Building a Livestock Manure Organic Fertilizer Production Line in East Java

LANE (Interviewer): Thank you for taking the time to speak with us. To start, could you briefly introduce your farm and why you chose to build a livestock manure organic fertilizer production line?

Operations Manager (East Java poultry farm): Thank you. We run a medium-sized poultry farm near Surabaya. We had two problems: growing costs to dispose of chicken manure, and poor soil fertility on nearby plots. We wanted a solution that turned waste into a product — so a livestock manure organic fertilizer production line made sense. It reduces waste, creates a new revenue stream, and supplies our own fields with organic fertilizer.

Why convert manure into organic fertilizer?

LANE: What convinced you that composting and granulation was the best route?

Operations Manager: Two things — speed and safety. With the right equipment we can complete aerobic composting in a few weeks rather than months, and high temperatures kill pathogens. Also, granulated fertilizer is easier to store and sell. We wanted a turnkey line that handles everything from raw manure to packed bags.

Project overview — scope & capacity

LANE: Tell us about the scale of the line LANE supplied.

Operations Manager: We chose a 3–5 t/h line — suitable for our waste volume and local market. LANE designed a livestock manure organic fertilizer production line that includes pre-treatment, aerobic fermentation, crushing & screening, granulation, drying & cooling, coating, and automatic packaging.

The production flow — step by step 

LANE: Could you walk us through the production flow and the key machines?

Operations Manager: Sure — here’s the flow LANE installed and we now operate daily:

  1. Raw material mixing (Horizontal / Double-shaft Mixer)
    Fresh chicken manure is mixed with rice husk and straw in a horizontal mixer to reach the proper C/N ratio and moisture. This improves aeration and fermentation.

  2. We use a crawler type compost turner for windrow composting. It moves over the windrows, turning and aerating the pile. With regular turning and controlled moisture, the pile reaches thermophilic temperatures (55–65°C) quickly.

  3. After primary fermentation, the material goes through a vertical shaft crusher to break clumps and improve uniformity before screening.

  4. A rotary drum screener separates fine compost from large pieces. Oversize is returned for re-crushing.

  5. For our product we use a stirring pin granulator for big-batch specialty pellets and a double roller granulator for dry, energy-efficient continuous output. Both machines form pellets suitable for sowing and packaging.

  6. Drying (Rotary Drum Dryer)
    Wet granules are dried in a rotary drum dryer until moisture is around 10–15%.

  7. Cooling (Rotary Drum Cooler)
    The dryer output is hot; the rotary drum cooler reduces temperature and increases pellet hardness.

  8. Coating (Rotary Coating Machine — optional)
    We use a rotary coating machine to apply a thin protective layer that reduces dust and improves shelf life.

  9. Packaging (Automatic Weighing & Bagging Machine)
    Finally, an automatic packing machine fills, seals and stacks 10–50 kg bags ready for sale.

Operation details & control systems

LANE: How automated is the line? How do you monitor quality?

Operations Manager: LANE installed a PLC control cabinet that centralizes dosing, mixing times, turning intervals, dryer temperature, and filling parameters. We also have temperature and moisture sensors in compost piles and torque sensors on granulators. This allowed us to standardize batches and reduce operator guesswork.

Challenges during setup and how they were solved

LANE: What were the main challenges during installation or early operation?

Operations Manager: Three things: odor control, moisture management, and operator training.

  • Odor: LANE recommended covers and a simple biofilter at the composting area. That cut complaints from neighbors.

  • Moisture: Food-waste and poultry manure have variable moisture. The horizontal mixer and dosing system helped us keep the right range.

  • Training: LANE’s on-site engineers trained our staff — after two weeks they could run daily checks and adjust parameters.

Results & benefits after commissioning

LANE: What improvements did you see after the line was running?

Operations Manager: The results were immediate and measurable:

  • Processing time for raw manure to mature compost fell from ~60 days to 18–22 days.

  • Output value: We produced stable pellets with ~40–45% organic matter and 2–3% total N. These now sell to nearby vegetable farms.

  • Cost savings: We cut manure disposal costs and created a new income source.

  • Environmental: Odor and fly problems have decreased; methane emissions from open piles are avoided.

Why choose LANE’s solution?

LANE: Why did you choose LANE over others?

Operations Manager: LANE provided a tailored line — not one-size-fits-all. The team designed layout, advised on the best mix ratio for our manure, and suggested the right combination of flat die and roller granulation to match market demand. Their after-sales support and spare parts availability in Southeast Asia were decisive.

This interview was recorded by LANE Heavy Industry during a 2023 project in East Java. LANE provides turnkey livestock manure organic fertilizer production line solutions: feasibility consulting, equipment supply (mixers, compost turners, crushers, screeners, granulators, dryers, coolers, coaters, packers), installation, training, and after-sales support.

For more details, please feel free to contact us.

Henan Lane Heavy Industry Machinery Technology Co., Ltd.

Email: sales@lanesvc.com

Contact number: +86 13526470520

Whatsapp: +86 13526470520

评论

发表评论

此博客中的热门博文

Fertilizer Mixer: The Hidden Heart of Every Fertilizer Production Line

图片
When people talk about fertilizer production, they often think about composting, granulation, or packaging. But one piece of equipment silently ensures that every batch of fertilizer is balanced, uniform, and ready for the next stage — the fertilizer mixer . Whether in organic, compound, or bulk blending fertilizer plants, the fertilizer mixer is the link that determines the quality and consistency of the final product. Why Mixing Matters In fertilizer production, achieving a uniform nutrient distribution is critical. Imagine producing NPK fertilizer where one batch is rich in nitrogen while another lacks potassium — plants would receive unbalanced nutrition, and product quality would drop. That’s where the fertilizer mixer plays a key role. By evenly blending various raw materials such as compost, urea, phosphate, potassium salt, and microelements, it ensures that each granule or batch carries the same nutrient ratio. A good fertilizer mixer doesn’t just mix — it prevents segreg...
阅读全文

How to Make Organic Fertilizer for Sustainable Agriculture

图片
How to make organic fertilizer is one of the most important questions in modern agriculture. As the world faces soil degradation, high chemical input costs, and increasing environmental pressure, more farmers, agronomists, and agricultural investors are turning to organic fertilizers as a sustainable solution. Learning how to make organic fertilizer allows communities and industries to recycle waste into valuable, nutrient-rich soil amendments that support long-term fertility and productivity. Why Learning How to Make Organic Fertilizer Matters Understanding how to make organic fertilizer is not just about producing nutrients for plants—it’s about restoring balance to the ecosystem. Organic fertilizers supply essential nutrients such as nitrogen, phosphorus, potassium, and trace minerals, but in a slow-release, natural way that strengthens soil biology rather than depleting it. When compared to chemical fertilizers, organic fertilizers improve soil structure, boost microbial activi...
阅读全文

Smart Composting Solutions: Compost Turner Machine for Pig Manure Composting

图片
Why Choose a Compost Turner Machine for Pig Manure Composting ? A compost turner machine for pig manure composting is the most efficient and eco-friendly solution for transforming raw pig waste into high-quality organic fertilizer. Traditional manure handling often results in odor, pollution, and nutrient loss. With the help of modern compost turner machines, farmers and commercial fertilizer producers can accelerate fermentation, control moisture, and ensure uniform composting. LANE’s Advanced Compost Turner Machines At LANE Heavy Industry , we specialize in designing and manufacturing durable and high-performance compost turner machines tailored for pig manure composting . Our equipment stands out because of: Efficient Aeration System – speeds up microbial activity. Stable Structure – strong frame suitable for continuous operation. Customizable Models – groove type, crawler type, and wheel type compost turners for different farm scales. Low Operation Cost – optimi...
阅读全文