Author: organic fertilizer production line

As the fertilizer and chemical industries develop towards large-scale and intensive production, the demand for large-capacity packaging is increasing daily. Ton bag fertilizer packaging machines (also known as large bag packaging machines), as automated equipment specifically designed for large-capacity packaging, have become core equipment for bulk material packaging due to their precise weighing control, high efficiency, and fully automated operation. They provide comprehensive solutions for enterprises to improve production efficiency, reduce costs, and ensure packaging safety.

The core advantage of the ton bag fertilizer packaging machine stems from its scientifically designed and sophisticated structure, with various systems working together to achieve fully automated operation. The equipment mainly consists of six core parts: a material feeding system, a weighing system, a packaging actuator, a control system, a conveying system, and a dust removal system. The feeding system, comprising a hopper and a screw or vibrating feeder, is responsible for material pretreatment and stable supply, ensuring a continuous and smooth feeding process. The weighing system employs high-precision electronic weighing devices, often equipped with suspended weighing systems, suitable for accurately weighing heavy materials, ensuring that the weight error of each bag is controlled within a reasonable range. The packaging execution mechanism, through the coordinated operation of bag clamping devices, filling mechanisms, and sealing equipment, completes the fixing of the ton bags, material filling, and sealing, ensuring the airtightness and stability of the packaging.

Its workflow is clear and efficient, achieving full automation from empty bag preparation to finished product stacking. First, empty ton bags are precisely transported to the packaging position via a conveyor system and securely fixed by a bag clamping device to prevent displacement or leakage during filling. Then, material is fed into the ton bags at a uniform speed via a feeder, and an electronic weighing system monitors the weight in real time. When the preset weight is reached, the feeding system immediately stops feeding to ensure accurate weight measurement. After filling, the sealing equipment seals the ton bags to prevent leakage during storage and transportation. Finally, the sealed ton bags are transported to a designated area by a conveyor system, where they can be automatically stacked with an automatic stacking system, significantly reducing manual handling.

The ton bag fertilizer packaging machine possesses five core features: high-precision weighing, large-capacity packaging, high automation, strong adaptability, and environmentally friendly design. It is specifically designed for large-capacity packaging needs ranging from 1 ton to several tons, precisely matching the pace of large-scale production. The fully automated operation fundamentally reduces manual operation, lowering labor intensity and labor costs. The equipment is not only suitable for ton bag packaging of various fertilizers but also adaptable to different types of bulk materials such as chemical raw materials and mineral powders, including powdered and granular materials, demonstrating extremely high adaptability. Meanwhile, the dust removal system effectively collects dust generated during the packaging process, preventing environmental pollution and maintaining a clean production environment. The user-friendly human-machine interface makes parameter settings convenient and easy to understand, significantly reducing operation and maintenance difficulties.

In the context of large-scale production, ton-bag fertilizer packaging machines, with their high efficiency, precision, and stable performance, have become the preferred equipment for large-capacity packaging in the fertilizer and chemical industries. Their application not only improves enterprise production efficiency and packaging quality but also promotes the automation and green transformation of industry production models, providing solid support for the back-end support of large-scale production and helping enterprises gain an advantage in fierce market competition.

The Final Link in an Integrated Production Chain

The ton-bag packaging machine represents the essential final stage in a modern, high-volume fertilizer manufacturing operation. Its high-speed, automated operation is critical for efficiently handling the output of a large-scale production facility, completing the value chain from raw material to shippable product.

This packaging unit is designed to receive the finished granules from upstream professional fertilizer manufacturing equipment. For mineral-based products, it would typically be connected to the end of a complete npk fertilizer production line, which includes an npk blending machine for formulation and various granulation options like a disc granulation production line using a disc granulator machine, or a roller press granulator production line. For organic products, it would receive output from an organic fertilizer production line, which might begin with a windrow composting machine and use an organic fertilizer disc granulation machine for shaping. Regardless of the source—be it a bio organic fertilizer production line or a standard NPK line—the high-capacity packager is the common endpoint that prepares the product for bulk logistics, seamlessly integrating into the overall npk fertilizer production process.

Thus, the efficiency of the entire plant, from blending and granulation to packaging, depends on the synergy between each specialized piece of equipment, with the ton-bag packager ensuring the final product is delivered to market efficiently and reliably.

In agricultural production, the rational combination of fertilizers is crucial to maximizing nutrient efficiency and promoting healthy crop growth. A common question among farmers is whether DAP (Diammonium Phosphate) can be mixed with NPK fertilizers. The answer is affirmative: mixing DAP with NPK fertilizers can achieve a synergistic effect of balanced nutrient supply, especially beneficial for establishing strong root systems in the early growth stage of crops. However, this combination requires scientific methods and attention to application details to avoid potential risks such as seed burn or over-fertilization.

To understand the value of mixing DAP and NPK, it is first necessary to clarify the nutrient characteristics of each. DAP is a high-phosphorus and nitrogen fertilizer, typically with a nutrient ratio of 18-46-0. Phosphorus, as a core nutrient for root development, enables crops to form robust root systems in the seedling stage, enhancing water and nutrient absorption capacity. The nitrogen component in DAP also provides essential energy for early vegetative growth. In contrast, NPK fertilizers are balanced blends containing three key elements: nitrogen (N), phosphorus (P), and potassium (K). With flexible ratios such as 10-10-10 or 12-6-10, they can meet the comprehensive nutrient needs of crops throughout the vegetative and reproductive stages, especially supplementing potassium that is lacking in DAP—potassium plays a vital role in promoting flowering, fruiting, and improving crop resilience.

When mixed properly, DAP and NPK fertilizers complement each other perfectly. In the early planting stage, the high phosphorus in DAP lays a solid foundation for root establishment, while the balanced nutrients in NPK ensure sustained growth in subsequent stages. This combination avoids the one-sidedness of using a single fertilizer: using only DAP may lead to insufficient potassium supply in the later growth stage, affecting flowering and fruiting; relying solely on NPK may not provide the concentrated phosphorus needed for early root development.

To ensure the safety and effectiveness of mixing, several best practices must be followed. Firstly, conduct a soil test. Understanding the existing nutrient levels in the soil helps determine whether both fertilizers are needed, preventing waste and nutrient imbalances caused by blind application. Secondly, grasp the application timing reasonably: use the mixed fertilizer mainly at the planting stage to support early root growth, and then supplement with appropriate NPK fertilizers according to crop growth needs in the later stages to maintain balanced nutrition. Thirdly, avoid direct contact with seeds. DAP may release ammonia, which can burn tender seedlings. Therefore, the mixed fertilizer should be first blended with soil or compost, and applied several centimeters away from the seeds.

It is also important to distinguish the focus of fertilizer use in different growth stages. At the planting stage, the mixed fertilizer of DAP and NPK is ideal for giving crops a strong start; in the later growth stages (such as flowering and fruiting periods), selecting NPK fertilizers with appropriate potassium ratios is more conducive to improving crop yield and quality. Additionally, when blending, pay attention to the total nutrient content to avoid over-fertilization, which may cause soil salinization or crop nutrient poisoning.

Conclusion: From Agronomic Science to Industrial Production

The scientific combination of DAP and NPK in the field relies on a sophisticated manufacturing industry capable of producing precise and consistent fertilizer products. The balanced nutrient ratios needed for such strategies are achieved through advanced industrial processes.

This production is enabled by modern npk fertilizer production technology within a complete npk fertilizer production line. The process begins with precise formulation using an npk bulk blending machine or bulk blending fertilizer machine to combine raw materials like DAP with other nutrients. The blended mixture is then shaped using npk granulation machine technology. Key equipment like an npk fertilizer granulator machine (part of the npk fertilizer granulator machine equipment suite) transforms the powder into uniform granules via processes such as drum or extrusion granulation as part of the overall npk fertilizer manufacturing process. The scale and efficiency of this process determine the final NPK compound fertilizer production capacity, ensuring a reliable supply of the quality products that modern, precise agriculture depends on.

Ultimately, the synergy between field-level nutrient management and industrial-scale precision manufacturing is what allows farmers to implement effective strategies like DAP-NPK blending to optimize crop health and yield.

In conclusion, mixing DAP with NPK fertilizers is a feasible and effective fertilization strategy, as long as it is based on soil tests, adheres to scientific application methods, and matches crop growth needs. This synergistic fertilization approach not only improves nutrient utilization efficiency but also promotes healthy crop growth from seedling to maturity, laying a solid foundation for high yield and quality.

In the agricultural input market, “Formula Fertilizer No. 7” is a frequently chosen option by farmers when purchasing fertilizers for the fruit enlargement period. However, it is not a nationally standardized number, but rather a custom-designed formula code used within the industry. As a specialized fertilizer designed specifically for the reproductive growth stage of crops, Formula Fertilizer No. 7 features “high potassium, low nitrogen, and medium phosphorus” as its core characteristics, precisely matching the nutrient requirements for fruit enlargement, coloring, and sweetening. It has become a key fertilizer for improving the yield and quality of fruits and cash crops, and is also a standard “fruit enlargement fertilizer” commonly used in the agricultural input industry.

The core advantage of Formula Fertilizer No. 7 lies in its scientific nutrient ratio. The classic formula ratios for mainstream Formula Fertilizer No. 7 in the industry are mostly 15-5-20, 16-6-22, etc., with the core characteristics of potassium content not less than 20%, nitrogen content moderate to low, and phosphorus content moderate. Potassium, known as a “quality element,” promotes the transport of photosynthetic products to fruits and seeds, effectively improving fruit sweetness, color, and firmness, and reducing fruit cracking and deformities. A low-nitrogen design prevents excessive vegetative growth, avoids nutrient competition, and ensures nutrient supply for reproductive growth. Appropriate phosphorus levels maintain root vitality, ensuring successful pollination and preventing empty seeds and fruit drop. Some manufacturers also add micronutrients such as calcium, magnesium, boron, and zinc to further enhance fertilizer efficiency.

Compared to other numbered fertilizer formulas, Formula 7 is highly targeted in its application. In the agricultural input industry, fertilizer formulations are typically categorized by crop growth stage and nutrient emphasis: Fertilizer No. 1 is high in nitrogen, low in phosphorus, and low in potassium, suitable for promoting seedling growth and leaf development; Fertilizer No. 2 has a balanced nitrogen, phosphorus, and potassium content, suitable for general supplemental fertilization throughout the crop’s growth period; Fertilizer No. 3 is high in phosphorus, medium in nitrogen, and low in potassium, primarily promoting root and flower development; while Fertilizer No. 7, with its “low nitrogen, medium phosphorus, and high potassium” formulation, is specifically targeted at critical reproductive stages such as fruit expansion, grain filling, and coloring, making it a dedicated fertilizer for the crop’s yield and quality formation stages. This clear positioning allows farmers to quickly and accurately select the right fertilizer.

Fertilizer No. 7 has a wide range of applications, especially suitable for crops with high potassium requirements. In fruits and vegetables such as watermelon, strawberries, tomatoes, grapes, and citrus, application significantly improves fruit expansion speed and fruit quality; in cash crops such as peanuts and soybeans during the pod-setting stage, and sweet potatoes and potatoes during the tuber enlargement stage, application increases yield and marketability; even in field crops such as rice and corn, application during the grain-filling stage and the late trumpet stage can improve grain plumpness. The optimal application time is during the fruit enlargement stage after flowering, typically 2-3 times consecutively, with an interval of 10-15 days, to maximize its effectiveness.

When applying Formula 7 fertilizer, attention must be paid to its suitability and scientific formulation. For chlorine-sensitive crops such as grapes, citrus, and sweet potatoes, potassium sulfate-based Formula 7 fertilizer should be chosen; for field crops, potassium chloride-based formula can be used to reduce planting costs. It is mainly used as a top dressing or fertigation fertilizer and cannot replace base fertilizer; it should be used in combination with organic fertilizer or balanced fertilizer as a base fertilizer. Foliar spraying with potassium dihydrogen phosphate and boron fertilizer during the fruit enlargement stage can further enhance the quality improvement effect. In addition, some manufacturers adjust the formula according to regional soil characteristics; for example, Formula 7 fertilizer for acidic soils in the south adds calcium and magnesium to adjust the acidity, while Formula 7 fertilizer for greenhouses uses a fully water-soluble formula suitable for drip irrigation. Farmers can choose according to their needs.

Manufacturing Precision: From Formula No. 7 to Professional Production

The widespread use of specialized formulas like Fertilizer No. 7 is enabled by sophisticated, flexible production systems. This precise formulation of “high potassium, low nitrogen, medium phosphorus” requires a manufacturing process that can accurately blend and shape specific nutrient ratios to meet exacting market demands.

The creation of such products is the domain of modern professional fertilizer manufacturing equipment. A typical npk fertilizer production line for this purpose would begin with a precise npk blending machine to mix raw materials to the exact No. 7 specification. This mixture is then formed into granules using specialized fertilizer granulator technology. Manufacturers might choose a disc granulation production line featuring a disc granulator (or disc granulator for shaping) for rounded particles, or a roller press granulator production line with a double roller press granulator for high-density granules. This entire sequence forms the core of the npk fertilizer production process. For producers also offering organic options, this specialized NPK line could be complemented by a separate organic fertilizer production line that begins with raw material processing using a windrow composting machine.

Ultimately, the availability of targeted fertilizers like Formula No. 7 is a direct result of advanced, adaptable manufacturing technology that can efficiently translate agronomic science into precise, high-quality products for farmers.

In summary, Formula 7 fertilizer is a high-potassium fertilizer specifically designed for the reproductive growth stage of crops. Its scientific nutrient ratio precisely addresses the nutrient requirements during the fruit enlargement stage. For farmers pursuing high and high yields, choosing the right No. 7 compound fertilizer and applying it scientifically can safeguard crop quality and yield, becoming an important aid to precision fertilization in modern agriculture.

The sodium carbonate (soda ash) extrusion granulation production line focuses on the solidification and molding needs of powdered sodium carbonate. With “precise pretreatment – high-pressure extrusion – grading and screening – finished product output” as its core process, it achieves a stable production capacity of 4m³/hour (approximately 6.8 tons, based on a sodium carbonate density of 1.7g/cm³) through customized equipment configuration and process optimization. The finished granules are characterized by high strength, good flowability, and low moisture absorption, making them suitable for applications in chemical, building materials, and environmental protection industries.

Production Line Configuration and Core Details

I. Raw Material Pretreatment Unit: Ensuring Basic Granulation Quality

(I) Raw Material Storage and Feeding System

Raw Material Silo: Equipped with one 10m³ conical raw material silo, made of 304 stainless steel (resistant to slight corrosion from sodium carbonate). The silo has a 60° cone angle and is equipped with a vibrator and a star-shaped unloader at the bottom to prevent powder bridging and blockage. The raw material silo is equipped with a pulse dust collector at the top to collect dust generated during the feeding process. The dust emission concentration is ≤10mg/m³, meeting environmental protection standards.

Quantitative feeding device: A variable frequency controlled screw feeder (model LS300) is used, with the feeding rate precisely adjustable within the range of 2-5m³/h, suitable for a production capacity of 4m³/h. The feeder shell adopts a sealed design, and the internal spiral blades are treated with a wear-resistant coating to reduce wear on the equipment caused by sodium carbonate powder and prevent moisture absorption and agglomeration.

(II) Raw material drying and crushing pretreatment

Low-temperature dryer: Because sodium carbonate is prone to moisture absorption and agglomeration, one Φ1.2×6.0 meter drum dryer is configured. Hot air circulation heating is used, and the drying temperature is controlled at 80-100℃, reducing the raw material moisture content from ≤5% to ≤0.5%, avoiding agglomeration that affects extrusion molding. The dryer has a built-in lifting plate spiral layout, ensuring uniform heating of the material, with a drying uniformity error of ≤2%. Fine Pulverizer: A 400-type vertical pulverizer is selected, with a cutter disc made of high-chromium wear-resistant alloy. It pulverizes any lumps (particle size ≤20mm) that may exist after drying into uniform powder ≤1mm, ensuring consistent raw material fineness and improving extrusion granulation rate. The pulverizer is equipped with a grading screen, allowing flexible adjustment of the discharge particle size. The pulverizing efficiency reaches 6m³/h, meeting the continuous operation requirements of the production line.

II. Core Extrusion Granulation Unit: Key Link in High-Pressure Molding

(I) Precise Feeding and Pre-compression

Twin-Screw Pre-compressor: The pulverized sodium carbonate powder is conveyed to the twin-screw pre-compressor via a 1.5-meter belt conveyor. Through spiral extrusion, the loose powder is pre-compressed into a dense column with a density of 1.2g/cm³, avoiding problems such as uneven pressure and low granulation rate caused by direct entry into the granulator. The pre-compressor is equipped with a material level sensor, automatically linking with the front-end feeder to adjust the feed rate, ensuring stable material supply.

(II) High-Pressure Extrusion Granulation Main Unit

Core Equipment Selection: Two 2.5-type double-roller press granulators, each with a capacity of 2 m³/h, operate in parallel, achieving a total capacity of 4 m³/h. The granulator rollers are made of wear-resistant alloy steel, hardened to a hardness of HRC62 or higher, and feature customized anti-slip textures (0.8 mm depth) to enhance powder penetration.

Key Parameter Design: The extrusion pressure is precisely controlled at 12-18 MPa via a hydraulic system, ensuring that sodium carbonate powder is fully extruded and shaped within the die, resulting in granules with a compressive strength exceeding 3.0 MPa and minimal pulverization. The roller diameter is 400 mm, the roller width is 250 mm, and the die diameter can be customized (3-8 mm). A single unit achieves a stable hourly output of 2 ± 0.2 m³/h. Auxiliary Function Configuration: The granulator is equipped with an automatic roller cleaning device and a die hole unblocker to remove material adhering to the roller surface in real time, preventing die hole blockage and extending continuous operating time (≥8 hours per continuous run). Equipment operating noise is controlled below 75dB, meeting industrial production noise standards.

III. Post-processing and Finished Product Output Unit: Optimizing Quality and Efficiency

(I) Particle Crushing and Grading Screening

Roller Crusher: The extruded flaky granules are conveyed to a double-roller crusher via a 4-meter belt conveyor, crushing the flaky granules into irregular particles (3-8mm in diameter). The crusher roller gap is adjustable (1-5mm) to ensure uniform particle size after crushing.

Grading and Screening Machine: Equipped with one Φ1.5×4.0 meter drum screen, featuring a double-layer screen design. The upper screen (8mm aperture) separates oversized particles, while the lower screen (3mm aperture) screens for qualified particles. Unqualified particles (too coarse or too fine) are returned to the crusher for reprocessing via a return conveyor belt, achieving a material utilization rate of 98%. The screen is equipped with a vibration cleaning device to prevent screen clogging, achieving a screening efficiency of 5 m³/h.

(II) Finished Product Cooling and Moisture Prevention Treatment

Cooler: Qualified particles enter a Φ1.0×8.0 meter counter-current cooler, using ambient air to rapidly reduce the particle temperature from 60-80℃ to room temperature (±5℃), preventing high-temperature particles from absorbing moisture and clumping. The cooler is equipped with an induced draft device to enhance heat exchange efficiency, with cooling time controlled within 15 minutes. After cooling, the particle moisture content stabilizes at ≤0.5%. Moisture-resistant coating (optional): One Φ1.0×3.0 meter coating machine can be added according to customer needs. Using atomized spraying technology, a small amount of anti-moisture agent (such as calcium stearate, ≤0.3%) is evenly adhered to the granule surface, forming a dense protective film to further enhance the finished product’s moisture resistance and extend its shelf life.

(III) Finished Product Storage and Packaging

Finished Product Warehouse: Two 10m³ finished product warehouses (total volume 20m³) are configured. They feature a sealed design and are equipped with dehumidification and ventilation devices to maintain a relative humidity of ≤50% to prevent moisture absorption by the finished product. A star-shaped unloader is installed at the bottom of the warehouse for quantitative discharge.

Automated Packaging: A dual-station automatic packaging scale is used, supporting rapid switching between 25kg and 50kg specifications. The metering error is ≤±0.2kg, and the packaging speed reaches 120 bags/hour. The packaging machine is equipped with a dust cover and bag sealing device to reduce powder flying. Packaged finished products are transferred to the finished product stacking area via belt conveyor.

IV. Environmental Protection and Auxiliary Systems: Ensuring Stable and Environmentally Friendly Production

(I) Dust Control System Each dust-generating stage of the production line (raw material silo feeding, crusher, screening machine, packaging machine) is equipped with a pulse dust collector. A total of 3 MC-96 pulse dust collectors are installed, with a total air volume handling capacity of 15,000 m³/h and a dust collection efficiency of 99.5%, ensuring that the dust concentration in the workshop is ≤8 mg/m³, meeting national environmental protection standards.

The dust collected by the dust collectors is returned to the raw material pretreatment stage via a screw conveyor and reused in production, avoiding material waste.

(II) Intelligent Control System An integrated PLC central control system is provided, equipped with a touch screen operating interface. It can monitor the operating parameters of each piece of equipment in real time (feed rate, extrusion pressure, drying temperature, particle temperature, etc.), and supports automatic fault alarms and data recording (recording cycle ≥30 days). The system supports manual and automatic mode switching, facilitating operator management and maintenance.

(III) Equipment Protection and Adaptation Design

All equipment in contact with sodium carbonate (raw material silos, feeders, granulators, etc.) is made of mildly corrosive materials or treated with anti-corrosion coatings to prevent sodium carbonate from corroding the equipment.

The production line has a compact overall layout, occupying an area of ​​approximately 600 square meters. Maintenance access channels (≥1.2 meters wide) are reserved between each piece of equipment for easy future maintenance. The equipment foundations are designed to withstand vibrations, reducing the impact of vibrations during the extrusion granulator operation.

Core Advantages and Application Value of the Production Line

Stable and Efficient Production Capacity: The dual-machine parallel extrusion granulation design achieves a precise hourly output of 4 m³, with an annual capacity of up to 30,000 tons (based on 300 days of operation per year and 8 hours per day), meeting the needs of large-scale production.

Excellent Finished Product Quality: The high-pressure extrusion molding process ensures high particle strength, resistance to pulverization, low moisture content, and strong moisture resistance, making it suitable for long-distance transportation and long-term storage. Environmentally friendly and energy-saving: The fully sealed design and pulse dust removal system result in minimal dust pollution; the dryer uses hot air circulation, which reduces energy consumption by 15% compared to conventional drying equipment, and keeps operating costs under control.

From Industrial Chemicals to Agricultural Inputs: A Shared Technology Base

The successful application of this sodium carbonate extrusion granulation line underscores the versatility of modern dry compaction technology. While designed for industrial chemicals, its core principles are directly transferable to the agricultural sector, highlighting a shared foundation in precision npk granulation machine technology.

The high-pressure extrusion process used here is essentially the same technology employed in a roller press granulator within a dedicated roller press granulation production line for fertilizer. This demonstrates how equipment like a npk fertilizer granulator machine operates on similar mechanical principles. For agricultural applications, a complete npk fertilizer production line integrates this granulation step into a broader npk fertilizer manufacturing process. This process begins with precise formulation using an npk blending machine or npk bulk blending machine, followed by granulation via the npk fertilizer granulator, and concludes with coating and packaging. The entire npk fertilizer production technology is an integrated system where each machine, from blender to granulator, plays a specific role in the npk fertilizer production process.

Thus, expertise in granulating sodium carbonate translates directly into the capability to produce high-density, low-dust NPK fertilizers, showcasing the interdisciplinary nature of advanced granulation engineering.