits

The cattle manure fertilizer production line in Morocco project delivers significant environmental and social benefits:

• Waste reduction – recycling 100,000 tons of manure and residues annually
• Soil improvement – boosting soil organic matter, reducing desertification risks
• Reduced chemical fertilizer dependence – lowering Morocco’s import reliance
• Job creation – employing 120 workers directly and supporting hundreds more indirectly
• Carbon footprint reduction – cutting methane emissions from unmanaged manure

Market Prospects in Morocco

The market for organic fertilizer pellets in Morocco is expanding rapidly. Demand is driven by:

• Rising awareness of sustainable agriculture
• Government support for organic farming initiatives
• Growing export opportunities to nearby regions such as Spain, France, and West Africa
• Increasing cost of imported synthetic fertilizers

Given Morocco's agricultural base, especially in olives, cereals, and vegetables, the demand for high-quality organic fertilizers is set to grow steadily.

Conclusion: Future Outlook and RICHI 's Role

This project stands as a landmark example of how a cooperative in Morocco successfully transformed agricultural waste into a profitable and sustainable business. The combination of abundant local resources, advanced technology, and professional engineering support made the project both environmentally and economically viable.

By investing in this cattle manure fertilizer production line in Morocco, the client not only secured a stable supply of organic fertilizer for its members but also opened new business opportunities in domestic and export markets.

As Morocco continues to prioritize sustainable agriculture, the demand for fertilizer pellet production lines will only increase. RICHI Machinery, with its proven expertise, tailored engineering solutions, and high-quality equipment, is ideally positioned to support investors, cooperatives, and agribusinesses in replicating this success across the region.

For clients seeking to enter the organic fertilizer market with confidence, RICHI Machinery offers end-to-end solutions: from feasibility studies and design, to manufacturing, installation, training, and after-sales service. This Moroccan case demonstrates not only the viability of such projects but also the strength of partnering with a reliable equipment supplier and engineering company.