At a glance
Customer: Regional fertigation fertilizer brand
Problem: Manual batching could not hold the micro-nutrient accuracy their label promised
Solution: We started from the recipe, not from the machines. Micro-dosing scales were placed before the mixer so trace elements were metered at the accuracy the formula required; the QL urea crusher was moved upstream to protect m...
Result: Consistent batch-to-batch uniformity with recipe traceability
| Customer type | Regional fertigation fertilizer brand |
| Industry / project type | Линия порошковых водорастворимых удобрений |
| Capacity | 5 t/h · 5–25 kg bags |
| Country / region | Middle East |
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Why the project happened
The customer is a fertilizer brand serving drip and greenhouse farmers, expanding from imported finished product into in-house powder WSF production. They needed consistent batch quality, traceability for their COA, and export-grade packing - not just a set of machines.
What the customer faced
These are the specific issues the project was built to solve.
- Manual batching could not hold the micro-nutrient accuracy their label promised
- Caked urea and brittle salts created lumps that failed solubility checks
- Dust at mixing and packing made the plant unpleasant and wasted product
- They had no batch record, so every shipment needed extra lab re-testing
- Packing was manual, limiting output and weight compliance
Limits we designed around
Real projects are never ideal. These constraints shaped the configuration and delivery plan.
- Frequent formula changes across 10+ WSF SKUs
- Corrosive salts required stainless contact parts
- 5-25 kg bag flexibility plus ton-bag export runs
- Site space was limited, so the line had to be compact and dust-tight
Why we configured it this way
We started from the recipe, not from the machines. Micro-dosing scales were placed before the mixer so trace elements were metered at the accuracy the formula required; the QL urea crusher was moved upstream to protect mixing; a ribbon mixer with fast cleanout handled formula changeover; and a dust-controlled buffer plus automatic bagging and robotic palletizing closed the train. Every batch weighing is logged in the PLC, which gives the customer the data for a COA.
How it was delivered
From requirements confirmation to commissioning - the key nodes of this project.
Requirements & design
Collected formula, bulk density, bag sizes and automation target; produced process flow and layout in 2 weeks.
Fabrication
Stainless contact parts, micro-scales and PLC built and no-load tested in our plant.
Quality control
Pre-shipment test run, weighing calibration and packing documentation confirmed.
Delivery & installation
Export-packed and shipped; installation supervised on site with operator training.
Commissioning & acceptance
Run at target capacity with 20-bag weight audit and batch traceability report.
Difficult points and how we solved them
Micro-ingredient accuracy at 0.01-0.1% of batch
Independent micro-scales with loss-in-weight dosing and recipe lock-in, verified with trial batches.
Caked urea in hot climate
QL stainless crusher upstream with 20-30 mesh target before metering.
Dust control in a compact plant
Negative-pressure de-dusting at every transfer point and a low-drop buffer.
What changed after delivery
Verifiable changes from this project. Where specific figures are confidential, we state the direction and the evidence.
- Consistent batch-to-batch uniformity with recipe traceability
- 3-person packing operation replacing a larger manual crew
- COA-ready batch reports from the PLC for every production run
- Customer expanded the SKU range without reconfiguring the line
Project outcome
Стабильная однородность партий с прослеживаемостью рецептур и операцией фасовки в 3 человека.
What similar customers can learn
For other WSF brands, this project shows that accuracy and traceability are line-design decisions, not add-on options. If you export or sell to regulated buyers, put micro-dosing, stainless contact parts and batch logging into the base configuration - retrofitting them later costs more than designing them in.
Questions from similar projects
How do you guarantee micro-ingredient accuracy?
What bag sizes can this line handle?
Can the line produce a COA automatically?
Your conditions, our configuration
The fastest way to a useful answer is to compare your project against this one: raw materials, capacity, bag size, site and destination.
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