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Straw and hay pellet machine — turning agricultural residues into profit

When a straw or hay is fine milled you can produce straw pellets or hay pellets. Pure straw or hay pellets for heating or animal bedding. Or mixed with some components like chicken litter and use as a fertilizer. You can also add some other components to make even more advanced pellets. It is just a question of demands.

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Image by Lucas Gallone

What can straw pellets be used for? Bedding, feed, fertilizer and biomass fuel

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Straw pellets for poultry bedding: market price and production economics

Processing straw through a high-torque pellet mill into pelleted bedding for poultry completely alters its physical properties:

  • Maximum Absorption: up to 400% of its own weight in water.

  • Pathogen Elimination: The friction and pressure inside the machine for pellets - miniPelleter - generate operating temperatures between 80°C and 90°C. This thermal treatment effectively neutralizes Salmonella, E. coli, and harmful fungal spores.

  • Ammonia Reduction: Dry, highly absorbent pelleted bedding locks in nitrogen, reducing ambient ammonia levels in the poultry house by up to 60%, which directly decreases flock mortality.

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Straw Pellets for Organic Fertilizers

With the global push toward sustainable agriculture and the rising costs of synthetic chemicals, pelleted organic fertilizers present a massive market opportunity.

  • Nutrient Retention: Hay and straw pellets act as an excellent slow-release carbon base. When combined with organic waste (such as post-cycle poultry litter or digestate), they create a stabilized NPK (Nitrogen, Phosphorus, Potassium) fertilizer.

  • Logistical Superiority: Raw straw is notoriously expensive to transport due to its low bulk density (often below 50 kg/m³). Pelleting increases this density to over 600 kg/m³, reducing storage and transportation volume by over 70%.

  • Soil Amendment: Once applied to the field, these pellets expand upon contact with water, significantly improving soil aeration, water retention capacity, and microbiological activity.

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Biomass fuel pellets from straw: calorific value and ENplus classification

As industrial and residential sectors move away from fossil fuels, agricultural biomass is stepping in to fill the energy gap. Straw and hay pellets are a highly viable, carbon-neutral heating alternative.

  • Calorific Output: Properly conditioned and pelleted straw achieves a pretty interesting heating value (LHV) of approximately 15 to 17 MJ/kg, making it highly competitive with more expensive wood pellets.

  • Controlled Combustion: Automated industrial biomass boilers require a standardized fuel format. Uniform 6 mm or 8 mm agricultural pellets ensure smooth auger feeding and a stable combustion profile without the risk of system jamming.

  • Ash Management: While agricultural biomass naturally has a higher ash content (typically 4% to 8%) compared to premium wood, modern specialized burners are designed to handle this efficiently, often repurposing the mineral-rich ash back into the soil as a secondary fertilizer.

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Straw & Hay Pelleting Preparation: Particle Size and Moisture

To fulfill the stringent requirements of global norms for agricultural biomass (such as the ISO 17225-6 standard for non-woody pellets), pellet makers must keep basic straw feedstock parameters within strictly defined ranges prior to the pelleting process.

Particle Size

1 - 3 mm

for regular straw or hay pellets fi6-8mm. Try a hammer mill with mesh like 5-8mm for fine milling.

Moisture

11 - 13%

of water content is optimal for most feedstocks. After cooler the moisture will go down to 9 - 10%. It is OK.

Uniformity

95%

Make sure 95% of your feedstock keeps the size and moisture within the given ranges.

Discrepancy

max 5%

Each die is designed for a specific feedstock. Allow only 5% of discrepancy for high pellets quality. 

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PELLETING IDEAS

What about
Bio-Secure Bedding Solutions? 

Okrągłe bele siana

FAQ: Technical Answers
for Straw and hay Pellet Producers

  • Yes. The Nawrocki LLC pellet machine - miniPelleter - features a rapid die-change system. By simply swapping the die to adjust the compression ratio and pellet diameter, you can switch from producing dense fuel pellets to softer, highly absorbent poultry bedding in 20 minutes.

  • To maintain industrial throughput and achieve a high Pellet Durability Index (PDI), the absolute moisture content of the milled straw must be strictly maintained between 10% and 14%. It is for the best results and high pellets quality regardless of the feedstock.

     

  • The answer ususally begins with... "it depends". But generally by converting surplus hay into dense feed pellets or premium bedding, farms can drastically reduce winter feed waste and open up new B2B revenue streams, often achieving a full ROI on the equipment within 12 to 18 months.

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