Fertilizer Manufacturing Plant In Pakistan
installation country
Pakistan
Production Capacity
6T/H
Project Investment
$130,000
Product type
Powder
This is an expansion project of fertilizer manufacturing plant in Pakistan .
The client is a biotechnology company. In 2020, it invested in the “Earthworm Breeding and Organic Fertilizer Production Construction Project”. The main construction contents include: fermentation area, earthworm breeding greenhouse, drying area, processing and packaging area, finished product warehouse, etc. The project is mainly engaged in earthworm breeding and bio-organic fertilizer (earthworm manure) production, with an annual output of 12,000 tons of bio-organic fertilizer (earthworm manure).
In order to seize market opportunities and improve market competitiveness, the client gave full play to the advantages of the project’s regional location, agricultural resources, and its own industrial advantages. In November 2023, the client invested 130,000 US dollars to expand the original project, adding an annual output of 18,000 tons of organic fertilizer.
This fertilizer manufacturing plant in Pakistan expansion project mainly uses dehydrated pig manure, forest grass green manure, cereal and potato crop straw, beet pulp, kitchen waste degradation, organic by-products of food and beverage processing, biogas residue/liquid, peat/peat/charcoal ash, etc. to ferment and process into organic fertilizer.
This expansion project adjusts the existing plane layout within the original project area, increases the production of organic fertilizer by 18,000t/a, and the project area and building area remain unchanged. The expansion project adds 6 employees.
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Construction content of fertilizer manufacturing plant in Pakistan
The earthworm breeding area is located in the middle of the factory area, with office buildings and dormitory buildings in the south of the factory area, fermentation areas in the east and northeast, and finished product areas, production and packaging areas, and drying areas in the west.
The project plane layout makes the production and auxiliary functions clearly divided, production management is convenient, land is saved, and the layout is relatively reasonable.
This fertilizer manufacturing plant in Pakistan expansion project will adjust the existing layout within the scope of the original project, increase the production of organic fertilizer by 18,000t/a, and adjust the three earthworm breeding greenhouses to the organic fertilizer fermentation area of the expansion project. The content of the project after the expansion is as follows.
| Category | Engineering Name | Construction Content of the Original Project | Construction Content of the Expansion Project |
| Main engineering | Fermentation Area | The land area and building area are both 2000m2, and 4 fermentation areas are set up, mainly for natural fermentation of cow dung. | The expansion project will adjust 3 earthworm breeding greenhouses to the organic fertilizer fermentation area of the expansion project, and the fermentation area will increase the land area and building area by 2000m2. |
| Earthworm Breeding Greenhouse | The land area and building area are both 20000m2. The project sets up 7 breeding areas for breeding. The breeding area is a semi-enclosed plastic greenhouse with a color steel shed on the top. It is used for earthworm breeding. | The expansion project will adjust the three earthworm breeding greenhouses to the organic fertilizer fermentation area of the expansion project, and the earthworm breeding greenhouse will reduce the land area and building area by 2000m2. | |
| Drying area | The land area and building area are both 900m2, used for drying earthworm manure. | No change | |
| Processing and packaging area | The land area and building area are both 300m2, used for crushing and screening earthworm manure. | No change | |
| Storage and transportation engineering | Finished product warehouse | The land area and building area are both 1600m2, used for temporary storage of finished products. | No change |
| Auxiliary engineering | Office area | The floor area and building area are both 60m2, mainly for daily office and rest room. | No change |
| Staff accommodation area | The floor area and building area are both 140m2, including toilets, dormitories and other living areas. | No change | |
| Others | The floor area is 14000m2, mainly for aisles, parking areas and open spaces. | No change |
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economic parameters of fertilizer manufacturing plant in Pakistan
| Before expansion | After expansion | ||||||
| Number of floors | Occupied area | Building area | Number of floors | Occupied area | Building area | Purpose | |
| Fermentation area | 1 | 2000 | 2000 | 1 | 4000 | 4000 | 7 fermentation areas, used for natural fermentation of organic fertilizer |
| Earthworm breeding greenhouse | 1 | 20000 | 20000 | 1 | 18000 | 18000 | 4 breeding areas, earthworm breeding |
| Drying area | 1 | 900 | 900 | 1 | 900 | 900 | Drying organic fertilizer |
| Processing and packaging area | 1 | 300 | 30 0 | 1 | 300 | 300 | Organic fertilizer crushing and screening |
| Finished product warehouse | 1 | 1600 | 1 | 1600 | 1 | 1600 | Temporary storage of finished products |
| Office area | 1 | 60 | 60 | 1 | 60 | 60 | Daily Regular office and rest |
| Staff accommodation area | 1 | 140 | 1 | 140 | 1 | 140 | Toilet, dormitory living area |
| Others (aisles, parking areas, open spaces) | / | 14000 | / | / | 14000 | / | Aisles, parking areas, open spaces |
| Total | 39000 | 25000 | / | 39000 | 25000 | / | |
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Product scale
This fertilizer manufacturing plant in Pakistan project mainly uses dehydrated pig manure, forest and grass green manure, cereal, wheat and potato crop straw, beet pulp, kitchen waste degradation, organic by-products of food and beverage processing, biogas residue/liquid, peat/peat/charcoal ash, etc. to make organic fertilizer through fermentation. The expansion project produces 18,000 tons of organic fertilizer per year. The various products before and after the project expansion are detailed in the table below.
| No. | Product name | Specifications | Shape | Annual output | Change (t/a) | ||
| Original project (t/a) | Expansion project (t/a) | Full expansion after expansion Factory (t/a) | |||||
| 1 | Earthworm manure | 20kg/bag | Powder/granules | 12000 | 0 | 12000 | ±0 |
| 2 | Organic fertilizer | 20kg/bag | Powder/granules | 0 | 18000 | 18000 | 18000 |
| Total | 12000 | 18000 | 30000 | 18000 | |||
The quality of the organic fertilizer products produced by this project should meet the industry standards. After aerobic fermentation of the raw and auxiliary materials used in this project, the organic fertilizer produced is solid and has a water content of about 30%. The specific implementation standard values of the organic fertilizer of this project are shown in the table below.
| Item | Indicator |
| Mass fraction of organic matter (on a dry basis), (%) | ≥45 |
| Mass fraction of total nutrients (nitrogen + phosphorus pentoxide + potassium oxide) | ≥5.0 |
| (on a dry basis), (%) | |
| Mass fraction of water (fresh sample), (%) | ≤30 |
| Acidity, (pH) | 5.5~8.5 |
| Total arsenic (As) (on a dry basis) | ≤15 |
| Total mercury (Hg) (on a dry basis) | ≤2 |
| Total lead (Pb) (on a dry basis) | ≤50 |
| Total cadmium (Cd) (on a dry basis) | ≤3 |
| Total chromium (Cr) (on a dry basis) | ≤150 |
| Effective viable count (cfu), billion/g | ≥0.20 |
| Organic matter (on a dry basis), % | ≥40.0 |
| Moisture, % | ≤30.0 |
| pH value | 5.5~8.5 |
| Fecal coliform count, pieces/g | ≤100 |
| Ascaris egg mortality, % | ≥95 |
| Validity period, months | ≥6 |
| Total arsenic (As) (on a dry basis) | ≤15 |
| Total mercury (Hg) (on a dry basis) | ≤2 |
| Total lead (Pb) (on a dry basis) | ≤50 |
| Total cadmium (Cd) (on a dry basis) | ≤3 |
| Total chromium (Cr) (on a dry basis) | ≤150 |
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Main raw and auxiliary materials
This fertilizer manufacturing plant in Pakistan project uses dehydrated pig manure, forest and grass green manure, cereal, wheat and potato crop straw, beet pulp, kitchen waste degradation, organic by-products from food and beverage processing, biogas residue/liquid, peat/peat/charcoal ash, etc. to make organic fertilizer through fermentation. The raw and auxiliary materials before and after the project expansion are detailed in the table below.
| No. | Raw material name | Annual usage (t/a) | Variation (t/a) | Maximum storage capacity (t) | Remarks | ||
| Original project | Expansion project (t/a) | The entire factory after expansion | |||||
| 1 | Cow dung | 24000 | 0 | 24000 | ±0 | 200 | / |
| 2 | Earthworm | 6 0 | 0 | 60 | ±0 | 20 | / |
| 3 | Dehydrated pig manure | 0 | 4000 | 4000 | 4000 | 200 | Main ingredients: organic matter. |
| 4 | Forest grass green manure | 0 | 4000 | 4000 | 4000 | 200 | Main ingredients: plant fiber. |
| 5 | Grain, wheat and tuber straw | 0 | 2000 | 2000 | 2000 | 100 | |
| 6 | Beet pulp | 0 | 2000 | 2000 | 2000 | 100 | |
| 7 | Food waste | 0 | 2000 | 2000 | 2000 | 100 | Classified and fermented Cooked kitchen waste degradation products; main components: organic matter, nitrogen, phosphorus and potassium nutrients. |
| 8 | Organic by-products of food and beverage processing | 0 | 2000 | 2000 | 2000 | 50 | Mainly wine lees, soy sauce lees, tea lees, edible fungus lees, fruit lees, sugar lees, etc.; main components: organic matter, nitrogen, phosphorus and potassium nutrients. |
| 9 | Biogas residue/liquid | 0 | 1000 | 1000 | 1000 | 5 | Main components: organic matter, nitrogen, phosphorus and potassium nutrients. |
| 10 | Peat/charcoal ash | 0 | 1000 | 1000 | 1000 | 5 | |
| 11 | Probiotic fermentation agent | 0 | 70 | 70 | 70 | 5 | Fermentation agent |
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Equipment List of fertilizer manufacturing plant in Pakistan
The renovation and expansion of the main production and auxiliary equipment of this fertilizer manufacturing plant in Pakistan project are shown in the table below.
| No. | Equipment name | Model | QTY | Changes (units) | Purpose | ||
| Original project | Expansion project | After expansion | |||||
| 1 | Forklift | 932/946 | 2 | 0 | 2 | ±0 | Transporting raw materials. |
| 2 | Truck | / | 2 | 0 | 2 | ±0 | Transport raw materials. |
| 3 | Packaging machine | / | 1 | 0 | 1 | ±0 | Used for packaging earthworm manure and organic fertilizer. |
| 4 | Crusher | / | 1 | 0 | 1 | ±0 | Used for crushing earthworm manure and organic fertilizer. |
| 5 | Screening machine | / | 1 | 0 | 1 | ±0 | Used for sieving and removing impurities from earthworm manure and organic fertilizer. |
| 6 | Compost turner | / | 0 | 2 | 2 | 2 | Used for composting and fermentation of earthworm manure and organic fertilizer. |
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Personnel and production system
The fertilizer manufacturing plant in Pakistan project does not involve production at night before and after the expansion. Before the expansion, there were 6 project employees, all of whom stayed in the factory area and did not eat in the factory area; the expansion project added 6 new employees, none of whom ate and slept in the factory area. The changes in labor quotas before and after the fertilizer processing plant project expansion are shown in the table below.
| No. | Category | Original project | Expansion project | Entire factory after expansion |
| 1 | Number of employees | 6 | 6 | 12 |
| 2 | Work system | 8-hour work system per day | 8-hour work system per day | 16-hour work system per day |
| 3 | Working days | 280 days | 280 days | 280 days |
| 4 | Food and lodging | All stay in the factory area, and do not eat in the factory area | All do not eat in the factory area. | 6 people stay in the factory area, and do not eat in the factory area. |
| 5 | Annual production time | 2240h/a | 2240h/a | 4480h/a |
| 6 | Production scale | Annual production of earthworm manure 12,000 tons. | Annual production of organic fertilizer 18,000 tons. | Annual production of organic fertilizer 30,000 tons |
| (including earthworm manure). |
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Public works
(1) Power supply
The power supply of this fertilizer manufacturing plant in Pakistan project is supplied by the municipal power grid, with an annual power consumption of approximately 10,000 kWh. No generators are installed in the project.
(2) Water supply
The domestic water and fermentation supplementary water of this expansion project are directly supplied by the municipal water supply network, of which the domestic water consumption is 60t/a and the fermentation supplementary water consumption is 126t/a, with a total project water consumption of 186t/a.
(3) Drainage
This organic fertilizer production plant project implements rainwater and sewage diversion, and independent pipeline systems are set up for rainwater and domestic sewage. The fermentation leachate of the project is reused as fermentation water after passing through the fermentation area ditch to the next batch of material fermentation, and is not discharged externally;
The fermentation supplementary water is all evaporated naturally, and no wastewater is generated; the domestic sewage is treated in a three-level septic tank to meet the farmland irrigation water quality standard and then reused for earthworm breeding farm spraying, and is not discharged externally; the rainwater is discharged into the municipal rainwater network.
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organic fertilizer Process design
This fertilizer manufacturing plant in Pakistan project uses dehydrated pig manure, forest and grass green manure, cereal and potato crop straw, kitchen waste degradation, organic by-products of food and beverage processing, biogas residue/liquid, peat/peat/charcoal ash, etc. to ferment and process into organic fertilizer. The expansion project produces 18,000t/a of organic fertilizer annually.
Brief description of the process:
(1) Mixing:
Mix the raw materials in the fermentation area in proportion using a forklift and a compost turner.
(2) Composting:
The mixed materials are composted and fermented in the fermentation area. During the composting fermentation process, probiotic fermentation agents need to be added to allow the raw materials to quickly heat up and ferment and mature. The highest temperature during the composting process is about 65°C. During the fermentation process, heat will be generated and water will evaporate.
Therefore, a compost turner is used to turn the compost every 3-4 days to allow oxygen to be supplied to the internal raw materials to continue fermenting and maturing, so that the raw materials can be fermented and matured evenly. After turning the compost, the temperature will continue to rise and then drop. After 15-20 days of fermentation, the raw materials are basically fermented and mature, and the temperature immediately drops to room temperature.
During the fermentation process, when the moisture content is low, in order to ensure the reproduction of microorganisms and maintain the moisture content of the fermented materials between 60% and 65%, the materials need to be properly replenished with water. During the fermentation process, part of the moisture of the materials evaporates due to the increase in temperature, and part is lost by microorganisms.
Therefore, under the condition of controlling the initial moisture of the fermented materials, the amount of leachate produced during the fermentation process is small. The leachate is collected by the grooves in the fermentation area and reused for the next batch of materials to ferment.
(3) Drying:
After the compost fermentation is completed, the materials are dried in the drying area for about 15 days. The drying area is a steel frame greenhouse. The moisture content of the materials is controlled to not exceed 30% through drying.
(4) Crushing and screening:
After the dried organic fertilizer is simply crushed by the crusher, it is sent to the screening machine for screening and impurity removal.
(5) Packaging:
The screened organic fertilizer is packaged by the packaging machine and sold.
Original project production process
The original fertilizer plant project production process is as follows:
(1) Raw material transportation:
In order to avoid the odor generated by raw material transportation affecting sensitive points along the transportation route, it is necessary to reasonably select the transportation route, try to choose a transportation route with good road conditions and avoid sensitive areas such as the main urban area of the city; avoid transportation during peak traffic hours; during the transportation of cow dung, strengthen the management of cow dung transportation, and seal the transportation vehicles. It is prohibited to omit and throw along the way to avoid secondary pollution during transportation.
(2) Fermentation:
After mixing, the raw materials enter the fermentation stage. This project adopts room temperature fermentation. The fermentation process first decomposes easily decomposable organic matter to produce CO2 and H2O, and at the same time generates heat to increase the temperature. Microorganisms use carbon, nitrogen and other nutrients in organic matter to synthesize cytoplasm for their own reproduction while releasing heat to decompose organic matter.
The decomposition of organic matter in the early stage of fermentation is carried out by mesophilic bacteria (the optimal temperature for growth and reproduction is 30-40℃). As the temperature of the pile increases, thermophilic bacteria with an optimum temperature of 45-65℃ replace mesophilic bacteria and decompose efficiently. The fermented material is decomposed organic matter with low water content, solid form, and pH between 6 and 8.
(3) Earthworm feeding:
Transfer cow dung to the breeding area and pile it into an earthworm breeding bed with a height of 40cm and a width of 1.5m-2m, and put earthworm seeds in it. Earthworms have obvious tendencies to suitable temperature, fresh food and suitable humidity layer, and have strong agglomeration. When these basic conditions are met, earthworms will not escape.
During the breeding process, spraying is carried out once every 7 days on average, for about 10 minutes each time, and it is advisable to keep the soil moisture at about 50%. In summer, when the temperature is high, the spraying interval can be appropriately shortened, depending on the weather and temperature conditions.
(4) Earthworm separation:
Earthworms are separated by taking advantage of their light-avoiding properties. Manual separation is performed, and the upper layer of earthworm manure is taken away. When the earthworms see the light, they will move to the lower layer. In this way, the upper layer of earthworm manure is taken away in a cycle, and finally the earthworms are hidden in the bottom layer.
Feeding: Earthworms turn the base material into earthworm manure during their growth period. Therefore, timely feeding is required. Feeding is implemented by directly covering the ridge with new material. Feeding is done about once a week, and the number of feedings is consistent with the fermentation cycle and fermentation volume; earthworms can digest the raw materials and turn them all into earthworm manure.
(5) Drying:
The separated earthworm manure is placed on a hardened ground for drying for about 15 days.
(6) Crushing and screening:
After the dried earthworm manure is simply crushed by a crusher, it is transferred to a screening machine for screening and impurity removal.
(7) Packaging:
The screened organic fertilizer is packaged by a packaging machine and sold.
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Prospect Analysis and Investment Strategy for Building an Organic Fertilizer Production plant in Pakistan
Pakistan is a major agricultural country, but its long-term dependence on chemical fertilizers has led to soil degradation, and the market demand for organic fertilizers is growing rapidly. At the same time, government policy support, low-cost raw material supply and environmental protection needs provide huge business opportunities for organic fertilizer production.
1. Strong market demand
Agriculture-dominated economy: Agriculture accounts for 24% of Pakistan’s GDP, and major crops include wheat, rice, cotton, sugarcane and fruits (such as mangoes and citrus).
Problem of excessive use of chemical fertilizers: Pakistan ranks among the top countries in the world in terms of fertilizer use, but the organic matter content in the soil has dropped to <1% (healthy soil requires 3%-5%), resulting in a decline in yields, and farmers are beginning to turn to organic fertilizers.
Starting of organic agriculture: Currently, organic cultivation accounts for only 1%, but the government’s goal is to increase it to 10% by 2030, and the demand for organic fertilizers is expected to grow by 15%-20% annually.
2. Strong policy support
Subsidies and tax incentives:
Some provinces (such as Punjab and Sindh) provide tax exemptions for 3-5 years or low-interest loans for organic fertilizer production.
In 2023, the Pakistani government launched the “Green Pakistan Initiative” to encourage organic fertilizers to replace chemical fertilizers.
Environmental regulations promote:
Restrict straw burning and encourage composting (fines for violators).
Large farms (such as poultry and dairy farms) need to deal with manure, otherwise they will face penalties.
3. Adequate supply of raw materials and low cost
Agricultural waste: rice husks, bagasse, cotton straw, etc., priced at $10-30/ton.
Livestock and poultry manure: Pakistan is the world’s fifth largest poultry producer, and chicken manure is in sufficient supply (available for free or at a low price). Cow manure and sheep manure are very easy to purchase in livestock areas (such as Sindh).
4. Competitive landscape and opportunities
Local enterprises have backward technology: Most of the existing organic fertilizer factories are small workshops, and the product quality is unstable (high moisture content, not fully decomposed).
High dependence on imports: High-end organic fertilizers (such as granular fertilizers and bio-organic fertilizers) are mainly imported from China and India, and are expensive (about $400-600/ton).
Market gap: There is a great demand for granular organic fertilizer (convenient for mechanized fertilization) and biological organic fertilizer (containing nitrogen-fixing bacteria and phosphate-dissolving bacteria), but the local supply is insufficient.
Pakistani agriculture has a great demand for organic fertilizer, local policies support it, raw materials are almost free, and the profit margin is considerable. In Pakistan, it is very suitable to start with a medium-sized granular fertilizer production line to test market acceptance. Pakistan’s organic fertilizer market is on the eve of an explosion, and those who take the lead can occupy a dominant position!
If you are interested in building a fertilizer manufacturing plant in Pakistan, feel free to contact RICHI MACHINERY for civil engineering plans, fermentation tank construction plans, organic fertilizer formulas, process design plans, fertilizer making machine configuration plans and quotation information!
