Scale: Small, Medium, Large
Daily Production Capacity: 5-10 tons/day, 10-50 tons/day, 50-100 tons/day
Floor Area: 100-300 square meters, 300-800 square meters, 1000 square meters
Main Equipment: Dynamic batching machine + BB fertilizer mixer + packaging machine
Processed Materials: Primarily granular or powdered single-element fertilizers, compound fertilizers, and functional additives
1. Batching System
● Raw Material Silos: Stores basic fertilizers such as nitrogen, phosphorus, and potassium, as well as additives. These silos are typically divided by raw material type and equipped with level meters to monitor storage levels.
● Weighing Sensors: Monitor feed levels in real time. Closed-loop control via a PLC system ensures metering accuracy (typically ≤1%).
2. Mixing and Stirring Equipment
● BB Fertilizer Mixer: Quickly and evenly blends multiple metered raw materials to prevent stratification. Mixing uniformity is a key performance indicator (coefficient of variation CV ≤5%).
3. Packaging System
● Quantitative Packaging Scale: Automatically weighs and bags the mixed BB fertilizer to a set weight. It is equipped with bag clamping and sealing (sewing or heat sealing) functions.
● Conveyor: Transports packaged finished products to the palletizing area, enhancing automation.
4. Control System
● PLC Control System: Integrates the coordinated control of metering, mixing, and packaging equipment. It allows for preset recipes and monitoring of production parameters (such as output and accuracy) to achieve automated production.
BB fertilizer production line process flow:
1. Raw material pretreatment: Lumpy raw materials are crushed and screened to remove impurities, and then stored in corresponding silos.
2. Automatic batching: Based on the recipe, the control system instructs the feeder to deliver the raw materials in proportion to the metering device for weighing.
3. Mixing: The prepared raw materials enter the mixer and are thoroughly mixed within the set time (uniformity must reach at least 95%).
4. Post-processing: The mixed materials are screened and coated (if necessary) to improve physical properties.
5. Packaging and warehousing: The finished products are bagged by the packaging machine and transported via a conveyor line to the warehouse for storage.
Advantages of the BB fertilizer production line:
1. High Flexibility:
Formulas can be quickly changed to suit the needs of different crops (such as wheat, corn, and fruits and vegetables) and soils, achieving customized fertilization.
2. Low Cost:
Compared to compound fertilizers (which require high-temperature granulation), BB fertilizers do not require chemical reactions or granulation, resulting in lower energy consumption and investment.
3. Balanced Nutrients:
Precisely controls the ratios of nitrogen, phosphorus, potassium, and trace elements, avoiding nutrient waste and complying with the "soil testing and formula fertilization" policy.
4. Environmentally Friendly:
The production process eliminates waste and produces high raw material utilization, aligning with the trend of green agriculture.
Type | Core equipment | How it works | Hybrid | Mixing uniformity | Material properties | Material residue | Raw material type |
Rotary drum BB fertilizer production line | Drum mixer (cylindrical drum, tilted installation, with a lifting plate on the inner wall) | When the drum rotates, the raw materials are lifted up and thrown down by the inner wall lifting plate, and are mixed by the combined motion of gravity falling and drum rotation. | The "passive mixing" that relies on the material's own gravity and the rotation of the drum has a weak impact force. | Medium (uniformity 85%-90%), suitable for general formulations with low requirements for uniformity. | Suitable for granular raw materials (such as urea and ammonium phosphate granules), the granules are not easy to break. | High (the inclination angle of the drum causes some material to be retained, with a residual rate of 3%-5%). | Use granular fertilizer as the main method and avoid powder. |
Horizontal BB fertilizer production line | Horizontal mixer (rectangular/horizontal cylinder, built-in stirring shaft + paddle/ribbon) | The stirring shaft rotates at high speed, and the blades/ribbons push the raw materials horizontally and vertically to shear and convect, achieving mixing through forced stirring. | The "forced mixing" that relies on the active shearing and pushing of the blades is more powerful. | High (uniformity 90%-95%+), suitable for complex formulas containing trace elements and small proportions of additives. | It can process granular and powdered raw materials (such as potash fertilizer powder and organic fertilizer powder), but the blade speed needs to be controlled to avoid excessive crushing. | Lower (the blades are close to the cylinder wall, the residual rate is 1%-2%), and the cleaning is more thorough. | Compatible with granules + powders |
When changing the formula of a BB fertilizer production line, does it need to be readjusted?
Yes, adjustments are required, but the process is simple. Fully automated production lines allow the new raw material ratios to be directly input through the PLC control system. The system automatically adjusts the feeder speed and metering parameters, eliminating the need for mechanical modifications. Semi-automated production lines require manual adjustment of the feed valve or belt scale parameters, which can be completed in 5-10 minutes by a skilled worker. This is the core feature of the BB fertilizer production line's "high flexibility."
Does the production process generate dust or pollution? Are environmental protection equipment required?
Raw material handling and mixing may generate a small amount of dust, but no wastewater or exhaust emissions are emitted. Simple dust removal equipment is recommended, installed at the silo outlet and above the mixer. This effectively controls dust and meets environmental requirements. For smaller production lines with limited budgets, enclosing the silo and improving ventilation can also reduce dust dispersion.
How many people are needed to operate the production line?
The level of automation determines the number of employees required: a fully automated production line requires only 2-3 people (responsible for raw material replenishment and packaging assistance); a semi-automated production line requires 4-5 people (with additional manual batching and equipment startup and shutdown procedures). No specialized skills are required; workers can begin work after 1-2 days of training.
Does varying raw material particle sizes affect mixing uniformity? How can product quality be ensured?
It does have some impact. If the raw material particle size varies significantly, stratification may occur. Solutions:
① Control raw material particle size through screening during pretreatment;
② Use high-efficiency mixing equipment and extend mixing time;
③ Conduct regular sampling and testing, verifying uniformity using the "four-part method."
What precautions should be taken during daily equipment maintenance? What are the wearing parts? Is replacement cost high?
Daily maintenance priorities:
① Regularly clean residual material from the mixer;
② Check the wear of the feeder's spiral blades and belt;
③ Lubricate transmission components. Consumable parts include spiral blades, belts, screening meshes, etc., with unit prices ranging from tens to hundreds of yuan, and a replacement cycle of 3-6 months. The maintenance cost is low, and the annual maintenance cost accounts for about 2%-5% of the total equipment price.
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