Innovative Craftsmanship Creates a Promising Future | Automated Production Line of High-Flow Disc Bead Mill and Spray Granulation Dryer Enables Mass Industrial Production of DF Dry Flowables

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Innovative Craftsmanship Creates a Promising Future | Automated Production Line of High-Flow Disc Bead Mill and Spray Granulation Dryer Enables Mass Industrial Production of DF Dry Flowables

2026-07-03

Driven by accelerated global agricultural modernization and increasingly stringent environmental regulations, pesticide formulations are undergoing a profound shift from traditional highly polluting, low-efficiency varieties to eco-friendly, efficient and precision-oriented products. As a premium type of water-dispersible granule, Dry Flowable (DF) features zero dust, solvent-free composition, high suspension rate and long-lasting efficacy. It has become an ideal alternative to conventional wettable powders and emulsifiable concentrates, accompanied by explosive growth in market demand.

From the market perspective, food security pressure brought by population growth fuels continuous expansion of the pesticide industry. Capable of cutting pesticide dosage and improving efficacy utilization, DF conforms to the national strategy of pesticide reduction in agriculture and is widely favored by growers. In terms of environmental policies, traditional pesticide formulations face strict restrictions due to dust pollution and volatile organic solvent emissions. In contrast, the eco-friendly properties of DF comply with regulatory standards, leading to steady expansion of its market share. Meanwhile, modern agriculture puts forward higher requirements for convenient and precise pesticide application. DF is easy to measure and compatible with various spraying methods, further expanding its application range. Widely applicable to field crops and cash crops alike, DF has evolved into one of the mainstream pesticide formulations. In the future, with continuous upgrading of core technologies including spray drying and ultrafine grinding, DF will develop toward higher purity, better stability and lower production costs. Industrial competition will center on technological innovation and mass production capacity.

Production Process Analysis of DF Dry Flowables

The manufacturing process of DF consists of four core procedures: raw material pretreatment, wet bead milling, spray granulation & drying, and post-treatment. Precise technical control of each procedure directly determines final product quality.

Raw Material Pretreatment
Strictly control the particle size and mixing ratio of pesticide technical materials and auxiliary agents. Pre-crush raw materials to meet particle size requirements, then conduct precise batching to optimize the physicochemical properties of the system, laying a solid foundation for subsequent suspension preparation.
Wet Bead Milling
This is the critical procedure to prepare fine-particle suspension. High-efficiency grinding equipment refines material particles to guarantee superior dispersibility and suspension performance of finished products.
Spray Granulation & Drying
The suspension after milling is atomized into tiny droplets via atomizers, which exchange heat and mass with hot air to form hollow spherical solid particles. This procedure requires precise control over atomization parameters, drying temperature and airflow distribution to ensure uniform and stable particles.
Post-Treatment
Remove unqualified particles through mechanical screening and air classification. A full-process quality control system is implemented to guarantee the finished products meet specified particle size distribution standards.

Breakthroughs Brought by Our Innovative Craftsmanship

Longxin Drying independently developed a complete automated production line integrating grinding and spray drying equipment for DF. It deeply combines high-flow disc bead mills and dedicated spray granulation dryers to realize full-process automatic control from raw material feeding to finished product output.

Centered on three design concepts: high efficiency, high precision and environmental protection, the line leverages process optimization and intelligent control technology to tackle persistent drawbacks of traditional production, such as low efficiency, inconsistent product quality and high pollution risks.
Equipped with an advanced real-time monitoring platform, it supports full-process digital collection and adjustment of key parameters including grinding temperature, material flow, atomization pressure, drying temperature & humidity and particle size, ensuring stable and traceable production.
The one-touch cleaning system paired with a dead-space-free design eliminates cross-contamination at the source, greatly boosting flexibility for multi-product manufacturing and delivering reliable support for large-scale industrial production.

High-Flow Disc Micron Bead Mill: High-Efficiency Milling for Superior Slurry Quality

As the core grinding equipment of the whole line, the WSP-E high-flow disc micron bead mill developed by Longxin Intelligent serves as the key facility for DF wet milling with multiple proprietary technical innovations.

It adopts a composite grinding structure of disc plates and pin rods. Disc plates break up materials and generate strong high-speed shear force, while pin rods reinforce grinding effects. Compared with traditional single-disc structures, it achieves higher grinding efficiency, eliminates most grinding dead zones and reduces material residue.
Multiple customized material options are available: ceramic, polyurethane (PU) and hardened German steel. Ceramic and PU components deliver zero metallic contamination, meeting DF’s strict purity standards and preventing impurities from damaging pesticide active ingredients.
Designed for high throughput with an increased filling rate of the grinding chamber far exceeding conventional models. Its maximum hourly processing capacity reaches 1,000 liters, greatly outperforming traditional equipment to fully satisfy mass production demands.
The jacketed cooling system realizes heat exchange with process liquid to accurately stabilize grinding temperature and effectively prevent thermal decomposition of pesticide active ingredients.
Complete safety protection configuration: an automatic pressure protection device and comprehensive electrical protection system. The machine will automatically stop and release pressure once the pressure inside the grinding chamber exceeds the preset threshold (0.2–0.4 MPa as standard). The electrical system monitors operating status in real time to guarantee safe and stable production.
The front discharge valve shortens cleaning and product switching time, improves changeover efficiency and significantly cuts time costs for multi-variety production.

Spray Granulation Dryer: Precision Drying for One-Step Pellet Forming

Custom-built for DF manufacturing, this spray granulation dryer undergoes comprehensive technical optimization targeting industry pain points, with outstanding performance in energy conservation, efficiency and product quality control.

The straight cylindrical tower body ensures uniform distribution of wind speed and heat to avoid material adhesion on tower walls.
The improved conical hot air distributor works together with baffle rectifying plates to convert hot air into stable straight airflow, reducing heat loss caused by turbulent flow and raising thermal efficiency.
Rotary pressure nozzles are adopted to solve the defects of traditional nozzles such as narrow atomization angle, short service life and high energy consumption. Droplet size can be precisely adjusted according to product requirements to ensure uniform particles.
An enlarged section or cyclone structure at the tower bottom improves material output and pellet forming rate. Matched with innovative fine powder recovery technology and dust suppression devices, it reduces material loss and optimizes the operating environment.

In terms of process control, energy utilization efficiency is maximized by optimizing the temperature difference between air inlet and outlet as well as pre-dehydration treatment. On the premise of guaranteeing product quality, the air inlet temperature can be moderately raised while exhaust temperature is lowered to reduce heat waste. Raw materials are pre-dehydrated and preheated before entering the drying tower to cut evaporation load and further improve energy-saving performance. During drying, pellet particle size can be precisely regulated by adjusting atomization pressure and hot air velocity. Combined with anti-agglomerant addition, particle adhesion is effectively inhibited, enabling finished products to feature excellent disintegration and suspension performance. Pellets produced by this dryer boast high sphericity and good flowability. They disintegrate within seconds after contacting water and maintain a high suspension rate, fully meeting core application requirements for pesticides.

Lead Industrial Transformation, Embrace a Greener Future

Featuring technological innovation as its core competitiveness, the automated DF production line combining high-flow disc bead mills and spray granulation dryers from Longxin Drying closely follows the global trend of green and reduced-dose pesticide formulations, injecting powerful momentum into agricultural green transformation. The deep integration of high-efficiency grinding and precision drying technology achieves dual improvements in DF production efficiency and product quality. Its strengths including zero metallic contamination, low energy consumption and full automation not only help manufacturers cut production costs and strengthen market competitiveness, but also drive the pesticide industry toward high-quality and sustainable development.

In the future, Longxin Drying will continue to focus on grinding and drying technology research and development. Relying on the innovation capability of its technical team, we will continuously optimize production line performance and develop more intelligent equipment tailored to diverse industrial demands. Through in-depth integration of premium equipment and self-developed proprietary processes, Longxin Drying will provide superior and more efficient solutions for the agrochemical industry, supporting more manufacturers to complete production upgrading and industrial transformation. Empowering the development of green agriculture with our innovative craftsmanship, we will write a new chapter of innovative development for the whole industry.