The Russian client acquired a disk granulator for granular fertilizers.

Russia, large agricultural country, has rich reserves of raw materials for mineral fertilizers, such as potassium and apatite. Our client runs a mineral fertilizer company. However, the company faced such problems, low adaptability of equipment, insufficient production capacity and unstable product quality. The company is faced with a dilemma: “inability to accept orders and deterioration of the product’s reputation”. At the same time, equipment often breaks down, and maintenance costs remain high.

In an effort to modernize your equipment, they turned to us for help. After purchasing our custom disk granulator for mineral fertilizers and its introduction into production, we have finally achieved a double breakthrough in productivity and production quality. Take back the initiative in the market. Are you also worried about such problems?, such as reduced production and high equipment maintenance costs? Contact us, and we will help you solve this problem.

The Russian customer ultimately chose disc granulator for the production of mineral fertilizers. The key factor was its adaptability in three key parameters: raw material compatibility, cost control and quality of finished products. Our disc granulator accurately solves the company's production problems and fully meets customers' needs.

Raw material: Main raw materials (potassium and apatite), used by a Russian customer for the production of mineral fertilizers, has high moisture absorption and hardness. The special design of the disc granulator solves these problems. The disc granulator uses variable frequency motor to adjust the speed (potassium: 18–22 rpm, apatite: 22–25 rpm), which allows you to quickly change the recipe without replacing equipment. This increases equipment utilization to 95%, eliminating the need for excess investment in “one machine for one raw material”.

Price: Previously, the Russian customer faced frequent equipment breakdowns, high energy consumption and high labor costs. Our disc granulator has a simple structure and requires 40% less investment, than an extrusion granulation line of the same capacity. Moreover, Custom-made wear liners extend wear part replacement cycles. Maintenance frequency reduced from 8 to 2 once a month. Variable speed motor (with Efficiency transmission ≥95%) and waste heat recovery system reduce overall operating costs for 15%.

Finished product: The customer had previously lost orders due to “high rates of pellet breakage and uneven quality.”. Precise granulation control of the disc granulator ensures uniform, цельный внешний вид. Это значительно повышает качество готового продукта. Конструкция «округлительная машина + возврат барабанного сита» позволила повысить процент годности готовой продукции с 75% to 92%. Регулируя дозировку распыляющей жидкости (с точностью ±0,1%) и скорость вращения диска. The strength of apatite fertilizer granules can be stabilized at 2.0–2.5 N. The percentage of destruction during transportation can be reduced with 10% to less 3%.

В связи с высокими требованиями к объёмам производства заказчик в конечном итоге приобрёл два дисковых гранулятора: один для производства калийных удобрений, and the other for the production of apatite fertilizer granules. We have optimized our disc granulator specifically for two main raw materials, used by our clients:

• Suitable lining material: The potassium fertilizer granulation unit is equipped with a rubber lining (excellent surface elasticity and non-stick properties). The apatite granulation plant uses stainless steel lining 304 (wear resistance coefficient in 3 times higher, than carbon steel). In this case, the edge of the disk is thickened to 12 mm, чтобы выдерживать воздействие высокотвердых материалов.

• Преобразование частоты + точное распыление: оснащено мощным двигателем с преобразователем частоты мощностью 30 kW. Скорость плавно регулируется в диапазоне 12–28 об/мин (18–22 об/мин для грануляции поташа во избежание прилипания; 22–25 об/мин для грануляции апатита для повышения эффективности формования). Equipped with a ring spray system, controlled by PLC, the dosage error of the sprayed liquid is ±0.1%. Considering, that potassium salt easily absorbs moisture, специально для наших российских клиентов мы добавили модуль «низкотемпературного предварительного нагрева и отпуска» (50°С). Уменьшите влажность сырья до 12–15 %, to further reduce sticking.

If you also have problems with granulation, you can send raw materials (10-20 kg) to our factory. Мы проведем бесплатное испытание грануляции на нашем предприятии. Запишите для себя весь процесс грануляции (скорость формования, однородность частиц, параметры работы оборудования). We also provide you with particle samples and strength/uniformity test reports, to help you intuitively understand the suitability of your equipment. На основании результатов испытаний, а также характеристик Вашего сырья, требований к производственной мощности и размерам участка мы составим схему расположения оборудования. And clearly indicate the lining material, engine power, auxiliary equipment (such as a crusher, bolt) and other configurations. Prices are clearly stated, no hidden fees.

If you encounter such problems, as rapid wear and tear of equipment, severe pellet clumping or poor performance. Or are you planning to purchase equipment?, For example, mineral fertilizer granules production line or disk granulator for mineral fertilizers, Contact us. Click the "Consult" button below or leave a message "Test Machine + Your type of raw material", and our technical consultant will contact you within 1 hours. Solve your mineral fertilizer granulation problems with targeted services!

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