Tons Bag Fertilizer Packing Machine

Equipment Introduction

The ton bag fertilizer packaging machine, also known as a ton bag scale or FIBC packaging machine, is a specialized automated equipment for filling large-tonnage finished products (500-2000 kg) in fertilizer plants. It is compatible with PP flexible ton bags (FIBCs) and comes in three types: granular, powder, and fully automatic bag-loading. It is specifically designed to solve the needs of large-volume fertilizer sales and bulk filling of raw materials during transit, replacing the inefficient methods of manual weighing and manual ton bag loading.

(I) Core Industry Advantages

1. Precise and Stable Metering: Coarse + Fine dual-stage feeding and weighing, dynamic error ≤ ±0.5%, meeting agricultural input trade settlement standards and reducing material loss;
2. Corrosion and Dust Resistance, Compatible with Fertilizers: All materials in contact with the filling material are made of 304 stainless steel, and the filling port is under negative pressure with fully enclosed dust removal, preventing dust leakage from organic fertilizers and high-salt compound fertilizers;
3. Dense Material Compactness and Anti-caking: Standard configuration includes a bottom vibration platform, which compacts the fertilizer during filling, eliminating loose gaps inside the ton bag and preventing caking and bag breakage during long-distance transportation;
4. Extremely Low Labor Costs: Semi-automatic models require only one person to hang the bags, while fully automatic models can be equipped with robotic arms for unmanned operation, reducing manpower by 60% compared to manual filling;
5. Compatible with Powders/ Dual-form granules: Granules are fed by gravity gate feeding, while powders are fed by variable frequency screw feeding. One machine is suitable for both organic and inorganic fertilizers.
6. High integration: Can be connected to bucket elevators, finished product silos, belt conveyors, and automatic palletizing robots to form a complete ton bag packaging production line.

(II) Machine Model Differentiation

1. Granule Ton Bag Packaging Machine: Grate feeding (fast and slow speeds), suitable for compound fertilizers, organic fertilizer granules, and urea, with higher production capacity.
2. Powder Ton Bag Packaging Machine: Double screw feeding (coarse and fine) + silo arch breaking, suitable for humic acid powder, phosphorus and potassium powder, and microbial powder.
3. Fully Automatic Ton Bag Packaging Machine: Equipped with a robotic arm to automatically grab and open ton bags, eliminating the need for manual bag hanging, suitable for large-scale fertilizer bases.

Equipment Structure and Components

The ton bag fertilizer packaging machine mainly consists of the following systems:

1. Feeding and Feeding System

Includes a buffer hopper and feeding device (screw feeder, gravity feeder, or vibratory feeder, etc.). It adopts a variable speed feeding mechanism, consisting of an adjustable speed motor, belt drive, screw shaft, and feeding nozzle. A dust suction port is provided next to the feeding nozzle.

2. Weighing System

A metering and control system is composed of high-precision sensors (accuracy up to 0.02%) and high-resolution control instruments. The weighing frame is connected to the sensor, transmitting the material weight signal to the electrical box. Based on the metering method, it is divided into net weight type (material is weighed before being placed in the bag) and gross weight type (material is directly weighed after entering the bag).

3. Bag Hanging and Clamping System

Includes bag hanging hooks, pneumatic bag clamping devices, and a lifting mechanism. The four corner straps of the ton bag are manually hung on the hooks, and the discharge port is fitted onto the sealed discharge port. The lifting function can accommodate ton bags of different sizes.

4. Control System: The PLC-based electrical control system features both automatic and manual operation modes. It can perform functions such as parameter setting, weighing calibration, automatic tare, automatic zeroing, automatic drop correction, out-of-tolerance alarm, and fault self-diagnosis. It is equipped with a communication interface for easy network connection and remote monitoring.
5. Dust Removal System: A dedicated dust removal device is provided to simultaneously remove dust that overflows with the air during the feeding process, preventing on-site dust pollution.
6. Conveying System: The packaged ton bags are transported to the designated location via roller conveyors, belt conveyors, or forklifts.

Working Principle

The entire machine adopts a two-stage feeding, segmented weighing, negative pressure sealed filling, and synchronous vibration compaction integrated process:

1. Finished fertilizer is fed into the top buffer silo via a bucket elevator. The powder feeder starts vibrating to break bridging and prevent material breakage;
2. Manually or robotically, the ton bag is hung on four load-bearing hooks, a cylinder clamps the bag opening, the dust-collecting sealing skirt fits the discharge port, and the dust collector is activated simultaneously;
3. PLC controls the coarse feeding mechanism to quickly fill to the target weight. 85% coarse material gate stops, switching to fine material feeding for micro-feeding; sensors provide real-time weight feedback to compensate for material inertia during descent.
4. Throughout the filling process, the bottom vibration platform intermittently starts to compact the loose fertilizer inside the bag, reducing bag expansion.
5. Once the set ton bag weight is reached, the feeding mechanism stops completely, and a delayed dust removal process recovers residual dust from the bag opening.
6. The clamping clamps and hooks are released, and the ton bag filled with fertilizer falls onto the belt conveyor, transporting it to the sealing and pallet stacking station for the next bag’s operation.

Applicable Raw Materials (Covering All Fertilizer Categories)

Suitable Packaging Materials:

1. Granular Fertilizers: Organic fertilizer granules, compound fertilizers, BB fertilizers, urea, slow-release coated granules, extruded granulated products;
2. Powdered Fertilizers: Humic acid powder, chicken manure organic fertilizer powder, monoammonium phosphate, potassium sulfate, microbial agents, soil conditioners;
3. Small Organic Raw Materials: Fermented and decomposed compost, crushed cake fertilizer, microbial residue (particle size ≤ 15mm).

Unsuitable Materials: Moisture content > 12%; High-viscosity slurry; Extra-long wound fibers; Large hard rocks > 20mm in particle size; High-temperature molten fertilizers.

Application of Ton Bag Packaging Machines in Fertilizer Production Lines

(I) Complete Process Link: Granulation/Crushing Section → Drum Screen → Finished Product Silo → Bucket Elevator → Ton Bag Fertilizer Packaging Machine → Belt Conveyor → Sealing/Pallet Palletizing → Warehouse/Truck Transportation

(II) Section Support Logic

1. Large-volume Export Support: Supports bulk raw material shipments from fertilizer plants and full-truckload shipments from farms/agricultural wholesalers in ton bags, replacing a large number of 25/50kg small bags and significantly reducing packaging and transportation labor costs;
2. Raw Material Transfer and Recycling: Fermentation raw materials and purchased mineral powder in ton bags are directly fed into the batching section after warehousing;
3. Dual-line Parallel Solution: The production line is simultaneously equipped with small bag packaging machines and ton bag packaging machines at the back end, accommodating both retail small bag and bulk ton bag orders;
4. Dust Closed-Loop Recovery: Fine fertilizer powder collected during filling and dust removal is returned to the buffer silo, resulting in zero raw material loss.

Standard Operation and Full Lifecycle Maintenance

(I) Start-up and Shutdown Procedures

Start-up Procedure

1. Check that the hopper is free of clumps, the sensors are free of fertilizer buildup, the dust collector filter is unobstructed, and the air pressure is stable at 0.5–0.7 MPa;
2. First, start the dust collector, vibrating platform, and arch-breaking motor, and run them unloaded for 2 minutes;
3. Retrieve the corresponding fertilizer formula on the touchscreen, perform zero-point calibration of the weighing, and begin bagging production after confirming that the accuracy meets the standards.

Shutdown Procedure

1. Stop the front-end lifting and feeding mechanism, and wait for all material to be emptied from the hopper and feeding mechanism;
2. Turn off the feeding, dust collector, and vibrating motors in sequence;
3. Clean the weighing bridge and sealing skirt of any residual fertilizer, and loosen the lifting hook cylinder for long-term storage. (II) Tiered Maintenance
4. Daily Inspection: Clean dust from the load cells, check the operation of the hooks, clamps, and cylinders, and calibrate the zero point of the weighing system every shift;
5. Weekly Maintenance: Lubricate the feed gate/screw and drive chain with grease, and clean the dust collector filter bags;
6. Quarterly Maintenance: Replace the gear oil in the reducer with new gear oil, and check the sensor wiring and shock absorber pads for aging and cracking;
7. Annual Overhaul: Replace aged sealing skirts and damaged dust collector filter bags, and fully calibrate the accuracy of the weighing system.

(III) List of Vulnerable Parts

Dust collector sealing skirt, pulse filter bag, load cell, cylinder seal ring, screw blade (powder type), gate wear-resistant liner, lifting hook.

Target Customers for this Equipment:

1. Large-scale Fertilizer Manufacturers: Manufacturers of organic fertilizers, compound fertilizers, and BB fertilizers with an annual output of tens of thousands of tons, requiring large-volume shipments. Ton bag packaging is standard for industrial-grade fertilizer products.
2. Fertilizer Raw Material Manufacturers: Manufacturers of fertilizer raw materials such as urea, phosphate fertilizer, potash fertilizer, and ammonium sulfate; ton bag packaging is the industry standard.
3. Export-oriented Fertilizer Companies: Exported fertilizers typically use ton bag packaging for easy container transport and port handling.
4. Chemical and Mining Companies: Companies requiring large-bag packaging for chemical raw materials and non-metallic mineral powders.
5. Companies Building or Expanding Fertilizer Production Lines: Fertilizer production projects requiring a complete packaging system. Ton bag packaging machines can be combined with small bag packaging machines, allowing for flexible switching between the two specifications. 6. Key Selection Points:

Material Characteristics Priority: For powdery materials, choose screw feeder with strong dust removal; for granular materials, choose gravity feeder.

Accuracy Requirements: For general fertilizers, choose ±0.4%-0.6%; for high-end products, choose ±0.1%-0.2%.

Capacity Matching: Calculate the required packaging speed based on daily output, allowing for a 10%-20% margin.

Automation Level: In areas with high labor costs, prioritize fully automatic models.