10,000 Tons/Year Chicken Manure Organic Fertilizer Production Line: Comprehensive Plan

1.Solution Introduction

Driven by sustainable development and the market demand for green agriculture, countries are increasingly using chicken and cow manure as high-quality organic raw materials to produce organic fertilizers rich in nutrients such as nitrogen, phosphorus, and potassium . Converting chicken manure into organic fertilizer not only recycles farm waste but also generates significant economic benefits. The project proposal for a 10,000-ton annual chicken manure organic fertilizer production line focuses on the use of a tooth-pumped granulator for granulation to meet market demand for high-quality organic fertilizer.

2. Planning of the production line of chicken manure organic fertilizer with an annual output of 10,000 tons

(1) Production capacity target
Assuming 300 working days per year, to achieve an annual production target of 10,000 tons, approximately 33 tons of organic fertilizer must be produced daily. Equipment selection and configuration for each production link are designed around this production capacity requirement, ensuring stable and continuous operation of the production line and avoiding capacity bottlenecks. Of course, if the annual production target is 10,000 tons, a daily output of 50 tons and 200 working days per year is also feasible. The work plan will be based on actual requirements.
(2) Design principles
1.High efficiency : Use advanced production technology and equipment to optimize the process flow, reduce time loss in the production process, and improve overall production efficiency.
2.Environmental protection : We attach great importance to environmental protection issues, are equipped with complete environmental protection facilities, and effectively treat the waste gas, waste water and waste residue generated during the production process to achieve standard emissions in compliance with national environmental protection standards.
3.Energy saving : Select energy-saving equipment, reasonably design equipment operating parameters, make full use of energy, reduce energy consumption, and reduce production costs.
4.Flexibility and scalability : Considering future market demands and the needs of enterprise development, the production line is designed with flexibility and scalability in mind. Production processes can be adjusted based on actual conditions, facilitating the addition of equipment, capacity increases, or technological upgrades.

(Production process)

3. Production process

(1) Preprocessing stage

1.Crushing and Screening : Chicken manure is often contaminated with debris such as feathers, stones, and plastic, and the raw material particles are large, making them unsuitable for subsequent fermentation and processing. Therefore, a crushing and screening machine is first used to process the chicken manure. This equipment crushes the manure to a suitable particle size of 3-5 cm while simultaneously removing impurities through a screening device. Its processing capacity should reach 5-8 tons per hour to meet the overall production capacity requirements of the production line. The blades inside the machine are made of wear-resistant material, sharp and durable, and can effectively withstand the impact of hard impurities in the chicken manure. The screening mesh aperture can be adjusted according to actual needs to ensure the stability of the pretreatment effect.
2.Mixing and agitation : To adjust the carbon-nitrogen ratio of chicken manure and make it more suitable for microbial fermentation, an appropriate amount of auxiliary materials such as straw and sawdust is added. A twin-shaft paddle mixer is used for mixing. Its powerful agitating blades ensure thorough and even mixing of the chicken manure and auxiliary materials. This mixer boasts high mixing uniformity (coefficient of variation ≤ 5%), a short mixing time of only 3-5 minutes per batch, and a processing capacity of 6-10 tons per hour. This ensures a more complete reaction of the materials during subsequent fermentation, improving fermentation efficiency and fertilizer quality.

(2) Fermentation stage

1.Tank fermentation : Tank fermentation is a common and effective method for large-scale chicken manure treatment. The length of the fermentation tank is designed based on site conditions and production capacity, generally ranging from 30 to 50 meters, with a width of 2 to 3 meters and a depth of 1.5 to 2 meters. A trough-type turner is installed, which moves back and forth along the fermentation tank, regularly turning the material. The turner must have a turning capacity of 80 to 100 cubic meters per hour. This turning promotes oxygen circulation throughout the material, accelerates the fermentation process, and evenly distributes temperature and humidity. Under favorable fermentation conditions, the fermentation cycle can be shortened to 15 to 20 days, achieving harmless treatment of the chicken manure and sufficient decomposition of organic matter.
2.Intelligent Control : To ensure precise fermentation results, the fermentation process is equipped with an intelligent control system. This system uses multiple sensors, including temperature, humidity, and oxygen content, to monitor various parameters within the fermentation tank in real time. It automatically controls the operating frequency of the turner and the start and stop of ventilation equipment within preset parameter ranges. This precisely controls the fermentation temperature within the optimal range of 55-65°C, creating a suitable environment for microbial growth and reproduction, improving fermentation efficiency and ensuring the stability of fertilizer quality.

(3) Post-processing stage

1.Crushing : After fermentation and composting, the particle size and texture of chicken manure organic fertilizer are still uneven, requiring further crushing and refinement for the subsequent granulation process. A twin-shaft pulverizer is used, featuring a large crushing ratio and high production efficiency. It can crush materials to a particle size of 1-2mm, with an hourly processing capacity of 8-12 tons, meeting the needs of large-scale production and providing suitable raw materials for the agitator granulator.
2.Granulation (agitator granulator) : The agitator granulator is the core granulation equipment of this production line and has many advantages. It has a wide range of material adaptability and can directly process wet materials with a moisture content of 20%-30%. The requirements for raw material particle size are relatively loose (particle size ≤5mm is sufficient), and no additional complex crushing process is required. By adjusting parameters such as the equipment's rotational speed, granulation time, and screen aperture, it is possible to produce granules with high strength and good sphericity to meet the needs of different markets for organic fertilizer granules. In terms of operational economy, compared with traditional granulation equipment, the agitator granulator has low unit power and a more economical cost per ton of material processing, making it particularly suitable for small and medium-sized production lines with an annual output of 10,000 tons. At the same time, its closed stirring chamber design effectively reduces dust and noise pollution, meeting the requirements of environmentally friendly production. During the granulation process, the material enters the rotating cylinder, and the agitator teeth vigorously stir, shear and mix the material through high-speed rotation, so that the material is evenly distributed and initially agglomerated; under the mechanical force of the agitator teeth, the wet material is squeezed and kneaded, gradually forming tiny particles ("nuclei"), and the particles are further combined by capillary force and mechanical pressure; as the cylinder rotates, the particles roll along the cylinder wall under the action of centrifugal force, and fine powder continues to adhere to the outer layer, and the particles gradually increase in size; the formed particles are separated by the screen at the discharge port, and the particles that are too small or too large are screened and returned for re-granulation to ensure the uniformity and quality of the finished particles.
3.Drying : Granulated organic fertilizer granules contain a certain amount of moisture and require drying to reduce the moisture content and improve storage stability. A drum dryer utilizes hot air circulation to rapidly evaporate the moisture from the material, reducing the moisture content to below 15%. The dryer's processing capacity must match the production capacity of the agitator granulator to ensure smooth operation of the production line. To improve energy efficiency, consider adding a waste heat recovery device to the dryer's exhaust system to recycle some of the heat for other uses, such as preheating raw materials, thereby reducing energy consumption and production costs.
4.Cooling : The pellets are hot after drying and require cooling for storage and transportation. A cooler uses forced air cooling to quickly lower the pellet temperature to near ambient temperature, preventing agglomeration and deterioration during storage due to high temperatures, thereby ensuring product quality. The cooler's processing capacity must also be compatible with the dryer and pelletizer to ensure overall coordination of the production line.
5.Screening : After drying and cooling, the granules are screened to remove unqualified large particles and fine powder, ensuring a uniform particle size in the finished product. A vibrating screener, with its high screening efficiency, can increase the qualified product rate to over 95%. Large particles that are screened out are returned to the grinder for further crushing, while fine powder is re-entered into the granulation process, enabling material recycling and reducing waste.
6.Coating (Optional) : To further enhance the organic fertilizer's moisture and caking resistance and extend its shelf life, a coating machine can be configured based on market demand and product positioning. This machine evenly coats the surface of the granules with a protective film and can also add functional coatings, such as trace elements and beneficial microorganisms, as needed, to enhance the product's added value and market competitiveness.
7.Automatic Packaging : Utilizing a combination of a quantitative packaging scale and an automatic bag sewing machine, we achieve precise metering and rapid packaging of organic fertilizer. Packaging sizes can be flexibly adjusted to meet market demand, such as 5kg, 10kg, 25kg, and 50kg. The packaging equipment can process 800-1200 bags per hour, significantly reducing labor costs and improving production efficiency. Furthermore, the packaging process ensures a tight seal and clear, accurate labeling to facilitate storage, transportation, and sales.

4. Equipment selection and investment budget

(1) Equipment selection

(2) Investment budget

1. Equipment Investment : The total investment for the aforementioned equipment is approximately RMB 1.41 million to 2.12 million, with specific costs fluctuating depending on equipment brand, configuration, and market price fluctuations. Key equipment such as the agitator granulator, dryer, and fermentation equipment account for a significant portion of the total investment, comprising approximately 70% to 80%.

2. Other investments : In addition to equipment investment, the following costs must also be considered:

◦ Factory construction or leasing costs : If a new factory is built, the estimated investment is RMB 500,000 to 1,000,000, based on local construction costs and land prices; if a factory is leased, the annual rent is approximately RMB 100,000 to 200,000.

◦ Installation and commissioning costs : The installation and commissioning of the equipment requires professional and technical personnel, and the estimated cost is 100,000 to 150,000 yuan.

◦ Working capital : used for daily operations such as raw material procurement, employee salaries, water and electricity bills, and marketing promotion. The estimated working capital demand is 500,000 to 1 million yuan.

In summary, the total investment for building a 10,000-ton chicken manure organic fertilizer production line is between RMB 2.51 million and RMB 4.47 million (including the construction of a new plant). If leasing a plant is adopted, the total investment can be reduced by a corresponding amount for the plant construction portion.

5. Factory Planning

(1) Functional area division

1. Raw material storage area : This area is used to store raw materials such as chicken manure, straw, and sawdust. It should be located in a high, well-drained area within the factory. The ground should be hardened and protected with a rain shelter to prevent rainwater from washing away the raw materials and causing environmental pollution. The raw material storage area should also be located near pretreatment equipment to facilitate the transportation and handling of raw materials.

2. Fermentation area : Fermentation equipment such as fermentation tanks and trough turners should be placed in the fermentation area. The fermentation area should be kept at a certain distance from other areas to reduce the impact of odors generated during the fermentation process on the surrounding environment. At the same time, ensure that the fermentation area is well ventilated to facilitate the supply of oxygen and the discharge of waste gases during the fermentation process.

3. Production workshops : Centrally install various post-processing equipment, such as crushers, agitator granulators, dryers, coolers, screeners, film coating machines, and packaging machines. The production workshop should be rationally laid out according to the process flow to minimize material transport paths between equipment and improve production efficiency. Furthermore, the workshop should be equipped with necessary ventilation and dust removal facilities to improve the working environment.

4. Finished product warehouse : used to store packaged finished organic fertilizer. The warehouse should be kept dry and well ventilated, and the floor should be moisture-proof. The finished product warehouse should be close to the factory exit to facilitate product transportation and delivery.

5. Office area : Provides office space for management, technical personnel, and sales personnel. The office area should be relatively separate from the production area to create a quiet and comfortable working environment. At the same time, it should be equipped with necessary office facilities and communication equipment to ensure the smooth operation of daily business operations.

(2) Layout of environmental protection facilities

1. Waste gas treatment facilities : Biofilters, spray towers, and other waste gas treatment equipment are installed at the exhaust outlets of the fermentation area and production workshops. These effectively treat malodorous gases like ammonia and hydrogen sulfide generated during the fermentation process, as well as dust generated during the production process, to ensure that waste gas emissions meet emission standards. The treatment capacity of the waste gas treatment facilities must match the amount of waste gas generated by the production line. Regular maintenance and servicing of the equipment is required to ensure normal operation.

2. Wastewater treatment facilities : Build sedimentation tanks, grease traps, and other wastewater treatment facilities to collect and treat wastewater from equipment cleaning and floor washing processes. Once treated, the wastewater meets national discharge standards and can be used for irrigation of plant landscaping or discharged as required. A rainwater collection system should also be installed to collect and treat rainwater within the plant, ensuring the optimal use of water resources.

3. Solid Waste Storage Area : A dedicated solid waste storage area is set up to categorize and store solid waste generated during the production process, such as screening residues and discarded packaging materials. Recyclable solid waste, such as discarded packaging materials, is regularly recycled and processed. Non-recyclable solid waste is properly disposed of in accordance with environmental protection requirements to prevent environmental pollution.

Zhengzhou Tianci Heavy Industry Machinery Co., Ltd.

Established in 2000, Zhengzhou Tianci Heavy Industry Machinery Co., Ltd. is a prominent manufacturer in China, specializing in the design, production, and supply of high-quality fertilizer machinery. With over 24 years of production experience and 16 years of export expertise, we have built a reputation as a leading brand in the fertilizer machinery industry. Our commitment to innovation and quality has allowed us to become a trusted partner for fertilizer producers around the world.

Expertise in Fertilizer Machinery

We specialize in the research, development, and production of machinery for various types of fertilizers, including organic, compound, and blended fertilizers. Our product range is designed to meet the diverse needs of fertilizer manufacturers, offering robust and efficient solutions. With an annual production capacity ranging from 10,000 to 200,000 tons, we are capable of providing both small-scale and large-scale fertilizer production systems, ensuring flexibility for our customers.

Skilled Technical Team

Our success is driven by a highly skilled technical team, consisting of more than 50 experienced engineers and a dedicated R&D team of over 20 experts. Together, they continuously work to develop innovative, energy-efficient, and eco-friendly solutions for fertilizer production. By leveraging the latest technology and industry know-how, our team ensures that all our machines deliver superior performance and meet the highest quality standards.

Comprehensive Solutions and Services

At Tianci, we are committed to providing comprehensive solutions to meet our clients' specific needs. We offer customized designs and production lines tailored to the individual requirements of each customer. Our services go beyond just supplying machines—we also provide pre-sales consultations, on-site installations, and after-sales support to ensure seamless operations. Additionally, we offer professional training programs to help our clients optimize machine performance and extend their lifespan.

Global Reach and Future Vision

With over 50 countries served, Tianci Heavy Industry Machinery Co., Ltd. has established a strong global presence. We pride ourselves on our ability to deliver fast and reliable solutions, regardless of location, through efficient logistics and a dedicated customer service team.

Looking ahead, we remain committed to continuous innovation and the development of advanced fertilizer production equipment. We aim to provide high-quality machinery that supports the growth and success of fertilizer plants worldwide. Through our ongoing dedication to quality, sustainability, and customer satisfaction, we will continue to be a trusted partner in the global fertilizer industry.