6T/H Pig Manure Poultry Litter Fertilizer Production Plant in France

How This Project Landed in Our Lap

I got the first inquiry in early 2024. A French cooperative in Brittany—let's just say they're in the heart of pig and poultry country—had a problem. Actually, they had several problems, all connected.

Brittany produces a lot of meat. Something like 55% of French pigs come from this region, plus millions of poultry. That means a lot of manure. Under the EU Nitrates Directive, there are strict limits on how much nitrogen you can spread per hectare. The cooperatives' members were hitting those limits, and the surplus manure was becoming a logistical nightmare. They were trucking it hundreds of kilometers to other regions, paying a fortune, and still getting complaints about odors.

At the same time, French farmers are buying more organic fertilizer every year. The market share of organic fertilizers in France hit 42.5% of total fertilizer volume by 2022, up from 33% a decade earlier. The government's "Stratégie Nationale Bas Carbone" targets a 26% reduction in mineral fertilizer use by 2030. So there's this perfect storm: too much manure in one place, growing demand for organic fertilizer everywhere else.

The cooperative had been thinking about this for years. They knew about Fertival, another Breton company that's been making organic fertilizers since 1993 and now produces 50,000 tons annually. They figured if Fertival could do it, they could too.

They called us because they'd seen our work in other European countries. We'd just finished a 30 t/h organic fertilizer plant in Romania, and they'd heard good things through the grapevine. The brief was simple: design a pig manure poultry litter fertilizer production plant in France that could take their members' waste and turn it into a saleable product. 15,000 tons per year. No more, no less. They wanted to start at a manageable scale before thinking bigger.

Site and Layout: 8,188 Square Meters in the Breton Countryside

The site is in the Côtes-d'Armor, surrounded by rolling hills and farms. You'd never know it's an industrial site from the road—the buildings are set back, and there's a green buffer. The French are strict about that.

The key design decision: we don't store raw manure on site. The client brings in pre-fermented manure from the farms. They have a network of collection points where the initial anaerobic fermentation happens. What arrives at our plant is already 50% moisture, partially stabilized, and much less smelly than fresh manure. This was a requirement from the local prefecture—no fresh manure storage allowed in this catchment area.

The production building is fully enclosed. We learned from past projects in Europe that open-sided sheds don't cut it here—the neighbors will complain, and the inspectors will cite you. All air from the fermentation area is extracted and treated.

The Raw Material Reality: What Goes In

The cooperative has about 150 member farms supplying material. The ratios are pretty consistent:

Yield: About 15,000 tons of finished organic fertilizer per year. The weight loss is mostly water evaporation during processing.

The pig manure comes from farms using the TRAC system—a scraper system under slatted floors that separates urine from solids immediately. This reduces ammonia emissions at the farm level and means the manure we receive has higher solids content and less odor. The French are ahead of many countries on this technology—over 40 installations already operational in Brittany.

The poultry litter is a mix of manure and bedding material (straw, wood shavings). It's drier than pig manure and has higher fiber content, which helps with the carbon-to-nitrogen ratio in the final product.

Equipment Configuration: What We Installed

The client's original equipment list was basic—they'd priced some local fabricators who offered "custom" machines at attractive prices. We sat down with them in Rennes and walked through the process. By the end, they'd agreed that proven technology was worth the premium. Here's what we supplied:

Total installed power: approximately 150 kW

We also supplied the drying aid ("Mianhongsu") dosing system. This is clever—instead of thermal drying (which is energy-intensive and expensive in France with current gas prices), we use a chemical drying agent that binds with free water to form crystalline water. It drops moisture from 45% to below 30% without heat. The client was skeptical until we ran a pilot test with their material. It worked.

The compost turners are the workhorses. They run on rails along the 100m fermentation lanes, slowly moving through the pile, aerating and mixing. The client runs them twice per day during the 4-7 day active fermentation phase.

Process Flow: From Manure to Market

Step 1 – Receiving and Fermentation

Trucks arrive at the weighbridge, then back into the production building. They dump pre-fermented manure into the fermentation lanes—two lanes, each 100m long, 20m wide. Total pile depth about 1.5m.

We mix in straw at a ratio of roughly 7:3 manure:straw by weight. The straw adds carbon and structure. The compost turners run daily, moving slowly through the pile, flipping material to introduce oxygen. Temperature climbs to 60-65°C within days—hot enough to kill pathogens and weed seeds.

This is where the bio-deodorizer gets applied. It's a microbial product that suppresses odor-forming bacteria. We spray it on during turning. The building is under negative pressure, so any escaping air is captured, but honestly, with the deodorizer and the fact we're using pre-fermented manure, the smell is minimal.

Fermentation takes 4-7 days. By the end, the material has stabilized—it doesn't heat up anymore when turned, and it has that earthy smell of good compost.

Step 2 – Crushing

Fermented material goes through the crusher. This breaks up any clumps and reduces particle size for granulation. The material at this stage is about 45% moisture, so it's damp but not wet. Crushing is enclosed with dust extraction.

Step 3 – Granulation

This is the heart of the organic fertilizer production line. The granulator uses wet granulation—we add a small amount of water or steam to help the fines agglomerate. The rotating drum rolls the material into spherical pellets, typically 3-5mm diameter. It's gentle compared to extrusion, which is good because we don't want to damage the microbial life we'll add later.

Step 4 – Drying (Chemical)

Instead of a rotary dryer (which would require a burner, fuel, and an air permit), we add "Mianhongsu"—the drying aid. It's a powder that we meter into the granulator discharge. The chemistry: it binds with free water molecules to form crystalline hydrates. Moisture drops from 45% to under 30% in about 24 hours, just sitting in a holding bin. No energy input.

The client was worried about this step—would it affect fertilizer value? We tested samples in a French lab. NPK values were unaffected, and the product met all the specs in NY 884-2012 (the Chinese standard they referenced) and, more importantly, the French NFU 42-001 standards for organic fertilizers.

Step 5 – Microbial Inoculation

We add Bacillus subtilis at this stage—about 0.05% by weight. It's mixed in gently to distribute evenly. Bacillus is a beneficial soil bacterium that suppresses pathogens and promotes plant growth. For the French market, having a bio-enhanced product is a selling point, especially for vegetable growers and vineyards.

Step 6 – Screening and Packaging

The material goes through a vibrating screener. Oversize pellets (>5mm) get crushed and recycled. Fines (<2mm) go back to the granulator. On-spec product goes to the packaging machine, which fills 40kg bags at about 4 bags per minute. Bagged product gets palletized and moved to the finished product storage area (within the main building).

Utilities: Keeping It Simple

The water comes from a well on site—the previous landowner had a agricultural water right that transferred with the sale. We had it tested; quality was fine for process use and sanitation.

Power is the main operating cost. At French industrial rates (about €0.12-0.15/kWh), that's €7,200-9,000 per year. Not nothing, but tiny compared to what a thermal dryer would cost to run.

Environmental Controls: Staying Legal in France

France has strict environmental rules, especially in Brittany where nitrate zones are heavily regulated. We designed for compliance with:

• ICPE (Installations Classées)—the French permitting system for industrial facilities
• Nitrates Directive (91/676/EEC)
• EU Fertilizer Regulation (2019/1009) for product quality

Air Emissions

• Fully enclosed building
• Fermentation lanes under negative pressure
• Bio-deodorizer application during turning
• No fresh manure storage on site

Dust from crushing and granulation is captured by the baghouse and returned to the process. The exhaust is clean enough that we didn't need a tall stack—just a roof vent.

Wastewater

Zero process discharge. The only moisture leaves as:

• Water vapor from fermentation
• Bound water in the product
• A small amount from equipment washing (which goes to a holding tank and is used for dust suppression)

Staff facilities have a septic tank ("fosse septique"). The local commune requires periodic pumping by a licensed contractor.

Solid Waste

The hazardous waste storage (5 m²) has a sealed concrete floor and secondary containment, per French regulations. A licensed hauler takes the oil and oily rags every six months.

Soil and Groundwater Protection: We did a full hydrogeological study for the permit. The site has:

• Critical zones (hazardous waste storage): 1m clay liner + HDPE membrane
• Secondary zones (septic tank, washdown area): 1.5m compacted clay (K < 1×10⁻⁷ cm/s)
• Non-critical areas (offices, roads): Concrete hardstand

Project Economics: What It Cost

The client's original budget was €700,000 total. They got some grant funding—€300,000 from French national programs supporting circular economy projects—and put up the rest themselves.

The equipment cost—€210,000 FOB Qingdao—was about 60% of what European suppliers quoted for comparable capacity. Shipping to Le Havre port added €28,000. From there, trucks hauled everything to site—about a 4-hour drive west.

We shipped in February 2024, and the containers arrived in Le Havre in late March. Customs clearance took longer than expected—about two weeks—because the French authorities wanted detailed specs on the compost turners. We'd sent the paperwork ahead, but there was still a delay. Lesson learned: allow extra time for French bureaucracy.

Operational Learnings: What Worked and What Didn't

The Good

• Chemical drying works. Material goes from 45% moisture to under 30% in 24-36 hours with no energy input. Product doesn't cake or mold. Client loves it.
• Compost turners are robust. Run 2-3 cycles per day, no major issues after six months. Rails need occasional alignment checks.
• Building ventilation design worked. Roof vents with misting systems for summer, negative pressure during fermentation keeps odors inside. No complaints from neighbors.

The Challenging

• Straw supply was inconsistent initially. Some loads too wet or chopped too coarse. Turning frequency adjusted. Now written specification for straw suppliers.
• Bacillus subtilis viability: tested final product after 30 days—counts still good but drop over time. Client monitors monthly.
• French paperwork is real. ICPE permit took four months, not two. Start early and hire a local consultant.

What We'd Do Differently

• Bigger bagging machine—current 4 bags/minute fine for now, future growth will need faster.
• Dedicated QC lab space—currently using office corner, cramped.
• More bin capacity between steps—small surge bin to smooth granulator workflow.

Market Outlook: Why This Plant Makes Sense in France

France is the largest agricultural producer in the EU, with 49% of the country's land in agriculture. The organic fertilizer market is growing steadily, driven by:

• Policy: Stratégie Nationale Bas Carbone targets 26% reduction in mineral fertilizer use by 2030.
• Market: Organic fertilizer share increased from 33% to 42.5% in ten years, could hit 50% by 2030.
• Supply: France imports large quantities of manure from the Netherlands—47% of all Dutch manure exports by phosphate volume go to France.

Brittany context: manure surplus about 200,000 tonnes of nitrogen and 120,000 tonnes of phosphorus generated annually from 1,100 farms. Turning that surplus into exportable fertilizer is environmentally necessary.

Client targets:

• Grandes cultures (wheat, corn, oilseeds) in Paris Basin and northern France
• Viticulture—Bordeaux, Champagne, Loire Valley growers using organic amendments
• Market gardening—vegetable producers around major cities
• Export—potentially other EU countries under EU Fertilizer Regulation

15,000 ton/year capacity is modest—Fertival produces 50,000 tons annually—but it's a start. Cooperative plans to expand if successful.

Final Thoughts: Why RICHI for This Project

• Experience: Heard about 30 t/h plant in Romania, and manure-based fertilizer work in other countries.
• Flexibility: Integrated chemical drying concept, helped source dosing equipment, tested material. Other suppliers insisted on thermal dryer.
• Price: European quotes significantly higher. RICHI Machinery fit within budget.
• After-sales support: Six weeks onsite commissioning, operator training, ongoing support via WhatsApp.

Tip: start permitting early. Once permit is obtained, equipment can be at Le Havre in 5-6 weeks. Rest is turning manure into money.