For SA Deronne JMF, Royal EMT engineered and supplied a complete continuous fertilizer blending and bagging installation. The system combines accurate continuous dosing, intensive fertilizer mixing, liquid inhibitor application, vertical product transport, bulk truck loading and high speed big bag filling in one integrated production line.
The installation is designed for flexible fertilizer production, accurate recipe control and efficient handling of different finished products. Operators can direct the blended fertilizer either to the truck loading position or to the Big Bag High Speed filling system.
The production line is built around a five hopper Weighcont continuous blender. Each stainless steel hopper is installed on an independent electronic weighing system, allowing the machine to continuously monitor and automatically correct the flow of each fertilizer component.
Variable speed dosing conveyors discharge the individual raw materials onto the central blending conveyor. The recipe and total production capacity are controlled through the PLC and EMT blending software. This enables accurate fertilizer blending based on percentages or weight, while providing operators with continuous insight into the material level and actual weight of every hopper.
The Weighcont system has a working capacity of approximately 20 to 120 tonnes per hour. Each hopper can hold approximately 7,000 kg, providing a total storage capacity of approximately 35,000 kg at a product density of one tonne per cubic metre.
After the initial dosing and blending process, the fertilizer enters a four metre inclined stainless steel mixing screw. This screw provides an additional mixing stage and improves the distribution of smaller components and liquid additives throughout the fertilizer blend.
A loss in weight liquid adding unit is integrated into the process for the accurate application of liquid fertilizer inhibitors or coating liquids. The system monitors the weight of the liquid container and automatically adjusts the pump output to maintain the required application rate.
The liquid adding system includes a stainless steel progressive cavity pump and an open hole shower plate. This configuration supports an even distribution of liquid across the fertilizer flow while reducing the risk of blocked spray nozzles.
ollowing the blending and liquid adding process, the product is transported by an eleven metre stainless steel bucket elevator. The elevator has a capacity of approximately 140 tonnes per hour and is designed for handling granular fertilizers in demanding and corrosive production environments.
At the top of the elevator, a pneumatic two way valve directs the finished fertilizer towards one of two discharge routes. The product can either be loaded directly into a bulk truck or transferred to the big bag filling installation. This gives the customer the flexibility to select the required packaging or loading method for each production order.
For bulk fertilizer deliveries, the system is equipped with stainless steel truck loading pipes. The product is discharged at a height of approximately 4.5 metres, allowing trucks and trailers to be filled directly from the production line.
This integrated truck loading solution reduces additional handling stages and allows blended fertilizer to be transferred efficiently from production to transport.
The second discharge route feeds a stainless steel storage hopper positioned above the Big Bag High Speed filling machine. The system uses a net weighing hopper to weigh each quantity before releasing the fertilizer into the big bag.
The filling unit is suitable for big bags from approximately 100 to 1,250 kg. With one tonne big bags, the system can reach approximately 60 bags per hour, depending on the product characteristics, material supply and operator performance.
A filling spout clamp holds the bag securely during filling. An integrated fan inflates the big bag before filling, while a second fan extracts displaced air and directs it towards a filter sleeve. This supports controlled filling and helps reduce dust around the filling position.
Filled bags are discharged onto a six metre big bag conveyor, providing sufficient space for closing, checking and removing the bags with a forklift
The complete fertilizer blending and bagging line is operated through EMT control panels and dedicated software. Recipes can be stored and selected digitally, while production quantities, raw material consumption and blending information can be recorded for future reference.
The installation is precabled and tested at the Royal EMT factory before delivery. Remote access is included, allowing Royal EMT technicians to support the customer and assist with diagnostics when a reliable internet connection is available.
The result is a reliable safe and flexible fertilizer handling installation for Sertorius. Thanks to the modular design and mobile equipment the customer can easily adapt the line to changing production requirements while maintaining high product quality and operational reliability.
Royal EMT develops and manufactures complete fertilizer blending, coating, bagging and transport systems for customers worldwide. Contact us at emt@emt.tech or explore our fertilizer machinery and factory projects at www.emt.tech.
