Amid the roar of fertilizer production workshops, bags of 50 kg compound fertilizers are being filled, sealed and stacked at a speed of 12 bags per minute. This automatic packaging line of large bag fertilizers independently developed by ply-pack is solving three long-standing problems for a northern fertilizer manufacturer with a precise and stable rhythm: high labor costs, poor environmental adaptation, and large packaging errors.
Aiming at the characteristics of fertilizer manufacturers with diverse raw material formulas and variable packaging specifications, this automatic packaging line of large bag fertilizers adopts a modular assembly structure. The engineering team independently designed the filling module, sealing module and palletizing module, and customers can freely combine them according to the production line space. When a northeastern customer proposed that four specifications of packaging from 30 to 80 kg should be compatible, it was only necessary to replace the adjustable bag clamp and dynamic weighing scale module to achieve "one machine for four uses". Test data showed that the time required for specification switching was shortened from 45 minutes for traditional equipment to 8 minutes, and the packaging efficiency was increased by 23%.
In the open-air operation area of an organic fertilizer factory in Inner Mongolia, the strong winds carrying sand often caused traditional equipment to "strike". The ply-pack technical team developed a three-level protection system for this purpose: dust covers were added to the core transmission components, military-grade moisture-proof coatings were used for the circuit system, and constant temperature protection chambers were equipped for key sensors. The on-site monitoring screen showed that even in an extremely cold environment of minus 25°C or in coastal areas with 85% humidity, the heavy bag packaging machine can still maintain a filling accuracy of ±0.2%. The solution has been successfully applied to 12 fertilizer production companies in border areas, and the equipment failure rate has dropped by 67% year-on-year.
"In the past, manual inspections were always worried about missed inspections, but now the system will automatically warn." The technical supervisor of a phosphate fertilizer plant in Yunnan pointed to the control screen and introduced. The new generation of large-bag fertilizer automatic packaging lines is equipped with an AI visual inspection system, which can capture 12 types of abnormalities such as sealing wrinkles and blurred inkjet codes in real time. When the weight of a bag of fertilizer exceeds the set threshold, the robotic arm will automatically transfer it to the re-inspection channel and send positioning information to the central console. What is more noteworthy is that the energy consumption optimization algorithm built into the equipment can dynamically adjust the motor power according to the packaging rhythm, and the daily power saving can reach 18-22 kWh.
Faced with fluctuations in the global supply of parts, ply-pack has established a dual-track supply system: high-precision metering scales have strategic cooperation with German century-old brands, and general parts are deeply bound with three domestic high-quality suppliers. Last fall, an urgent order required the delivery of three large-bag fertilizer automatic packaging lines in 45 days. The supply chain team completed the delivery three days ahead of schedule by pre-storing core components and parallel assembly processes. At present, the factory has achieved a standard cycle of 30 days from order receipt to shipment, which is 40% shorter than the industry average.
As night falls, the packaging workshop of a biofertilizer production base in Guangxi is still brightly lit. Three parallel large-bag fertilizer automatic packaging lines are packing fermented organic fertilizer into biodegradable packaging bags. The robotic arms draw smooth arcs in the air and neatly stack the finished products on the smart logistics vehicles. Through the glass of the central control room, the factory manager looked at the real-time updated production data and sighed: "This system not only solves the problem of heavy bag packaging, but also gives us the confidence to accept overseas 10,000-ton orders." Thousands of miles away at the ply-pack R&D center, engineers are testing the equipment operation and maintenance system that incorporates blockchain technology. In the future, every heavy bag packaging machine will have a traceable "digital life."
