A disc granulator (also known as pan granulator) is a piece of equipment that utilizes a rotating disc to agglomerate and granulate powdery or granular materials. It serves as a core forming unit in the production of fertilizers——such as organic, compound, and blended fertilizers——and is also widely used in industries including pharmaceuticals, food processing, chemicals, metallurgy, and mining.
The equipment features a disc body with an arc-shaped design, typically lined with high-strength fiberglass-reinforced plastic (FRP) or stainless steel. It is characterized by uniform granulation, a high pelletization rate, smooth operation, robust construction, and a long service life.
The disc granulator employs a wet rolling-agglomeration granulation process. The entire forming process is visible and allows for real-time adjustment—key features that distinguish it from double-roller extrusion and rotary drum granulation methods:
Qualified powdered raw materials are continuously fed into an inclined, rotating disc, while a spray system simultaneously applies water, humic acid binder, or a fermented microbial solution;
A motor drives the disc to rotate at a constant speed; the material is subjected to the combined forces of centrifugal action, gravity, and disc-surface friction, causing it to tumble in a spiral motion within the disc;
Fine powder particles initially bond to form tiny nuclei, and subsequent powder layers continuously adhere to these nuclei, causing the granules to grow in size; a stationary scraper continuously removes sticky, wet material from the disc bottom to prevent caking;
Once the granules reach the target diameter (adjustable between 2-10 mm), their weight overcomes the disc's centrifugal retention force, causing them to automatically spill over the disc edge for discharge, while fine, unformed powder remains inside the disc for continued granulation;
The discharged granules are conveyed directly to the subsequent drying and screening stages, while undersized fines are recycled back into the disc for re-granulation, keeping raw material loss below 7%.
The complete granulation process can be integrated into a small-scale organic fertilizer production line for automated, continuous operation; a single unit achieves a stable granulation rate of 93%–95%, producing round, uniform granules with a commercial appearance superior to the flattened pellets produced by extrusion granulation.
Granulation Disc: Features a unitary arc-shaped structure; the interior is lined with high-strength fiberglass or anti-stick, wear-resistant material, ensuring corrosion resistance and durability. The disc bottom is reinforced with multiple radial steel plates to prevent deformation during long-term use.
Drive System: The motor drives the disc's rotation via a speed reducer. A flexible belt drive connects the reducer and motor, ensuring smooth startup, effectively cushioning impact forces, and extending the equipment's service life.
Tilt Angle Adjustment Mechanism: The disc's tilt angle can be adjusted within a specific range, allowing for control over the material's rolling trajectory and granulation results.
Liquid Spray and Scraper Assembly: The liquid spray system evenly applies the binding agent, while the scraper assembly continuously removes material adhering to the disc walls to prevent buildup.
The disc granulator is primarily used in the following areas:
Organic fertilizer production. It is used to granulate fermented materials—such as livestock and poultry manure, crop straw, and spent mushroom substrate—facilitating standardized production.
Compound and blended fertilizer production. It is suitable for granulating various types of fertilizers, including NPK compound fertilizers, humic acid fertilizers, and slow-release compound fertilizers, enabling the integration of ingredient mixing and granulation.
Other industrial sectors. It is used for raw meal pelletization in the cement industry and finds extensive application in fields such as metallurgy, chemicals, animal feed, and pharmaceuticals.
When selecting a disc granulator, it is recommended to consider the following factors comprehensively:
Choose a model based on your required hourly processing capacity. Small-scale units handle 1-5 tons per hour, while large-scale units can process over 15 tons per hour.
Materials vary significantly in terms of moisture content, viscosity, and particle fineness; the disc material and liquid spraying system must be matched accordingly. For materials with high moisture and viscosity, it is advisable to choose a model equipped with anti-stick liners and adjustable scrapers.
Consider the equipment's footprint, height, and installation method. Some models feature a weighted base design that eliminates the need for anchor bolts, offering greater installation flexibility.
Compared to other granulation processes, using disc granulation to produce spherical granules can reduce total investment costs by 10–30%. With lower equipment power requirements and reduced auxiliary energy consumption, operating costs are also more economical.
Prioritize manufacturers that offer comprehensive services, including installation, commissioning, training, and maintenance.
The disc base is strengthened with multi-layer radial steel plates to prevent deformation; the main gear undergoes integral high-frequency quenching, doubling its service life; the interior is lined with thickened, corrosion-resistant fiberglass (FRP), ensuring durability even when processing high-moisture manure over long periods.
Features three sets of independent, non-powered scrapers that simultaneously clean the disc bottom and edges; this solves the common issue of high-moisture organic materials sticking and caking on the disc, thereby reducing the frequency of downtime for cleaning.
Utilizes a belt and soft-start gearbox configuration to prevent impact-induced gear breakage, ensuring a very low failure rate during continuous 24-hour operation.
Offers a full range of models with diameters from 1m to 3.2m; tilt angles, spraying systems, and automatic discharge aids can be customized based on hourly output requirements; supports modifications for non-standard voltages and dimensions for export markets.
Provides free production line layout drawings, granulation mix ratio formulas, and equipment installation videos; on-site commissioning by engineers is available for overseas clients, ensuring a complete service package.
The entire machine passes mechanical safety inspections and features an anti-rust industrial coating suitable for high-temperature, high-humidity overseas environments; comes with a complete export packaging solution.
| Model | Capacity(t/h) | Diameter(mm) | Side Height(mm) | Rotation Speed(r/min) | Motor Power(Kw) |
| ZL-500 | 0.05-0.15 | 500 | 150 | 25 | 1.5 |
| ZL-800 | 0.1-0.3 | 800 | 200 | 25 | 1.5 |
| ZL-1000 | 0.1-0.35 | 1000 | 250 | 25 | 2.2 |
| ZL-1200 | 0.1-0.35 | 1200 | 250 | 25 | 3 |
| ZL-1500 | 0.3-1 | 1500 | 300 | 18 | 3 |
| ZL-1800 | 0.5-1.2 | 1800 | 350 | 18 | 4 |
| ZL-2000 | 0.5-1.5 | 2000 | 400 | 18 | 5.5 |
| ZL-2500 | 1-2.5 | 2500 | 400 | 13.6 | 7.5 |
| ZL-2800 | 2-3 | 2800 | 500 | 13.6 | 11 |
| ZL-3000 | 2-3 | 3000 | 500 | 11 | 11 |
| ZL-3200 | 3-5 | 3200 | 500 | 10 | 11 |
| ZL-3600 | 3.5-6 | 3600 | 500 | 10 | 18.5 |
