BioGro Solves Milling Challenges With Custom Fertilizer Crusher Machine
Challenge
BioGro needed a reliable way to crush dried fertilizer particles into consistent sizes without generating excessive fines that reduced usable product.
Solution
RMS tested BioGro’s material and designed a custom fertilizer crusher machine using an industrial roller mill configuration tailored to the product.
Result
The new mill increased throughput, produced three consistent fertilizer grades, and reduced fines from roughly 20% – 30% to about 10% – 15%.
Consistent sizing of fertilizer granules is essential for product quality. Oversized particles affect blending and application, while excessive fines reduce yield and create handling issues.
BioGro, a biofertilizer manufacturer based in Mabton, WA, encountered this challenge during production. To solve the problem, BioGro partnered with RMS Roller-Grinder and installed a fertilizer crusher machine built around a custom industrial roller mill design.
In a recent interview, senior members of BioGro’s operations team shared how the company improved throughput while cutting fines nearly in half.
From Liquid Inputs to Finished Fertilizer Granules
BioGro produces organic fertilizer and humic products by drying liquid material into hard particles that are milled into several controlled sizes.
BioGro described the process:
“We take a liquid, we dry it into a hard particle, and then we mill the product into three different sizes.”
That milling stage is critical. The particles must be crushed into specific sizes so the fertilizer spreads evenly and performs as expected. Finding the right particle size reduction equipment for the job became the next challenge.
Testing the Material To Find the Right Solution
Before installing new equipment, BioGro explored several milling options but struggled to achieve consistent results.
Instead of trial and error, RMS tested the material in our lab.
BioGro explained the process:
“They took our product to their lab in South Dakota and went right through it. Then they engineered the roller mill specifically for what we were making.”
This testing phase allowed RMS engineers to evaluate the material and determine the best mill configuration. The final fertilizer crusher machine was designed around BioGro’s product and production process.
Why Roller Mills Work Well for Organic Materials
The system RMS delivered uses two rotating rolls that compress the material as it passes through the mill. The spacing between the rolls determines the final particle size.
This compression method provides better control than many high-speed impact grinders and helps prevent unnecessary overprocessing.
BioGro noted that the rolls themselves were designed specifically for their material.
“They designed the rollers specifically for our products.”
For BioGro, this approach allowed the mill to produce three consistent fertilizer grades, giving the company the flexibility to create multiple fertilizer products from the same material.
Higher Throughput and Stronger Production
After installing the new mill, BioGro quickly saw an improvement in production capacity.
“We’ve definitely seen an increase in production. Our throughput’s way higher.”
The upgraded fertilizer crusher machine allows the facility to process larger volumes while maintaining the particle sizes required for their products.
Durability also proved important because the material being processed is abrasive. RMS addressed this by equipping the mill with Endurance Rolls designed for longer service life.
BioGro reported strong results from the new system:
“We’ve already put about a million pounds through it, and the rolls still look like new.”
For facilities processing abrasive materials such as fertilizer, peat, or biochar, longer roll life reduces downtime and helps control maintenance costs.
Reducing Fines by Nearly Half
One of the most noticeable improvements BioGro experienced involved the reduction of fines.
Before upgrading their milling system, the facility produced a significant amount of unwanted small particles.
“With the old system we were getting twenty to thirty percent fines.”
After installing the RMS mill, those numbers improved considerably.
“Now we only get about ten to fifteen percent.”
Reducing fines improves production efficiency because more material ends up in usable product sizes instead of being recycled through the system. This improvement also helps maintain consistent fertilizer quality.
Expert Setup and Operator Training
BioGro also highlighted the support provided by RMS during installation.
A technician visited the facility during startup to help commission the equipment and train operators.
“He spent a couple days with us, helped set everything up, and showed us how to properly set the rolls.”
Proper roll setup plays a major role in maintaining consistent particle size and maximizing mill performance. With the right training, BioGro was able to integrate the new fertilizer crusher into its production process quickly.
Test Your Material and See What RMS Can Do
If you are evaluating a fertilizer crusher machine, RMS can test your product material in our lab to determine how it will respond during crushing and grinding with an industrial roller mill.
