Drum-to-Disc Combination Chicken Manure Organic Fertilizer Production Line
In commercial bio-organic fertilizer processing, achieving both high hourly throughput and tight pellet size distribution poses a major challenge.
Using a standalone drum granulator often yields wide particle size variation, while a standalone disc array struggles to process massive material volumes continuously. The Rotary Drum to Disc Granulation Process solves this by pairing primary high-volume drum agglomeration with secondary disc precision rounding, creating a high-efficiency processing line for commercial poultry manure plants.
1. Step-by-Step Processing Flow
The production line converts raw chicken dung into uniform, dense bio-organic fertilizer pellets:
[Raw Chicken Dung + Bulking Straw] ──► [In-Vessel Aerobic Fermenter]
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[Semi-Wet Material Crusher] ────────► [Horizontal Double Shaft Mixer]
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[Rotary Drum Granulator (Primary)] ──► [Disc Pan Granulator (Secondary Rounding)]
│
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[Rotary Dryer & Cooler Unit] ─────► [Rotary Screening Machine]
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[Rotary Coating Drum Machine] ────► [Automatic Packaging Scale]
- Aerobic Composting & Deodorization: Raw chicken dung (60%–70% moisture) is blended with crop residues (rice husks, straw dust) to adjust the C/N ratio (25–30:1) and moisture (50%–55%). An enclosed in-vessel vertical fermentation tank or hydraulic trough compost turner completes thermophilic decomposition (55°C–65°C) in 7–10 days, destroying pathogens and weed seeds.
- Pulverization & Homogeneous Blending: Aged compost passes through a screenless semi-wet material crusher to break sticky lumps into a fine 40–80 mesh baseline, followed by thorough blending with humic acid or functional bio-inoculants inside a horizontal double shaft mixer.
- Two-Stage Granulation (Core Stage):
Primary Agglomeration (Rotary Drum Granulator): Homogenized compost feeds first into the rotary drum granulator. Internal tumbling action under liquid moisture spraying rapidly forms dense base granules and handles high hourly material volume.
Secondary Precision Rounding (Disc Pan Granulator): The pre-formed pellets and residual fine powders transfer directly onto high-speed disc pan granulators. The disc tilt angle and centrifugal forces perform precision spherical rounding, catching ungranulated fines and standardizing pellet sizing to 2–5mm.
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Thermal Drying & Counter-Flow Cooling: Damp granules pass through a direct-fired rotary drum dryer to lower moisture below 12%, followed by a counter-flow cooler to lower pellet temperatures to ambient level.
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Screening, Coating, & Automated Bagging: A double-deck rotary screen isolates target 2–5mm granules. Oversized pellets are crushed and returned alongside fines to the granulation loop via recycle conveyors. Target granules pass through a rotary coating drum machine for anti-caking micro-oil treatment before dropping into an automatic quantitative packaging scale for commercial bagging.
2. Engineering Advantages of the Drum-to-Disc Process
| Operational Parameter | Standalone Granulation | Drum-to-Disc Combination Line |
| Single-Pass Granulation Yield | 75% – 85% | 92%+ (Significantly reduced recycling load) |
| Line Hourly Capacity | 1 – 3 Tons / Hour | 5 – 15+ Tons / Hour (High volume continuous line) |
| Pellet Uniformity & Shape | Wide size variation | High bulk density from drum + superior roundness from disc |
| Fine Powder Capture | Fines bypass to recycling loop | Disc rounding stage binds residual fines into active granules |
- Sequential Processing Efficiency: The primary rotary drum handles bulk density compaction and high material throughput without clogging. The secondary disc pan acts as a sizing and surface finisher, polishing rough granules into uniform spheres.
- Lower Recirculation OPEX: Capturing fine dust in the secondary disc phase reduces recycling loop volumes, cutting downstream rotary dryer thermal fuel consumption.
3. Core Equipment Lineup (10,000–50,000 Ton/Year Capacity)
- Fermentation System: Automatic Vertical In-Vessel Fermenter or Hydraulic Trough Compost Turner
- Preparation Machinery: High-Speed Semi-Wet Material Crusher + Horizontal Double Shaft Continuous Mixer
- Two-Stage Granulation Engine: Heavy-Duty Inclined Rotary Drum Granulator (Primary) + Adjustable-Tilt Disc Pan Granulators (Secondary Rounding)
- Thermal Handling: Direct-Fired Rotary Drum Dryer + Counter-Flow Rotary Drum Cooler (with Cyclone & Wet Scrubber Dust Collectors)
- Screening & Finishing: Rotary Drum Screener + Rotary Liquid Coating Machine + Double-Bucket Automatic Bagging Scale
Get Your Custom Poultry Manure Plant Blueprint
Designing an efficient drum-to-disc combination chicken manure fertilizer line requires matching raw waste moisture profiles with exact drum dimensions and disc angles. Contact our technical engineering team today to receive custom plant layout blueprints, machine specifications, and factory-direct equipment proposals!
