The Bio Fertilizer Production Technology is built on the technical knowledge on how to efficiently control and accelerate the aerobic composting process. The process takes place in a closed and controlled environment, whereby microorganism is degrading and transforming biomass into a mixture of mineralized and organic composition known as loam/compost. Our technology is reducing production time; giving farmers access to cost effective and reliable bio-fertilizers. Depending on soil conditions and crop requirement, the bio-fertilizer product will have the same nutrient value as the standard NPK fertilizer with 3 kg of bio-fertilizer to 1 kg NPK fertilizer. It is strictly recommended that micro nutrients are added per soil conditions to allow retention of macro minerals.
Step 1: Testing and Analysis Testing and analysis of soil conditions, raw material, minerals and bio-fertilizer product shall be carried out at each stage.
Step 2: Collecting and Transporting Organic waste such as green waste and animal manure are important raw material sources. This waste is collected and transported to preferred location.
Step 3: Sorting Waste is sorted according to type and all inorganic materials must be separated from the organic waste.
Step 4: Crushing and Mixing Mechanized Productivity. Organic waste is loaded according to type into the Crusher-Mixing Machine. The open top wagon sits on an axel unit and can monitor the weight of each feed. The chopping-mixing augers starts crushing, pushing and mixing the feed. Rock phosphate and ash are added and mixed to the feed. Additional types of feed are added accordingly. It is very important that the correct ratio between the different input materials are obtained as well as mixed properly to control the further process. The Weighing System can weigh up different types of waste and minerals and accommodates different type of bio fertilizer recipes. Once ready, the feed is discharged to the Container Unit by the conveyor belt which sits on the top side of the wagon and is controlled by a hydraulic arm.
Step 5: Heat Controlled Composting: The aerobic composting process is activated by blowing in oxygen over the biomass using an aerator and if higher moisture is needed. After 24-48 hours, the biomass will reach +70° C and is kept at this temperature for the next 24 hours (may vary), whereby any pathogenic bacteria, protozoa and weed seeds has been destroyed and the feed is completely sterilized. This process also starts the chemical breakdown of the rock phosphate enabling its nutrients to be released and made suitable for absorption by plants. Then the biomass is left to mature. The composting process is constantly monitored by the control system which monitors and controls temperature and oxygen content. Within another 3 days the material has become a dark brown colored and sweet smelling humus with high organic matter. Once the matter has stabilized at an ambient temperature the product has matured and is ready for screening.
Step 6: Screening and Quality Control: During the screening and quality control process, any oversized or contaminant items shall be removed. The bio-fertilizer can be divided into two grades: 1) Fine grade bio-fertilizer is for quick assimilation by plants, particularly nurseries and germinating crops. 2) Second grade bio-fertilizer is for grownup crops as it contains more moisture than the fine grades.
Step 7: Blending: Macro nutrients as nitrogen as well as micro minerals as boron, Sulphur, chlorine, copper, iron, manganese, molybdenum, nickel and/or zinc are now added to the bio-fertilizer and blended according to crop requirements and soil conditions including type and status.
Step 8: Granulating Mill: Customers who are interested in commercial production of bio-fertilizers have the option of utilizing a Granulating Mill.
Step 9: Bagging Machine When a bag is filled, the bag clamping device will automatically open and the bag will be conveyed for sealing. Each bag is labelled showing content of nutrients and application
20-Foot Container: The BFP-Unit is constructed by customizing a 20-foot container. This allows for easy transportation and scalability by adding extra container units to your system. The BFP Container is fitted with a top cover allowing biomass to be filled from the top. It has double layered bottom with perforated top layer (ensuring aeration) which can be removed for easy emptying of biomass. Each BFP-Unit has capacity to compost 18t organic waste and will produce 12-15t tailored bio-fertilizer per week. The annual production capacity is 6-800 tones bio-fertilizer annually.
Control System: Primary innovation is the design of the Control System. This technology is regulating and monitoring the temperature and humidity of the biomass; thereby controlling the heat composting process. The Control system comes with Personal Logical Controller, Aerator and Sensors.
Personal Logical Controller (PLC) monitors and controls composting process and can be operated at location or using remote control (cloud) making our technology very user friendly.
Tractor With Frontloader The tractor comes with front-loader for loading the Mixer-Crusher as well as the BPF-Unit.
Mixer-Crusher The machine is built on a high strength steel frame wagon with open top and a loading capacity of 5m³. The machine has an epicycloidal gearbox and hydraulic coupling to tractor for mobility. It comes with high strength steel chopping-mixing augers, revolving star shaped chopping blades and toothed demountable, adjustable counter blades. The axel unit has weighing sensors controlling the weight of the input feed. The Weighing System can accommodate different ingredients (waste and minerals) and will allow for production of different bio-fertilizer “recipes”. The conveyor belt which sits on the top side of the wagon is controlled by a hydraulic arm, making discharge of the crushed feed to the container unit easy.
Granulating Mill. The Granulating Mill will have an open funnel that feeds the granular to the compression zone. This part is fitted with a rotating driven roller that moulds, slides, rolls and presses the material through the die hole giving it the required size and lengths of pellets. After cutting, the pellets are dropped into a crate.
Bagging Machine The Bagging Machine comes with a funnel, balance weight, loading hopper with level control, alarm function and interchangeable spouts for various bag sizes. Optional, the machine can be delivered with software, conveyor belts and a sewing or heat sealing machine. Specific brand, type and model will be quoted based on a customer preference to scale, quality and price.
Transport and Logistic Transform will assure the BFP-Unit as well as additional machinery and equipment is delivered to preferred location.
Installation of Machinery and Equipment Transform will assure the BFP-Unit as well as additional machinery and equipment is installed and to good working order at preferred location.
After Sale Service and Maintenance. The Local Service Provider shall provide rapid after-sale maintenance and service to customers. The service agreement includes service, maintenance and repair for the first 2 years which shall be included in the sales price with optional customer payment for the following years.
Transform will provide technical assistance to you and ensure your staff is trained to operate the BFP Unit, Mixer-Crusher, Pelleting Mill and Bagging Machine. We will also make sure staff understands the heat controlled composting process and are able to produce tailored bio-fertilizers which meet soil requirements.
Supply Management of Biomass Feed and Minerals Transform and yourself will map supply of organic waste as well as macro and micro minerals. Transform will also perform laboratory testing and analysis of biomass as well as soil conditions in specific arable areas. Based on this, Transform will supply you with “recipes” for producing 3-5 standardized bio-fertilizer products.
Operation of Machinery and Equipment Transform will train relevant staff to operate BFP-Unit, Mixer-Crusher, Pelleting Mill,Bagging Machine.
Heat Controlled Composting Process Transform will train relevant staff to undertake production of composting process. Please see for Section III for full description.