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 Composition
The entire machine is divided into five main modules: a buffer feeding unit, a weighing and metering unit, a ton bag clamping and lifting unit, a dust removal and vibration unit, and a PLC electrical control system.
1. Buffer Feeding Mechanism: High-level buffer hopper; powder mill models have a built-in vibrating arch-breaking motor + stirring rod; pellet mill models are equipped with double-layer gates (coarse material gate, fine material gate); screw feeder models use variable frequency double screw independent speed regulation.
2. Core Weighing Unit: Heavy-duty weighing bridge + high-precision tension/pressure sensors, available in net weight type (weighing before filling) and gross weight type (simultaneous weighing with bag hanging); the weighing base is equipped with shock-absorbing pads to isolate external vibrations from interfering with metering accuracy.
3. Ton Bag Clamping and Lifting Assembly: Four lifting hooks/pneumatic clamps, large-diameter sealed dust removal skirt, and lifting cylinder; manual hanging straps for the manual version, and a mechanical bag-supporting robot for the fully automatic version, completely covering the outlet of the bag to prevent powder spraying.
4. Dust Removal and Compaction Auxiliary Unit: High-power pulse negative pressure dust collector, simultaneously removing dust during filling; low-frequency vibration platform at the bottom, intermittent vibration during filling to compact the fertilizer.
5. Intelligent Electrical Control System: Touch screen PLC control cabinet, supporting multiple formula storage, automatic tare, out-of-tolerance audible and visual alarms, production statistics, and fault self-diagnosis; the entire machine is anti-static grounded, and explosion-proof electrical control is optional for powder workshops.
6. Supporting Auxiliary Equipment: Finished product belt conveyor, ton bag sealing and sewing machine, forklift pallet conveyor line, palletizing robot (optional).
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.
Common Faults, Causes, and Standardized Solutions
| Fault Phenomenon | Root Cause | Professional Solutions |
|---|---|---|
| Excessive packaging weight error | Dust accumulation on weighing bridge frame, aging shock‑absorbing pads, excessive fine feeding flow | Clean weighing platform daily, replace shock‑absorbing pads, reduce fine feeding speed, perform zero‑point calibration |
| Massive dust overflow during filling | Damaged sealing skirt, insufficient dust‑removal fan air volume, blocked filter bag | Replace dust‑proof skirt, clean blocked filter bag, inspect and repair induced‑draft fan |
| No powder discharging, material bridging in bin | Failed vibration anti‑bridging motor, fertilizer caking caused by moisture absorption | Increase vibration frequency, install stirring device on bin, dehumidify and control temperature in workshop |
| Ton‑bag hook / clamp jaw fails to act | Insufficient air pressure, clogged solenoid valve, faulty sensor probe | Adjust air source pressure, clean solenoid valve, replace proximity switch |
| Motor overload of feeding mechanism | Jammed large material agglomerates, screw / gate plate blockage | Stop machine and empty materials inside bin, add impurity‑removal sieve at front‑end |
| Continuous weighing drift of complete machine | External vibration interference, loose sensor wiring | Build independent concrete foundation for equipment, fasten sensor wiring terminals |
Target Customers:
1. Large-scale production plants of organic fertilizer, compound fertilizer, humic acid powder, and water-soluble fertilizer;
2. Large-scale livestock and poultry breeding groups and farms with their own fertilizer processing workshops, storing large quantities of fertilizer in bulk in ton bags;
3. Agricultural input wholesale distribution centers and fertilizer trading transit warehouses, repackaging bulk fertilizer into ton bags for export;
4. Municipal sludge and kitchen waste resource utilization enterprises, packaging fermented organic fertilizer in large quantities for shipment;
5. Fertilizer complete equipment integrators and suppliers of fully automated packaging and palletizing lines;
6. Overseas fertilizer and organic fertilizer processing plants purchasing export equipment.
Comprehensive Technical Features of the Equipment:
1. High-capacity, high-efficiency filling: 500–2000kg per bag, significantly reducing packaging steps and suitable for bulk shipments.
2. Dual compatibility for powder and granules: a dual-stage coarse and fine feeding structure that balances high granule capacity with high-precision powder metering.
3. Environmentally friendly, dust-free production: fully enclosed negative pressure dust removal, ensuring compliance with environmental standards for high-dust organic fertilizer and phosphate-potassium fertilizer production.
4. Anti-caking vibration compaction design: simultaneous vibration compaction during filling solves the problem of fertilizer caking during long-distance transport of ton bags.
5. Wide range of automation options: semi-automatic (low cost) and fully automatic (labor-saving), suitable for fertilizer companies of different sizes.
6. Durable and corrosion-resistant: stainless steel material in contact with fertilizer, suitable for long-term continuous production of acidic and high-salinity fertilizers.
