8T/H Livestock and Poultry Manure Fertilizer Production Line in Paraguay

Project Background and Investment Rationale

Paraguay's economy is heavily reliant on agriculture, with a massive and growing livestock sector, particularly cattle and poultry. While this brings economic benefits, it also generates substantial amounts of manure, which can pose environmental challenges if not managed properly. Concurrently, intensive farming practices are depleting soil organic matter, creating a pressing need for organic fertilizers to maintain long-term productivity. A forward-thinking local agribusiness group identified a strategic opportunity to bridge this gap.

The impetus for investing in this livestock and poultry manure fertilizer production line in Paraguay was clear: to create a profitable enterprise that provides an environmental solution. The primary objective was to build a facility capable of processing 20,000 tons of manure and straw annually into a standardized, market-ready organic fertilizer.

This translates to a production rate of approximately 8 tons per hour over an 8-hour shift. The final product is designed to meet stringent quality standards, targeting the needs of Paraguay's large-scale soybean, corn, and wheat farms, as well as the horticultural sector, with potential for export to neighboring Brazil and Argentina.

Project Location and Infrastructure

The strategic placement of this livestock and poultry manure fertilizer production line in Paraguay was critical to its operational efficiency and economic viability. The plant is situated on a 20,000 m² greenfield site in an emerging agro-industrial zone.

• Proximity to Raw Materials: The Canindeyú department is a major hub for cattle ranching and poultry farming, ensuring a consistent and low-cost supply of the primary raw materials—manure and straw. This minimizes transportation costs and secures the supply chain.
• Logistical Advantage: The site boasts excellent access, with a frontage on a departmental road that connects directly to major national highways, facilitating the smooth inbound receipt of raw materials and outbound distribution of the finished fertilizer.
• Controlled Environment: The location provides sufficient buffer distance from residential areas, which is essential for managing odors during the initial fermentation stages, even with advanced mitigation systems in place.

The livestock and poultry manure organic fertilizer production line in Paraguay project involved the construction of new, purpose-built facilities, including a two-story main production workshop, enclosed raw material and finished product storage warehouses, a four-story office building, and a dormitory for shift workers. The total constructed area is 12,588 m².

Production Process and Technology

The core of this livestock and poultry manure fertilizer production line in Paraguay is a two-stage aerobic fermentation process, which efficiently stabilizes organic matter and transforms waste into a nutrient-rich, humus-like product. RICHI Machinery engineered a complete, automated line that optimizes this biological process for industrial-scale production.

The transformation from raw waste to premium fertilizer involves several key stages:

Raw Material Reception and Preprocessing

Raw materials are delivered via sealed tanker trucks (for manure) and covered trucks (for straw). The straw is immediately transferred to the enclosed storage hall, where it is pre-processed using an industrial crusher to achieve a uniform particle size. This is crucial for creating the right structure and carbon-to-nitrogen (C:N) balance in the fermentation pile.

Primary Fermentation (Windrow Composting)

The crushed straw is mixed with livestock manure and a specialized bacterial inoculant (Bacillus strains) in a predetermined ratio. This mixture is formed into long windrows inside a dedicated, partially enclosed fermentation area. A RICHI mobile compost turner regularly moves through these windrows, turning and aerating the mixture. This introduces essential oxygen, homogenizes the pile, and regulates temperature. The fermentation process enters a thermophilic phase, with temperatures reaching 50-60°C, which is critical for pathogen elimination and rapid decomposition. This primary stage lasts 3-4 days.

Secondary Fermentation (Curing)

The material from the primary stage is then conveyed via enclosed belt systems to fermentation tanks within the main production workshop for a longer secondary fermentation period of 10-15 days. This curing phase allows for further stabilization and the development of beneficial microbial communities. The Bacillus inoculant plays a dual role here, accelerating decomposition and actively suppressing odor-causing compounds.

Drying, Granulation, and Packaging

The cured compost is then dried in a rotary dryer to reduce moisture content to below 30%, as required by product standards. After cooling, the material is screened to ensure consistency. The fine, uniform compost is then fed into a high-pressure fertilizer granulator machine system, which forms dense, durable pellets. These pellets are cooled again before being automatically weighed and packaged into 25kg or 50kg bags for storage and shipment.

Raw Materials and Utilities Consumption

The economic foundation of this livestock and poultry manure fertilizer production line in Paraguay is its utilization of low-cost, locally sourced agricultural waste streams.

Major Equipment List

The livestock and poultry manure fertilizer production line in Paraguay is built around a comprehensive suite of equipment from RICHI Machinery, ensuring reliability and efficiency.

Environmental Protection Measures

A cornerstone of the organic fertilizer production project's design is a comprehensive environmental management system to minimize its footprint.

• Dust Control: Dust generated during crushing, drying, and screening is captured at source by hoods and conveyed to a high-efficiency baghouse dust collector, with cleaned air discharged through a 15-meter stack.
• Odor Management: The potential for odor, primarily from the fermentation halls, is proactively managed. These areas are designed with negative air pressure. Fugitive gases are captured and treated using a advanced biological odor scrubber, which uses microorganisms to break down odor-causing compounds like Ammonia (NH₃) and Hydrogen Sulfide (H₂S). The treated air is released via a dedicated 15-meter exhaust stack, ensuring compliance with national air quality standards.
• Water and Wastewater: The facility operates a rain-sewer separation system. Process water usage is minimal. Sanitary wastewater from the office and dormitory is treated in a septic system, with effluent safely dispersed via a subsurface leach field.
• Noise Control: Equipment was selected for low noise emissions, and strategic placement within buildings, along with vibration damping mounts, ensures operational noise remains within permissible limits at the site boundary.

Economic and Operational Details

• Total Investment: The total capital expenditure for this turnkey livestock and poultry manure fertilizer production line in Paraguay was approximately $420,000 USD. This investment covered site development, all civil works, the complete RICHI machinery package, and environmental control systems.
• Work Schedule: The plant operates with a team of 15 personnel, working a single 8-hour shift, 300 days per year, reflecting a focus on efficient and stable operation rather than continuous 24/7 production.
• Economic Model: The business model is based on low-cost inputs (waste materials) transformed into a higher-value product, sold to a receptive domestic and regional market.

Market Prospects for Organic Fertilizer in Paraguay

The outlook for the output of this livestock and poultry manure fertilizer production line in Paraguay is exceptionally positive. Paraguay's agricultural sector is increasingly aware of the need for sustainable practices to preserve its most valuable asset: the soil.

• Soil Health Demand: The dominance of export-oriented soybean and grain production has led to a decline in soil organic carbon. Farmers are actively seeking organic amendments to improve soil structure, water retention, and long-term fertility.
• Regulatory and Market Drivers: Both domestic policies and international market preferences are increasingly favoring sustainable agriculture. The use of organic fertilizers aligns perfectly with this global trend.
• Regional Export Potential: Paraguay's membership in Mercosur provides tariff-free access to massive markets like Brazil, where the demand for organic inputs is growing rapidly.

This project is strategically positioned to become a key supplier, supporting the sustainability of Paraguayan agriculture while creating economic value from waste streams.

Why RICHI Machinery Was the Partner of Choice

The client selected RICHI Machinery based on our proven ability to deliver integrated solutions tailored to specific local conditions. For this livestock and poultry manure fertilizer production line in Paraguay, we provided end-to-end support, from initial plant layout and process engineering to equipment supply, installation supervision, and operator training.

Our technology, particularly the efficient fermentation turners and the high-capacity extrusion granulation system, was critical in ensuring the project's productivity and the high quality of the final pelletized product. Our commitment to providing robust, easy-to-maintain equipment that minimizes operational costs was a decisive factor for the client.

Ready to convert agricultural waste into a profitable and sustainable business?

If you are planning an investment in organic fertilizer production, whether it's a livestock and poultry manure fertilizer production line in Paraguay or any other location, RICHI Machinery is your ideal partner. We offer customized solutions from feasibility study to full turnkey project delivery. Contact us today for a free consultation and a detailed quotation. Let's work together to build a greener, more profitable future for your agribusiness.