Intensive Mixer as Granulator for Organic/Compound Fertilizer Production

Solution

Fertilizer

AKW provides a wide range of system solutions for the production of fertilizers and soil conditioners. It completes the mixing, granulation and coating processes in one intensive mixer. The highlights of AKW preparation technology: Mixing, granulating and coating in a single machine Optimum distribution of trace elements and additives Use of secondary raw materials in the form of filter cakes, sludges and nutrient salt solutions Environmentally friendly granulating process, no escaping fine dust or aerosol Systematic production of long-term fertilizers

Production process

In the modern fertilizer production industry, efficient, uniform, and cost-effective granulation is the core requirement for improving product quality and market competitiveness. Our AKW company’s Intensive Mixer as Granulator integrates mixing and granulation functions into one, breaking the limitations of traditional separate equipment, and becoming the preferred equipment for large, medium and small fertilizer factories. AKW company is a leader in mineral processing and environmental protection technology, and our intensive mixer granulator is designed based on advanced co-current differential speed and three-dimensional mixing principles, realizing high-efficiency granulation while ensuring the uniformity and stability of fertilizer particles, perfectly matching the production needs of compound fertilizer, organic fertilizer, bio-organic fertilizer and other products.

What is Intensive Mixer as Granulator for Fertilizer?

The AKW company’s Intensive Mixer as Granulator is a professional fertilizer granulation equipment that combines intensive mixing and high-efficiency granulation in a single machine. What makes it stand out is the core highlight of AKW preparation technology: mixing, granulating and coating in a single machine, which further optimizes the production process and eliminates the need for additional equipment. Different from the traditional granulation mode that requires separate mixing and granulation equipment, AKW’s intensive mixer granulator completes the two core processes of material mixing and granulation in one operation, which not only saves production space but also reduces energy consumption and labor costs. With decades of experience in process equipment research and development, AKW company has specially optimized this equipment for fertilizer raw materials; it can achieve optimum distribution of trace elements and additives, and can efficiently use secondary raw materials in the form of filter cakes, sludges and nutrient salt solutions, realizing resource reuse. Whether it is dry powder materials, semi-solid materials, or materials containing additives, it can achieve efficient mixing and uniform granulation, ensuring that each fertilizer particle has consistent nutrient content and particle size. In addition, the equipment adopts an environmentally friendly granulating process, with no escaping fine dust or aerosol, fully complying with global environmental protection standards, and supporting systematic production of long-term fertilizers.

As a key equipment in the fertilizer production line, the intensive mixer as granulator is widely used in the production of compound fertilizer, organic fertilizer, bio-organic fertilizer, slow-release fertilizer, and other products. It is suitable for various raw material formulas, including urea, ammonium phosphate, potassium chloride, organic matter, microbial agents, etc., and can meet the granulation needs of different particle sizes (0.5-5mm) and different types of fertilizers, helping enterprises flexibly respond to market demand.

Core Advantages of Our Intensive Mixer as Granulator

1. Integrated Design, High Production Efficiency

The biggest advantage of AKW company’s Intensive Mixer as Granulator is the integrated design of mixing and granulation, which is closely linked to AKW’s core preparation technology—mixing, granulating and coating in a single machine, enabling one-stop completion of multiple key processes. The equipment is equipped with a three-dimensional dynamic rotating pan and a high-speed rotating rotor at the centrifugal position. The mixing pan tilted at a specific angle transports the material upward during rotation. When the material reaches a certain height, it falls under the action of gravity, forming rough mixing through horizontal and vertical movement; then the material rushes to the high-speed rotor at the eccentric position to perform high-intensity mixing and granulation, realizing fine mixing and granulation in one step. Adhering to AKW company’s consistent pursuit of high quality and efficiency, this equipment saves 30% of production time and 25% of energy consumption compared with traditional separate equipment, and the daily output can reach 5-50 tons, which is suitable for large-scale continuous production and small-batch customized production. Moreover, the equipment supports selective coating with hydrophobing agents and minerals, which can flexibly influence the duration of effectiveness, solubility and stability of the granulates, further expanding the application scope of the product.

2. Uniform Granulation, High Product Quality

Adopting advanced counter-current mixing and high-shear granulation technology, the intensive mixer as granulator ensures that the fertilizer raw materials are fully mixed, and the nutrients are evenly distributed in each particle. The rotor blades are designed in a blade shape with a special streamline, which can generate a strong shearing force to cut the material, making the prepared fertilizer particles round, uniform in size, high in strength, not easy to break and agglomerate, and the qualification rate of particles is as high as 95% or more. At the same time, the equipment can adjust the rotating speed of the mixing pan and the rotor according to the process requirements, realizing the staggered mixing process, and flexibly adjusting the particle size and hardness of the fertilizer to meet the different quality standards of the market.

3. Wide Adaptability, Strong Versatility

Our AKW company’s Intensive Mixer as Granulator is highly adaptable to fertilizer raw materials, which is fully reflected in AKW’s preparation technology advantages. It can be used for granulation of various raw materials such as organic fertilizer, compound fertilizer, bio-organic fertilizer, and slow-release fertilizer, and supports systematic production of long-term fertilizers. It can handle both dry powder materials and materials with a certain moisture content (15%-30%), and can efficiently utilize secondary raw materials in the form of filter cakes, sludges and nutrient salt solutions, helping enterprises reduce raw material costs and realize environmental protection and resource reuse. Whether it is granular, powdery, or pasty raw materials, it can achieve efficient granulation without adding a large amount of binder, reducing production costs and ensuring the environmental protection of the product—its environmentally friendly granulating process ensures no escaping fine dust or aerosol, protecting the production environment and operators. In addition, in line with AKW company’s concept of providing customized solutions, the equipment can be customized according to the actual production needs of customers, including production capacity, particle size range, and material of wearing parts, to meet the personalized needs of different enterprises. More importantly, it can help customers design products according to their own wishes, realizing flexible customization of fertilizer mixers.

4. Durable Structure, Easy Maintenance

The main body of the intensive mixer as granulator is made of high-quality carbon steel or stainless steel, which has strong corrosion resistance and wear resistance, and can withstand the long-term friction and corrosion of fertilizer raw materials. The key components such as the mixing pan, rotor, and scraper are made of wear-resistant alloy materials, which have a long service life and reduce the frequency of replacement of wearing parts. The equipment adopts a simple and reasonable structural design, with a humanized operation interface, easy operation and debugging. The detachable structure is convenient for cleaning and maintenance, reducing the labor intensity of operators and ensuring the stable operation of the equipment for a long time.

5. Energy Saving and Environmental Protection, Cost Reduction

In the design process, we pay attention to energy saving and environmental protection. The intensive mixer as granulator adopts an optimized motor and transmission system, which has high energy utilization rate and low noise (≤75dB), meeting the national environmental protection standards. The closed structure design prevents dust leakage during the production process, protects the production environment and the health of operators. At the same time, the integrated design reduces the number of equipment, saves the investment cost of equipment, and reduces the floor space of the production line. The one-step granulation process reduces the loss of raw materials, the material utilization rate is as high as 98%, and the comprehensive production cost is reduced by 20%-30% for enterprises.

Working Principle of Intensive Mixer as Granulator

The working principle of our Intensive Mixer as Granulator is based on the co-current differential speed principle and combined with three-dimensional mixing flow behavior, which subverts the traditional mixing and granulation mode. The specific working process is as follows:

Feeding Stage: The fertilizer raw materials (powdery, granular, or additive-containing materials) are evenly fed into the mixing chamber of the equipment through the feeding system, and the feeding speed can be adjusted according to the production capacity.
Mixing Stage: The mixing pan tilted at a specific angle rotates, transporting the material upward. When the material reaches a certain height, it falls under the action of gravity, forming macro mixing in the vertical direction. At the same time, the multi-functional scraper disrupts the material flow direction, preventing material accumulation on the wall and bottom, and assisting in thorough mixing.
Granulation Stage: The material after rough mixing is transported to the high-speed rotating rotor at the eccentric position with the rotation of the mixing pan. The rotor with blade-shaped blades generates strong shearing force to cut and stir the material, making the material form uniform particles under the action of extrusion and adhesion. The rotating direction of the mixing pan and the rotor can be set to the same direction or opposite direction according to the material characteristics to achieve the best granulation effect.
Discharging Stage: The prepared fertilizer particles are discharged through the discharge port, and then enter the next process (drying, cooling, screening) after being screened. The discharge process is smooth, without material residue, ensuring the continuity of production.

Application Scenarios of Intensive Mixer as Granulator

Our Intensive Mixer as Granulator is widely used in the fertilizer production industry, suitable for various scales of fertilizer enterprises and production scenarios:

Compound Fertilizer Production: Suitable for the granulation of nitrogen, phosphorus, potassium compound fertilizers, including granular compound fertilizer, slow-release compound fertilizer, and controlled-release compound fertilizer, ensuring uniform nutrient distribution and stable particle quality.
Organic Fertilizer Production: It can realize the granulation of organic fertilizer made from livestock and poultry manure, crop straw, kitchen waste, and other raw materials, solving the problem of difficult granulation of organic materials, and improving the utilization rate of organic waste.
Bio-organic Fertilizer Production: It is suitable for the granulation of bio-organic fertilizer containing microbial agents. The gentle mixing and granulation process can protect the activity of microbial agents, ensure the fertility effect of the fertilizer, and meet the requirements of green agriculture.
Small Batch Customized Production: For enterprises that need to produce multiple types and specifications of fertilizers, the equipment can quickly adjust parameters to realize the granulation of different formulas and particle sizes, improving the flexibility of production.
Why Choose Our Intensive Mixer as Granulator?
In the fierce market competition, choosing a high-quality AKW company’s Intensive Mixer as Granulator is the key to improving the core competitiveness of fertilizer enterprises. With a global business network , AKW company’s equipment has the following advantages that are unmatched by peers:
- Professional Customization: According to the customer's production capacity, raw material characteristics, and product requirements, we provide personalized customization solutions to ensure that the equipment perfectly matches the production needs. Specifically, we support customers to design their products according to their own wishes, including individual definition of grain size distribution, small grain size range (e.g. 0.2 – 2.0 mm) with high yield, optimization of granule shape and surface structure, coating with coloring agents, chalk and pigment blends, wetting with anti-caking agents and hydrophobing agents, use of odor-neutralizing minerals such as zeolites and adsorbents, influence over look and feel by rolling-in plant fibers, and reduction of dust content to a minimum—fully meeting the personalized customization needs of different customers.
- Advanced Technology: Integrating the world's advanced mixing and granulation technology, with independent research and development capabilities, the equipment performance is stable and reliable, and the technical level is in the leading position in the industry.
- Full Service: Provide one-stop services from equipment design, production, installation, commissioning to after-sales maintenance, with a professional technical team to solve various problems in the production process for customers in a timely manner.
- Cost-Effective: High production efficiency, low energy consumption, long service life, and low maintenance cost, helping enterprises reduce production costs and improve economic benefits.