Organic fertilizer dry granulation, double roller machine can?

A double roller extrusion granulator helps because it uses dry materials. It does not need drying steps. This saves energy and money. It makes strong, dense granules fast.

Table of Contents

• Double Roller Extrusion Granulator: What Is It? Why Dry Granulation?
• Why Choose Double Roller Granulation? What Are the Main Benefits?
• My Material Is Wet and Sticky. Can a Double Roller Machine Handle It? What Materials Work?
• How Does a Double Roller Machine Work? How Does It Make Dense Granules?
• Double Roller Machines: What Are Success Cases in Organic Fertilizer, Compound Fertilizer, Chemical, Sludge?

Double Roller Extrusion Granulator: What Is It? Why Dry Granulation?

A double roller machine uses pressure, not water or heat. It presses powder into shapes. It works on dry or low-moisture materials. That is why it does “dry” granulation.

This machine is a type of press. It has two rollers. These rollers turn towards each other. Material goes between the rollers. The rollers have special shapes on their surface. These shapes can be like pillows or strips.

When the material goes between the rollers, the rollers press it hard. This pressure makes the powder stick together. It forms a solid sheet or strip. This happens without adding liquid. It also happens without heating the material. That is why we call it “dry” granulation.

It handles materials that have low moisture content. Many organic materials can be dried or pre-treated to low moisture. Then they can go into this machine. This avoids the big drying step. Drying needs a lot of energy. So, dry granulation saves energy. This makes your process cheaper.

How the Rollers Work

• Two Rollers: The machine has two main rollers. They are strong metal rollers. They turn in opposite directions.
• Surface Shapes: The rollers have patterns. These patterns are pockets or grooves. The material is pushed into these shapes. The shapes decide the granule size or shape after crushing.
• High Pressure: The rollers are set very close. They apply high pressure. This pressure squeezes the air out. It makes the powder particles come together.

Why “Dry” Granulation?

This method works on powders or materials with low moisture. Low moisture means less than 20%. Some materials need less than 10%.

• No Water Added: Wet granulation adds water or binder liquid. This method does not add much or any.
• No Drying Needed: Because you use dry material, you do not need a dryer after granulation. This is a big cost saving. Dryers use a lot of fuel or electricity.
• Energy Efficient: Not needing a dryer makes the process very energy efficient.

Wet vs. Dry Granulation Basics

Here is a simple look at the difference:

Why Choose Double Roller Granulation? What Are the Main Benefits?

You have different choices for making fertilizer granules. You can use disc granulators. You can use drum granulators. These are wet methods. They need water. Then they need drying. A double roller machine is different. It uses pressure to make granules.

This pressure method has strong advantages for certain materials and goals. The biggest advantage is the energy saving. Drying is expensive. It uses a lot of heat. The double roller machine skips this step. It makes granules directly from powder or low-moisture material. This cuts your fuel bill. It also makes the process shorter.

You need fewer machines. This lowers your investment cost. The granules this machine makes are also very dense. The high pressure pushes the particles very close. Dense granules are strong. They do not break easily during transport. They do not turn back into powder easily.

This means less product loss. It also means the granules dissolve slower in the soil. This can help plants use nutrients better over time. The machine can handle many kinds of powders. It works for single materials or mixed materials.

My Material Is Wet and Sticky. Can a Double Roller Machine Handle It? What Materials Work?

Double roller machines work best with low moisture (<20%) and lower stickiness. But we can customize. We test your materials. It suits organic waste, manure, sludge, some chemicals.

Suitable Materials

This machine works for many things:

• Composted Organic Materials: Animal manure (chicken, cow, pig, etc.), mushroom residue, straw compost, food waste compost. These are often dry after composting.
• Sewage Sludge: Dried municipal or industrial sludge. This needs to be dried first.
• Industrial Waste: Some factory waste materials that are powdery or can be dried.
• Mineral Powders: Phosphate rock powder, gypsum powder, clay.
• Chemical Fertilizers: Ammonium chloride, potassium sulfate, some NPK blends.
• Other Powders: Some animal feeds, catalyst carriers, salt.

How Does a Double Roller Machine Work? How Does It Make Dense Granules?

You see the machine. How does it do the magic? Let me explain the process step-by-step.

The machine feeds powder between two rotating rollers. These rollers have pockets. High pressure forces the powder into the pockets. This makes strong, dense sheets or shapes. A crushing step breaks these into granules.

The Process Steps

• FeedingMaterial enters the hopper. A screw feeder pushes material into the gap between the rollers. This keeps material supply steady.
• Compaction (Rolling)The two rollers turn towards each other. They pull the material in. They apply very high pressure as the material passes through the small gap (nip). The material is pressed into the roller pockets. This forms a solid sheet or strip.
• Shaping and CrushingThe solid sheet comes out. It goes to a unit that breaks it apart. This unit usually has rotating blades or a breaking mechanism. It breaks the sheet into individual granules. The size of the pockets on the rollers and the crushing method determine the granule shape and size.
• Sieving (Optional but common)The granules go through a screen. Granules of the correct size pass through. Too big or too small granules are sent back. Big ones go back to the crusher. Small ones go back to the feeder.

This simple process makes very dense granules. This is different from wet methods that rely on drying and crystallization or binders to form bonds.

Double Roller Machines: What Are Success Cases in Organic Fertilizer, Compound Fertilizer, Chemical, Sludge?

You wonder if this works in real life. Is it proven? Let me share some examples.

Yes, this machine is used in many industries. It is a proven technology. In the organic fertilizer industry, large farms and fertilizer makers use it. They take composted animal manure, chicken manure, or other organic waste. The compost is often dry enough after the composting process.

They put the compost powder into the double roller granulator. The machine makes granules. These organic granules are easy to bag and sell. In the compound fertilizer industry, this machine is also used. It makes NPK fertilizers. It can granulate mixtures of different chemical powders.

For example, it can make granular fertilizers from ammonium chloride, potassium sulfate, or urea (with specific handling). It makes uniform granules from dry blends. This is efficient for many fertilizer mixes. The chemical industry uses this machine for many different powders.

It can granulate catalysts, pigments, mineral powders, and more. It is good for materials that react with water. It is also good for materials that are sensitive to heat. It makes a dust-free product. This is important for safety and handling. Dried sewage sludge is a big problem for cities.

It needs treatment. Drying it makes it a powder. This powder can be granulated using a double roller machine. This turns a waste product into a useful granular material. This material can be used as soil improver. It saves a lot of money for cities and treatment plants.

Application Examples

• Organic Fertilizer Production
  • Materials: Composted animal manure (cow, chicken, pig), mushroom residue, straw compost, food waste compost.
  • Benefit: Makes dry compost into marketable granules. No damage to microbes. Saves drying cost.
• Compound Fertilizer Production
  • Materials: Blended NPK powders, ammonium chloride, potassium sulfate, urea blends (specific types).
  • Benefit: Granulates dry powder mixes. Makes uniform, strong NPK granules. Efficient for many formulations.
• Chemical Industry
  • Materials: Many chemical powders, catalysts, mineral powders, pigments.
  • Benefit: Granulates materials sensitive to water or heat. Creates dust-free product. Makes materials easy to handle.
• Sludge Treatment
  • Materials: Dried municipal or industrial sewage sludge.
  • Benefit: Turns dried sludge powder into granules. Saves significant energy by not needing a post-granulation dryer. Makes a usable product from waste.

These examples show this machine works. It solves problems in different areas. It helps businesses make good granules.

Double roller extrusion is good for dry granulation. It saves energy and makes quality granules. It helps you profit from your materials.