This is a large-scale organic manure production plant in Indonesia. The project is very special in that it uses earthworm manure as the main raw material.
The client of this project, a fertilizer company, is from Indonesia. It was established on February 14, 2012 and is mainly engaged in the production and sales of compound microbial organic fertilizers.
In order to meet the local market demand and increase the company's turnover, an investment of US$870,000 was made to build an organic fertilizer production workshop construction project.
The organic manure production plant in Indonesia project covers a total area of 2,076m2 and a total construction area of 1,865m2. The main construction is the production workshop and other ancillary facilities, with an annual output of 150,000 tons of powdered compound microbial organic fertilizer and 50,000 tons of granular compound microbial organic fertilizer. The project has a labor quota of 18 people, an annual production operation of 300 days, three shifts, and 8 hours per shift.
Name:
Earthworm manure fertilizer factory
Country:
Indonesia
Date:
February 21, 2024
Capacity:
25-30T/H
Product Size:
Powder & 2-4mm pellets
The install period:
60 Days
Control Mode:
Semi-automatic
Guiding Price:
US$870,000
In 2023, Indonesia's total agricultural output value will reach about 453.75 trillion rupiah (about US$2.9 billion), and the trading volume of agricultural products will reach 3.71 billion tons. In 2024, the total agricultural output value will increase further.
Overall, the strong development momentum of Indonesia's agricultural market is emerging. The improvement of agricultural technology, the popularization of agricultural machinery and the return of young labor are all affecting this development trend. As one of Indonesia's pillar industries, the continuous improvement of the agricultural economy has accelerated the growth of demand for the fertilizer industry, and the vitality of the fertilizer industry continues to promote the development of Indonesia's agriculture.
The total area of this organic manure production plant in Indonesia project is 2076m2, with a total construction area of 1865m2. It mainly constructs an organic fertilizer production workshop and supporting quantitative feeders, crushers, organic fertilizer pellet machines, electric drying and other equipment. The project composition of this project is shown in the table below.
| Category | Engineering composition | Engineering content |
| Main engineering | Production workshop | 1F, construction area 1865m2, building height 8m, color steel structure, from west to east are office area, finished product area, production area and raw material area. Among them, the west side of the production area is the granular compound microbial organic fertilizer production area, arranged with silos, crushers, screening machines, quantitative belt feeders, quantitative feeding silos, mixers, granulators, electric dryers, coolers, bacteria adding machines, quantitative packaging scales, palletizers and other equipment; the east side is the powdered compound microbial organic fertilizer production area, arranged with silos, crushers, screening machines, bacteria adding machines, quantitative packaging scales and other equipment. |
| Storage and transportation engineering | Raw material area | 1F, with a construction area of 290m2, is located on the east side of the production workshop. It is mainly used for the transfer of earthworm castings and humus soil and the storage of large and medium trace elements, biological agents, and product packaging bags. After the earthworm castings and humus soil are transported to the factory, they are temporarily placed in the raw material area and loaded to the production line by a forklift. The earthworm castings and humus soil are purchased from outside according to production needs and are not stored in the factory. |
| Finished product area | 1F, with a construction area of 100m2, is located on the west side of the production workshop. It is mainly used for the storage of organic fertilizer samples and provides space for product transportation vehicles. After the finished products are packaged, they are directly transported away by transportation vehicles in the finished product area and are not stored in the factory. | |
| General solid waste room | is located in the southeast corner of the raw material area, with a construction area of 10m2, and is used for temporary storage of solid waste. | |
| Raw materials are loaded by forklifts, and conveyor belts are used for material transportation and transfer during the production process. Silos are used for temporary storage of some materials. | ||
| Auxiliary Engineering | Office Area | 1F, building area 16m2, located on the west side of the production workshop, used for daily office |
| Car Washing Station and Sedimentation Tank | Located next to the east gate of the production workshop, the sedimentation tank is underground, with a volume of 2m3 | |
| Public Engineering | Water Supply | Provided by the local tap water network |
| Power Supply | Provided by the local power supply station | |
After completion, this organic manure production plant in Indonesia project will produce 200,000 tons of compound microbial organic fertilizer per year, including 150,000 tons/year of powdered compound microbial organic fertilizer and 50,000 tons/year of granular compound microbial organic fertilizer.
| Number | Product name | Annual output | Product specifications | Packing specifications | Remarks |
| 1 | Powdered compound microbial organic fertilizer | 150,000 tons | -- | 20kg/bag, 25kg/bag, 40kg/bag, 50kg/bag | Woven bag packaging, lined with plastic film |
| 2 | Granular compound microbial organic fertilizer | 50,000 tons | Diameter 2mm~4mm | 20kg/bag, 25kg/bag, 40kg/bag, 50kg/bag |
The compound microbial fertilizer processed in this organic manure production plant in Indonesia project meets the following standards. The specific indicators are shown in the table below.
| 1 | Appearance | No obvious mechanical impurities, uniform size, water absorbent | No obvious mechanical impurities, uniform size, water absorbent | |
| 2 | Number of jelly-like Bacillus | 100 million/g | 0.18 | ≥0.01 |
| Number of Bacillus subtilis | 100 million/g | 46 | ≥0.01 | |
| Number of effective live bacteria | 100 million/g | 46.18 | ≥0.20 | |
| 3 | Mass fraction of N (on dry basis) | % | 3.69 | ≥15% of total nutrients |
| Mass fraction of P2O5 (on dry basis) | % | 3.48 | ≥15% of total nutrients | |
| Mass fraction of K2O (on dry basis) | % | 2.44 | ≥15% of total nutrients | |
| Total nutrients | % | 9.61 | 8 | |
| 4 | Organic matter (dry basis) | % | 37 | ≥20.0 |
| 5 | Miscellaneous bacteria rate | % | Not detected | ≤30.0 |
| 6 | Water | % | 11.5 | ≤30.0 |
| 7 | pH | 6.2 | 5.5~8 .5 | |
| 8 | Fecal coliform count | pieces/g | Negative | ≤100 |
| 9 | Ascaris egg mortality rate | % | Ascaris eggs not detected | ≥95 |
| 10 | Total lead (on dry basis) | mg/kg | Not detected (<1.2) | ≤50 |
| 11 | Total cadmium (on dry basis) | mg/kg | Not detected (<0.1) | ≤3 |
| 12 | Total Mercury (on dry basis) | mg/kg | 0.1 | ≤2 |
| 13 | Total Arsenic (on dry basis) | mg/kg | 5.5 | ≤15 |
| 14 | Total Chromium (on dry basis) | mg/kg | 29 | ≤150 |
The main equipment of this organic manure production plant in Indonesia project is shown in the table below.
| Number | Equipment name | QTY | Specification model |
| （1） | Powdered compound microbial organic fertilizer production line | ||
| 1 | Hopper | 1 | 5m3 |
| 2 | Crusher | 1 | Φ0.8m |
| 3 | Screening machine | 1 | Φ1.5*3m |
| 4 | Bacterial Adder | 1 | 100 Type |
| 5 | Quantitative Packaging Scale | 1 | 400 Packs/Hour |
| 6 | Conveyor Belt | 50m | -- |
| （2） | Granular compound microbial organic fertilizer production line | ||
| 1 | Hopper | 1 | 5m3 |
| 2 | Crusher | 1 | Φ0.6m |
| 3 | Screening machine | 3 | Φ1.8*6m |
| 4 | Quantitative feeder | 1 | 1.1kw |
| 5 | Quantitative feed bin | 5 | 3m3 |
| 6 | Mixer | 1 | Φ2*0.5m |
| 7 | Fertilizer granulator machine | 5 | Φ3.5*0. 5m |
| 8 | Electric drying machine | 2 sets | Φ2*20m |
| 9 | Cooling machine | 1 set | Φ1.8*18m |
| 10 | Bacterial adding machine | 1 set | Type 100 |
| 11 | Quantitative packaging scale | 1 set | 400 bags/hour |
| 12 | Palletizer | 1 set | 5kw |
| 13 | Conveyor belt | 60m | -- |
| 14 | Forklift | 1 set | -- |
| （3） | Auxiliary equipment | ||
| 1 | Biological deodorization tower | 1 | -- |
| 2 | Bag dust collector | 1 | -- |
| 3 | Settling chamber | 3 | -- |
| 4 | Cyclone dust collector | 3 | -- |
The raw materials of this organic manure production plant in Indonesia project are mainly earthworm manure, which mainly comes from local earthworm breeding projects.
The earthworm manure used in this project does not involve raw materials such as sludge from sewage treatment, and there is no other process such as fermentation, exposure or drying. The raw and auxiliary materials and energy consumption are detailed in the table below.
| Number | Name | Specification | Quantity | Packing/Transportation method | Remarks |
| （1） | Powdered compound microbial organic fertilizer production line | ||||
| 1 | Earthworm manure | -- | 112500t/a | Granular, bulk, truck transportation | Derived from earthworm breeding project. The earthworm manure is dehydrated or dried and preliminarily fermented, with a moisture content of about 30%, and no free water is drained out. |
| 2 | Humus | -- | 44000t/a | Block, bulk, truck transportation | The purchased humus has a moisture content of about 30% |
| （2） | Granular compound microbial organic fertilizer production line | ||||
| 1 | Earthworm manure | -- | 37500t/a | Granular, bulk, truck transportation | Originated from earthworm breeding project. Worm manure is dehydrated or dried and preliminarily fermented, with a moisture content of about 30%, and no free water is drained out. |
| 2 | Humus | -- | 15000t/a | Block, bulk, truck transportation | The moisture content of the purchased humus is about 30% |
| （3） | Auxiliary materials | ||||
| 3 | Major, medium and trace elements | 20kg/bag | 1,000 t/a | Powder, bagged, transported by car | Purchased from outside, mainly major, medium and trace elements such as zinc, manganese, copper, calcium, magnesium, nitrogen and phosphorus |
| 4 | Biological agents | 20kg/bag | 0.01 million t/a | Powder, bagged, transported by car | Purchased from outside, mainly functional bacteria such as Bacillus subtilis and Bacillus licheniformis |
| 5 | Product packaging bags | -- | 4 million/a | -- | -- |
| （4） | Energy consumption | ||||
| 6 | Water | -- | 3054m3/a | -- | supplied by local water supply network |
| 7 | Electricity | -- | 2.5 million kWh/a | -- | supplied by local power supply station |
Compared with raw materials, the content of soluble salts, cation exchange performance and humic acid content in earthworm manure have increased significantly, that is, organic matter has been converted into stable humus-like complex substances. Many organic wastes, especially livestock and poultry manure, are generally alkaline, while most plants prefer acidic growth media (pH: 6~6.5).
During the digestion process of earthworms, organic acids are produced during the metabolism of microorganisms, which reduces the pH of the waste and tends to be neutral.
The content of nutrients in earthworm manure varies with the raw materials, but generally speaking, some nutrients and trace elements necessary for plant growth are not only present in earthworm manure, but also in high content, in a form that is easily absorbed by plants.
Earthworm manure is rich in bacteria, actinomycetes and fungi. These microorganisms not only mineralize complex substances into effective substances that are easily absorbed by plants, but also synthesize a series of biologically active substances, such as sugars, amino acids, vitamins, etc. The production of these substances gives earthworm manure many special properties.
Leaf humus, also known as humus soil, is a culture soil made by mixing leaves and weeds of various plants with garden soil, adding water and human feces and urine, and then piling, fermenting and composting. The pH value is acidic and needs to be exposed to the sun and sieved before use.
New biological strains with the characteristics of powder have the characteristics of rapid reproduction, strong vitality, safety and non-toxicity.
Characteristics: pure strain, high number of live bacteria, no foreign bacteria; promotes crop growth, improves agricultural product quality, prevents diseases; improves soil, dissolves inactive phosphorus; is resistant to high temperatures, does not lose activity during granulation and drying, and can be preserved for a long time.
Trace elements refer to chemical elements with very low content in nature. Some trace elements have biological significance and are necessary for the normal growth and life of plants and animals. They are called "essential trace elements" or "trace nutrients", usually referred to as "trace elements".
The effects of essential trace elements in plants and animals are highly specific and are indispensable and irreplaceable. When the supply is insufficient, plants often show specific deficiency symptoms, crop yields decrease, quality declines, and in severe cases, there may be no production. The application of trace element fertilizers is conducive to increasing yields.
The water used in this organic manure production plant in Indonesia project is provided by the local water supply network. The water is mainly used for granulation process, vehicle washing, biological deodorization tower, workshop spraying and domestic water. The total fresh water consumption is 10.18m3/d and 3054m3/a.
The power supply for this project is provided by the local power supply station, and the total power consumption is 2.5 million kW•h/year.
In this organic manure production plant in Indonesia project, each production batch of the powdered composite microbial organic fertilizer production line is about 5min, and the raw material hopper is 5m3, that is, the maximum temporary storage of raw materials is about 4.2t (1.2m3≈1t), the operating time is 300d/a, 16h/d, so the maximum design production capacity of the production line equipment is about 241920 tons/year, the raw materials used in the production line are 112500 tons of earthworm manure and 44000 tons of humus soil, a total of 156500 tons, because this production equipment can meet the production needs of the organic manure production plant in Indonesia project.
Each production batch of the granular composite microbial organic manure production plant is about 15 minutes, and the raw material loading hopper is 5m3, that is, the maximum temporary storage of raw materials is about 4.2t (1.2m3≈1t), the operating time is 300d/a, 16h/d, so the maximum design production capacity of the production line equipment is about 80640 tons, and the raw materials used in the production line are 37500 tons of earthworm manure and 15000 tons of humus, a total of 52500 tons, so the production equipment can meet the production needs of the project.
This organic manure production plant in Indonesia project purchases earthworm manure and humus soil by order, and purchases them as needed. The purchased earthworm manure and humus soil are unloaded to the raw material area by a 20-ton closed transport vehicle for temporary storage, and then loaded by a forklift according to the proportion.
The building area of the raw material area is 290m2, and the maximum turnover of earthworm manure and humus soil in the raw material area is 40 tons. The raw material turnover frequency of this project is 5225 times/year. Therefore, by increasing the number of transportation times of raw material transport vehicles, the area of the raw material area of this project can meet the demand for raw material turnover.
The organic fertilizer products produced by this organic manure production plant in Indonesia project have a short shelf life. In order to prevent the fertilizer efficiency from decreasing, the products are not stored in the factory area.
The finished products finally packaged by the production line are directly loaded and sold. The area of the finished product area is 100m2, which is used to park product transport vehicles. The load capacity of the product transport vehicle is 20 tons. The maximum turnover of the product in the finished product area is 40 tons.
The turnover times of the products in this project are 5,000 times/year. Therefore, by increasing the number of transportation times of product transport vehicles, the area of the finished product area of this project can meet the demand for product turnover.
In summary, the material turnover and storage capacity of this project are feasible.
This organic manure production plant in Indonesia project mainly constructs a production workshop, the gates are located on the west and east sides of the workshop, and a car wash station and sedimentation tank are set up next to the east gate. The production workshop is divided into finished product area, production area and raw material area from west to east.
The office area is located on the south side of the finished product area. Among them, the south side of the production area is the powdered compound microbial organic fertilizer production area, the north side is the granular compound microbial organic fertilizer production area, and the southeast corner of the raw material area is set up with a general solid waste room.
The layout of the plant area is clearly structured and the functional areas are clearly divided, which is convenient for organizing production and management, and meets local fire prevention, safety, environmental protection and other requirements.
On the premise of meeting the production process, operation requirements and use functions, the buildings are arranged in a centralized manner, which can make economical, reasonable and effective use of land.
Considering the convenience of production, safety management, environmental protection and other aspects, the overall layout of the project is relatively reasonable.
Organized waste gas: earthworm manure and humus soil are loaded by forklift, biological agents and trace elements are added manually, and the crusher, screening machine, mixer, granulator, electric dryer, cooler, bacteria adding machine and other equipment are placed in a slightly negative pressure secondary closed room.
The earthworm manure and humus soil loading hopper and quantitative packaging scale are equipped with a gas collection hood. The waste gas generated by the loading, crushing, screening, mixing, granulation, bacteria adding, packaging and other processes is collected and enters a set of "bag dust collector TA001 + biological deodorization tower TA005 + 15m exhaust pipe DA00 1 emission".
The electric dryer and cooler enter 3 sets of "sedimentation chamber + cyclone dust collector" (TA002, TA003, TA004) through the gas collection pipeline on the top of the equipment for treatment, and then are discharged through the biological deodorization tower TA005 + 15m exhaust pipe DA001".
Unorganized waste gas: The production workshop is closed, and the raw material storage, loading and unloading processes are all carried out in the production workshop; the floor of the production workshop is hardened and cleaned in time, and the material area and road boundaries are divided.
The production workshop is sprayed regularly to suppress dust; the workshop door is equipped with vehicle cleaning equipment for in and out vehicles, and the in and out material transport vehicles are cleaned, The vehicle is covered with tarpaulin.
The water used in the granulation process enters the product, and the water used for spraying in the workshop and the water used for biological deodorization tower are all lost and not discharged; the vehicle washing wastewater is reused in the granulation process and not discharged.
The domestic wastewater is used for dust suppression in the factory area, and the anti-seepage dry toilet is regularly cleaned and used as agricultural fertilizer, which is not discharged.
Select low-noise equipment, foundation vibration reduction, workshop sound insulation, and distance attenuation.
Dust removal ash, sedimentation tank sediment and biological deodorization tower sediment are collected and reused in production; waste packaging materials are collected and sold out To the waste collection station; screened debris and domestic garbage are collected and handed over to the sanitation department for removal.
The floor of the production workshop is first compacted with Sanqi lime soil, and then 15mm thick anti-seepage concrete is constructed for anti-seepage treatment, and the anti-seepage coefficient is not less than 1.0×10-7cm/s.
The sedimentation tank is paved with 15cm mortar, and then 15-20cm cement concrete is poured on the upper layer. The surrounding walls are brick-built and then hardened with cement for anti-seepage, so that the equivalent clay anti-seepage layer Mb≥6.0m, K≤1×10-7cm/s; the factory roads are hardened.
The prospects for building an organic fertilizer production project in Indonesia are generally optimistic, but attention should be paid to changes in the market and policy environment.
If you want to build an organic manure production plant in Indonesia, feel free to contact RICHI MACHINERY to get free customized solution design, equipment quotation, project video and other information!
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