Equipment Introduction
The fully automatic fertilizer packaging machine is an integrated, unmanned finished product packaging line. Unlike semi-automatic standalone machines, it eliminates the need for manual bagging and sewing. It integrates automatic bag picking, opening, weighing and filling, dust removal, folding and sewing, conveying, and re-inspection throughout the entire process. It is available in three main categories: fully automatic granule packaging lines, fully automatic powder packaging lines, and small bag vertical fully automatic packaging machines. It is suitable for large-scale continuous production of organic fertilizers, compound fertilizers, and water-soluble fertilizers.
(I) Core Advantages
1. Highly Unmanned: Only one inspector is needed throughout the entire line, replacing 5-8 bagging and sewing operators, significantly reducing labor costs;
2. Precise and Stable Measurement: Dual-stage feeding + independent net weight weighing ensures a weight error of ≤±0.2%, complying with agricultural input measurement regulations;
3. Fully Enclosed and Environmentally Friendly: Negative pressure dust removal throughout the process prevents dust leakage during powder and granule filling, easily passing environmental inspections;
4. Wide Material Adaptability: Granular/powder fertilizers can be switched by changing the feeding mechanism; the hopper is equipped with vibration + stirring for double anti-bridging;
5. Intelligent Management and Control: A PLC touchscreen stores multiple fertilizer formulas, automatically calculating output, issuing over-tolerance alarms, and performing fault self-diagnosis;
6. Seamless Backend Integration: Can be integrated with metal detection, weight re-inspection, coding, and palletizing robots to form a complete finished product production line. (II) Machine Type Classification
1. 20–50kg Open Bag Fully Automatic Packaging Line: Supporting mainstream large-scale production lines for compound fertilizer and organic fertilizer granules/powders;
2. 1–10kg Vertical Fully Automatic Packaging Machine: Retail packaging for water-soluble fertilizers, foliar fertilizers, and trace element small bags;
3. Ton Bag Fully Automatic Packaging Line: Automatic filling of ton bags for large-tonnage raw materials and large-volume export fertilizers.
Equipment Structure and Components
The fully automatic packaging machine mainly consists of six core systems:
1. Bag Feeding and Automatic Bag Loading System
This includes an exchangeable bag storage box, a bag picking and sorting device, and a bag loading robot. The bag storage box can hold hundreds of bags at a time (up to 500 in some models), and bags can be added without stopping the machine. The robot handles various bag types, including nylon woven bags, paper-plastic bags, and film bags. The bag loading method typically uses a pick-and-place system—retrieving a bag from the spare bag storage, centering and positioning it, pre-opening the bag, inserting the robot's blade into the bag opening, and then gripping it with a pneumatic gripper.
2. Weighing and Metering System
This consists of a weighing sensor, a weighing controller, and a metering hopper. It employs alternating/stacked/independent dual-weighing modes, significantly improving packaging speed. Feeding methods can be selected based on material characteristics, including screw feeding, pneumatic double-door feeding, belt feeding, and vibratory feeding. A common feeding method is a twin-screw system (one large and one small): the large screw ensures speed, while the small screw provides graded speed changes to ensure accuracy.
3. Filling and Bag Clamping System
Includes bag clamping and feeding device, bag opening detection device, etc. A microswitch is installed at the bag opening position to detect whether the bag opening is fully clamped and open.
4. Sealing System
Includes automatic folding machine, automatic bag sewing/heat sealing machine, etc. Capable of performing various sealing methods such as folding, rolling, and heat sealing.
5. Conveying and Post-Processing System
Includes finished bag conveyor, bag turning mechanism, metal detection, weight detection, coding, etc.
6. Electrical Control System
Based on a PLC (Programmable Logic Controller), equipped with a human-machine interface touch screen. Features include fault self-diagnosis, automatic alarm, parameter storage, and cumulative production statistics.
Working Principle
Fully automated closed-loop packaging process with servo linkage:
1. Qualified fertilizer is screened and fed into a buffer silo via bucket elevator. Vibration and stirring continuously break up clumps to prevent material interruption.
2. Vacuum suction cups automatically grab packaging bags from the bag hopper. A robotic arm opens the bag opening and conveys it to the filling station. Cylinders automatically clamp the bag opening, and a sealing dustproof skirt is applied to the bag opening while negative pressure dust removal is activated simultaneously.
3. PLC controls coarse feeding to quickly fill to 85% of the target weight. Fine feeding is then switched for micro-feeding. Sensors provide real-time weight feedback, compensating for material inertia during descent. Feeding stops once the standard weight is reached.
4. After filling, the grippers release, and the full bag is conveyed to the folding station where the bag opening is automatically folded before being sent to the sewing/heat-sealing equipment for sealing.
5. Sealed finished products undergo weight re-inspection, metal detection, and inkjet marking. Qualified products are conveyed to the palletizing area.
6. Filling dust is filtered and recovered by a dust collector, and fine material is returned to the silo, achieving zero raw material loss.
Applicable Raw Materials
1. Granular Fertilizers
Urea, NPK Compound Fertilizer, BB Fertilizer, Slow-Release Coated Granules, Disc/Drum Granulated Organic Fertilizer, Bio-based Granular Fertilizer.
2. Powdered Fertilizers
Humic Acid Powder, Chicken Manure Organic Fertilizer Powder, Monoammonium Phosphate, Potassium Sulfate, Microbial Agents, Water-soluble Powders of Macronutrients.
3. Small-Package Specialty Fertilizers
1–10kg Water-soluble Fertilizer, Foliar Fertilizer, Micronutrient Granules/Powders.
Restricted Materials
Moisture Content > 12%
High-viscosity Slurry, Extra-long Wounded Fibers, Particle Size > 10mm
Extra-large Hard Lumps (Easily Damages Robotic Arms and Weighing Components).
Equipment Applications in Production Lines
1. Core Position in Fertilizer Production Lines
The fully automatic packaging machine is the final piece of equipment in the entire fertilizer production line, located after screening and before warehousing and logistics.
Complete Processing Flow:
Raw Material Pretreatment → Fermentation and Composting → Crushing → Batching and Mixing → Granulation → Drying → Cooling → Screening → Coating → Fully Automatic Packaging → Warehousing/Transportation
2. Application in Powdered Organic Fertilizer Production Lines
Powdered organic fertilizer production lines require only a few pieces of equipment from production to finished product—fermentation turning machine, crusher, and packaging machine. As the final piece of equipment, the fully automatic packaging machine directly determines whether the finished product can enter the market efficiently and in a standardized manner.
3. Application in BB Fertilizer/Compound Fertilizer Production Lines
The fully automatic batching, mixing, and packaging production line for BB fertilizer integrates automatic batching, automatic mixing, and automatic packaging. The prepared fertilizer is automatically unloaded into the mixer, mixed evenly, and then automatically lifted to the packaging machine's hopper, where it is automatically filled according to the set weight and automatically sewn into a package. This production line technology is mature and has been adopted by large fertilizer companies such as Kingenta Group.
4. Fully Automated Packaging and Palletizing Production Line
Modern fully automated packaging lines achieve unmanned operation from packaging to palletizing:
Automatic bag loading → Automatic weighing → Automatic filling → Automatic sealing → Metal detection → Weight re-checking → Automatic palletizing
5. Supporting Equipment
Fully automated packaging machines are typically used in conjunction with the following equipment:
Screw conveyor: lifts materials to the packaging machine's hopper
Conveyor: transports finished bags
Bag sewing machine/heat sealing machine: completes sealing
Metal detector, weight sorter: quality inspection
Palletizer: automatic palletizing
Common Faults, Causes, and Standardized Solutions
| Fault Phenomenon | Root Cause | Professional Solutions |
|---|---|---|
| Bag picking & opening failure | Worn suction cup, insufficient bags in magazine, insufficient suction‑cup air pressure | Replace suction cup, replenish packaging bags, adjust air‑source pressure |
| Excessive packaging weight deviation | Material accumulation on weighing platform, excessive coarse feeding speed, aging damping pad | Clean weighing platform daily, reduce coarse feeding speed, replace damping pad |
| Massive dust overflow during filling | Damaged dust‑proof skirt, clogged dust‑removal filter cartridge | Replace sealing skirt, clean or replace dust‑removal filter bag |
| Robot jamming & position offset | Lack of rail lubrication, drifted servo parameters, dirty photoelectric sensor | Apply lubricating grease to guide rail, wipe photoelectric probe, reset servo parameters |
| Skipped stitching & poor sealing | Residual fertilizer at bag mouth, worn sewing needle | Blow clean bag mouth, replace sewing machine needle |
| No discharging from hopper, material bridging | Failed vibration/stirring arch‑breaker, fertilizer moisture caking | Increase vibration frequency, control workshop humidity and temperature |
Target Customers:
1. Large-scale organic fertilizer, compound fertilizer, water-soluble fertilizer, and slow-release fertilizer manufacturers with an annual output of over 50,000 tons;
2. Large-scale high-tower fertilizer production bases and integrated fertilizer industrial parks;
3. Agricultural input export fertilizer processing plants with large-volume standardized packaging needs;
4. Large-scale municipal sludge and kitchen waste resource recovery enterprises;
5. Fertilizer complete intelligent production line integrators and fully automated palletizing and packaging line service providers;
6. Overseas large-scale fertilizer and organic fertilizer factories purchasing complete sets of automated equipment.
Comprehensive Technical Features of the Equipment:
1. Fully automated, unmanned process, significantly reducing labor costs in the packaging stage and adaptable to large-scale mass production;
2. Dual compatibility for granules and powders; changing the feeding mechanism allows switching between fertilizer types, enabling flexible production;
3. High-precision weighing + automatic re-inspection eliminates missing packages and overweight products, ensuring consistent finished product quality;
4. Sealed negative pressure dust removal system ensures a dust-free workshop, meeting environmental standards, and zero waste in fine material recycling;
5. Intelligent PLC control enables formula storage, production statistics, and fault alarms, facilitating digital management of the factory;
6. Corrosion-resistant and durable; all materials in contact with the equipment are made of 304 stainless steel, resistant to acid and alkali corrosion from urea and potassium fertilizers;
7. Highly expandable production line; can be freely combined with inkjet printing, metal detection, and robotic palletizing to create an intelligent fertilizer production line.
| No. | Device Name | Technical parameters | DCS-25F |
| 1 | Computer quantitative scale | Weighing range (kg) | 20-50 |
| Weighing speed | 200-3000 | ||
| Permissible error | 0.20% | ||
| Equipped with power | 2.2KW | ||
| Air supply | 0.4-0.6Mpa,0.1m3/min | ||
| Weight (kg) | 500 | ||
| 2 | Weighing control instrument | GM8804C | |
| 3 | Folder bag body | Weight (kg) | 60 |
| 4 | conveyor | Conveying distance(m) | 2 |
| Equipped with power | 0.37 | ||
| Weight (kg) | 240 | ||
| 5 | hemming machine | Equipped with power | 0.55 |
| Weight (kg) | 100 | ||
| 6 | overall dimensions | Overall dimensions(mm) | 2332×1225×1058 |
| Weight (kg) | 450 |
