Large Wheel Compost Turning Machine

Equipment Structure and Composition

The large wheel compost turner mainly consists of the following systems:

Key Structural Features:

1. The disc is equipped with a double-stage, four-layer spatial three-dimensional structure blade, enabling stepped progressive cutting and long-distance throwing (3-5 meters), ensuring full contact between the material and air.

2. The transmission and speed change system is fully enclosed, using direct transmission via shafts and gear sets, providing strong resistance to impact loads.

3. Four-stage spatial curved surface cutting and turning teeth, with replaceable wear-resistant blades, resulting in low operating costs.

4. Longitudinal and lateral displacement coordination ensures no dead angles in turning, eliminating the need for a return path within the fermentation tank.

Applicable Raw Materials

The large wheel compost turner can process a wide variety of raw materials, mainly including:

1. Livestock and Poultry Manure: Pig manure, cow manure, chicken manure, sheep manure, and other types of livestock and poultry manure. Whether it's highly moist and viscous fermentation material or loose fibrous materials, it can achieve thorough turning and breaking up without dead angles.

2. Agricultural Waste: Various crop straws, straw sawdust, garden branches and fallen leaves, etc.

3. Industrial Organic Waste: Sugar factory filter mud, residue cake, mushroom residue, distiller's grains, etc.

4. Urban Organic Waste: Urban sludge, sludge garbage, etc.

The suitable moisture content for raw material fermentation is around 55%. The equipment has excellent adaptability to material moisture content and bulkiness.

Working Principle of the Equipment

The large wheel compost turner operates on the basis of aerobic fermentation technology. The core mechanism is as follows:

I. Power Transmission Principle: The electric motor directly transmits power to the reducer, which is connected to the main shaft of the compost turner. The disc is fixed by coupling flanges at both ends of the shaft. The transmission system consists of the motor, main shaft, and embedded hardened gear sets with variable-direction arc gears, providing strong power to the compost turner.

II. Turning and Turning Operation Principle

1. Longitudinal Movement: The entire machine moves longitudinally along the tracks on both sides of the fermentation tank, with an adjustable speed (1–15 m/min).

2. Lateral Movement: The turning trolley drives the wheel to move left and right in the width of the tank, achieving full coverage and no dead angles during turning and turning.

3. Wheel Cutting: The wheel rotates at high speed (20–40 r/min), and the equipped double-stage 4-layer spatial three-dimensional structure blades perform stepped progressive cutting of the material.

4. Lifting and Throwing: The material in the fermentation tank is lifted from the bottom of the tank to the surface of the pile, and then turned, stirred, and moved to a position 3–5 meters away.

5. Aeration and Oxygen Supply: During the turning and turning process, the material has full and large-area contact with air, quickly replenishing the oxygen inside the pile.

III. Aerobic Fermentation Principle

Through regular turning and turning, the pile temperature rises rapidly to 50–65℃. Under this high-temperature condition:

1. Pathogens, insect eggs, and weed seeds are effectively killed.

2. Microorganisms fully decompose organic matter.

3. The fermentation cycle is shortened.

4. 5. Maintain the oxygen content of the compost pile within the ideal range.

Avoid problems such as odor and seedling burn caused by anaerobic fermentation.

Equipment Operation Method

I. Pre-Trial Run Inspection

1. Check that the reducer and all lubrication points have sufficient lubricating oil.

2. Check the power supply voltage. The rated voltage is 380V, and the voltage drop should not be less than 10% (i.e., 340V) or more than 10% (i.e., 415V). Do not start the machine if it exceeds the range.

3. Check that the connections of the motor and electrical components are secure, and ground the motor with a wire for safety.

4. Check that all connections and bolts are secure. If any are loose, tighten and weld them firmly.

5. Check the material accumulation height.

II. No-Load Trial Run

1. First, run the turning equipment. If the rotation direction is reversed, stop immediately and change the three-phase circuit connection.

2. While the equipment is running, listen for any abnormal noises from the reducer.

3. Touch the temperature of each bearing to see if it is within the temperature range.

4. Observe whether the rotating wheel rake teeth rub against the ground. If there is friction, adjust the wheel bolt angle.

Operating Sequence (Manual Mode):

1. Start the power; turn on the trolley power and move it to the designated position, then stop.

2. Pump station operation, lower the wheel.

3. Start the main motor, the wheel rotates.

4. Start the trolley, bring the wheel into contact with the material, the trolley stops; the trolley starts and moves to one side. When the trolley moves from left to right, the trolley automatically shuts off power.

5. Start the trolley, the trolley moves forward (the distance depends on the width of the material being turned and the depth of the trough) to the specified distance, the trolley stops.

6. Start the trolley's other switch, the trolley moves back. When the trolley automatically shuts off power, the trolley starts.

7. Stop: the trolley and main motor shut off power, the hydraulic cylinder works, the wheel retracts to a horizontal position, power is cut off.

III. Load test run

1. Start the turning equipment, start the hydraulic lifting device, and place the wheel at the bottom of the fermentation tank.

2. Depending on the ground level, if the overall level error of the same ground is less than 15 mm, the wheel can be controlled at about 30-50 mm off the ground.

3. If the fermentation tank ground is not level, the turning blades can only be controlled at more than 50 mm off the ground.

4. After adjusting the wheel's distance from the ground, set the equipment to the working walking speed for turning.

5. During the turning process, observe carefully. If the blades hit the ground, immediately lift the turner to avoid damaging the equipment.

6. During load testing, the transmission components should operate smoothly without abnormal noise.

7. The electrical control system should operate stably, with sensitive start-stop and accurate action.

IV. Safety Precautions

1. No one should pass in front of or behind the turner during production. Warnings should be given before starting the machine, and personnel should stay away from the machine.

2. No maintenance or lubrication should be performed during production.

3. When turning, the machine must travel at the specified speed and must not exceed the speed limit.

4. No one other than the machine operator should operate the machine without authorization.

5. To avoid overloading the motor during the turner's operation and damaging it, check for any accumulated material in front of the reamer before shutting down the machine. Avoid stopping the machine when there is any material.

6. Operators should not operate the turner after drinking alcohol, or when feeling unwell or unwell.

7. For safety reasons, all tracks of the turner must be grounded.

8. When replacing cable trays or cables, the power must be disconnected.

Common Equipment Problems and Solutions

Equipment Maintenance Methods

1. Pre-shift Inspection Items (Before starting each shift):

Check that fasteners are secure;

Check that the bearing clearances of transmission components are appropriate: too loose will cause slippage, too tight will result in excessive rotational resistance;

Add grease/butter (the diagram clearly states: add grease to the bearing housing);

Check the gearbox oil level;

Check that electrical connectors are secure.

2. Post-shift Maintenance (At the end of each shift):

Clean up any residue and leftover materials from the machine and surrounding area;

Add lubricating oil to all lubrication points;

Disconnect the power switch.

3. Weekly Maintenance Items:

Check the gearbox oil level and replenish the gear oil;

Clean up any residual or accumulated materials from the equipment to ensure proper heat dissipation and normal operation;

Check the contactor contact condition in the electrical control cabinet; replace any damaged contactors immediately.

4. Periodic Inspection Items:

Check the operation of the motor and reducer: if there is any abnormal noise/overheating, stop the machine immediately;

Check bearing wear: replace bearings if excessively worn.

Application of Equipment in Production Lines

The large wheel compost turner is the core fermentation equipment in an organic fertilizer production line. In a complete organic fertilizer production line, this equipment is located at the front-end fermentation stage of the process.

1. Typical Organic Fertilizer Production Line Process Flow:

Raw Material Pretreatment (Ingredient Mixing) → Fermentation Turning (Disc Compost Turner) → Crushing → Mixing → Granulation → Drying → Cooling → Screening → Packaging

2. Specific Working Process:

1) Fermentation Material Preparation: Organic waste (such as straw, animal manure, etc.) is mixed in proportion to form a fermentation material suitable for microbial growth.

2) Turning Fermentation: The disc compost turner periodically turns the material, increasing the permeability of the raw materials, accelerating high-temperature composting, and removing odors.

3) Composting and Discharge: After further composting and dehydration, the fermented material is screened to obtain powdered finished organic fertilizer. Disc compost turners can be configured for small production lines with an annual output of 10,000–20,000 tons to medium-sized production lines with an annual output of 50,000–100,000 tons. For large production lines with an annual output of over 100,000 tons, a continuous daily processing capacity of 800–1,500 tons can be achieved through multi-stack cyclic operation.

Fermentation Process of the Equipment

1. Aerobic Fermentation Process Flow

Raw Material Pretreatment: Mix livestock and poultry manure with straw powder and other auxiliary materials in a certain proportion, adjust the moisture content to 50-65%, and the C/N ratio to about 25:1.

Inoculation with Microorganisms: Add a special organic fertilizer fermentation agent.

Pile Construction and Feeding: Feed the mixture into the fermentation tank using a loader, with a pile height of 1.5-3 meters.

Turning and Fermentation: Use a large disc turner to turn the pile regularly, generally every 2-3 days.

Temperature Monitoring: The pile temperature rises to 50-65℃ and is maintained, with the high-temperature period lasting 5-7 days.

Transfer and Push: Each time the pile is turned, it is pushed forward a certain distance, gradually moving from the feeding end to the discharge end.

Post-Ripe Aging: After the temperature drops below 40℃, the aging stage begins.

Discharge: The fully decomposed material reaches the end of the fermentation tank and is discharged by a loader to enter the next process.

2. Key Control Parameters for Fermentation

3. Fermentation Cycle

High-Temperature Fermentation Period: 7–10 days (temperature 50–65℃)

Transfer Fermentation Period: Material is gradually moved from the feed end to the discharge end

Post-Ripe Aging Period: 7–10 days

Total Fermentation Cycle: Typically 15–30 days, depending on tank length and turning frequency

Target Users of the Equipment:

1. Organic Fertilizer/Compound Fertilizer Production Enterprises: Requires automated aerobic fermentation and turning for uniform composting.

2. Livestock Farms (with supporting treatment): Harmless treatment and resource utilization of livestock and poultry manure.

3. Wastewater Treatment and Sludge Disposal Enterprises: Core equipment for industrialized harmless treatment.

4. Sugar Mills and Related By-product Resource Utilization Enterprises: Treatment of filter mud, lees, and cake residue.

5. Horticulture and Button Mushroom Cultivation Enterprises: Substrate/fermentation composting and stable supply.

6. Industrial Parks/Agricultural Complexes: Reuse of organic waste such as straw and sawdust.

Advantages of the Equipment

Compared to traditional trough-type compost turners, the large wheel compost turning machine offers the following advantages:

1. Larger Turning Depth: The turning depth can reach 2.6 meters, meaning a larger material load per unit area and saving factory floor space.

2. Wide Span: A single machine can span 24-30 meters, suitable for ultra-large fermentation tanks.

3. Low Energy Consumption: Utilizing a unique disc structure, the turning resistance is lower, resulting in lower energy consumption compared to traditional compost turners for the same workload.

4. No Dead Corners: With the trolley's lateral movement, turning can be achieved without dead corners throughout the entire fermentation tank.

Safe Operating Procedures

1. Operators must not operate the compost turner after drinking alcohol, or when feeling unwell or unwell.

2. All tracks of the compost turner must be grounded to ensure safety.

3. Power must be disconnected when replacing cable trays or cables.

4. No one may pass in front of or behind the compost turner during production. Warnings should be given before starting the machine, and personnel must stay away from it.

5. No maintenance or lubrication should be performed during production.

6. The machine must travel at the specified speed during turning; exceeding the speed limit is prohibited.

7. Unauthorized operators are prohibited from operating the machine.

8. The traveling and lateral tracks must be parallel. Limit switches must be moisture-proof and sealed to withstand the high temperature and humidity fermentation environment.

9. Daily maintenance requires close monitoring of chain tension, hydraulic station oil quality, and wheel bearing temperature.

As a core piece of equipment in the fermentation section of large and medium-sized organic fertilizer production lines, the large wheel compost turner, with its advantages of large span, deep depth, high automation, and low energy consumption, has become the preferred fermentation equipment for large-scale organic fertilizer plants, large-scale livestock farms, and sludge treatment centers. Its ground-trough aerobic fermentation technology can convert organic raw materials such as livestock manure and agricultural waste into high-quality organic fertilizer within 15-30 days, achieving the dual goals of resource utilization and environmental protection.

During selection and use, users should choose the appropriate model based on the actual fermentation tank size, raw material quantity, site conditions, and budget, and strictly adhere to operating procedures and maintenance requirements to ensure safe, efficient, and long-term stable operation of the equipment. The large-disc compost turner features a reasonable design structure, high efficiency, low energy consumption, high degree of automation, ease of use, low cost, and wide application, making it a popular and efficient machine.

If you have any questions about fertilizer production equipment, fermentation equipment, production processes, granulation processes, fermentation processes, or would like to learn more about customized solutions, please contact us immediately. Whether it's equipment selection and pricing, installation, commissioning and operation training, or later maintenance and process upgrades, we can provide you with professional and timely answers and support, offering you a full-process service.