10T/H Integrated Chicken Sheep and Cow Manure Fertilizer Production Line in New Zealand

Project Background and Investment Rationale

New Zealand's economy is deeply rooted in agriculture, with a world-leading dairy industry, significant sheep farming, and a growing poultry sector. These industries generate substantial quantities of manure, which, under increasing environmental scrutiny, requires careful management to protect water quality and reduce greenhouse gas emissions. Simultaneously, the intensive nature of pasture-based systems depletes soil nutrients, creating a strong demand for effective organic fertilizers to maintain soil health and productivity.

The client, a consortium of progressive farmers and agricultural investors, recognized the strategic imperative to develop a local solution. The decision to invest in this chicken sheep cow manure fertilizer production line in New Zealand was driven by the need for a circular economy model that could process diverse manure streams into a standardized, high-value product.

The primary goal was to build a facility capable of producing 50,000 tons of certified organic fertilizer annually (approximately 10-111 tons per hour over a two  8-hour shifts). This product is targeted at the country's large-scale dairy, sheep, and arable farms, as well as the lucrative horticulture and viticulture sectors, helping farmers meet increasingly stringent environmental regulations while improving on-farm sustainability.

Project Location and Infrastructure

The strategic siting of this chicken sheep cow manure fertilizer production line in New Zealand was critical for its operational and economic success. The plant was developed on a 21-acre (approx. 8.5-hectare) site within a designated rural-industrial zone in the Selwyn District, Canterbury.

• Heart of Raw Material Supply: The Canterbury Plains are home to a high density of dairy farms, sheep stations, and poultry operations, ensuring a consistent and logistically efficient supply of the primary raw materials—chicken, sheep, and cow manure.
• Transport and Market Access: The site has excellent access to State Highway 1, the main transport artery of the South Island, facilitating the collection of raw materials from surrounding farms and the distribution of the finished product to markets nationwide.
• Environmental Compliance: The location was chosen with ample buffer distances to sensitive receptors, which was a key factor in obtaining resource consent from the local council, particularly for managing potential odors through state-of-the-art containment and treatment systems.

The organic fertilizer production project involved the construction of a new, large-scale fermentation hall and the retrofitting of two existing empty warehouses on the property into a production workshop and a finished product warehouse.

Production Process and Technology

The core of this chicken sheep cow manure fertilizer production line in New Zealand is a sophisticated aerobic composting process specifically designed to handle a varied mix of animal manures. RICHI Machinery provided a complete system that ensures efficient decomposition, pathogen elimination, and the production of a consistent, high-quality granular fertilizer.

The production process is a carefully controlled biological transformation, detailed below:

• Raw Material Reception and Blending: Chicken, sheep, and cow manures, each with slightly different nutrient profiles and physical characteristics, are delivered separately. They are immediately blended with a carbon-rich amendment—spent mushroom substrate—in a predetermined ratio. This step is crucial for achieving the optimal Carbon-to-Nitrogen (C:N) ratio and porosity for effective composting. A specialized bacterial inoculant is added to accelerate the decomposition process from the outset.
• Primary Fermentation (In-Vessel): The blended material is conveyed into a newly constructed fermentation hall, which houses nine dedicated fermentation troughs. A fleet of RICHI trough turners runs on rails along these troughs. The turners systematically mix and aerate the compost piles, ensuring uniform oxygen distribution, temperature control, and homogenization. The process reaches thermophilic temperatures (55-65°C), which is critical for pathogen destruction and rapid decomposition. This primary fermentation stage lasts for 20 days.
• Curing (Secondary Fermentation): After the intensive primary phase, the compost is moved to a static pile area for a curing period. This 40-day stage allows for further stabilization and maturation of the organic matter, resulting in a more consistent and phytotoxin-free product. The final moisture content is reduced to below 30%.
• Screening and Crushing: The cured compost is then fed into a screening system. Oversized particles are separated and sent to a crusher for size reduction before being recycled back into the process. The fine, consistent material proceeds to the next stage. This step ensures a uniform feedstock for granulation.
• Mixing and Granulation: The screened compost is mixed with minor amendments like vermiculite and perlite to enhance the final product's physical properties. The homogeneous mixture is then fed into a fertilizer granulator machine, where it is formed into uniform, hard pellets.
• Packaging and Storage: The dried and cooled pellets are automatically weighed and packaged into 25kg bags. The bagged product is palletized and stored in the finished product warehouse, ready for dispatch to customers.

Raw Materials and Utilities Consumption

Major Equipment List

Environmental Protection Measures

• Odor Management: The entire fermentation hall is a fully enclosed, negatively pressurized building. Captured air containing ammonia (NH₃) and hydrogen sulfide (H₂S) is treated by a multi-stage biological odor control system before being discharged through a 15-meter high stack. This effectively mitigates impact on the surrounding environment.
• Dust Control: Dust generated during crushing and screening is captured by hoods and ductwork and treated by a high-efficiency baghouse filter, with cleaned air vented through a dedicated 15-meter stack.
• Water Management: A full stormwater and wastewater separation system is in place. Sanitary wastewater is treated in a septic system. Process water usage is minimal, with no industrial wastewater discharged from the site.
• Noise Control: Equipment was selected for low noise emissions, and buildings provide acoustic buffering to ensure compliance with district plan rules.

Economic and Operational Details

• Total Investment: The total capital expenditure for this chicken sheep cow manure fertilizer production line in New Zealand was approximately $850,000 USD. This included site works, the new fermentation hall, retrofitting existing structures, and the complete RICHI machinery and pollution control package.
• Work Schedule: The plant operates with a team of 20 personnel, working a two 8-hour shifts, 300 days per year. This reflects a focus on stable, efficient production aligned with the seasonal nature of agriculture.
• Business Model: The venture is based on receiving manure (often at a low cost or tipping fee) and transforming it into a branded, value-added organic fertilizer sold to a receptive market.

Market Prospects for Organic Fertilizer in New Zealand

• Freshwater Reform: New Zealand is implementing major reforms to improve freshwater quality, which includes stricter controls on nutrient runoff from farms. This encourages the use of slow-release organic fertilizers over soluble synthetic ones.
• Soil Health Focus: There is growing recognition among farmers of the need to build soil organic matter for long-term resilience and productivity. Organic fertilizers are key to this strategy.
• Export Market for Food Products: New Zealand's agricultural exports rely on a "clean, green" image. Using sustainable inputs like organic fertilizer enhances this brand story for international consumers.

Why RICHI Machinery Was the Partner of Choice

The client selected RICHI Machinery for our demonstrated expertise in designing fertilizer plants that handle diverse feedstocks and meet high environmental standards. For this chicken sheep cow manure fertilizer production line in New Zealand, we provided a customized solution that included the efficient trough-turner system for the large fermentation hall and the integrated crushing-screening-granulation line. Our ability to deliver a project that successfully navigated New Zealand's rigorous resource consent process was a critical factor in the project's timely completion.

Ready to develop a sustainable fertilizer solution for your region?

If you are considering an investment in organic fertilizer production line, whether it's a chicken sheep cow manure fertilizer production line in New Zealand or a project tailored to your local agricultural waste streams, RICHI Machinery has the expertise and technology to ensure your success.

We offer end-to-end solutions from feasibility study to commissioning. Contact us today for a confidential consultation and discover how we can help you build a profitable and environmentally positive business. Let's work together to cultivate a more sustainable future for agriculture.