Case Study: Chicken Manure Fertilizer Line with Drum & Pan Granulation in Russia

Establishing a high-capacity organic fertilizer processing facility in cold climates requires robust machinery and continuous, steady wet agglomeration technology. A leading agricultural producer in Russia recently partnered with Gofine to install a custom bio-organic fertilizer production line capable of converting wet poultry litter into high-density, uniform spherical pellets.

To solve the dual challenges of high moisture variability in raw chicken manure and high particle strength requirements for long-distance transit across Eurasia, Gofine engineered a hybrid rotary drum granulator + pan granulator combination processing system.

Project Overview & Russia Plant Requirements

• Raw Material Feedstock: Fresh Chicken Manure + Peat (as a moisture absorber) + Straw Dust

• Target Output Capacity: 5–8 Tons per Hour (TPH) finished fertilizer granules

• Finished Product Specification: 2–4 mm highly spherical bio-organic fertilizer pellets (95%+ sphericity rate)

• Core Technological Challenge: Raw chicken manure contains sticky fibers and variable moisture. Standard single-stage extrusion often leads to uneven sizing or high dust formation during harsh Russian winters.

The Dual-Granulation Solution: Rotary Drum + Disc Granulator Synergy

The standout engineering feature of this Russian plant is the sequential integration of a rotary drum granulator for primary agglomeration, followed by a disc granulator (pan granulator) for micro-shaping and sizing control.

[Fermented Chicken Manure] ➔ Fine Crusher ➔ Rotary Drum Granulator (Primary Micro-Pelletizing) ➔ Pan Granulator (Spherical Finishing) ➔ Rotary Dryer ➔ Cooler ➔ Screening ➔ Bagging

Phase 1: Primary Agglomeration in the Rotary Drum Granulator

The conditioned chicken manure compost feeds into a heavy-duty continuous rotary drum fertilizer granulator. As the drum rotates, high-pressure liquid mist (or bio-liquid) sprays over the rolling material bed. The gentle continuous tumbling action aggregates fine organic powders into initial, wet micro-pellet seeds without mechanical crushing.

Phase 2: Fine Spherical Finishing in the Pan Granulator

The pre-formed micro-pellets transfer directly into a specialized wet granulator pan granulator. The inclined rotating disc acts as a physical sizing classifier:

Micro-seeds roll continuously over the pan, gathering fine powder and building strong concentric layers.

The tilt angle (35°–55°) and variable drum speed ensure that only fully formed, dense 2–4 mm organic fertilizer spheres overflow the rim.

This two-stage setup increases total pelletization efficiency to over 95%, drastically reducing material recycling ratios.

Core Machinery List for the Russian Bio-Organic Fertilizer Line

To withstand sub-zero ambient factory conditions and heavy material abrasiveness, the complete line utilizes fortified, corrosion-resistant equipment:

• In-Vessel Compost Turner / Chain Plate Turner: Ensures rapid aerobic fermentation and odor control of wet chicken manure.

• Semi-Wet Material Crusher: High-speed twin-rotor crusher designed to break sticky, high-moisture compost lumps without clogging.

• Dynamic Horizontal Batching System: Precision multi-hopper dosing unit for mixing organic compost with trace minerals or NPK additives.

• Rotary Drum Granulator & Disc Granulator Combination: Dual-stage agglomeration section for maximum granule density.

• Rotary Drying Drum & Cooling Drum System: Heavy-duty thermal dryers equipped with stainless steel lifting flights to prevent internal sticking.

• Rotary Sizing Screen & Automatic Bagging Scale: Separates off-spec granules and seals finished pellets into moisture-proof 25–50 kg bags or 1-ton bulk sacks.

Operational Results & Client Feedback

Since commissioning in Russia, the plant has operated at full commercial capacity:

• Particle Durability: Pellets exhibit high crush strength (>25 N), resisting powdering during bulk rail transport across Russian distribution networks.

• Energy Savings: The high pelletization rate of the dual drum-and-pan setup reduces wet material recycling by 40%, lowering rotary dryer fuel consumption.

• Low Maintenance: Engineered stainless steel and rubber anti-stick drum liners eliminate internal buildup despite cold ambient operating environments.

Frequently Asked Questions

Q: Why combine a rotary drum granulator with a pan granulator for chicken manure?

A: A rotary drum granulator excels at high-throughput continuous mixing and initial seed formation, while a disc granulator provides precise size classification and rounding. Combining both yields high hourly capacity with smooth, dense spherical pellets.

Q: Can this chicken manure organic fertilizer line operate in low-temperature climates?

A: Yes. Gofine equips thermal insulation around drying drums, installs cold-weather synthetic lubricants in gearboxes, and uses anti-stick internal liners to maintain smooth material flow in winter environments.

Build Your Custom Organic Fertilizer Production Line with Gofine

Whether you are processing poultry manure, cattle dung, or agricultural residues, Gofine delivers customized chicken manure organic fertilizer production line designs engineered for your specific regional climate and capacity needs.

Contact our technical engineering team today for custom equipment layouts, ROI calculations, and direct factory pricing!