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Poultry Litter Processing Line

Litter arrives dry, fibrous and ash-rich, which changes both the fermentation design and the granulation recipe compared with slurry-based poultry manure.

Dry fibrous feedAsh & salt awareCompost first

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Quick answer

What this line is

Poultry litter is manure mixed with bedding. It ferments faster than slurry because it already has structure, but its ash and salt load limits how much can go into a bag. The line is built around screening out foreign matter early and keeping the recipe inside the salt budget.

Solution

Poultry Litter Processing Line

Primary feed

Poultry litter with wood shavings, rice husk or straw bedding

Finished product

Organic or organic-inorganic granules from litter

Process route

Pre-treatment → Fermentation → Batching → Granulation → Drying & cooling → Packing

Main constraint

Ash and salt content, not moisture

Project scope

Process, equipment, controls, layout and service as agreed

Litter is screened before fermentation so stones, wire and plastic never reach the granulator.

Inputs

Suitable raw materials

Bedding type decides the carbon-to-nitrogen ratio and the fibre length, which in turn decides how much crushing the line needs.

Poultry litter

Manure plus bedding from broiler or layer houses. Dry, fibrous, high in ash and calcium.

Straw or husk bedding

Adds carbon and porosity; long fibres need shredding before batching.

Composted base

Matured litter compost used to seed new batches and stabilise moisture.

Binder

Bentonite or lignin where litter fibre alone will not hold a granule.

Mineral filler

Used to dilute salt load and reach the declared analysis.

Output

Target finished product

The product competes with ordinary manure compost, so granule quality and a clean analysis are what justify the price.

Granule size

3–5 mm typical; screened to a declared range.

Salt load

Electrical conductivity checked on the finished product, not only on the feed.

Organic matter

Declared after ash correction; litter ash varies widely between houses.

Dust & foreign matter

Screening before fermentation is what keeps glass and wire out of the bag.

Production sequence

Process flow

Six stages. Pre-treatment exists because litter cannot be fed straight into a granulator.

Stage	Purpose	Key equipment	Control point
1. Pre-treatment	Break bedding, remove stones, wire and plastic	Vertical crusher, rotary drum screener	Screen aperture vs bedding length
2. Fermentation	Stabilise and sanitise the litter	Groove-type compost turner	Temperature curve and turning
3. Batching	Balance carbon, binder and filler	Automatic batching machine	Ash and salt budget
4. Granulation	Form the granule	Disc granulator or double roller	Moisture at the press
5. Drying & cooling	Reach spec moisture, stabilise	Rotary drum dryer and cooler	Material discharge temperature
6. Screening & packing	Classify and bag	Screener, packing machine	Oversize recycle

Why this order: screening before fermentation, not after, is what protects the granulator and the customer. Wire and glass that pass through a turner come out as fines that no screen will catch later.

Equipment

Equipment configuration

Typical equipment scope for this route. Final selection follows the approved mass balance and site conditions.

Pre-treatment

Vertical Crusher

Pre-treatment

Rotary Drum Screener

Fermentation

Groove-Type Compost Turner

Granulation

Disc Granulator

Drying

Rotary Drum Dryer

Packing

Fertilizer Packing Machine

Capacity

Capacity bands

Bands describe typical project scale; the actual figure is confirmed by mass balance, not by a nominal model number.

2–5 t/h

Single line; yard fermentation, one granulator and dryer.

5–12 t/h

Parallel granulators with shared drying and automatic bagging.

12–20 t/h

Multi-line plant with separate pre-treatment and buffer silos.

Operation

Utility requirements

Basis for the utility sheet. Local voltage, fuel and water quality are confirmed during engineering.

Power

Crusher and dryer dominate the load.

Fuel

Dryer heat source; litter burns readily, so fire risk in the dryer needs a spark arrestor.

Water

Small make-up for granulation; litter is already dry.

Dust collection

Fibrous litter dust bridges in filters; use a pre-separator.

Fire safety

Litter dust is combustible. Earthing, spark detection and housekeeping are part of the scope.

Storage

Covered bays, since rain turns litter into an unmanageable mass.

Quality

Quality control points

Controls that decide whether the line holds its specification in daily operation.

Foreign matter

Checked at the pre-treatment screen, not at the bag.

Ash content

Sampled per batch; it moves with bedding and feed changes.

Salt load

EC test on the finished granule for sensitive crops.

Moisture at press

The variable that decides recycle load.

FAQ

Questions buyers ask

Straight answers on scope, limits and what we need to quote.

Can fresh litter be granulated directly?

No. It must be fermented and stabilised first, otherwise the bag reheats and the analysis drifts.

How much bedding is acceptable?

It is a design input: long bedding needs more shredding and lowers bulk density. Send the bedding type and share.

How do you handle the salt load?

By capping the litter share in the recipe and diluting with filler or lower-salt organic matter.

What do you need to quote?

Litter tonnage, bedding type, target granule size, and whether the product is organic-only or organic-inorganic.

Next step

Request a project review

Send material, capacity and site constraints; the engineering team replies with a route recommendation.