Large-Scale 50% Moisture Chicken Manure Bio-Organic Fertilizer Production Line in Poland

Project Background and Investment Rationale

Poland is one of the European Union's leading agricultural producers, with a particularly strong and concentrated poultry industry. This sector, while economically vital, generates significant quantities of manure, presenting a waste management challenge under stringent EU environmental regulations.

Simultaneously, the need to maintain and enhance soil organic matter for sustainable crop production is increasingly recognized by Polish farmers. A major Polish agri-holding company, with interests in both animal husbandry and crop production, identified a strategic opportunity to create a vertically integrated solution.

The primary driver for investing in this 50% moisture chicken manure bio organic fertilizer production line in Poland was to internalize waste management costs while creating a new revenue stream from a previously underutilized resource. The project's core objective was to establish a facility capable of processing 100,000 tons of raw materials annually into a standardized, high-quality bio-organic fertilizer, compliant with EU standards.

This translates to a production capacity of approximately 13.9 tons per hour over a 16-hour, two-shift operation. The final product is targeted at large-scale grain, potato, and sugar beet farms across Poland and for export to other EU member states, capitalizing on the growing market for organic inputs within the Common Agricultural Policy framework.

Project Location and Infrastructure

The strategic location of this 50% moisture chicken manure bio organic fertilizer production line in Poland was paramount to its logistical and economic success. The organic fertilizer production project was constructed on a 20,000 m² greenfield site in an industrial zone in the Greater Poland Voivodeship, a region known for its high agricultural output.

• Proximity to Raw Materials: The location is central to a high density of poultry operations, ensuring a consistent and cost-effective supply of the primary raw material—chicken manure with an initial moisture content of approximately 50%. This minimizes transportation costs and secures the supply chain.
• Advanced Logistics: The site boasts excellent access to the Polish national road network, facilitating efficient inbound logistics for raw materials and outbound distribution of the finished, palletized fertilizer products across the country and to border terminals for export.
• Regulatory Compliance and Community Relations: The industrial zoning and sufficient buffer distances to residential areas were critical for obtaining environmental permits, particularly for managing potential odors during the fermentation process, which is mitigated through fully enclosed buildings and advanced air treatment systems.

The project involved the construction of new, purpose-built facilities, including large-scale raw material storage, dedicated fermentation halls, a curing warehouse, and a fully equipped granulation and packaging plant. The total built-up area is 12,588 m².

Production Process and Technology

The core technology behind this 50% moisture chicken manure bio organic fertilizer production line in Poland is a meticulously controlled two-stage aerobic fermentation process, chosen for its efficiency in stabilizing organic matter and eliminating pathogens. RICHI Machinery supplied a complete, automated production line designed for high-volume, continuous operation.

The transformation process from raw manure to packaged, pelleted fertilizer involves several critical stages:

Raw Material Reception and Pre-Blending

Chicken manure, pre-treated (solid-liquid separated) at source farms to achieve the target 50% moisture content, is delivered in sealed tankers. It is immediately unloaded into a fully enclosed, negatively ventilated storage hall. Here, it is mixed with carbon-rich amendments like spent mushroom substrate and pre-crushed straw. This blending is crucial for achieving the optimal Carbon-to-Nitrogen (C:N) ratio and porosity necessary for efficient aerobic fermentation. A specialized bacterial inoculant is added to kick-start the decomposition process.

Primary Fermentation (In-Vessel and Windrow)

The blended material is then conveyed to the fermentation halls. The process utilizes a combination of technologies: a large trough fermentation system with a RICHI trough turner for intensive initial decomposition, followed by windrow fermentation in adjacent halls using a  crawler turner. The turners regularly aerate the piles, introducing oxygen, homogenizing the mixture, and controlling temperature. The process reaches thermophilic temperatures of 70-75°C, which is critical for pathogen elimination and rapid decomposition. This primary stage lasts about 20 days.

Secondary Fermentation (Curing)

The material from the primary stage is moved to a dedicated, enclosed curing warehouse for a secondary stabilization period of approximately 40 days. This "curing" phase allows for further decomposition of complex compounds like cellulose and lignin, leading to a more stable and mature product. The final moisture content after curing is below 30%.

Crushing, Screening, and Granulation

The cured compost is then processed through a crushing and screening circuit to achieve a uniform particle size. The fine material is then fed into a large organic fertilizer pellet machine where it is formed into uniform, hard pellets. The pellets are dried and cooled before proceeding to packaging.

Packaging and Storage

The final pelleted product is automatically weighed and packaged into 50kg bags using an automated sewing system. The bagged product is palletized and stored in the finished product warehouse before shipment.

Raw Materials and Utilities Consumption

The operational model of this 50% moisture chicken manure bio organic fertilizer production line in Poland is based on the efficient use of regional waste streams.

Major Equipment List

The production line is built around a comprehensive suite of heavy-duty equipment from RICHI Machinery, designed for continuous industrial operation.

Environmental Protection Measures

Given the scale of the operation and strict EU environmental regulations (IPPC/IED), the plant incorporates a comprehensive suite of pollution control technologies.

• Odor Control: The entire raw material storage and fermentation areas are fully enclosed buildings maintained under negative pressure. Captured foul air, rich in Ammonia (NH₃) and Hydrogen Sulfide (H₂S), is treated by a high-efficiency biological odor scrubbing system before being discharged through a 15-meter high stack (DA001). This system uses microorganisms to biologically degrade the odor-causing compounds.
• Dust Control: Dust generated during crushing and screening is captured by an integrated network of hoods and ducts and treated by a high-efficiency baghouse filter (bag dust collector), with cleaned air discharged via a separate 15-meter stack (DA002).
• Water Management: A fully segregated stormwater and sanitary system is in place. Process water usage is minimal. Sanitary wastewater is treated in a septic tank system. The biological scrubber's water is recirculated, with only periodic blowdown, which is managed appropriately.
• Noise Control: Major noise-generating equipment is housed within buildings and equipped with vibration dampers to ensure compliance with local noise ordinances.

Economic and Operational Details

• Total Investment: The total capital expenditure for this large-scale 50% moisture chicken manure bio organic fertilizer production line in Poland was approximately $1.4 Million USD. This investment covered land preparation, all civil works, the complete RICHI machinery package, and advanced environmental control systems.
• Work Schedule: The plant operates with a team of 5 core personnel per shift, working a two-shift system for 16 hours per day, 300 days per year, maximizing the utilization of the significant capital investment.
• Economic Model: The business model is based on a low-cost raw material (waste) transformed through an energy and capital-intensive process into a high-value, branded organic fertilizer sold into a premium market.

Market Prospects for Bio-Organic Fertilizer in Poland

The market outlook for the output of this 50% moisture chicken manure bio organic fertilizer production line in Poland is exceptionally strong, driven by powerful regulatory and market forces.

• EU Green Deal Influence: The European Union's Farm to Fork Strategy, a core part of the Green Deal, aims to reduce nutrient losses by at least 50% and the use of chemical pesticides by 50% by 2030. This policy directly incentivizes the use of organic fertilizers to improve soil health and reduce reliance on synthetic inputs.
• Soil Carbon Farming: There is growing interest and potential for financial compensation for farmers who adopt practices that increase soil organic carbon. The use of high-quality bio-organic fertilizer is a key strategy for achieving this.
• Export Potential: Poland's central location in Europe provides excellent access to the vast EU single market, where demand for organic inputs is uniformly high.

This project is strategically positioned to become a major supplier of certified bio-organic fertilizer, supporting the sustainable intensification of agriculture in Poland and beyond.

Why RICHI Machinery Was the Partner of Choice

For a project of this scale and technological complexity, the client required a partner with proven expertise in delivering industrial-scale organic fertilizer solutions. RICHI Machinery demonstrated this capability by providing a fully integrated system from initial design to commissioning.

Our ability to supply heavy-duty, reliable equipment like the large-span turners and high-capacity granulation line, coupled with our experience in designing effective odor and dust control systems that meet EU standards, was critical to the project's success. We provided not just equipment, but a complete production solution backed by extensive technical support.

Planning an Industrial-Scale Organic Fertilizer Project?

Whether you are considering a 50% moisture chicken manure bio organic fertilizer production line in Poland or a similar venture elsewhere, RICHI Machinery has the expertise and technology to deliver a successful, high-volume project. We specialize in designing and building turnkey solutions that are efficient, environmentally compliant, and profitable.

Contact our engineering team today for a comprehensive feasibility analysis and a detailed proposal tailored to your specific raw materials and market goals. Let us help you build a leading enterprise in the sustainable agriculture sector.