Windrow Compost Turning Machine

Equipment Introduction

The windrow compost turner is the core unit for windrow aerobic fermentation. It is a heavy-duty, self-propelled ground-based organic fertilizer fermentation machine, designed for high-temperature composting of organic waste such as livestock and poultry manure, straw, mushroom residue, and biogas residue. It integrates four functions: material turning, crushing, aeration, and stacking, replacing manual loaders and small trough-type compost turners. It is the mainstream fermentation equipment for large-scale organic fertilizer plants, livestock farms, and environmental solid waste treatment projects.

The machine uses a diesel-powered tracked self-propelled chassis, hydraulically adjustable turning shaft height, continuously variable transmission for both walking and turning, and a self-enclosed cab with 360° on-the-spot turning capability. It is suitable for open-air, strip-shaped composting sites, not limited by factory buildings or tanks, and requires minimal infrastructure investment.

Core Differentiating Advantages (Comparison with Trench-Type and Wheeled Compost Turners)

1. Strong Site Adaptability: No need to build fermentation tanks; operation is possible only on leveled and hardened ground, reducing infrastructure costs by 70%; low ground pressure from tracks prevents the machine from getting stuck in muddy or wet fermentation sites.

2. Flexible Steering: 360° turn-around with lever, allowing free turning in narrow spaces; wheeled compost turners cannot turn in place and require more space.

3. Intelligent Dual Stepless Speed ​​Control: Independent speed adjustment for the walking and turning drums, matching the speed according to the material's moisture content and maturity stage, ensuring even oxygen supply during fermentation.

4. Heavy-Duty, Durable, and Corrosion-Resistant: Thickened national standard steel plates for the frame and guard plates, suitable for highly corrosive manure fermentation environments, with a service life far exceeding that of ordinary light-duty compost turners.

5. Large Processing Capacity: 600-1500 cubic meters of material per unit per hour, suitable for large-scale organic fertilizer production lines with an annual output of 10,000-100,000 tons.

6. User-Friendly Configuration: Standard cab, optional onboard air conditioning, diesel water-cooled engine with ample power and low fuel consumption.

Complete Equipment Structure

1. Tracked Chassis Assembly: Thickened steel track plates, drive wheels, guide wheels, track rollers, travel reducer, travel hydraulic control system; lever-type on-the-spot steering mechanism for 360° on-the-spot turning and high/low speed gear switching.

2. Turning and Crushing Drum Assembly (Core Working Component): 500mm diameter integrated roller with spirally distributed wear-resistant turning blades; equipped with an independent turning reducer and drive belt; hydraulic lifting cylinder controls the drum's ground clearance to prevent blade wear from ground contact.

3. Hydraulic Control System: Hydraulic pump station, lifting hydraulic cylinder, pressure regulating valve, hydraulic oil pipes; functions: adjusts the turning drum's ground clearance, assists in steering and buffering, and allows for fine-tuning of the turning depth according to material thickness.

4. Transmission and Speed ​​Change Assembly: Dual independent transmission system: continuously variable transmission (CVT) for travel (10-50 m/min), continuously variable transmission for tumbling/pouring (6-10 m/min); main clutch, travel disengagement clutch, gear reducer, and drive shaft locking mechanism.

5. Operating Electronic Control Assembly: Cab control panel, push-button switches, operating control levers, insulated circuitry throughout the vehicle, battery starting system; waterproof and insulated circuitry throughout the vehicle, suitable for damp and sewage-prone environments.

6. Enclosed Cab Assembly: Standard steel frame cab, shock-absorbing seat; optional onboard air conditioning and dustproof glass to isolate fermentation dust and odors, improving the operator's working environment.

7. Machine Frame Protection Assembly: Thickened national standard steel plate welded main frame, anti-corrosion side plates, transmission dust cover, material baffle; overall stress-relief welding, resistant to heavy loads and corrosion.

Equipment Compatible Raw Material List

1. Main Fermentation Raw Materials

Livestock and Poultry Manure: Chicken manure, cow manure, sheep manure, pig manure, duck manure, pigeon manure;

Agricultural and Forestry Waste: Corn stalks, wheat stalks, rice straw, sawdust, mushroom residue, garden leaves;

Organic Waste: Biogas residue, traditional Chinese medicine residue, sugarcane bagasse, kitchen waste, sludge, peanut shells.

2. Auxiliary Materials for Adjustment

Humic acid, peat moss, fermentation inoculants, straw powder, rice bran (used to adjust carbon-nitrogen ratio and moisture content)

3. Mandatory Requirements for Material Use (Original Factory Site Specifications)

The optimal moisture content for materials is 50%-65%. If too dry, spray water to increase humidity; if too wet, add dry straw to adjust.

Long straw materials must be crushed/chopped. Direct fermentation of whole bundles of long straw is prohibited to avoid tangling with the turning drum.

The materials must not contain bricks, stones, or hard metal objects, as these will directly break the turning blades and damage the drum.

Working Principle of the Equipment

The windrow compost turner operates based on aerobic fermentation technology. The core mechanism is as follows:

1. Power Transmission Principle: The diesel engine power is divided into two outputs:

Main Output: Drives the turning drum to rotate via a belt pulley reduction gearbox.

Side Power Output: Drives the hydraulic pump via a side power box, providing pressurized oil to the hydraulic system.

2. Turning Operation Principle

Saddle Operation: The machine straddles a pre-placed long strip of material.

Spiral Gathering: The drum spirals in opposite directions, gathering the material from both sides of the stack towards the center.

Turning and Mixing: The straight section of the throwing teeth in the middle turns the material backward, achieving:

Fully mixing of the top layer material with the internal material

Fully contact between the material and oxygen

Effective dissipation of heat (moisture) from the stack

Crushing Function: The crushing device on the cutter shaft effectively breaks up the compacted material formed in the later stages of fermentation.

3. Aerobic Fermentation Principle: The turning machine, through regular turning and tossing, rapidly raises the temperature of the compost pile to 50–65℃. Under these high-temperature conditions: Pathogens, insect eggs, and weed seeds are effectively killed; Microorganisms fully decompose organic matter; The fermentation cycle is shortened to 15–20 days; The oxygen content of the compost pile is maintained within the ideal range of 8%–18%.

Application of Equipment in Organic Fertilizer Production Lines

The windrow compost turner is the core fermentation unit in a windrow organic fertilizer production line. It is equipped with front-end raw material pretreatment and rear-end crushing, screening, hydraulic roller granulation, and packaging equipment. There are two production line configurations:

1. Small-scale organic fertilizer production line (10,000-30,000 tons/year)

Process flow: Mixing livestock manure and straw → Windrow stacking → Periodic turning and composting with tracked compost turner → Crushing of composted organic fertilizer → Screening → Hydraulic roller dry granulation → Packaging of finished granules

2. Large-scale organic fertilizer production line (50,000-100,000 tons/year)

Process flow: Solid-liquid separation of manure and sludge → Automatic batching and mixing of raw materials → Large windrow composting yard → Circulating turning by multiple tracked compost turners → Secondary composting and aging → Fine crushing → Screening and impurity removal → Hydraulic roller granulation/disc wet granulation → Coating and cooling → Automatic weighing and packaging

3. Standalone independent operation mode: For farms without a fixed production line, a tracked compost turner can be purchased separately, and a manual loader can be used to assist in stacking. After fermentation and decomposition, the powdered organic fertilizer can be sold directly without the need for granulation equipment.

Equipment Maintenance Methods

(I) Daily Maintenance: When the windrow compost turner is not frequently used, it should be maintained once a week; when it is frequently used, it should be maintained once a day. Maintenance Contents:

1. Check Fasteners: Check all connecting bolts, nuts, and drain plugs for looseness.

2. Check Pins: Check all pins and cotter pins for damage and replace them promptly (cotter pins must not be replaced with other materials).

3. Check Blades: Check the turning blades for damage and the fastening bolts for looseness. Replace, tighten, or replace blades as necessary.

4. Check Electrical Equipment: Check all electrical connections for tightness and the insulation of wires for good condition. Repair or replace as necessary.

5. Check Fastening Screws: Check the fastening screws of the diesel engine, gearbox, bearing housings, etc. for looseness.

6. Clean Equipment: Clean the caked and attached materials on the turner; clean the tangled material on the rollers.

(II) Regular Maintenance

1. Seasonal Maintenance: After the turner has been in operation for one season, change the gearbox gear oil (220#), add hydraulic oil (68#) to the travel gearbox, and add hydraulic oil (46#) to the hydraulic tank; check all bearings and chains, disassemble, clean, and apply new grease. Replace severely worn parts.

2. Transmission System Inspection: Remove the dust cover from the equipment and check and tighten the bolts on each transmission rod to prevent wear and tear on machine parts caused by loose bolts leading to improper transmission.

3. Drive Shaft Inspection: Remove the cab seat and cover plate and check and tighten the bolts on the drive shaft seat to prevent the drive shaft from loosening, causing it to tilt, break, and become unusable.

4. Winter Protection: Add antifreeze to the water tank during winter use; if antifreeze is not added, add warm water before operation and drain the water from the water tank, machine body, and cooler after operation to prevent freezing damage.

5. Electrical Inspection: Check whether the electrical components are working properly and whether the circuit insulation is good; replace the wires if necessary.

6. Belt Inspection: Regularly check the tension of the drive belt, adjust the tension if necessary, and check for cracks, wear, or other signs of aging. After replacing the belt, the new belt should be readjusted after two to three weeks of use to eliminate looseness.
7. Track Maintenance: Check the track tension daily; check the track tightness regularly to prevent it from being too loose or too tight.
8. Rust Prevention: When the turner is not in operation for a long time, all exposed parts should be coated with oil for rust prevention. When placed outdoors, it should be covered.
9. Hydraulic System: Regularly check the hydraulic oil quality and replace the hydraulic oil according to the specified cycle; check the sealing of the hydraulic pipeline.
(III) Maintenance of Important Components
1. Diesel Engine: Maintain and service the diesel engine according to the manufacturer's instruction manual.
2. Air Conditioner (if equipped): Refer to the air conditioner's instruction manual.
3. Battery: Securely fasten the battery; keep the terminals and connections clean and secure; frequently check the battery's charge and charge it promptly; when not in use for a long time, disconnect the battery wiring (disconnect the negative terminal first and install it last).
Common equipment malfunctions, causes of malfunctions and solutions