3-4T/H Poultry Livestock Cow Dung Pellet Production Line in Malaysia

Project Background

Agriculture in Malaysia has historically been dominated by plantations of palm oil, rubber, and rice. At the same time, the country maintains a robust poultry industry, producing nearly 2 billion chickens annually and a growing dairy sector, concentrated in Johor, Selangor, and Perak. This expansion has resulted in significant livestock waste, especially poultry litter and cow dung, which pose environmental and sanitary challenges if left untreated.

The cooperative behind this poultry livestock cow dung pellet production line in Malaysia project recognized the dual opportunities:

• Sustainable Waste Management: Livestock manure was previously underutilized, often disposed of in open fields, causing odor, water pollution, and greenhouse gas emissions
• Organic Fertilizer Demand: With increasing concerns about soil degradation due to chemical fertilizers, Malaysia’s Ministry of Agriculture has been promoting organic farming practices. Organic fertilizer consumption has been rising steadily, particularly for oil palm plantations where improving soil fertility is critical

By converting poultry and cow dung into pellets, this project not only solves waste problems but also creates a marketable, value-added product. The choice of a 15,000 t/a capacity aligns well with local supply and demand conditions: it is large enough to process manure from surrounding farms yet appropriately scaled to fit Malaysia’s mid-sized agricultural landscape.

The cooperative also benefited from Malaysia’s Green Technology Financing Scheme (GTFS), which encourages investments in sustainable projects. About USD 300,000 of the investment was self-financed, while the remaining USD 130,000 came from low-interest green loans.

Project Location and Site Layout

The organic fertilizer production line is located on an 8,188 m² site in Johor, strategically chosen due to:

• Proximity to poultry and dairy farms for steady raw material supply
• Good road access to the North–South Expressway, enabling efficient transport to fertilizer markets
• Availability of groundwater resources for process water
• Separation from residential areas, reducing the impact of odors

The facility layout follows international best practices for organic fertilizer plants. The main zones include:

• Production Plant (4,250 m² steel structure building): Houses fermentation, crushing, granulation, screening, and packaging units
• Auxiliary Building (150 m² brick-concrete structure): Used for offices and staff facilities
• Raw Material Storage: Dedicated enclosed areas for straw, additives, and pre-treated manure
• Finished Product Warehouse: Temporary storage for bagged fertilizer before dispatch
• Utilities: Water supply via borewell, power from the local grid, and internal roads for transport circulation

This structured layout ensures efficient workflow, reduces cross-contamination risks, and complies with Malaysian building and safety codes.

Production Capacity and Investment

Funding Source: Cooperative self-funding + GTFS green financing

This investment level is realistic for Malaysia, where construction costs and labor expenses are moderate. The project is expected to achieve a payback period of 3–4 years through sales of organic fertilizer.

Raw Materials

In Malaysia, raw material supply is reliable due to the high density of livestock farms and crop residues. The poultry livestock cow dung pellet production line in Malaysia project relies mainly on:

• Poultry manure (from broiler and layer farms)
• Cow dung (from dairy farms)
• Rice straw (common in northern Malaysia and available in Johor via supply contracts)
• Additives such as microbial agents (Bacillus subtilis) and odor control powder

Raw materials are pre-treated to ensure safety and consistency before entering the fermentation stage.

Equipment Configuration

The ring die organic fertilizer pellet machine is central to the production line, ensuring uniform pellets that meet international organic fertilizer standards. The choice of machinery balances automation with affordability, suitable for Malaysia’s mid-scale operation.

Production Process

• Fermentation: Semi-fermented poultry and cow manure (50% moisture) is blended with rice straw in a 7:3 ratio inside two dedicated fermentation channels (100 m x 20 m x 6 m). Compost turners maintain aeration, while microbial inoculants accelerate decomposition. Temperature reaches 55–60°C, ensuring pathogen and parasite destruction. Fermentation lasts 4–7 days;
• Crushing: After fermentation, the composted material is crushed into fine powder, facilitating pellet formation;
• Granulation: Powdered material is fed into the ring die fertilizer granulator machine, producing uniform pellets. Moisture content is reduced to ~30%;
• Additive Mixing: Anti-drying additives and Bacillus subtilis are introduced, enhancing storage stability and biological activity;
• Screening: Pellets are screened to ensure size consistency (≤3 mm acceptable). Oversized material is recycled back to crushing;
• Packaging: Final products are automatically bagged (40 kg per bag) and stored in the finished goods warehouse.

Environmental Protection Measures

• Air Quality: Odor during fermentation is controlled with microbial deodorizing agents and mechanical ventilation. Kitchen exhaust passes through purification units
• Wastewater: No production wastewater is generated; staff sewage is treated via septic tanks and used for landscaping
• Solid Waste: Non-organic waste is collected and sent to municipal facilities
• Noise Control: Equipment is installed with vibration-dampening bases and enclosed walls

These measures ensure compliance with Malaysia's Environmental Quality Act .

Staffing and Operations

The plant operates 300 days/year, with two shifts per day (8 hours/shift). Staffing includes:

• 2 Managers (operations & quality)
• 3 Technicians (process monitoring, equipment handling)
• 5 Workers (material handling, packaging)

A total of 10 employees run the facility. Salaries are aligned with Malaysia’s agricultural wage standards, averaging USD 400–600/month.

Economic Feasibility

At full capacity (15,000 t/a), sales revenue is projected as:

• Average selling price: USD 120/ton (domestic market)
• Annual sales: USD 1.8 million
• Operating cost: ~USD 1.2 million
• Net profit: ~USD 600,000

This ensures payback within 3–4 years, highlighting strong profitability.

Market Prospects in Malaysia

• Oil Palm Plantations: Covering over 5 million hectares, they require soil-enhancing fertilizers. Organic pellets reduce chemical dependence
• Rice Cultivation: Malaysia’s paddy farmers face declining soil fertility; organic inputs are increasingly promoted
• Government Support: Incentives under the National Agro-Food Policy (NAP 2.0) encourage sustainable practices
• Export Opportunities: Neighboring Indonesia and Thailand are large markets for organic fertilizers

Thus, the poultry livestock cow dung pellet production line in Malaysia is positioned not only as a waste management solution but also as a profitable agribusiness venture.

Conclusion: Why RICHI Machinery?

This case demonstrates how a well-planned poultry livestock cow dung pellet production line in Malaysia can address pressing agricultural and environmental challenges while generating economic returns.

By leveraging RICHI Machinery's advanced ring die pelletizers and integrated process design, the cooperative has built a facility that is cost-effective, eco-friendly, and market-driven.

For investors and agricultural enterprises in Malaysia and beyond, such projects prove that livestock waste can be transformed into a profitable, sustainable business model. With decades of expertise, RICHI stands ready to provide turnkey solutions—from feasibility studies and equipment supply to installation and after-sales service—tailored to the unique conditions of each country.