NPK fertilizer bulk blend production line

Fertilizer bulk blending production lines are designed to combine different types of fertilizers according to specific ratios to create a complete production process. The main process flow is: "Raw material storage → batching → mixing → screening → packaging → finished product storage." While equipment configurations vary for production lines with different capacities (e.g., 50,000 tons/year, 100,000 tons/year, and 200,000 tons/year) and levels of automation, the core equipment system remains largely the same. The following is a breakdown and detailed description of the main equipment used in a fertilizer blending production line :

( From left to right, they are: process flow diagram, fully automatic batching system, customer site.)

Main Equipment of BB fertilizer blending production line

1.Raw material collection and transportation

    This link is mainly used to receive and temporarily store different types of basic fertilizer raw materials (such as urea, monoammonium phosphate, diammonium phosphate, potassium chloride, potassium sulfate, organic fertilizer granules, etc.) to ensure continuous supply of production.Equipment Price: Starting from $1,300.
    • Raw material bucket elevator : It transports bulk or bagged raw materials from the ground to the top of the raw material warehouse. It is the core equipment of vertical transportation. It is divided into belt type, plate chain type, etc. according to the characteristics of the raw materials to avoid raw materials from breaking or sticking.
    • Raw material batching silos : used for classified storage of different raw materials, usually cone-bottom steel silos (capacity varies from 5-50m³, configured according to production capacity and raw material types and quantity, generally 3-8 silos are required ). The silo walls need to be treated with anti-sticking treatment (such as polishing or applying wear-resistant coating) to prevent raw materials from sticking to the walls; the bottom is equipped with arch-breaking devices (such as vibration motors, air cannons) to prevent raw materials from caking due to moisture absorption, resulting in poor material discharge.

1. Precision batching equipment

The 60TPH production line utilizes a three-bin dynamic batching system. Batching is a core process in fertilizer production , directly determining the accuracy of the product's nutrient ratios. The primary equipment consists of a "feeder + weighing system" combination.Equipment Price: Starting from $3,000 per silo.

• Quantitative feeder : According to the recipe requirements, the materials in different raw material bins are continuously and evenly transported to the weighing system in the set ratio. Common types include:

◦ Screw feeder : Suitable for granular raw materials with good fluidity (such as urea, potassium chloride). The feeding amount is controlled by adjusting the screw speed, with high accuracy (±0.5%).

◦ Belt feeder : suitable for easily broken or sticky raw materials (such as diammonium phosphate, organic fertilizer particles), avoiding the breakage of raw materials caused by spiral extrusion, and ensuring smooth feeding.

◦ Vibrating feeder : Suitable for raw materials with high specific gravity or poor fluidity. It makes the material fall evenly through vibration and realizes quantitative control with the speed regulating motor.

• Weighing sensor/belt scale : Installed under the feeder or on the conveyor belt, it collects material weight signals in real time and feeds them back to the control system (PLC), automatically adjusting the feeder speed to ensure batching accuracy.

2. Mixing equipment

A fertilizer blender is also essential equipment for a fertilizer blending production line. Evenly mixing the various ingredients that have been proportioned is key to ensuring the "nutrient uniformity" of the blended fertilizer. Equipment Price: Starting from $4,850.Common fertilizer blenders include the following:

• The BB fertilizer mixer , also known as a blended fertilizer mixer, is a mixing device designed and manufactured specifically for blended fertilizer production. It features a self-falling double-cone mixer with forward and reverse rotations for feeding and discharging , and mixing and blending within the drum . The BB fertilizer mixer offers high production efficiency, uniform mixing, minimal particle breakage, and a compact footprint . The equipment can produce 3-20 tons per hour. Depending on your needs, you can choose between a continuous feed mixer and an intermittent feed mixer.

• Horizontal Ribbon Mixer : Suitable for small to medium-capacity production lines (5-15 m³/h), this mixer utilizes counter-rotating inner and outer ribbons to promote convection mixing. It boasts a simple structure and easy maintenance, while achieving high mixing uniformity . This type of mixer is classified as a batch mixer.

• Drum-type fertilizer mixer : Generally used for large-scale mixing needs, it uses a continuous mixing device to achieve rapid, uninterrupted mixing, with simultaneous feeding and discharging, and high production efficiency . It is mainly used for the production of fertilizer blends with low uniformity (≤5%).

3. Screening and crushing equipment (optional, configured on demand)

If a small amount of lumps appear after mixing (due to moisture absorption or mixed extrusion of the raw materials), large lumps need to be removed by screening to ensure uniform particles of the finished product; if there are many lumps, they need to be crushed first and then screened.

• Finished product vibrating screen : Usually a linear vibrating screen (1-2 layers of screens). The upper screen (aperture 4-5mm) separates large lumps and agglomerates, and the lower screen (aperture 1-2mm) removes fine powder. Qualified particles enter the packaging stage; large lumps and agglomerates on the screen need to be manually cleaned or sent to a crusher.

4. Finished product packaging equipment

The evenly mixed qualified materials are quantitatively packaged into 25kg, 50kg bags or ton bags for easy storage and transportation.Equipment Price: Starting from $3,500.

• Automatic quantitative packaging scale : Core equipment, divided into "single-bucket packaging scale" and "dual-bucket packaging scale" (higher production capacity), uses weighing sensors to control the discharge amount, with an accuracy of up to ±0.2kg/bag. Combined with conveyor belts, it realizes the "automatic bag supply → filling → weighing → sealing → conveying" assembly line operation, with a single packaging speed of 200-600 bags/hour.

• Bag sewing machine/heat sealing machine : used for bag sealing. Electric bag sewing machines (single or double seams) are commonly used for woven bags, and heat sealing machines (hot melt sealing) are commonly used for PE film bags to ensure the package is sealed and prevent moisture absorption and agglomeration.

• Finished product conveyor belt : Conveys sealed bagged finished products to the finished product warehouse or palletizing area, usually a belt conveyor belt or roller conveyor belt . Some production lines are equipped with automatic palletizers (robotic arm or gantry type) to achieve unmanned palletizing and reduce labor costs.

5. Dust removal and environmental protection equipment

During the production of blended fertilizers, dust (such as urea and potassium chloride fine powder) is generated during the transportation, mixing and screening of raw materials. A dust removal system is required to meet environmental protection requirements (dust emission concentration ≤ 30mg/m³).

• Pulse bag dust collector : mainstream dust removal equipment, filters dust through filter bags and regularly cleans with compressed air pulses. The dust removal efficiency is ≥99.5%. Dust suction ports can be installed on the top of the raw material silo, the top of the mixer, and the top of the screening machine to collect dust and return it to the production line or treat it as a by-product.

• Fan and pipe : used in conjunction with a pulse dust collector, the fan provides negative pressure suction, and the pipe introduces dust from various dust-generating points into the dust collector. The pipe needs to be insulated (to prevent dust from agglomerating and clogging in a low-temperature environment).

6. control system

Realize the automated control of “batching, mixing, and packaging” of the production line to improve production efficiency and product quality stability.

• PLC control system : The core is a programmable logic controller, which works with a touch screen (HMI) to implement functions such as "recipe storage (can store 100+ recipes), parameter setting (ingredient ratio, mixing time, packaging weight), real-time monitoring (equipment operating status, fault alarm), and data recording (production batches, output, raw material consumption)". Some high-end production lines can be connected to the MES system (manufacturing execution system) to achieve intelligent management of the entire process.

7. auxiliary equipment

• Bucket elevator/belt conveyor : used for transporting materials between various links (such as from mixer to screen, screen to packaging scale).

• Finished product bin : used for temporary storage of packaged finished products, usually a steel warehouse or a brick-concrete warehouse, which needs to be ventilated and moisture-proof to prevent the finished products from absorbing moisture and clumping.

Project Plan for Blended Fertilizer Production Line:

Features:

1. Advanced technology

       This production line is a fully automatic packaging system controlled by PLC. It integrates the scientific and technological essence of Tianci Heavy Industry's long-term research and development of multi-material batching and packaging lines and fully automatic metering and packaging machines. From equipment configuration schemes, functional requirements to structural design, it fully reflects the concept of humanized design and safety design. It is currently the most advanced BB fertilizer batching, mixing and packaging special equipment in China. The production line design is novel and unique, with high technological content.

2. Scientific process

       This production line integrates batching, mixing and packaging, and is particularly suitable for batching and mixing of BB fertilizers. Each time the mixed material is unloaded into the lifting hopper by the mixer once, and after being lifted to a high position, it is unloaded into the packaging scale silo again. There is no diversion of the mixed material during the flow process, especially when the batching ratios of different raw materials are very different and the amount of a certain fertilizer added is particularly small, the batching can still be guaranteed to be accurate and mixed evenly.

3. Low requirements for plant buildings and small equipment investment

       irectly loading materials on the ground, no raw material lifting equipment is required, and the production line occupies a small area. Due to the low height, there are no special requirements for the factory building, and the capital investment in the factory building and equipment is small. It is particularly suitable for small fertilizer plants and fertilizer distribution companies. If the high-platform batching method is adopted, multiple long belt conveyors or bucket elevators must be equipped, the equipment investment is large, and the factory building is high.

4. Low long-term operating cost

       A significant advantage of this production line is that it directly feeds materials on the ground, reducing the number of loading workers, reducing the labor intensity of loading materials, and avoiding many safety issues of high-platform batching. Due to the large output, especially saving manpower and high efficiency, the comprehensive production cost is greatly reduced. Although digging a pit requires investment, it is a one-time solution. Among the three items of BB fertilizer packaging costs, including labor costs, packaging material costs, and electricity costs, labor costs are the highest, followed by packaging material costs, and electricity costs account for a small proportion. Reducing labor can greatly reduce production costs.

5. Convenient operation, maintenance, and cleaning

       The batching system, mixing device, and packaging system all have manual operation status. In the manual state, each single machine can act independently, which brings great convenience to debugging, maintenance, and cleaning. The batching system and packaging system are equipped with maintenance tables, which make the equipment maintenance convenient and safe, and the equipment can be completely cleaned when leaving get off work.

6. Long service life

The equipment adopts anti-corrosion measures such as stainless steel, and the main electrical parts are imported components. Through long-term operation in users, it has been proved that the performance is stable and reliable. In particular, the electrical protection level is high and the anti-corrosion measures are effective, which greatly improves the working reliability and equipment service life.

7. High cost performance

Finished product display:

BB fertilizer or blended fertilizer is a fertilizer containing any two or three of the three nutrients nitrogen, phosphorus and potassium. It is made by simple mechanical mixing without significant chemical reactions during the mixing process. The advantage of BB fertilizer is that it can produce various specifications of special fertilizer according to user needs, which is more suitable for soil testing and formula fertilization.

Customer Cases:

Tianci Heavy Industry focuses on technological innovation and product quality, provides customers with one-stop service, is market-oriented, seeks development through innovation, survives by quality, and wins the trust of customers with perfect after-sales service.

Equipment delivery:

Tianci Heavy Industry has more than 20 years of experience in the production of organic fertilizer and compound fertilizer equipment. It has worked closely with many customers at home and abroad and is deeply favored by new and old customers.

About the Company:

Established in 2000, Zhengzhou Tianci Heavy Industry Machinery Co., Ltd. is a prominent manufacturer in China, specializing in the design, production, and supply of high-quality fertilizer machinery. With over 24 years of production experience and 16 years of export expertise, we have built a reputation as a leading brand in the fertilizer machinery industry. Our commitment to innovation and quality has allowed us to become a trusted partner for fertilizer producers around the world.

FAQ:

Q1: What are your company's advantage?
A: We are professional fertilizer equipment manufacturer with more than 20 years production experience and 10 years exports experience. We have own factory which can produce high quality equipment with competitive prices.

Q2: What is your main products?
A: Our main products include complete equipment of fertilizer production line. There are many types of granulator and some auxiliary equipment (drying&cooling machine, screening machine, coating machine, packaging machine and so on).

Q3: How to choose the right fertilizer equipment?
A: In order to choose the appropriate equipment, we need to know your fertilizer raw materials and production capacity, so that we can give you a right choose. It’s best for us if you can provide the production area.

Q4: How can I know my raw material is suitable for your machine?
A: If we can buy the same raw material from our market, we will test the machine, then send the video and show the final effection. If we can't buy it from our market, you can send it to our company, then we will arrange to test machine for you.