01"Shmel" crusher
The rotary crusher grinds biochar down to a 0–5 mm fraction. With the screen removed it also works as a pneumatic conveyor, feeding the charcoal further along the line itself.
OMEGA LLC carries out deep processing of birch biochar on its own line: crushing, metered mixing with solutions (NPK, micronutrients, humates or a binder — natural potato starch), extrusion and forming. This yields two product lines: premium charcoal briquettes (bar, stick, cube) and enriched biochar, including "Omega-Turbo". The line runs under software control.
01The rotary crusher grinds biochar down to a 0–5 mm fraction. With the screen removed it also works as a pneumatic conveyor, feeding the charcoal further along the line itself.
02Receiving hopper with bag filters: it accumulates the ground biochar before dosing.
03A weight batcher for the bulk charcoal and a liquid-solution batcher are installed above the mixer. The solution (NPK, micronutrients, humates or starch binder) is prepared in a separate tank with an agitator and pumped to the batcher. The charcoal is mixed with the solution according to the program.
04The prepared blend leaves the mixer, drops onto the inclined conveyor and is fed into the upper extruder.
05Two extruders are mounted one above the other. The upper one plasticises the blend into "sausages" that drop into the lower one. The lower extruder forms a continuous bar (or stick) — or discharges loose Turbo biochar.
06The sheet/strip leaves the lower extruder and is cut to length by a knife into bars, sticks or cubes.
07The cut bars are placed on mesh trays, and the trays go into the dryers. Turbo biochar is packed straight away — into boxes with a PE liner.
08The control cabinet with a touch panel manages dosing, moisture and processing modes according to the recipe — ensuring batch-to-batch repeatability.
The key to quality is not "heating it harder", but controlling the state of the blend: its moisture, the solution dosage and the plasticising mode across the pair of extruders. The upper one prepares a uniform plastic mass, the lower one forms the product at a set density — from a dense briquette to loose Turbo biochar. Dosing and processing modes are held by the automation, which gives batch-to-batch repeatability.