Pig Manure Organic Fertilizer Production Line: Complete Turnkey Plant from Pre-Treatment to Packing

Project Overview

Agriculture — a pig farm operations group based in Southeast Asia commissioned a turnkey organic fertilizer plant to convert pig manure and rice husk into high-quality granular fertilizer. The line was designed for an initial capacity of 5–8 tons per hour, with future expansion capability up to 10 t/h. Shenghong Heavy Industry supplied the complete production line including pre-treatment, deep fermentation, disc pan granulation, drying, cooling, screening, coating and automatic packing.

Key Challenges

The client faced three core issues:

• Fibrous raw material — pig manure mixed with straw and rice husk contains high fiber content that makes conventional rotary drum granulators inefficient (low ball forming rate).
• Nitrogen-rich feedstock — fermented pig manure has nitrogen content above 8%, which causes wall-sticking problems on spiral-tooth granulators.
• Bio-hazardous wastewater — the pig farm needed a system that could handle wet manure directly without extensive pre-drying, reducing energy consumption and disease transmission risk.

Complete Plant Process Flow

The Shenghong turnkey line comprises the following stages:

1. Pre-treatment stage: Fresh pig manure is dewatered via an SHLX series screw press dewatering machine (typically SHLX280 or SHLX300) to reduce moisture from ~80% to 30-40%. Rice husks and straw are crushed separately and screened to uniform particle size.
2. Formulation mixing: Dewatered manure, crushed rice husk, NPK additives and commercial microbes are batched and thoroughly mixed in a SH600x1200 or SH700x1500 horizontal mixer (spiral ribbon type) to achieve the target formula.
3. Deep fermentation (in-vessel): The mixed material enters a fermentation tank where temperature reaches 60-70 °C over 7-10 days, completing pathogen elimination and odor reduction.
4. Disc pan granulation: Fermented material enters the SHQ series Disc Pan Granulator (SHQ-20 or SHQ-25). Powder rises along the rotating arc disc while water is sprayed; particles adhere into seed cores, grow layer-by-layer into round balls, and overflow at the disc edge. Disc angle is set to 42° for optimal rolling path.
5. Rotary drying: Wet granules (moisture ~35%) pass through a SHG8800 or SHG10100 rotary dryer, reducing moisture to below 15% and hardening the pellets.
6. Rotary cooling: Hot dried granules are cooled to ambient temperature by counter-flow air in a cooler drum.
7. Sieving: Oversize granules are crushed and returned; undersize fines are recycled back to the disc granulator inlet via a 1.2x4.0 or 1.5x5.0 rotary screener.
8. Coating: A thin anti-caking or nutrient film is applied in a 1000x3000 or 1200x4000 drum coater.
9. Packing: Finished granules are weighed and bagged by a BLD-K50/S automatic packer (25 kg/bag).

Main Equipment Configuration

Why the Disc Pan Granulator?

For pig manure organic fertilizer, the disc pan granulator offers several advantages over alternatives:

• High finished-product rate — typically 93-97%, far above the ~60% of drum granulators for fibrous materials.
• No wall-sticking — unlike spiral-tooth machines, the smooth glass-fibre reinforced plastic disc lining resists adhesion of nitrogen-rich, moist material.
• Rounded, uniform granules — the tumbling action produces smooth spherical pellets 2-6 mm in diameter, ideal for mechanical spreading.
• Low energy cost — no pre-drying required; wet material feeds directly into the disc.
• Easy maintenance — simple structure with flexible belt drive and hardened main gear; base does not require anchor bolts.

Project Results

After installation and commissioning, the client achieved the following outcomes:

• Finished product rate: stabilized at 93-95% within the first week of operation.
• Granule quality: uniform round ball shape, diameter 2-5 mm, excellent spreadability in field trials.
• Odor reduction: deep fermentation eliminated >95% of original ammonia and methane odors.
• Revenue diversification: converted previously costly disposal of pig manure into a sellable organic fertilizer product at competitive price.

Plant Specification Snapshot

About This Solution

Every Shenghong production line is engineered to the client's raw material, site layout and budget. Whether you work with pig manure, chicken litter, cow dung, crop residues or industrial organic waste, our engineering team will design a customized line from fermentation through packing. Contact us with your target capacity and material profile, and we will prepare a detailed configuration proposal and quotation.