4-5T/H Complete Reed Cow Dung Pellet Production Line in Egypt

Project Background

Egypt’s agricultural sector is the backbone of its economy, employing more than a quarter of the workforce and serving as the foundation of food security in the country. However, over the last few decades, intensive farming has led to soil degradation, over-reliance on chemical fertilizers, and increased greenhouse gas emissions from untreated manure.

The Nile Delta region, where the project is located, is home to a large number of dairy farms and smallholder cattle raisers. Cow dung disposal has become an environmental challenge, often resulting in uncontrolled methane emissions, groundwater pollution, and unpleasant odors. At the same time, the wetlands and irrigation canals along the Nile produce vast amounts of reed biomass, which is traditionally discarded or burned, causing additional environmental stress.

Recognizing the dual challenge of waste management and the need for sustainable soil nutrition, a local agribusiness investor initiated the complete reed cow dung pellet production line in Egypt. The client is a mid-sized agricultural entrepreneur who owns cattle farms and has long-term supply contracts with nearby farms. Their main motivation was to close the nutrient cycle: converting waste into value-added pellets that can be sold to farmers, cooperatives, and commercial crop plantations.

This organic fertilizer production project responds to three key drivers in Egypt:

• Rising demand for organic fertilizers, both locally and in export markets such as Saudi Arabia and the UAE.
• Environmental compliance pressures, as Egypt seeks to align with global sustainability standards.
• Resource utilization efficiency, reducing open dumping and burning of agricultural residues.

Project Location and Layout

The project is strategically located in a rural community near the city of Tanta in the Nile Delta, chosen for its proximity to raw material sources and transportation networks.

• Land Area: 12,000 m²
• Construction Area: 8,400 m²

Functional Zoning

• Fermentation workshop (3,000 m²): equipped with reinforced concrete flooring, compost turner, and raw material storage areas.
• Production workshop (5,000 m²): houses crushing, screening, pelletizing, drying, and packaging systems.
• Office and staff building (400 m²): includes administrative offices, restrooms, and break areas.
• Utility infrastructure: water supply from municipal pipelines, power from the local substation, rainwater and wastewater separation, and solid waste management systems.

The layout ensures that fermentation units are positioned downwind of residential areas to minimize odor impact, while the production workshop and packaging areas are centrally located for logistical efficiency.

Raw Materials and Supply Strategy

One of the strengths of the complete reed cow dung pellet production line in Egypt is the abundance and stability of raw material supply. The client has secured agreements with multiple dairy farms and reed collectors to ensure uninterrupted feedstock availability.

This diversified input mix is carefully designed to balance carbon-to-nitrogen ratios, ensuring effective fermentation and high-quality pelletized organic fertilizer.

Equipment Configuration

The complete reed cow dung pellet production line in Egypt is equipped with advanced machinery supplied by RICHI Machinery, customized for the Egyptian client’s requirements.

All conveyors and transfer points are fully enclosed to minimize dust emissions. Equipment design emphasizes low energy consumption (490 kWh annually) and easy maintenance.

Production Process

Step 1: Raw Material Collection and Pre-Treatment

• Cow dung and reed residues are delivered to the fermentation workshop.
• Initial mixing with sawdust, rice bran, and mushroom residues balances moisture and nutrients.

Step 2: Fermentation and Composting

• Mixed raw materials are stacked in long rows inside the fermentation workshop.
• Temperature is monitored, and once it reaches 55–65°C, the compost turner aerates and mixes the pile.
• Microbial agents are added to accelerate decomposition.
• Fermentation cycle: 5–10 days, followed by curing for an additional 10–15 days.

Step 3: Crushing and Screening

• After fermentation, semi-finished compost is transferred to the production workshop.
• The vertical crusher breaks down clumps, followed by screening to remove oversized particles.
• Rejected particles are returned for re-crushing.

Step 4: Pelletizing and Packaging

• Screened compost is fed into the pelletizing system-ring die fertilizer granulator machine.
• Pellets made by cow dung pellet making machine are formed into standardized sizes (25 kg or 40 kg per bag).
• Automatic weighing and packaging machines prepare products for storage and sale.

This closed-loop process ensures that all emissions and by-products are managed responsibly.

Environmental Protection Measures

• Waste Gas: Odor from fermentation controlled with deodorizing sprays and biofilters.
• Dust: Enclosed conveyors and sealed crushers prevent particle emissions.
• Wastewater: No industrial wastewater; minimal domestic sewage treated in septic tanks, reused for landscaping irrigation.
• Noise: Equipment fitted with vibration dampers; workshops insulated.
• Solid Waste: Minimal; packaging waste collected for recycling.

These measures align with Egypt's environmental standards, ensuring compliance and community acceptance.

Labor and Operations

• Staffing: 10 full-time employees, covering operations, maintenance, and administration.
• Work Schedule: 270 working days/year, 8 hours/day, single shift.
• Training: Workers trained in equipment operation, composting techniques, and safety protocols.
• Safety: Fire extinguishers, protective gear, and emergency procedures in place.

Investment and Financial Analysis

• Total Investment: USD 750,000
• Breakdown:
  • Construction & infrastructure: USD 300,000
  • Equipment procurement: USD 250,000
  • Installation & commissioning: USD 70,000
  • Environmental measures: USD 30,000
  • Working capital: USD 100,000
• Production Cost: Estimated at USD 50–60 per ton (including raw material handling, labor, energy, and depreciation).
• Market Price: Organic fertilizer pellets in Egypt retail for USD 120–150 per ton.
• Annual Revenue: 10,000 tons × USD 120 = USD 1.2 million (minimum).
• Payback Period: 3–4 years.

Future Prospects in Egypt

• Domestic demand: Egypt’s farmers are increasingly aware of soil degradation from chemical fertilizers and are turning toward organic alternatives.
• Export opportunities: Egypt is geographically positioned to supply organic fertilizer to neighboring countries such as Sudan, Saudi Arabia, and Jordan.
• Policy support: The Egyptian government promotes sustainable agriculture under its “Green Egypt” initiative.

By converting waste into valuable fertilizer pellets, this project is not only profitable but also aligned with Egypt’s long-term environmental and agricultural strategies.

RICHI Machinery's Role

• Customized engineering design for the Egyptian raw material mix.
• Complete equipment supply, installation, and training.
• After-sales support, including spare parts, technical guidance, and optimization services.

With decades of expertise in organic fertilizer pellet production, RICHI ensures that each organic fertilizer production line project is tailored to local conditions, maximizing efficiency and profitability.

Conclusion

The complete reed cow dung pellet production line in Egypt is a forward-looking investment that successfully combines livestock waste management with agricultural sustainability. With a carefully designed process, stable raw material supply, reasonable investment cost, and strong market demand, this project demonstrates how waste-to-value solutions can thrive in developing economies.

RICHI Machinery remains a trusted partner in delivering such solutions, ensuring that clients not only achieve financial returns but also contribute to environmental sustainability and rural development.