3-4T/H Poultry Manure Pellet Machine in Germany

Project background

The farm alliance originally adopted the traditional manure treatment method: the collected poultry manure was crushed by a chain crusher and then processed into powdered organic fertilizer by a dryer. However, this powdered fertilizer has many problems:

• Dust flying during transportation causes environmental pollution;
• Inconvenient application leads to increased labor costs;
• More importantly, nutrients are released too quickly, often causing nitrate leaching problems and facing penalties from the environmental protection department.

After market research, the cooperative decided to invest in fertilizer granulator machine to convert powdered manure into granular organic fertilizer that is more in line with the requirements of modern organic agriculture.

Customer needs

In the early stage of the poultry manure pellet machine in Germany project, the customer elaborated on their needs in detail.

1. First, granulation can significantly improve the physical properties of the product. Granular fertilizers produce almost no dust during transportation, which meets the requirements of the German Federal Emission Control Act.
2. Second, the slow-release characteristics of granular products can better match the growth needs of crops, reduce nutrient loss, and help them meet the nitrate emission standards stipulated in the German Fertilizer Ordinance.
3. In terms of production capacity, the customer requires the new equipment to be able to process 3.5-4 tons of pre-dried powdered manure per hour, which needs to be perfectly matched with the existing drying system. They particularly emphasized that the equipment must adapt to Germany's changing climate conditions and can still operate stably in low temperatures in winter.
4. In terms of product quality, the particles need to meet the standards of 4-6 mm in diameter, 10-15 mm in length, and a compressive strength of no less than 10 Newtons to meet the requirements of mechanized fertilization equipment.
5. Environmental compliance is the core consideration of the organic fertilizer production project. The noise during operation of the equipment must be controlled below 75 decibels, and the dust emission must not exceed 20 mg/m3. These indicators are directly related to whether the operation license of the local environmental protection department can be obtained.
6. In addition, the customer also hopes that the equipment can be integrated with their energy management system to monitor energy consumption data in real time to meet the energy efficiency requirements under the German Industry 4.0 standard.

Raw material used for poultry manure pellet machine in Germany

The raw materials processed by this project mainly come from laying hen and broiler manure from farms within the alliance. These raw materials undergo a strict pre-treatment process.

1. Fresh chicken poultry manure is first separated into solid and liquid by a screw press to reduce the moisture content from the original 70% to about 35%.
2. The material then enters a closed fermentation system and is treated for 72 hours under a precisely controlled environment of 55°C. In this process, pathogenic microorganisms are not only killed, but also organic matter is initially degraded.
3. The fermented material enters the customer's existing crushing and drying system. The chain crusher crushes the agglomerated feces to a particle size of 2-3 mm, and then the moisture content is further reduced to 12-14% through a fertilizer dryer.
4. In this process, the customer will add about 5% humic acid and 3% bentonite. The former is used to improve the cation exchange capacity of the fertilizer, and the latter is used as a natural binder to improve the subsequent granulation performance.

The customer plans to produce two specifications of granular products. Standard-grade organic fertilizer granules are mainly for field crop growers, requiring a total nutrient content (N+P2O5+K2O) of not less than 5% and an organic matter content of more than 60%. The other is high-end horticultural granules, which are specifically targeted at the home gardening market. In addition to higher appearance requirements, specific microbial agents need to be added. This type of product will be packaged in environmentally friendly paper bags and apply for EU EC 889/2008 organic certification.

technical advantages of poultry manure pellet machine in Germany

After a detailed comparison of the schemes, the customer finally chose RICHI's FZLH poultry chicken manure pellet machine. This equipment shows excellent technical characteristics in many aspects, which perfectly meets the strict requirements of the German market.

• The ring die of the equipment is made of special alloy steel. After carburizing and quenching, the surface hardness is extremely high, and the wear resistance is more than 1.5 times that of ordinary molds.
• The unique die hole design adopts a tapered structure. The larger diameter at the inlet end is convenient for high-fiber materials to enter, and the outlet end gradually shrinks to ensure the particle density. This design enables the equipment to easily handle difficult-to-form raw materials such as chicken manure.
• In terms of the transmission system, the RICHI poultry manure organic fertilizer pelletizer is equipped with heavy-duty bearings and a reinforced spindle. All lubrication points use a centralized automatic lubrication system to ensure reliability under continuous operation conditions.
• Particularly worth mentioning is the intelligent control system of the equipment, which can monitor key parameters such as the main motor load, bearing temperature and vibration in real time, and immediately alarm once an abnormality is found. This preventive maintenance function greatly reduces the risk of unexpected downtime.
• In response to Germany's strict environmental protection requirements, the equipment adopts a fully enclosed design, combined with a pulse dust removal system, so that the dust concentration in the working area is controlled below 10 mg/m3, which is far below the limit specified by the German TA Luft standard.
• In terms of noise control, by optimizing the gear transmission structure and installing a soundproof cover, the equipment operation noise is controlled at 72 decibels, which fully complies with German workplace safety regulations.

Project implementation and operation effect

The poultry manure pellet machine in Germany installation and commissioning process took three days. Our engineering team conducted a comprehensive assessment of the customer's existing production line, and especially adjusted the height and angle of the feeding and discharging system to ensure that the new equipment can be seamlessly integrated into the original system.

During the trial operation stage, we optimized key parameters such as the ring die compression ratio and the roller gap according to the customer's raw material characteristics to achieve the best performance of the equipment.

The operation data after production is satisfactory. Under the condition of 14% moisture content of the raw material, the equipment maintains a stable output of 3.8-4.2 tons per hour, and the particle forming rate reaches more than 97%. The compressive strength test result of the particles is 12-15 Newtons, which fully meets the requirements of mechanized fertilization. In terms of energy consumption, the electricity consumption per ton of product is controlled within 25 kWh, which is 15% lower than the customer's expectations.

The improvement of product quality has brought significant economic benefits. The selling price of granular organic fertilizer is 40% higher than the original powdered product, and the transportation cost is reduced by about 25% due to the increase in product density.

What makes customers more satisfied is that the effect of granular fertilizer is significantly improved after application. According to their tracking data, the nitrate leaching amount of farmland using granular fertilizer has been reduced by 35%, which helped them pass the inspection of the environmental protection department smoothly.

The successful implementation of this poultry manure pellet machine in Germany project has produced a demonstration effect in the field of organic agriculture in Germany. The granular organic fertilizer products processed by this project not only meet the needs within the alliance, but also begin to be sold to other organic farms. They particularly emphasize that the products meet the requirements of the German Circular Economy Law, which is very attractive in the German market with strong environmental awareness.

In the future, customers plan to further expand production capacity and consider developing special formula granular fertilizers for different crops. We will also continue to provide technical support, including regular repair services for ring molds and process optimization suggestions.

This case fully proves that advanced granulation technology not only solves the environmental problem of livestock and poultry manure treatment, but also creates significant economic value, providing a reliable solution for the sustainable development of organic agriculture in Germany.

If you are interested in this poultry manure pellet machine in Germany project, want to know more about the organic fertilizer production line and equipment, watch the operation video, feel free to contact RICHI MACHINERY!