Stainless steel disc granulator

The stainless steel disc granulator is a powder granulation equipment specifically designed for laboratory environments.

name：Stainless steel disc granulator

use to：Powder granulation into balls

granulation rate：≥93％

Particle size：1-10mm

Processing customization：Yes

defects liability period：12 months

material quality：Carbon steel/stainless steel

Table of Contents

• What is a stainless steel disc granulator
• How Does This Small Machine Create Granules?
• What Are the Key Features for Fertilizer Research?
• Parameter table of Disc Granulator Machine
• Application scope of fertilizer granulator
• Successful case of disc granulator
• What are the types of organic fertilizer granulators available
• Frequently Asked Questions (FAQ)
• Organic fertilizer production line process
• Introduction to Fude Machinery Company

What is a stainless steel disc granulator

The laboratory disc granulator is a key piece of equipment in fields such as materials science, chemical engineering, agriculture, and pharmaceuticals. With its compact structure, intuitive operation, and uniform granulation, it is an ideal tool for researchers exploring granulation mechanisms and optimizing process parameters. Its design combines the core principles of industrial-grade equipment with the specific requirements of laboratory settings, providing a reliable solution for small-scale, high-precision granulation experiments.

Stainless steel granulator

Small granulator

Why Is a Lab Granulator So Important for R&D?

A lab granulator is essential because it lets you test and perfect your fertilizer formula with very low cost and risk. It gives you real-world data without wasting tons of raw material on a large production line.

Think about the cost of a failed test on a full-size plant. You would need to prepare a large batch of material, maybe several tons. You would run it through a large crusher ¹, mixer, and granulator. If the granulation fails, all that material and energy is wasted. A lab scale disc granulator completely changes this equation. It provides a safe and affordable environment for experimentation.

Here are the core reasons why it is a vital tool:

• Massive Cost Savings: Instead of using tons of material, you can run a valid test with just a few kilograms of powder. This saves you an enormous amount of money on raw materials, especially when you are testing multiple formula variations.
• Formula Optimization: Is 25% moisture better than 30%? Does your binder work as expected? This machine allows you to answer these questions quickly. You can test dozens of different recipes and additives to find the one that produces the strongest, most uniform granules.
• Risk-Free Experimentation: You can try new, innovative ideas without fear. If a test fails in the lab granulator, you simply clean the small pan and start over. There is no major downtime and no significant financial loss. This freedom is key to developing a superior product.

How Does This Small Machine Create Granules?

This small machine works on the exact same principle as our large, industrial-scale disc granulators. It uses a rotating pan and a controlled water spray to roll fine powder into perfect spheres through the “snowball” effect.

Even though it is small enough to fit on a workbench, this is not a toy. It is a serious piece of engineering that replicates the real-world granulation process. We designed it this way so your lab results are accurate and scalable.

• Material Preparation: You start with a small, prepared batch of your dry, powdered formula.
• Tumbling Action: You place the powder into the stainless steel pan. The machine is turned on, and the pan begins to rotate at a controlled speed and angle.
• Moisture Application: A fine mist of water or a liquid binder is gently sprayed onto the tumbling powder. This controlled moisture makes the particles sticky.
• Granule Growth: The sticky particles begin to clump together, forming tiny seeds. As these seeds roll and tumble in the pan, they continuously pick up more powder, growing in smooth, even layers.
• Collection: After a few minutes, you will have a batch of perfectly formed, uniform granules ready for analysis. The process is identical to what happens in our largest machines, just on a much smaller scale.

What Are the Key Features for Fertilizer Research?

The most important features for research are the stainless steel construction, the fully adjustable disc angle, and the variable speed control. These features give you total control over the experiment and ensure reliable, clean results.

When you are doing research, you need equipment that gives you control and does not contaminate your samples. We built this lab scale disc granulator with the specific needs of a researcher in mind.

Full Stainless Steel Construction

To ensure the integrity of your research, the entire pan and all contact parts are made from high-quality stainless steel.

• No Corrosion: It will not rust or react with your fertilizer formula, even if it contains acidic or corrosive components.
• No Contamination: The smooth surface prevents material from sticking. This makes it extremely easy to clean thoroughly between tests, so the results from one formula do not get mixed with the next.
• Durability: Stainless steel is strong and built to last, even with constant use in a busy lab.

Parameter table of Disc Granulator Machine

Application scope of fertilizer granulator

• Organic Fertilizer Development: In granulation experiments using raw materials such as livestock manure and fly ash, adjusting the disk angle (45-55°) and rotational speed (20-30 rpm) can optimize particle strength (≥5 N) and porosity (30-40%), providing data support for industrial-scale production.
• Chemical Raw Material Modification: After disc granulation of non-adhesive materials such as coal powder and limestone, particle density increases by 15-20%, improving combustion efficiency or reaction activity.
• Preparation of pharmaceutical intermediates: In drug crystal form research, by controlling the spray liquid volume (0.5–0.8 L/kg of powder) and disk rotational speed (15–25 rpm), uniformly sized spherical particles can be produced, enhancing dissolution rate.
• New material synthesis: In granulation tests prior to calcination of materials such as clay and bauxite, the disc granulator can produce spherical green bodies, reducing calcination cracks and improving material density.

Using materials

Operation and maintenance: Details determine success or failure.

Operating procedure

• Equipment Inspection: Ensure that screws are secure, lubrication system oil levels are normal, and electrical connections are reliable.
• Raw Material Pre-Treatment: Dry the powder to a moisture content of ≤15% and grind it to a particle size of ≤200 mesh.
• Parameter Settings: Set the inclination angle (default 50°), rotational speed (25 rpm), and spray liquid volume (0.6 L/kg) based on material characteristics.
• Startup and Operation: First start the motor, then slowly add material once the disk is running smoothly, while simultaneously activating the spray system.
• Particle Collection: Obtain qualified particles through vibrating screen separation (screen mesh size 8–20 mesh), with undersize material returned for reprocessing.

Maintenance points

• Daily cleaning: Clean up any residue in the tray after each test to prevent clogging of the spray nozzle.
• Regular lubrication: Check the gearbox oil level every 50 hours and change the lubricating oil every 200 hours.
• Part replacement: Replace the scraper when it wears down to less than 2 mm to prevent scratching the bottom of the tray.
• Calibration and debugging: Check the tilt adjustment device and speed sensor every quarter to ensure parameter accuracy.

Successful case of disc granulator

Sent to the United States

Sent to Canada

What are the types of organic fertilizer granulators available

Organic fertilizer granulator is a specialized equipment used to granulate various organic compounds after fermentation. It has a variety of types, including double roll granulator, disc granulator, toothed granulator, drum granulator, compound fertilizer granulator, and round granulator, each with its own characteristics, suitable for different production needs and scenarios.

Disc Pelletizer

Rotary Drum Granulator

Roller granulator

Round pelletizer

Stirring toothed granulator

Compound fertilizer granulato

Frequently Asked Questions (FAQ)

• Question 1: What is the capacity or batch size of this machine?
• This is strictly a laboratory machine. A typical batch size is between 1 to 5 kilograms of material. It is designed for testing and data collection, not for small-scale production for sale.
• Question 2: Can I use it for pure organic fertilizer?
• Yes, absolutely. It is perfect for testing the granulation of finely powdered organic materials like compost, manure, and bio-solids. The key is that the material must first be properly composted with a compost turner ⁴ and powdered.
• Question 3: Is it difficult to operate?
• Not at all. The machine is very intuitive. After a short training period, a lab technician can easily operate it and adjust the key parameters to run tests. Its simplicity is one of its main advantages.
• Question 4: What is the difference between this and a lab-scale roller granulator?
• This machine uses wet granulation, which is ideal for organic materials and requires a dryer. A lab-scale double roller granulator ⁵ would use dry granulation, compacting dry powder under pressure, which is better for many chemical fertilizers and requires no heat. We can help you choose the right testing equipment for your specific material.

Organic fertilizer production line process

The organic fertilizer production line is a production system that integrates the steps of raw material collection, pretreatment, fermentation, granulation, drying, screening, packaging, etc. It can convert organic waste such as aquaculture waste, crop straw, and food processing waste into organic fertilizers rich in nutrients for agricultural production.

Laboratory disc granulators have become indispensable tools in the field of materials research and development thanks to their scientific working principles, flexible structural design, and wide range of applications. By precisely controlling granulation parameters, researchers can gain a deeper understanding of the mechanisms of nucleation, growth, and fragmentation of materials, providing reliable technical support for industrial production.

Introduction to Fude Machinery Company

The production equipment includes: fermentation raking machine, dryer, granulator, crusher, mixer, round throwing machine, organic fertilizer production line, etc. The company will continue to adhere to the business philosophy of “quality first, customer first” and provide higher quality metal equipment solutions for global customers.
Since its establishment in 2015, Fude Machinery has been committed to providing high-quality and high-performance metal equipment solutions to global customers. With advanced production technology, strict quality control, and continuous innovative research and development capabilities, we have received customer satisfaction praise.