The disc granulator is a core piece of equipment for shaping materials in the organic fertilizer processing and chemical powder industries. Thanks to advantages such as a simple structure, high pelletizing rate, uniform granule size, and low operation and maintenance costs, it is the preferred choice for small- and medium-sized granulation production lines. Unlike traditional extrusion or drum granulation equipment, this disc granulator offers greater versatility, capable of precisely granulating various dry powders, wet powders, and fine-grained materials. It is widely used across sectors including organic fertilizer production, compound fertilizer processing, ore powder granulation, chemical powder shaping, and animal feed granulation. To establish a complete fertilizer production line, it can be integrated with auxiliary equipment—such as compost turners, crushers,mixers, drum dryers, coolers, screener machines, belt conveyors, and packaging machines-to achieve an integrated workflow covering everything from material pre-treatment and granulation to drying and classification.

 

What are the main components of the disc granulator?

Granulating disc: The core working component, featuring an integrated arc structure; the disc bottom is reinforced with multiple radial steel plates to ensure it remains undeformed during long-term use. The inner wall is typically lined with high-strength fiberglass or stainless steel for corrosion and wear resistance.

Drive system: A motor drives the disc's rotation via a speed reducer; a flexible belt drive is employed to ensure smooth startup, effectively cushion impact forces, and extend the equipment's service life.

Tilt angle adjustment mechanism: An adjustment screw allows for the modification of the disc's tilt angle——typically within the 30° to 55° range——to control the material's residence time and rolling trajectory within the disc.

Scraper assembly: Comprising a disc-bottom scraper and a corner-cleaning scraper, this assembly prevents material from adhering to the disc surface, ensuring a smooth granulation process.

Liquid spraying system: Precisely controls the volume of water or binder sprayed; this is a critical factor determining the quality of the granules produced.
 

How does a disc granulator produce fertilizer granules?

In fertilizer production, the disc granulator utilizes a rolling agglomeration process. Fermented powdered organic fertilizer or prepared compound fertilizer raw materials are transported via conveyor belt to a position above the disc and fed continuously and at a controlled rate into the shallow pan.

Once the material enters the granulation disc, and with the aid of a spraying/moistening system, the powder continuously tumbles, rolls, and agglomerates under the combined forces of centrifugal action and gravity. The powder particles bind and layer upon one another, gradually growing into round, compact granules. The process involves natural formation and automatic granule classification: granules meeting the size specifications automatically spill over the edge, while finer particles remain in the disc to continue the agglomeration process.

The finished granules are round and plump with smooth surfaces and moderate hardness; they spread evenly during application, generate minimal dust, dissolve effectively, and offer excellent slow-release performance. Granule size can be precisely controlled by adjusting the disc's rotation speed, tilt angle, and spray volume, typically allowing for the production of fertilizer granules in specifications ranging from 2-6 mm (or 2-10 mm).

Key Performance Features of the Disc Granulator

High granulation rate. Featuring a granulating disc with an integrated arc design, the granulation rate exceeds 93%. The disc is typically equipped with three discharge outlets to facilitate intermittent production operations.

Stable and reliable operation. Designed with a thickened and weighted base, some models can operate stably without the need for anchor bolts. The main gear undergoes high-frequency quenching, effectively doubling its service life.

Flexible and controllable operation. Parameters such as the disc inclination angle, rotation speed, and liquid spray volume can be precisely adjusted based on material characteristics and product requirements, allowing for a wide range of granule size control.

Broad application range. Suitable for producing organic, compound, and blended fertilizers, as well as for granulating powdery materials in industries such as chemicals, animal feed, pharmaceuticals, metallurgy, and construction materials.

Are there requirements regarding the moisture content of raw materials for the disc granulator?

Yes, there are requirements, though the equipment accommodates a wide range of conditions.

Generally, it is recommended to maintain the moisture content of the granules between 12% and 14%. Most of the moisture should be added in the twin-shaft mixer, with only a small amount of supplementary water (approximately 0–3%) added in the granulating disc. For dry powder granulation, the dry powder can be fed directly into the disc while an appropriate amount of water is sprayed on.

The equipment can process powdered materials with a moisture content of ≤15%, and certain models can handle materials with moisture levels of 20%–35%. Excessive moisture tends to cause material to stick to the disc walls and reduces the granulation rate, while insufficient moisture makes it difficult for the material to agglomerate into granules. In actual production, moisture levels must be carefully controlled based on the specific characteristics of the material.

Why Choose Huaqiang Heavy Industry’s Disc Granulator?

Established in 2001, Zhengzhou Huaqiang Heavy Industry is a primary manufacturer of organic fertilizer equipment, operating a facility that spans over 50 mu (approx. 8 acres) with 20,000 square meters of factory space. The company holds ISO9001 and ISO14001 certifications, and its disc granulator has been selected for national environmental protection promotion programs.

The equipment features a disc body made of thickened steel plate with an anti-corrosive fiberglass lining, ensuring durability and a service life of 8-12 years. The main gear undergoes high-frequency quenching, doubling its lifespan, and the unit is equipped with a non-powered scraper for automatic material clearing. It achieves a granulation rate of 93%-95%, producing round, uniform granules, while requiring an investment more than 30% lower than extrusion-based equipment.

We provide comprehensive, one-stop services ranging from plant design and equipment customization to installation, commissioning, and technical training. With a track record of thousands of projects completed over two decades, we offer opportunities to visit nearby project sites and provide free granulation testing using your raw materials. Benefit from direct factory supply, excellent cost-performance, and reliable quality.