TONGLI BB(bulk blending) fertilizer production line has a variety of formula options and precise batching system, which can produce all kinds of fertilizers you need.

BB FERTILIZER PRODUCTION LINE EQUIPMENT LIST

Bulk blending fertilizer batching system

Accurately mix and proportion BB fertilizer raw materials (such as nitrogen, phosphorus, potassium and other basic fertilizers) to ensure that the proportion of each component meets the predetermined standard. Use automatic control technology to accurately control the amount of various raw materials added through high-precision electronic scales and ingredient controllers

Bulk blending fertilizer coating machine

The coating machine uses precise spraying technology to evenly coat the surface of each BB fertilizer particle with a thin film, thereby enhancing the storage stability and use effect of the particles.

ORGANIC FERTILIZER PRODUCTION LINE ADVANTAGES

The equipment manufacturing cycle is short, generally it can be completed in about a month, and the installation time is also short, and basically does not require too much civil engineering.

The surface of key equipment is coated with an anti-corrosion coating, which is suitable for various chemicals and prolongs the life of the equipment.

Equipped with an intelligent packaging machine, it can quickly switch between different specifications and types of packaging.

A high-precision belt scale is used to measure the raw material ratio, and the fertilizer ratio after mixing is uniform.

Compound fertilizers of any formula can be produced. Because only finished products are purchased for mixing, there is a large degree of freedom in the ingredients.

The precise quantitative batching system monitors the formula ratio in real time through an electronic scale to ensure the consistency of each batch.

The BB fertilizer mixing line has a small number of equipment, low investment cost, and very small footprint.

Pre-treat the raw materials to remove impurities and oversized particles to improve production quality.

BB FERTILIZER PRODUCTION PROCESS

zhejiang tongli heavy machinery bulk blending BB fertilizer blending production line solution process flow

Raw Material Preparation

The BB fertilizer (blended fertilizer) production line has a wide variety of raw materials, which is different from the ordinary NPK compound fertilizer production line. Whether it is a high tower compound fertilizer granulation line or a drum granulation line, powder is usually made into granules. The main principle of the BB fertilizer production line is to mix various compound fertilizers that have been made into different formulas into granules in a certain proportion, and then add trace elements to achieve the desired effect. The production of BB fertilizer is not to make powder into granules, but to mix granular fertilizers of different formulas, such as the 15-15-15 formula compound fertilizer of drum granulation or potassium sulfate and potassium chloride granules of extrusion granulation. After mixing, a scientific formula suitable for local soil composition is achieved.

Quantitative Batching

The second process is the quantitative batching of raw materials. We use a high-precision electronic belt scale (automatic batching system). The production line is equipped with seven high-precision electronic batching belt scales, which can mix seven different raw materials to make BB fertilizer. Since the raw materials of BB fertilizer are all granular, there is no need to use a large bulk crusher or cage crusher for crushing, and direct mixing can be done. The double belt scale we use has a feeding belt on the upper layer and a weighing belt on the lower layer. The two layers of scales are connected by a hanging weighing sensor, which improves the weighing accuracy and is easy to maintain. Compared with single belt scales and loss-in-weight scales, double belt scales are more cost-effective.

Mixing And Stirring

The third process is the mixing of finished products. The raw materials of the BB fertilizer production line are all finished compound fertilizers, which have been coated and will not stick together. After the raw materials are completed, they enter the drum mixer. The specifications of the mixer vary depending on the output. For example, the diameter of the mixer used in the BB fertilizer production line with an annual output of 200,000 tons is about 830mm. In the mixer, compound fertilizers of different formulas are mixed, and the fully mixed finished products enter the subsequent packaging section.

Coating (optional)

The coating process is optional. If the purchased raw materials contain semi-finished products, the coating machine can prevent the material from agglomerating and improve the particle strength. If the raw materials are already coated finished products, there is no need for a coating machine. An African customer cannot guarantee that the raw materials purchased every time are coated finished products, so he chose to install a coating machine. If you need to change the color of compound fertilizer, such as blue, yellow or pink, you need to use a coating machine. The coating machine system includes an anti-caking agent screw conveyor, a coating oil dissolving tank, and an oil injection pipeline, all of which are controlled by the DCS system.

Dust Removal System

The dust removal system is optional. BB fertilizer will produce a certain amount of dust during the mixing process, but this dust has no effect on product quality and production process. If the workshop has high dust removal requirements, it is recommended to use a dust removal system consisting of a bag dust collector and a centrifugal fan. Cyclone dust collectors are more suitable for handling dust with more moisture, while BB fertilizer production lines usually use dry processes, so bag dust collectors are more suitable.

Packaging

For finished product packaging, we provide semi-automatic and fully automatic solutions. The servo motor automatic quantitative packaging scale is fast and accurate, and the packaging speed can reach 800 to 1000 bags per hour. The packaging scale is made of S304 stainless steel, the main electronic components are Schneider, and the pneumatic components are imported from Japan. After the material comes out of the fertilizer coating machine, it first enters the buffer silo of the finished product packaging scale, and then automatically quantitatively packaged. The system is equipped with automatic folding and automatic sewing functions to achieve semi-automatic packaging. The fully automatic packaging system adds an automatic bagging machine to improve efficiency and save labor.

Palletizing

After the finished product is packaged, it enters the palletizing system. The system is mainly composed of an all-stainless steel SS304 conveying system. After the fertilizer bags are packaged, they are transported to the bottom of the palletizing robot for palletizing. ABB or Fanuc robotic arms are commonly used, with a speed of about 1000 to 1200 bags per hour. Palletizers are available in single-grip and double-grip forms. Compound fertilizer production lines usually use single-grip palletizing systems. In addition, the system is also equipped with a conveying system and an automatic rewinding system. For enterprises with high modernization requirements, the terminal is equipped with a pallet warehouse to automate the process, but the cost is relatively high. For enterprises with limited budgets, it is recommended to use a conventional wooden pallet system

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FAQ

1. What is the main function of the BB fertilizer production line?

The main function of the BB fertilizer production line is to produce fertilizers suitable for specific soil and crop needs through scientific formula mixing.

Unlike traditional NPK fertilizer production, the BB fertilizer production line adopts a granular mixing method instead of making powder into granules. The production line can accurately mix multiple raw materials in proportion through a high-precision electronic belt scale, and can usually handle up to 7 different raw materials. This method allows the addition of trace elements, thereby optimizing the nutritional content of the fertilizer, improving soil fertility and crop yields.

The effective formula of BB fertilizer can adapt to soil conditions in different regions and provide farmers with tailor-made fertilizer solutions. Whether it is large-scale agricultural production or small farms, the modular design of the production line enables it to be flexibly adjusted according to production needs to meet different market requirements.

2. What is the capacity of the BB fertilizer production line?

The capacity of the BB fertilizer production line depends on the equipment configuration and production needs, usually between 10,000 tons and 200,000 tons per year. The specific capacity depends on the design of the production line and the specifications of the selected equipment.
For example, a production line with an annual output of 200,000 tons is usually equipped with a mixer with a diameter of about 830mm to ensure sufficient mixing capacity and efficiency to meet the needs of large-scale agricultural production.

For small farms or regional markets, a production line with an annual output of 10,000 tons provides a more flexible option that can meet demand while controlling costs.

Regardless of the scale of the production line, Tongli design is designed to optimize production efficiency and energy use to ensure economic operation at maximum capacity. In addition, flexible production capacity enables the BB fertilizer production line to adapt to changing market needs and provide companies with a competitive advantage.

3. How to ensure accurate batching when producing BB fertilizer?

BB fertilizer production lines use high-precision electronic belt scales to achieve accurate batching. Each production line can be equipped with up to seven batching belt scales to support the mixing of seven different raw materials.

Dual belt scale systems are particularly commonly used, with the upper layer being the feeding belt and the lower layer being the weighing belt, connected by a suspended weighing sensor. This design improves the accuracy of weighing and simplifies maintenance.

To further ensure the accuracy of batching, the production line uses an automated control system for real-time monitoring and adjustment to prevent error accumulation.

Regular calibration of equipment is also a key step in maintaining accurate batching. Through these measures, the BB fertilizer production line can ensure that each batch of fertilizer has stable quality and composition, meeting the precise needs of agricultural production, while optimizing the ratio of nutrient components and improving crop yield and quality.

4. What is the degree of automation of the BB fertilizer production line?

The degree of automation of the BB fertilizer production line can be configured according to customer needs, from basic semi-automatic to fully automated systems, which can adapt to different production needs and budgets.

The automation system includes functions such as automatic batching, automatic packaging and automatic palletizing. Among them, the fully automatic packaging system uses a servo motor, which can achieve a packaging speed of 800 to 1,000 bags per hour, with high precision and fast response.

The palletizing system can be equipped with an automatic pallet warehouse to achieve a fully automated production process, significantly improve production efficiency and reduce labor costs. For companies with a low budget, a semi-automated system can be selected to meet basic automation requirements and reduce initial investment costs.

5. How to ensure the quality control of BB fertilizer production line?

1) High-precision electronic belt scale ensures the accuracy of ingredients and prevents ingredient deviation. Secondly, the mixing and stirring process uses advanced equipment and technology to ensure that the raw materials are evenly distributed and avoid uneven particles.

2) The automation system can monitor production parameters in real time, while automatically adjusting process conditions to adapt to changes and maintain product consistency. The finished product inspection system conducts strict quality inspections on each batch of fertilizer to ensure that it meets the predetermined standards.

3) The production line is usually equipped with an advanced traceability system that can record key data in the production process to help identify and solve potential problems.

6. How long does it take to install a BB fertilizer production line?

The time to install a BB fertilizer production line varies depending on the scale of the production line and site conditions. Typically, the installation cycle for a small production line is 2 to 3 weeks, while a large production line may take 4 to 6 weeks. The installation process includes equipment transportation, site layout, mechanical installation, and system commissioning.

In order to reduce installation time, it is recommended to prepare the site in advance, including infrastructure construction and the improvement of supporting facilities such as electricity and water supply.

Installation by an experienced technical team can ensure that the entire process is completed quickly and efficiently, reducing production losses caused by installation delays.

Choosing reliable equipment suppliers and installation service providers can not only ensure the quality of installation, but also provide subsequent technical support and maintenance services to ensure stable and efficient operation of the production line.

During the installation process, it is also crucial to follow safety regulations and process management to avoid potential safety hazards.

BULK BLENDING FERTILIZER PRODUCTION LINE TECHNICAL PARAMETERS

ItemProduction Capacity (t/h)SpecificationsPowerQuantity (sets)
Electronic Belt Scale Automatic Dosing System5~30Width 650 x 1700 mm1.1 + 1.1 kW7
Rotary Drum Coater30~402.2 x (8 + 1) m37 kW1
Raw Material #1 MAP Bucket Elevator10~15TL400 x 11 m7.5 kW1
Raw Material #2 DAP Bucket Elevator10~15TL400 x 11 m7.5 kW1
Raw Material #3 15-15-15 Bucket Elevator10~15TL400 x 11 m7.5 kW1
Raw Material #4 16-40-0 Bucket Elevator10~15TL400 x 11 m7.5 kW1
DAP Bucket Elevator10~15TL400 x 9.5 m7.5 kW1
Final Product Bucket Elevator10~15TL400 x 9.5 m7.5 kW1
Product Silo-2150 x 2150 x 4100 mm, 8-15 cubic metersNot applicable1
Belt Conveyor20-30 tons/hourWidth 800 x 8 m3 kW1
Bag Filter30,000 cubic meters/hourTL-4-27.5 kW1
Automatic Packing Machine-3000 x 3000 x 4000 mm, 1000 bags/hourNot applicable1
Automatic Stacking Machine-8000 x 2200 x 3000 mm, 800~1000 bags/hour15 kW1