Tons Bag Fertilizer Packing Machine
The ton bag fertilizer packaging machine (also known as a ton bag packaging scale, ton bag packaging machine, or large bag packaging machine) is an automated quantitative packaging equipment designed specifically for large-volume, heavy-duty packaging needs. It is used to fill powdered or granular fertilizers into large FIBCs (ton bags) according to a preset weight (usually 500-2000 kg/bag). This equipment integrates electronic weighing, automatic bag removal, and dust removal, offering a high degree of automation and packaging accuracy. It effectively reduces labor intensity, improves work efficiency, and enhances the on-site working environment.
In the fertilizer production field, the ton bag packaging machine plays a core role in the large-scale, standardized packaging of finished fertilizers. Traditional small packaging methods are inefficient and costly for large-scale fertilizer plants producing tens of thousands of tons annually. Ton bag packaging, with its large capacity of 500-2000 kg per bag, significantly reduces the frequency of packaging processes and labor input, providing an efficient solution for the large-scale transportation and storage of fertilizers. This equipment is widely used for bulk packaging of various fertilizers such as chemical fertilizers, compound fertilizers, organic fertilizers, urea, phosphate fertilizers, and potash fertilizers. It can also be used for ton bag packaging of bulk materials in industries such as chemicals, building materials, grains, feed, and minerals.
Equipment Structure
The ton bag fertilizer packaging machine adopts a modular integrated design. The whole machine is mainly composed of the following core components:
(I) Frame Components: This is the load-bearing foundation of the entire machine. It adopts a high-strength steel structure and can stably support the weight of a single bag of 1-1.5 tons, ensuring that the weighing process is stable and does not shift or shake.
(II) Feeding Mechanism (Feeder): This is responsible for quantitatively feeding the material from the hopper into the packaging bag. Various feeding methods can be selected according to the material characteristics—granular fertilizer uses gravity-fed feeding (pneumatic valve control), while powdered fertilizer uses a screw feeder for forced feeding. The feeding device usually adopts a two-stage feeding method: fast filling first to improve efficiency, and then switching to slow precision feeding when approaching the set value to ensure accuracy.
(III) Bag Clamping and Hanging Mechanism: This includes a bag clamping device and a bag hanging device (four hooks or hanging ears). The four straps of the ton bag are manually hung on the hanging ears, and the bag clamping cylinder clamps the bag opening onto the feeding pipe, ensuring a leak-proof seal during the filling process. At the end of packaging, the bags are unloaded and automatically opened, enabling quick loading and unloading.
(IV) Weighing System: Includes high-precision weighing sensors, a weighing platform, and weighing control instruments. The sensors use electronic platform scales for measurement, featuring automatic tare, automatic zeroing, and automatic drop correction functions. They are highly sensitive and have strong anti-interference capabilities. The protection level meets the environmental requirements of the fertilizer packaging workshop.
(V) Lifting and Top-Lifting System: Adopts a lifting structure design, automatically adjusting the discharge port height according to different ton bag sizes to ensure the packaging bags are in the optimal filling position. After filling, they automatically descend onto the conveyor.
(VI) Dust Removal System: Both the inlet and outlet are equipped with sealing covers, combined with pulse dust collectors or cyclone dust collectors to solve the dust leakage problem during large-volume filling and improve the working environment.
(VII) Conveying System: Includes lifting chain conveyors and transfer chain conveyors, responsible for transporting the packaged ton bags to the designated location. (viii) PLC Control System: This is the brain of the entire equipment, using a programmable controller to achieve integrated control of electricity, pneumatics, and instruments. It has functions such as weight accumulation display, automatic tare, automatic zeroing, automatic drop correction, out-of-tolerance alarm, and fault self-diagnosis.
Application range of equipment
Ton bag fertilizer packaging machines primarily focus on bulk material packaging in the fertilizer and chemical industries. In fertilizer production, they are suitable for ton bag packaging of various fertilizers, including compound fertilizers, organic fertilizers, blended fertilizers, urea, phosphate fertilizers, potash fertilizers, BB fertilizers, and water-soluble fertilizers. In the chemical industry, they can be used for ton bag packaging of fertilizer raw materials, inorganic salts, chemical powders, and additives. In building materials and mining, they can be used for packaging materials such as cement, mineral powder, lime powder, and ceramsite. Furthermore, they are widely used for large-bag quantitative packaging in industries such as grain, feed, rubber, plastics, and metallurgy.
Types of available raw materials
The ton-bag fertilizer packaging machine can handle a wide variety of raw materials. Granular fertilizers: compound fertilizer granules, urea granules, BB fertilizer granules, potash fertilizer granules, phosphate fertilizer granules, etc. Powdered fertilizers: organic fertilizer powder, phosphate powder, compound fertilizer powder, water-soluble fertilizer powder, ammonium sulfate powder, etc. Other bulk materials: chemical raw materials, mineral powder, grains, feed, building material powders, etc. All parts of the equipment that come into contact with materials are made of 304L stainless steel, effectively resisting the corrosiveness and abrasion of fertilizers.
Working principle of the equipment
The ton bag fertilizer packaging machine operates based on a collaborative mechanism of electronic weighing and PLC automatic control. Its workflow is as follows:
(I) Hanging and Clamping the Bag: The operator hangs the four straps of the ton bag onto the four hanging ears and places the bag opening over the sealed discharge port. Pressing the start button activates the clamping cylinder, which clamps the bag opening, and the lifting frame automatically rises to the set position.
(II) Tare and Inflate the Bag: The control system automatically tare the weight of the packaging bag. A blower inflates the ton bag, facilitating smooth material filling.
(III) Two-Stage Feeding (Fast and Slow): The weighing control system opens the feeding gate to begin feeding. This feeding device uses a two-stage feeding method—when the material weight reaches the fast feeding set value, fast feeding stops, and slow feeding continues. When the material reaches the corresponding set value, the feeding gate closes, completing the dynamic weighing process.
(IV) Unloading and Bag Removal: After weighing, the system opens the weighing hopper unloading gate, and the material enters the packaging bag. The filling process automatically vents and removes dust, and can also activate the automatic bag-stacking function. After the material is discharged, the unloading gate closes, the bag clamping device releases, the lifting straps automatically disengage, and the packaging bags automatically fall.
(V) Conveying: The conveyor automatically starts, transporting the packaging bags to the designated location, where forklifts move them into the warehouse. This cycle repeats automatically.
Equipment operation method
(1) Preparation before start-up: Operators should be familiar with the structure and working principle of the equipment, and can only operate after being trained. Check whether the connection parts are loose and whether the casing, feet and base are intact. Check the integrity of lifting tools such as hooks and straps. Check whether the dust removal fan is operating normally.
(2) Bag hanging operation: manually place the empty pallet on the packaging position under the weighing platform. Hang the four slings of the ton bag on the four hanging ears, and put the bag mouth on the unloading opening. Press the start button and the bag clamping device will automatically clamp the bag.
(3) Automatic operation: The equipment automatically completes the entire process of peeling, fast feeding, slow feeding, and unloading. Operators are not allowed to touch the load cell or adjust control parameters at will during operation.
(4) Conveying and warehousing: After the filled packaging bags fall on the pallet, the operator presses the conveying button to start the chain conveyor to transport the bags out of the packaging position. Wait for the forklift to transport the pallet away.
(5) Shutdown operation: After completing the packaging task, shut down each equipment in order. Keep equipment usage and maintenance records and shift handover work.
Equipment maintenance methods
(I) Daily Maintenance: Clean residual materials and dust from the equipment after each shift. Check if the load cells are damp or contaminated with material. Check the seals for integrity. Regularly clean dust from inside the electrical control box.
(II) Periodic Maintenance: Regularly inspect the mechanical structure to ensure all connections are secure. Clean and lubricate moving parts such as guide rails, bearings, and chains according to the prescribed schedule. Check that electrical system cables and terminals are securely connected.
(III) Calibration Management: Regularly calibrate the weighing system using standard weights. If drift occurs, first check for material accumulation. After troubleshooting, recalibrate the scale.
(IV) Electrical Maintenance: Check for loose or aged terminals. Test the emergency stop button and sensor sensitivity. Keep the inside of the electrical control box clean to prevent electrical malfunctions.
Equipment troubleshooting
Inaccurate weighing: Check the sensor installation environment to ensure it is stable and free from vibration interference. Clean the sensor surface to remove adhering powder. Recalibrate the weighing system using standard weights.
Insufficient material feeding: Stop the machine and clear any blockages. Check the wear of the auger blades; replace if severely worn. Check the material's moisture content to prevent clumping.
Poor bag sealing: Replace worn seals. Check the pneumatic system pressure. Adjust the bag opening positioning device to ensure accurate bag placement.
Equipment jamming: Clean foreign objects from the feed inlet. Add lubricating grease to the drive chain. Adjust the clearance between moving parts.
