Common Faults in Bio-organic Fertilizer Production Lines
The entire bio-organic fertilizer production line consists of four stages: fermentation, crushing and mixing, extrusion granulation, and packaging. Most faults are concentrated in inadequate raw material control and bio-organic fertilizer equipment maintenance. In the fermentation stage, the most common problems are imbalanced raw material moisture content, improper manure-to-straw ratios, and moisture levels exceeding 70%, resulting in a heavy, sticky pile and poor aeration during fermentation, while insufficient moisture leads to slow heating and poor decomposition. Untimely turning of the pile breeds insect eggs, produces strong odors, and results in numerous impurities in the semi-finished product, creating potential problems for subsequent processes.
In the crushing stage, raw materials mixed with stones or hard objects can damage the hammers, and coarse fibrous materials can clog the screens, resulting in uneven output particle size. Inconsistent raw material moisture content leads to excessive dust from dry materials and machine blockage from wet materials, delaying continuous feeding. In the mixing stage, the main problems are material sticking to the conveyor belt, residual composted manure becoming damp and acidic, corroding the cylinder, uneven addition of microbial inoculants, and inconsistent nutrient and live bacteria content in the finished product. Bearings lacking ash and prone to dust ingress frequently cause overheating and abnormal noise.
Extrusion granulation is a high-risk area for failures. When the moisture content of the mixture exceeds 13%, it sticks to the rollers and die grooves, causing granules to clump together. When the moisture content is below 7%, the powder is loose and difficult to form, leading to a surge in return material and increased equipment load. Hard impurities in the raw materials scratch the rollers, and long-term impact on the bearing housings causes them to loosen and wobble, resulting in granules that are uneven in thickness. Furthermore, high-temperature friction can kill beneficial bacteria, leading to substandard live bacteria counts in the finished product.
The packaging station is prone to material bridging and inaccurate metering, with dust settling on the electronic scales affecting weighing accuracy. Daily maintenance includes cleaning residual material from the equipment each shift, strictly controlling the moisture content of the raw materials, and regularly adding bearing grease to reduce various failures at the source and ensure stable live bacteria counts and production efficiency.
