Single Silo Single Weigh Dynamic Automatic Batching System

Equipment Introduction

The Single Silo Single Weigh Dynamic Automatic Batching System is the most basic and classic automated batching solution in the fertilizer production field. It adopts an independent configuration of "one silo, one scale"—each raw material silo corresponds to a dedicated high-precision weighing module.

The core value of this system lies in upgrading the traditional manual weighing or volumetric measurement method to automated, precise batching controlled by a microcomputer. It can independently weigh, distribute, and mix various raw materials according to a preset formula, avoiding interference and measurement errors between raw materials from the source.

Equipment Structure Composition

The entire system is divided into independent single-compartment units. Each silo is equipped with complete feeding, weighing, and control components. The whole machine consists of six main parts: raw material storage silo, independent feeding mechanism, independent weighing unit, centralized conveyor, PLC central control, and dust removal auxiliary equipment.

1. Independent Raw Material Silos: Each silo is an independent sealed storage tank, available in carbon steel/304 stainless steel, with an anti-stick coating on the inner wall; the silo side is equipped with a vibrating anti-bridging motor, and the bottom conical hopper guides the flow to prevent organic fertilizer and humic acid powder from absorbing moisture and bridging; the silo top has an inlet for connecting to a bucket elevator/belt conveyor.

2. Dedicated Feeding Mechanism (Matched to Different Materials)

Powdered fertilizer: Variable frequency double spiral coarse and fine feeder;

Granular fertilizer: Variable frequency speed belt/electromagnetic vibration feeder; Each silo has an independent motor, with two feeding speeds for precise control of the feeding flow rate.

3. Independent Weighing Unit (Core): Static version: Independent stainless steel weighing hopper + 4-point cantilever beam load cells; Dynamic version: Dedicated weighing belt bridge + high-precision weighing module; Each weighing unit is equipped with an independent signal transmitter, shock absorption, and anti-tipping limit structure to counteract workshop vibration interference.

4. Centralized Conveying Assembly: After weighing in each bin, the material falls uniformly to the bottom centralized belt/screw conveyor and is fed into a horizontal mixer for mixing.

5. PLC Centralized Electrical Control System: Touch screen human-machine interface, independently controls the feeding parameters of each bin, can store hundreds of fertilizer formulas, and has functions such as over-tolerance audible and visual alarms, production recording, automatic zero-point calibration, and fault bin indication.

6. Dust Removal Auxiliary System: Each bin's feeding port is equipped with an independent negative pressure dust suction port, and a centralized dust collector recovers dust, preventing powder spillage.

Operating Principle of the Equipment

The single-silo single-weighing system operates as an automated closed-loop control process, primarily divided into three stages:

Stage 1: Pre-dosing

After system startup, based on the preset formula, the feeding device rapidly delivers the target material to the weighing module in a "fast-feed" mode.

Stage 2: Dynamic Compensation

When the weight approaches the set value, the system automatically switches to a "medium-feed, slow-feed" stepped feeding mode. The dynamic weighing algorithm captures weight changes during the material's descent in real time, precisely controlling the feeding speed and effectively mitigating the impact of material impact on weighing accuracy.

Stage 3: Error Self-Correction

The system learns from historical data and compensates for system errors in real time. After each raw material is weighed independently, it is conveyed into the mixing equipment by a conveyor device.

Summary table of equipment application scope and applicable raw materials

Equipment Applications in Fertilizer Production Lines

(I) Complete Fertilizer Process Chain

Raw Material Yard Bucket Elevator → Single Silo Single-Weighing Batching System → Horizontal Mixer → Granulator / Direct Packaging (BB Fertilizer) → Drying / Cooling / Screening → Finished Product Packaging

(II) Core Value of the Equipment

1. Extremely High Formula Stability: Each raw material is independently metered, preventing material blockage or weighing drift from affecting the proportions of other raw materials, ensuring stable nitrogen, phosphorus, and potassium levels in the fertilizer;

2. Flexible Multi-Category Production: Switching between organic fertilizer, compound fertilizer, and water-soluble fertilizer does not require emptying the entire weighing system; only the PLC formula needs to be changed for production to begin;

3. Fault Isolation: Blockage or sensor failure in a single silo only shuts down that silo, while production of other raw materials can continue, significantly reducing downtime losses;

4. Closed-Loop Dust Recovery: Independent dust removal at each discharge port ensures zero powder leakage, meeting environmental protection standards;

5. Can be equipped with an automated feeding bucket elevator to achieve fully automated, unmanned operation from raw material warehousing to batching.

Standard Operation and Full-Cycle Maintenance

(I) Standard Start-up and Shutdown Procedures

Start-up

1. Check that there is no fertilizer buildup in the vibration motors, feeding mechanisms, and weighing sensors of each bin, and that the dust removal fan is functioning normally;

2. Start the entire system under no-load conditions, and perform independent zero-point calibration of each weighing unit on the touchscreen;

3. Retrieve the corresponding fertilizer formula, conduct a no-load test run of a whole batch, and formally feed the fertilizer after confirming that the accuracy meets the standards.

Shutdown

1. First, stop the front-end feeding elevator, and wait until all materials in each bin and weighing unit are emptied;

2. Sequentially shut down the feeding, vibration, dust removal, and collection conveyor equipment;

3. Clean the surface of each bin's weighing hopper and belt to remove any residual fertilizer, preventing clumping and corrosion of the sensors.

(II) Graded Maintenance Standards

1. Daily Inspection: Zero-point calibration of each bin's weighing system, cleaning of clumps at the discharge port, and checking for misalignment of the vibrating motor and belts;

2. Weekly Maintenance: Lubrication of the screw/belt drive bearings, and cleaning of the dust collector filter bags;

3. Quarterly Maintenance: Replacement of the reducer gear oil, and inspection of the load cell wiring and damping pads for aging;

4. Annual Overhaul: Disassembly and thorough cleaning of the feeding mechanisms and weighing units of each bin, and calibration of the entire metering system's accuracy.

(III) List of Vulnerable Parts

Weighing sensors, screw blades, belts, vibrating motors, dust collector filter bags, cylinder seals, and drive V-belts.

Common Faults, Causes, and Standardized Solutions

Target Customers:

1. Large-scale production plants of organic fertilizer, compound fertilizer, BB blended fertilizer, and water-soluble fertilizer;

2. Large-scale livestock and poultry breeding groups with their own manure-to-fertilizer processing workshops;

3. Agricultural input repackaging companies and bio-fertilizer processing plants that frequently switch between multiple formulas;

4. Large-scale fertilizer industrial parks with an annual output of over 100,000 tons requiring continuous and stable feed mixing;

5. Fertilizer complete equipment integrators and automated production line supporting service providers;

6. Overseas compound fertilizer and organic fertilizer processing plants' foreign trade procurement customers.

Comprehensive Technical Features of the Equipment:

1. Independent weighing in each bin, eliminating cross-weighing interference and achieving industry-leading precision in fertilizer nutrient ratio proportions;

2. Modular and freely expandable, with 2-12 bins that can be assembled as needed, suitable for small plants and large-scale bases;

3. Fault isolation design, ensuring continuous production of the entire batching line is unaffected by a single bin failure, minimizing downtime losses;

4. Full coverage of both dry and wet materials, with screw feed for powders and vibratory/belt feed for granules, and a built-in arch-breaking system to prevent organic fertilizer bridging;

5. Convenient material changes with no cross-contamination, as each bin is completely independent, allowing for fertilizer formula changes without emptying the entire equipment;

6. Automated and digitalized, with independent bin control, complete functions including formula storage, batching records, and out-of-tolerance alarms;

7. Environmentally friendly, sealed dust removal system, with independent dust extraction ports for each bin, preventing dust leakage during powder fertilizer production.