As a leading fertilizer equipment manufacturer in China, LANE recently collaborated with a Southeast Asian client specializing in black soldier fly (BSF) composting to design a tailored black soldier fly organic fertilizer production line. This case study highlights our expertise in adapting equipment to unconventional raw materials like BSF compost, ensuring efficient and sustainable fertilizer production.
Black soldier fly compost is a nutrient-rich organic material with distinct characteristics that demand specialized processing:
High Fiber Content: BSF compost contains chitin-rich insect exoskeletons and undigested organic fibers, requiring robust crushing and screening.
Moisture & Stickiness: Fresh BSF compost has 60-70% moisture, making it prone to clumping and adhesion during granulation.
Organic Matter Complexity: Its diverse microbial activity and organic components necessitate controlled fermentation and drying.
pH Sensitivity: BSF compost tends to be alkaline, influencing post-processing additives and granulation stability.
To address these challenges, our engineering team conducted on-site experiments and redesigned key stages of the production line:
Multi-Stage Crushing: We integrated a semi-wet material crusher to break down fibrous BSF residues and insect casings, ensuring uniform particle size.
Rapid Moisture Reduction: A dynamic dehydrator was added to lower moisture to 40-45% before granulation, preventing clogging in downstream equipment.
Enhanced Fermentation: Customized compost turners accelerated aerobic fermentation, balancing pH and stabilizing nutrients.
Roller Extrusion Granulator: Selected over traditional rotary drum machines, this equipment compresses BSF compost into dense, low-dust pellets without requiring high heat or binders.
Die Design Modifications: We increased the granulator’s die hole diameter (to 6-8mm) and adjusted compression ratios to accommodate the material’s fibrous texture.
Real-Time Moisture Monitoring: Sensors were installed to auto-adjust water or steam input during granulation, ensuring pellet integrity.
Low-Temperature Belt Dryer: To preserve heat-sensitive microbes in BSF compost, we implemented a three-stage drying system (<70°C) with adjustable airflow.
Anti-Caking Cooling: A counterflow cooler with vibration sieves prevented pellet agglomeration while reducing temperature to room level.
Double-Layer Rotary Screener: Separated oversized and fine particles for re-granulation, achieving a 95% qualified pellet rate.
Biofilm Coating Drum: A probiotic coating enriched with functional bacteria was applied to enhance fertilizer efficacy and dust resistance.
The finalized black soldier fly organic fertilizer production line delivers:
Capacity: 5-8 tons/hour of uniform 3-5mm pellets.
Energy Efficiency: 30% lower energy consumption vs. standard lines, thanks to moisture and heat optimization.
Nutrient Retention: Over 90% of nitrogen and organic matter preserved through gentle processing.
Adaptability: Handles varying BSF compost batches (e.g., feedstock changes) with minimal adjustments.
Client Feedback: Post-installation, the client reported a 20% increase in product market value due to improved nutrient consistency and reduced caking during storage.
Material-Specific R&D: We conduct free raw material tests to engineer data-driven solutions.
End-to-End Support: From fermentation aids to packaging machines, we provide full-line equipment and automation.
Sustainable Design: Low emissions, water recycling, and energy recovery systems align with circular economy goals.
Unlock the Potential of BSF Compost with Tailored Fertilizer Equipment
Whether you’re scaling a black soldier fly farm or venturing into insect-based organic fertilizers, our team has the expertise to transform your raw material into high-value products.
Our turnkey solutions include operator training and annual maintenance plans, ensuring long-term operational efficiency.
Contact us today for a free consultation and learn how our Black Soldier Fly Organic Fertilizer Production Line can boost your profitability and sustainability!
