6T/H Cow Manure Fertilizer Pellet Production System in Romania

Project Overview

The 6t/h cow manure fertilizer pellet production system in Romania is essentially a combined fermentation + extrusion granulation line. What makes it slightly different from many smaller European setups is that both organic fertilizer and compound fertilizer share the same production workshop and equipment set.

Instead of separating systems, the client preferred a flexible production approach:

• When manure supply is high → prioritize bio-organic fertilizer
• When market demand shifts → switch to compound fertilizer blending

This decision reduced initial investment and simplified operation, although it required tighter control in batching and cleaning between production cycles.

Another thing worth mentioning — water is barely used in production. Most of the moisture management happens during fermentation and raw material blending.

Who is the Client and Why This Project Started

The client operates a mid-sized cattle farm cooperative in western Romania. Over the years, manure accumulation became a real issue. Traditional open composting worked, but:

• It required large land area
• Odor complaints started increasing
• Product consistency was poor

At some point, they realized they were sitting on a resource, not waste.

Their original questions during consultation were quite typical:

• “Can we skip drying?”
• “What happens if moisture fluctuates?”
• “Can one system produce both organic and compound fertilizer?”

From there, the discussion gradually shaped into this 6t/h cow manure fertilizer pellet production system in Romania.

Site & Layout Notes

The organic fertilizer production line occupies about 7,200 m², with production taking up the majority.

Instead of building everything new, the client reused part of an existing structure and expanded it:

• Production workshop: ~2,670 m²
• Raw material areas separated by function
• Finished goods split into two storage zones

One small but practical decision — placing the finished product area downwind. That helped reduce dust returning into the workshop.

Raw Materials

Romania has a strong livestock sector, especially cattle farming, so raw material sourcing was not a concern. The key issue was consistency, not availability.

Main Raw Materials

Equipment Configuration

The equipment setup is not overly complex, but it’s balanced. The client didn’t want unnecessary machines.

Main Equipment List

A small note here — six granulators were installed not because of capacity alone, but to keep pellet size more stable when material conditions change.

Process Flow (How It Actually Runs)

The process is not complicated on paper, but in reality, most adjustments happen during fermentation and feeding.

Detailed Process Flow for Organic Fertilizer Line

1. Raw material reception and pre-treatment
   • Fresh cow manure (70% moisture) is delivered daily and stored in the dedicated raw material zone
   • Sawdust (10% moisture) is added to adjust carbon-to-nitrogen ratio and improve porosity
   • EM microbial agent is pre-mixed with water to activate beneficial microorganisms
   • Initial moisture is measured and adjusted to 55–60% for optimal fermentation conditions
2. Primary fermentation (10–12 days)
   • Material is arranged in long rows inside the fermentation area
   • Compost turner passes through each row 2–3 times daily, ensuring oxygen penetration
   • Temperature rises rapidly to 65–70°C within the first 72 hours, killing weed seeds and pathogens
   • Turning frequency increases as temperature climbs; operators monitor core temperature every 8 hours
   • Ammonia and moisture are released during this stage; odor control systems operate continuously
3. Secondary fermentation (10–15 days)
   • Material is consolidated into larger piles to retain heat while allowing further decomposition
   • Turning frequency reduces to once every 2–3 days
   • Temperature gradually drops to ambient levels as organic matter stabilizes
   • Moisture content decreases to approximately 25% through evaporation and biological activity
   • Humic substances begin forming, enhancing nutrient availability
4. Crushing
   • Fully fermented material is fed into the crusher via belt conveyor
   • Rotating hammers break down hardened lumps and fibrous particles
   • Output particle size is controlled to under 5 mm for consistent granulation
   • Magnetic separator removes any metal debris that may have entered during fermentation
5. Screening
   • Crushed material passes through rotary screening machine with 3 mm and 5 mm mesh layers
   • Oversized particles (>5 mm) are automatically returned to the crusher via closed-loop conveyor
   • Undersized fines (<3 mm) are collected separately for re-processing or blending
   • On-spec material (3–5 mm) proceeds to the mixing stage
6. Extrusion granulation
   • Screened organic powder enters organic fertilizer pellet machine
   • Material is compressed between two counter-rotating rollers, forming dense flakes
   • Flakes are immediately broken into uniform granules by built-in flaking knives
   • No chemical binders or drying heat are required — purely mechanical pressure shaping
   • Granule size typically ranges from 2.5 mm to 4.5 mm, ideal for broadcast application
7. Cooling and conditioning
   • Freshly extruded granules (still warm from friction) pass through an air-cooling conveyor
   • Ambient air removes residual heat, preventing moisture condensation during storage
   • Optional coating drum applies anti-caking agent for bulk storage stability
8. Inspection and packaging
   • Final product samples are taken hourly for moisture, organic matter, and nutrient analysis
   • Granules are weighed by automated packaging scales and filled into 25 kg or 50 kg bags
   • Bags are sealed, labeled, and palletized for distribution

Compound Fertilizer Line (Shared Equipment)

1. Raw material preparation
   • Organic fertilizer base (from the same production line) is crushed and screened to uniform powder
   • Inorganic raw materials (ammonium chloride, urea, MAP, KCl, K₂SO₄) are pre-crushed separately
2. Precise batching
   • Five-bin batching system with load cells measures each ingredient according to formula
   • Formulations are stored in the control system; changeovers take approximately 15 minutes
   • Trace elements are added manually through a dedicated micro-dosing station
3. Mixing
   • Batched materials discharge into double-shaft mixer for intensive blending (60–90 seconds per batch)
   • Disc mixer follows for gentle homogenization, ensuring uniform nutrient distribution
4. Extrusion granulation
   • Same cow dung pellet making machine used for organic fertilizer; rollers adjusted for compound formula density
   • No drying required — all raw materials are already within appropriate moisture range
5. Screening and packaging
   • Rotary screen separates on-size granules from fines and oversize
   • Oversize material is crushed and re-granulated; fines are returned to the mixer
   • Final product is weighed, bagged, and palletized

No drying section. That’s one of the reasons the client chose this system.

Environmental Handling (Adjusted for Local Conditions)

Romania has stricter environmental expectations compared to many developing markets, so a few systems were necessary:

• Dust collection with bag filters (~99% efficiency)
• Enclosed workshop design
• Bio-deodorization during fermentation
• Spray system for odor control

Wastewater is minimal since:

• No washing process
• No wet granulation

Most water loss happens through evaporation or material absorption.

Operational Observations (Real Notes from Commissioning)

During the first few weeks, the system didn’t run perfectly.

Some real issues:

• Initial batches were uneven in moisture
• Pellets cracked when manure ratio was too high
• Sawdust proportion had to be adjusted

After a few adjustments:

• Stable pellet size achieved
• Odor significantly reduced compared to open composting
• Production rhythm became predictable

One operator said something interesting: “Before this line, manure was something we had to get rid of. Now it’s something we schedule.”

Investment & Cost

This project was designed to stay within a reasonable budget for Eastern Europe.

• Equipment cost: around $180,000 – $220,000
• Civil works: moderate (existing structures reused)
• Labor: low (only 8 workers)

The client was quite sensitive to cost, so unnecessary automation was avoided.

Shipping & Delivery

All equipment was shipped from Qingdao Port, China.

• Destination port: Constanta Port, Romania
• Transport: sea freight
• Delivery time: ~35–40 days

Market Perspective in Romania

Organic farming is slowly expanding in Romania, especially in:

• Vegetable production
• Vineyards
• Small-scale organic farms

At the same time, livestock farms are under pressure to manage waste more responsibly.

This creates a situation where:

• Raw material is abundant
• Demand for organic fertilizer is rising

Projects like this 6t/h cow manure fertilizer pellet production system in Romania sit right in the middle of that gap.

A Few Practical Thoughts for Future Investors

If you’re considering a similar line, these are usually the real questions:

• Is your manure supply stable year-round?
• Can you control moisture before granulation?
• Do you need both organic and compound fertilizer?

These matter more than choosing a specific machine model.

About RICHI Machinery

RICHI has worked on enough manure-based projects to know that no two are exactly the same. Moisture, climate, raw material variation — they all change the design.

For this Romanian organic fertilizer production project, the key wasn’t just supplying equipment. It was:

• Adjusting fermentation logic
• Simplifying layout
• Keeping investment under control

If you're planning a 6t/h cow manure fertilizer pellet production system in Romania or in another region, it’s worth starting from your raw materials and working forward — not the other way around.

We usually begin with a simple question: “What does your material actually look like today?”

That's where most good projects start.