Fertilizer Granulation Plants and Blending Systems
Process engineering, equipment and turnkey plant solutions for NPK production and fertilizer blending.
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Turnkey Fertilizer Granulation Systems from Design to Commissioning
As a full-service engineering partner for fertilizer production, we design, manufacture and commission complete granulation plants around your raw materials, target capacity and product specifications. Each solution can integrate dosing, mixing, granulation, drying, screening, cooling, coating and packing into one coordinated production system.
- Granule-Uniformity
- In-House Fabrication
- Ultra-Low Dust
- As Built Documents after Delivery
Share your current land plan, and we'll design a 3-D drawing to clearly illustrate the most suitable production plant or fertilizer granulation processes, and send you a 48-hour quote complete with capacity and equipment specs, no strings attached.
From planning to production
A Complete Fertilizer Granulation Plant, Built Around Your Needs
With more than 25 years of experience in fertilizer plant design and manufacturing, we build solutions around your raw materials, fertilizer formula, and target output. Whether you’re starting a new facility or expanding production, our project experience ranges from 1-tonne-per-hour microgranular plants to 80-tonnes-per-hour NPK plants, including blending and liquid fertilizer plants.
Each plant brings the production stages together into one coordinated system. Ingredients are measured by weight, mixed if necessary, and formed into granules using wet or dry granulation methods. Drying removes excess moisture, while screening separates granules to your chosen size—typically 2–4 mm for standard NPK fertilizer. Material that is too small or too large returns for reprocessing, in continuous fashion.
The finished granules are then cooled and packed for storage and delivery. We match each stage to the plant’s required output, and with selected packing lines, we establish complete production plants with a focus on reliable operation, straightforward maintenance.
From layout and equipment manufacturing to installation and startup, we help you turn your production plans into a working facility.
8 Steps in Granular Fertilizer Production Plants
Fertilizer Granulation Process Timeline
1. Dosing System
Dosing is the first step of the turnkey fertilizer granulation system, our dosing systems precisely measure every solid or powder ingredient using loss-in-weight method. Loadcells calibrated with belt feeders connected to a local PLC is used to monitor the feed rate in real time.
Dosing is the first step of the turnkey fertilizer granulation system, our dosing systems precisely measure every solid or powder ingredient using loss-in-weight method. Loadcells calibrated with belt feeders connected to a local PLC is used to monitor the feed rate in real time.
2. Granulation
Granulation converts fine fertilizer particles into larger granules through rolling and tumbling inside a rotating drum or pan. With the addition of moisture or a binder, fine particles stick to seed particles, forming successive layers as the granules grow. Feed rate, moisture content, and operating conditions are adjusted to control granule growth before the material moves to the drying stage.
Granulation converts fine fertilizer particles into larger granules through rolling and tumbling inside a rotating drum or pan. With the addition of moisture or a binder, fine particles stick to seed particles, forming successive layers as the granules grow. Feed rate, moisture content, and operating conditions are adjusted to control granule growth before the material moves to the drying stage.
3. Drying
A rotary dryer uses hot air supplied by a dedicated burner to evaporate free moisture from the fresh granules coming out of the granulation stage, increasing their strength before classification and downstream processing. This is a crucial step in wet granulation plants, helping maintain consistent product quality through careful control of several operating parameters.
A rotary dryer uses hot air supplied by a dedicated burner to evaporate free moisture from the fresh granules coming out of the granulation stage, increasing their strength before classification and downstream processing. This is a crucial step in wet granulation plants, helping maintain consistent product quality through careful control of several operating parameters.
4. Screening & Sifting
Vibrating screens separate the dried fertilizer into three fractions: granules within the required size range, undersized fines, and oversized granules. Correctly sized granules continue to downstream processing, while fines return to the granulator and oversized material is sent to the crusher before recycling. This stage maintains a consistent product size while recovering material for reprocessing.
Vibrating screens separate the dried fertilizer into three fractions: granules within the required size range, undersized fines, and oversized granules. Correctly sized granules continue to downstream processing, while fines return to the granulator and oversized material is sent to the crusher before recycling. This stage maintains a consistent product size while recovering material for reprocessing.
5. Crushing
CEYLAN double-rotor hammer crushers break down oversized granules from the screens into fine particles for recycling into the granulation process. Rotating hammers crush the material through repeated impact, while hardened steel construction helps extend hammer service life. The crusher’s internal PE 1000 lining resists abrasion and helps reduce material buildup, supporting reliable operation.
CEYLAN double-rotor hammer crushers break down oversized granules from the screens into fine particles for recycling into the granulation process. Rotating hammers crush the material through repeated impact, while hardened steel construction helps extend hammer service life. The crusher’s internal PE 1000 lining resists abrasion and helps reduce material buildup, supporting reliable operation.
6. Cooling
A counter-current rotary cooler lowers the temperature of the granules before coating and packing. This reduces the risk of condensation and caking during storage and helps keep the finished fertilizer free-flowing.
A counter-current rotary cooler lowers the temperature of the granules before coating and packing. This reduces the risk of condensation and caking during storage and helps keep the finished fertilizer free-flowing.
7. Coating
Cooled granules pass through a coating drum, where a thin layer of oil, polymer or anti-caking agent is applied to help keep the fertilizer free-flowing during storage and handling.
Cooled granules pass through a coating drum, where a thin layer of oil, polymer or anti-caking agent is applied to help keep the fertilizer free-flowing during storage and handling.
8. Packing
Finished granules are transferred to a packing system and filled into bags. Depending on the bag type a open mouth bagging system or FFS bagging system is integrated. The bagging is handled fully automatically and finally the fertilizer is ready for storage or shipment.
Finished granules are transferred to a packing system and filled into bags. Depending on the bag type a open mouth bagging system or FFS bagging system is integrated. The bagging is handled fully automatically and finally the fertilizer is ready for storage or shipment.
About
Our Processes
Latest Projects
Completed Fertilizer Facilities
Bolu NPK Production Plant 30 tons/hour
Ongoing project, where phosphorus-rich ash in the fertilizer granulation process is turned into a raw material to become granular NPK fertilizer.
Samsun NPK Production Plant 30 tons/hour
Fertilizer Production Plant System, where steam granulation is performed along with great dust reduction.
Iskenderun 80 tons/hour twin NPK Production Plant
A twin facility where a 3.6m diameter drum was selected to match the high production capacity and requirements of industrial fertilizer production.
Antalya Micro Granular Fertilizer Production Plant 10 tons/hour
Micro granular fertilizer production plant systems, where sieves are selected specifically for the process.
Izmir 15 tons/hour Bulk Blending Facility
Bulk Blending Facility, where the turnkey fertilizer granulation system grinds every raw material to achieve a high homogeneity blend.
Antalya Bulk Blending Facility 15 tons/hour
Powder mixing process, where high shear mixer is performing along with consistent packing machine.
We Design. We Build. You Grow.
From 3-D models that bring your ideas to life to precise 2-D drawings that guide our skilled craftsmen, we own every stage of the process. We are process equipment manufacturers with a team that delivers on spec and on schedule—whether you need a urea melter, a dust-control system, or a complete turnkey inorganic or organic fertilizer granulation process. Whatever shape or formulation your fertilizer requires, we design and build the production line that makes it happen.
PARTNERS WHO TRUST CEYLAN
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Our value
Build Smarter Plants for Your Needs
From first feasibility study to first ton out, we deliver digital-ready turnkey fertilizer granulation systems alongside chemical-process lines—safer, leaner, and greener.
Seasoned Specialists
With more than 30 turnkey projects on the board, our multidisciplinary crew of process engineers, mechanical designers, and automation experts speaks the language of the shop floor.
Industry 4.0 DNA
It’s not just an everyday fertilizer granulation process. Digital twins, closed-loop AI dosing, and PLC/SCADA architecture come standard—maximizing throughput while squeezing energy use and emissions.
Strong Partnership
24/7 remote monitoring, rapid-response field teams, and data-driven maintenance programmes keep your operational efficiency above 95 % year-round.
Have more questions? Visit our FAQ page to find answers and learn more about our fertilizer plant solutions.