20T/H Livestock Manure Fish Waste Fertilizer Production Line in Indonesia

Project Genesis and Indonesian Context

The National Imperative for Sustainable Waste Management

Indonesia, as the world's largest archipelago nation, possesses a thriving agricultural and fisheries sector. However, this prosperity generates significant organic waste. In provinces like Central Java, with its high density of dairy and beef cattle, and coastal areas with prolific fish processing industries, the disposal of manure and fish offal has traditionally been problematic. Open dumping or uncontrolled decomposition leads to severe odor issues, groundwater contamination through leachate, and the release of methane—a potent greenhouse gas.

Concurrently, decades of intensive chemical fertilizer use have degraded soils, reducing organic matter and leading to compaction and yield stagnation. The Indonesian government, through its Ministry of Agriculture, has been actively promoting integrated farming and the use of organic fertilizers to enhance soil health and reduce dependency on chemical imports.

The Client's Vision

Our client, a consortium of local farm cooperatives and a fish processing plant, identified a synergistic solution to these twin challenges. Instead of viewing waste as a liability, they saw it as a raw material for a valuable product. Their vision was to establish a centralized processing facility that could convert locally abundant organic wastes into a standardized, marketable organic fertilizer. This would not only solve their own waste disposal costs but also create a new revenue stream and provide local farmers with a superior soil amendment.

Why RICHI Machinery Was Chosen

• Proven Experience in Organic Waste: RICHI's portfolio included numerous successful projects dealing with high-moisture, high-odor materials like manure and slaughterhouse waste.
• Customization Capability: Unlike suppliers offering rigid, standard solutions, RICHI committed to designing a process tailored to the specific characteristics of the client's raw material mix.
• Comprehensive Service: From initial site assessment and process design to installation, training, and after-sales support, RICHI provided a single-point solution.
• Cost-Effectiveness: The proposed solution offered an optimal balance between capital expenditure, operational efficiency, and final product quality.

The livestock manure fish waste fertilizer production line in Indonesia project was officially commissioned in Q2 2023, with a targeted annual output of 100,000 tons of granular organic fertilizer.

Project Overview and Key Metrics

The organic fertilizer production project involved the construction of a new production facility on a repurposed 2-hectare site owned by the consortium. The livestock manure fish waste fertilizer production line in Indonesia was designed for efficiency, minimal environmental impact, and future expansion potential.

Raw Materials for livestock manure fish waste fertilizer production line in Indonesia

The success of any organic fertilizer project hinges on a deep understanding of the raw materials. RICHI's process engineers conducted a pre-project analysis of the client's waste streams to design the most effective pretreatment and fermentation recipe.

Raw Material Sourcing and Characteristics:

• Livestock Manure (70,000 TPY): Sourced from consortium-owned and local partner dairy and beef farms. The manure is partially sun-dried at source to achieve a delivery moisture content of <50%. Its high nitrogen and carbon content make it the primary "base" material for the compost recipe.
• Fish Waste (20,000 TPY): Procured from a nearby fish canning and processing plant. This material is rich in nitrogen, phosphorus, and proteins but has a high potential for putrefaction and intense odor. It is delivered in sealed containers to prevent spoilage and is used as a potent nitrogen booster.
• Food Factory By-products (1,000 TPY): This consists of fruit and vegetable scraps, grain dust, and other organic matter from local food processors. With a lower moisture content (<20%), these materials act as a "bulking agent," improving the porosity of the compost pile for better aeration.

1. Carbon-Nitrogen (C/N) Balance: The initial mix of manure and fish waste is nitrogen-heavy. The addition of bulking agents (sawdust, bark) and the food by-products adjusts the C/N ratio to an optimal 25:1 to 30:1, which is crucial for efficient microbial activity during fermentation.
2. Moisture Control: The target moisture for fermentation is 50-60%. The wet fish waste and manure are balanced with the drier bulking agents and food scraps. A dedicated water spray system in the mixer allows for fine-tuning.

RICHI's Custom-Engineered Process and Technology

Stage 1: Raw Material Receiving and Pre-Mixing (G1)

Incoming materials are unloaded in designated, partially enclosed bays with concrete floors and drainage. The plant deodorant system, a fine mist of plant-based extracts, is automatically activated in this area to neutralize odors at the source. Using a front-end loader, materials are batched according to the RICHI recipe into a 9x RICHI Double-Shaft Mixer. This fertilizer mixer is critical—its powerful counter-rotating shafts ensure a homogeneous blend of the diverse materials (wet sludge, dry straw, powders) in just 3-5 minutes per batch. Water or deodorant can be injected directly into the mixer to achieve the perfect consistency for fermentation.

Stage 2: Aerobic Fermentation & Bio-Oxidation (G1)

This is the heart of the process. The mixed material is conveyed into 10x RICHI In-Vessel Fermenters. Unlike open windrows, this closed-tank system provides total environmental control.

• Forced Aeration: Each fermenter has a perforated floor. A blower forces air from the bottom, providing oxygen for the aerobic microbes and removing excess heat and moisture.
• Automatic Turning: Inside each fermenter, a 5x RICHI Crawler Turner moves slowly through the material, turning and fluffing it.
• Pathogen Elimination: The sustained high temperature is lethal to pathogens, weed seeds, and fly larvae, resulting in a sanitized and stable product.
• Odor Control: The exhaust air is captured and treated in the central RICHI Biofiltration System.

The fermentation cycle is 8-10 days, after which the material is a stable, crumbly, dark brown compost.

Stage 3: Crushing and Sizing

The cured compost is discharged and conveyed to the next stage. It often contains clumps. It first passes through a 2x RICHI 11KW Semi-Moist Material Crusher. This specialized crusher uses a rotor with swinging hammers to pulverize the clumps without clogging, even with a moisture content up to 30%. This process generates some dust, which is immediately captured by hoods and ducted to a Pulse-Jet Baghouse Dust Collector.

Stage 4: Batching and Granulation

The crushed compost is the base for the final product. At this stage, specific additives can be blended in using a precision batching system to create customized fertilizer blends. The material is then fed into 3x RICHI organic fertilizer pellet machines. As the fine powder tumbles in the rotating drum, a fine mist of water or binder is sprayed, causing the particles to coalesce into strong, spherical granules.

Stage 5: Drying and Cooling

The green granules from the drum have high surface moisture and are too soft for handling. They enter 5x RICHI Low-Temperature Belt Dryers. These dryers use indirectly heated air to gently reduce the moisture content to below 30%, hardening the granules without destroying the beneficial microbes. The hot granules are then cooled in a RICHI Rotary Cooler.

Stage 6: Screening and Packaging

The cooled granules are passed over a RICHI Triple-Deck Vibrating Screen. Oversized granules are crushed and recycled back to the granulator. On-spec granules proceed to the 3x RICHI Automatic Weighing and Bagging Machines. Fines are also recycled as seed material for the granulation process. The screening process generates minimal dust, which is again captured by the baghouse.

Detailed Equipment List by RICHI Machinery

Environmental and Economic Impact

Environmental Stewardship

• Waste Reduction: Diverts over 91,000 tons of organic waste from landfills or open dumps annually.
• Water Protection: Eliminates the risk of leachate from waste piles contaminating groundwater.
• Air Quality: The biofiltration and dust collection systems ensure emissions are well within Indonesian regulatory limits.
• Soil Health: The final product helps Indonesian farmers rebuild soil organic matter, improve water retention, and reduce erosion.

Economic Viability

With a total investment of $1.2 million and an estimated average selling price of $35/ton for bagged organic fertilizer, the livestock manure fish waste fertilizer production line in Indonesia project achieves a gross annual revenue of approximately $3.5 million. After accounting for operational costs (labor, utilities, maintenance, and raw material transport), the projected payback period is 3 to 4 years. The plant also creates direct employment and stimulates local ancillary industries (logistics, packaging).

Market Outlook and Conclusion

The market for organic fertilizers in Indonesia is poised for robust growth, driven by:

1. Government Policy: Strong push for "Go Organic" initiatives and subsidies for organic fertilizer production and use.

2. Farmer Awareness: Increasing recognition of soil health issues caused by chemical overuse.

3. Export Potential: High-quality, certified organic fertilizer can find markets in other ASEAN countries and the Middle East.

4. Corporate Responsibility: Industries are seeking sustainable solutions for their organic waste, creating a low-cost or even revenue-generating disposal model.

Why Partner with RICHI Machinery?

This livestock manure fish waste fertilizer production line in Indonesia project is a testament to RICHI Machinery's capability to deliver not just machinery, but a complete, profitable, and sustainable solution.

We don't sell standalone machines; we engineer integrated production lines tailored to your unique raw materials and market goals.

Our expertise in handling challenging waste streams like fish and manure, combined with our focus on environmental controls, makes us the ideal partner for your venture into the organic fertilizer industry.

From concept to commissioning, and with lifelong technical support, RICHI Machinery is committed to being your trusted partner in building a greener, more profitable future.