Complete Set 50,000 TPY Compound Fertilizer Line

The Engineered Solution: A Complete, Automated Production Line

To meet the client's need for stability and efficiency, we designed a robust, continuous Granulation Production Line centered on a Rotary Drum Granulator—the industry standard for consistent, high-volume output. The solution was a complete system encompassing every stage from raw material to bagged product.

Core Process & Equipment Configuration:

1. Raw Material Reception & Pre-Processing: The line begins with receiving bulk raw materials (Urea, DAP, MOP, fillers). A Dynamic Batching System with multiple hoppers and precision electronic scales ensures formula accuracy. Materials are then crushed by a Chain Crusher to achieve uniform particle size, critical for smooth granulation.

2. Mixing & Granulation: Pre-weighed materials are homogenized in a Horizontal Mixer. The conditioned powder is then conveyed to the heart of the line: the Rotary Drum Granulator. Here, a controlled steam spray initiates the agglomeration process, forming uniform fertilizer granules through a tumbling and layering action within the rotating drum.

3. Drying, Cooling & Screening: The "green" pellets from the granulator, containing residual moisture, are hardened in a Rotary Dryer using hot air. They are subsequently cooled in a Rotary Cooler to near ambient temperature, stabilizing the product. A Multi-deck Screening Machine separates on-spec granules from fines (recycled to the mixer) and oversized particles (crushed and recycled), ensuring a perfect final product size.

4. Coating & Packaging: To prevent caking, the on-spec granules pass through a Coating Drum where a protective layer is applied. Finally, the finished fertilizer is automatically weighed and bagged by a high-speed Automatic Packaging Scale and palletized for storage and shipment.

Key Features Addressing Stability & Efficiency

• High-Degree Automation: The entire process is controlled from a central PLC Control System. This minimizes manual intervention, reduces human error, and ensures consistent product quality and stable, continuous operation—directly addressing the client's need for a "stable" solution.

• Proven Drum Granulation Technology: The Rotary Drum Granulator was selected for its unparalleled reliability, ability to handle a wide range of formulations, and high production efficiency. Its continuous operation mode is ideal for achieving the 50,000 TPY capacity.

• Closed-Loop Recycling System: All off-spec materials (dust and crushed oversize) are automatically returned to the process. This maximizes raw material utilization, reduces waste, and lowers production costs, contributing directly to operational efficiency.

• Robust Construction for Harsh Environments: All equipment, from the Bucket Elevators to the Belt Conveyors, was built with heavy-duty materials and components suitable for continuous industrial duty, ensuring long-term reliability with minimal downtime.

Project Execution & Commissioning

The project was executed as a full Turnkey Fertilizer Plant solution. Our scope included detailed plant layout design, supply of all Fertilizer Manufacturing Equipment, installation supervision, comprehensive operator training, and final commissioning. Despite logistical challenges, the line was successfully commissioned in April 2021 as planned. Our engineers worked on-site with the client's team to fine-tune the process, optimize formulations, and ensure the system met all performance guarantees for output and quality.

Results & Impact: Beyond Machinery

The successful launch of this Compound Fertilizer Line delivered transformative results:

• Capacity & Business Expansion: The client's production capacity increased exponentially, enabling them to fulfill larger contracts and expand into new regional markets.

• Product Quality & Diversification: The new line produces dense, spherical granules with excellent nutrient uniformity, allowing the client to offer a wider portfolio of premium NPK blends tailored to local crops.

• Supply Chain Security & Profitability: By becoming a manufacturer, the client gained control over their core product supply, reduced dependency on imports, and captured greater profit margins across the value chain.

Conclusion: A Partnership for Growth

This 50,000 TPY project in Algeria stands as a testament to how the right Fertilizer Equipment Solution can catalyze business transformation. By providing a complete, automated, and reliable Granulation Production Line, we enabled a trusted sales company to become a leading producer. The project underscores our commitment to delivering not just equipment, but Complete Set of Compound Fertilizer Line Equipment packages that drive productivity, profitability, and sustainable growth for our partners in the global agriculture industry.