The strong wind swept across the Xilin Gol Grassland in Inner Mongolia with yellow sand, and the open-air packaging area of an organic fertilizer production base was shrouded in sand and dust. Wang Jianguo, the workshop director, stared at the monitoring screen. The silver-gray large bag fertilizer automatic packaging line in the picture was running steadily at a rhythm of 8 bags per minute, filling the fermented sheep manure organic fertilizer into 50kg packaging bags. "In previous years, when encountering such sandstorm weather, the equipment would have ''struck'' long ago. Now this production line has withstood three sandstorms." He wiped the dust off the glass of the control cabinet while speaking, his tone revealing relief.
This organic fertilizer company with an annual output of 200,000 tons has long been trapped by the special climate of the grassland: dust intrusion into the equipment in spring causes sensor failure, and the extreme cold of -30¡æ in winter causes the lubricating oil to solidify. The traditional packaging line is shut down for maintenance up to 23 times a year due to environmental problems, which seriously affects order delivery. At the beginning of 2023, when the company decided to introduce the automatic packaging line for large-bag fertilizers, it specifically put forward a hard requirement to ply-pack that "the equipment should be operated outdoors all year round".
After field survey, the ply-pack technical team customized an extreme environment adaptation solution for the production line:
.Dustproof sealed cabin: The core metering unit adopts a double-layer stainless steel sealing design, which maintains a micro-positive pressure environment inside, and the dust concentration is 90% lower than that outside;
.Military-grade anti-rust coating: The circuit board is sprayed with a 0.3mm polyurethane-ceramic composite layer, and the insulation performance is still intact after a 72-hour salt spray test;
.Intelligent temperature control module: The reducer has a built-in heating belt and -50¡æ resistant gear oil to ensure smooth operation of the transmission system under -30¡æ environment.
During the installation and commissioning, technician Lao Li led local workers to reinforce the foundation of the equipment overnight: "The wind speed on the grassland can reach up to level 10. We have installed windproof cables for each heavy bag packaging machine, and the bolts are all equipped with anti-loosening gaskets."
Today, this production line has been running for 11 consecutive months, setting a new record for continuous operation of equipment in the fertilizer production enterprise. Data shows:
· The number of failures caused by sand and dust intrusion has dropped from an average of 17 times per year to 2 times
· The warm-up time in extremely cold weather has been shortened from 3 hours to 40 minutes
· The packaging efficiency has increased by 18%, saving more than 300,000 yuan in labor costs per year
The most praised by the workers is the humanized design of the equipment. Operator Battelle pointed to the automatic dust cleaning device and said: "It used to take 2 hours per shift to clean the sensor, but now it can be self-cleaned by pressing a button." The newly installed remote monitoring system in the central control room allows technicians to go out for maintenance on blizzard days without the risk of going out.
In late spring, the grassland is revived. When Director Wang accompanied the new customer on an inspection, he specially played the surveillance video during the sandstorm: "This set of large-bag fertilizer automatic packaging line not only withstood the test of nature, but also helped us win a 10,000-ton order from Mongolia." In the sunset, the anti-rust coating on the equipment shell reflected the orange-red afterglow, as if wearing the armor of a grassland warrior.
