Recently, Zhengzhou Huaqiang Heavy Industry Technology Co., Ltd. completed the installation and commissioning of a customized BB fertilizer coating production line for its client, officially commencing large-scale production. This production line focuses on the core needs of precise proportioning and enhanced efficiency through coating of BB fertilizer (blended fertilizer). It integrates key processes such as batching, melting, coating, storage, and packaging. With its compact layout, efficient equipment coordination, and stable coating effect, it provides fertilizer production enterprises with a high-quality customized BB fertilizer solution, helping to improve fertilizer utilization and crop yield.
Core Configuration and Full-Process Analysis of the Production Line
The entire BB fertilizer coating production line is built around the core logic of “precise batching – coating solution preparation – uniform coating – finished product output.” The equipment selection is professional, the process is seamless, and the functions of each unit are precisely matched, fully ensuring the accuracy of the BB fertilizer formulation and the quality of the coating.
Precision Batching Unit: Laying a Solid Foundation for Nutrient Balance
The production line is centered around a 5-compartment automated batching unit. Each of the 5 independent compartments stores nitrogen, phosphorus, and potassium as primary raw materials, as well as two different types of trace element additives. The compartments are designed with partitioned isolation to effectively prevent cross-contamination and ensure formula purity. A high-precision metering screw conveyor is installed at the bottom of each batch of batches. Combined with a PLC intelligent control system, it automatically adjusts the feed rate of each raw material according to the preset formula, with a metering error of ≤0.5%. This ensures that the nutrient ratio of each batch of product is accurately met, adapting to the fertilization needs of different crops and different growth stages.
After batching, the mixed raw materials are smoothly transferred to a 9-meter bucket elevator via a 9-meter belt conveyor. This elevator uses a plate chain drive design, has a strong load-bearing capacity, and operates stably. It can vertically transport materials to the subsequent coating stage, with a conveying efficiency of 8 tons/hour. The equipment also has excellent sealing, effectively reducing dust and material loss during the transport process.
Core Coating Unit: Achieving Efficient and Uniform Coating
Coating Solution Preparation System: Equipped with a dedicated coating solution melting and stirring tank. This equipment adopts a double-jacketed heating design, which can precisely control the temperature inside the tank (50-80℃), ensuring that the coating agent (such as anti-caking agent, slow-release agent) melts rapidly and mixes uniformly. The stirring speed can be adjusted by a frequency converter (20-40r/min) to avoid sedimentation and stratification of the coating solution, ensuring consistent coating effect. The tank is equipped with liquid level monitoring and automatic replenishment functions to maintain the coating solution level in real time and ensure continuous operation of the production line.
Core Coating Equipment: Employs a Φ1.8×7.0 meter drum-type coating machine. This equipment is the key equipment for BB fertilizer coating treatment. The inner wall of the drum is lined with special wear-resistant plates, combined with a spiral layout of lifting plates, which can drive the material to fully tumble and scatter within the drum, ensuring that each fertilizer particle is evenly contacted with the coating solution. The coating machine is equipped with an atomizing spraying system that evenly sprays the molten coating liquid onto the material surface in the form of micron-sized droplets. The spraying amount can be precisely controlled according to the material flow rate, ensuring uniform coating thickness (0.05-0.1mm) and a coating rate of over 98%. During equipment operation, the drum speed and material residence time can be flexibly adjusted to adapt to BB fertilizer raw materials of different particle sizes and characteristics, achieving customized coating effects.
Finished Product Storage and Packaging Unit: High-Efficiency Output Ensures Quality
After coating, the BB fertilizer granules are transferred to the finished product silo via a 6-meter bucket elevator. The silo features a sealed design and is equipped with dehumidification and ventilation devices to effectively prevent the fertilizer from absorbing moisture and clumping, ensuring product storage stability. Material level sensors are installed inside the silo to provide real-time feedback on inventory status, facilitating companies to rationally plan production and shipment schedules.
The packaging process is equipped with a dual-station automatic packaging scale, supporting rapid switching between various packaging specifications such as 25kg and 50kg. Utilizing gravity-based metering principles and high-precision sensors, the metering error is ≤±0.1kg. A single station can package up to 100 bags/hour, while parallel operation with two stations can achieve a packaging capacity of 200 bags/hour, perfectly matching the production line’s wrapping output efficiency. The packaging machine integrates automatic sewing and conveying functions. After metering, bagging, and sewing, materials are directly transported to the finished product stacking area via conveyor belt. The entire process is automated, reducing manual intervention, labor intensity, and material loss.
Core Advantages and Application Value of the Production Line
Compact and Efficient Layout: The entire production line adopts a modular and compact design, requiring only 300 square meters of space, saving 30% of space compared to traditional wrapping production lines. The reasonable spacing between equipment facilitates later maintenance and repair.
Superior Coating Quality: The precise coordination of the roller coating machine and the atomizing spraying system ensures a uniform and dense coating layer, effectively improving the BB fertilizer’s resistance to moisture absorption, anti-caking, and slow-release nutrient effect, increasing fertilizer utilization by 15%-20% compared to ordinary BB fertilizers.
Intelligent and Convenient Operation: The entire production line integrates a PLC control system with a Chinese touchscreen interface, allowing real-time monitoring of key parameters such as ingredient ratios, coating solution temperature, and equipment operating status. It supports automatic fault alarms and data recording, facilitating refined management for enterprises. The equipment operation process is simple, and users can become proficient after a short training period.
Integrated Solutions for Complete Fertilizer Production
This BB fertilizer coating line represents a specialized segment of modern fertilizer manufacturing. It demonstrates Huaqiang Heavy Industry’s capability in providing targeted solutions that enhance product value through precise blending and coating.
For clients requiring a more comprehensive production system, this line can be integrated as a finishing module within a complete npk fertilizer production line. The coated BB fertilizer produced here is a key product type within the broader npk fertilizer manufacturing process. The initial stage of this process often relies on core blending and granulation technologies. An npk bulk blending machine (or bulk blending fertilizer machine) is essential for creating the uniform raw material mix. For producing compound granules, advanced npk granulation machine technology is employed, utilizing equipment such as an npk fertilizer granulator machine to perform the fertilizer granulation that transforms powder into robust, market-ready NPK fertilizer granules.
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