Single Silo Single Weigh Type

Equipment Introduction

The single-silo single-weighing batching system, also known as a single-silo single-scale batching machine, is a core automatic metering and batching equipment in fertilizer production lines. It adopts a modular design with one independent weighing unit per raw material silo. It comes in two main models: dynamic belt conveyor type and static hopper type. Unlike multi-silo batching equipment that shares a single scale, each fertilizer raw material has its own independent storage, feeding, and weighing unit, ensuring no interference and resulting in higher batching accuracy and faster formula changes.
(I) Core Industry Advantages
1. High Metering Accuracy: Each bin weighs independently, eliminating interference from cross-weighing of materials. Static weighing error ≤ ±0.2%, dynamic belt conveyor error ≤ ±1%, ensuring stable and compliant fertilizer nutrient content.
2. Zero Cross-Contamination During Material Changes: Each bin is completely independent; switching formulas for organic fertilizer, compound fertilizer, and BB fertilizer requires not emptying the entire weighing hopper.
3. Adaptable to Both Dry and Wet Materials: Powders are fed by screw feeders, granules by belt/vibration feeders. Bins are equipped with vibration-damping systems to prevent moisture absorption and bridging.
4. Modular and Expandable: Bins can be freely combined from 2 to 12, with 2 to 4 bins for small plants and 6 to 12 bins for large compound fertilizer bases.
5. Complete Automated Closed-Loop System: PLC independently controls the start/stop and feeding speed of each bin, automatically recording batch batch data and allowing integration with factory digital systems.
6. Convenient Maintenance: A single bin failure does not affect production in other bins; maintenance can be performed independently without interrupting the entire production line. (II) Model Differentiation
1. Static hopper type single bin single scale: suitable for small batches, high-precision compound fertilizers and water-soluble fertilizers, intermittent batch weighing;
2. Dynamic belt type single bin single scale: suitable for continuous large-scale production of organic fertilizers, continuous and uninterrupted batching.

Equipment Structure

The core structure of a single-silo single-weighing system consists of four main components:

1. Storage Silo: Used to temporarily store a single raw material to be batched. Each silo is independently designed and corresponds to only one type of raw material, physically eliminating the risk of mixing. The silo body is usually made of stainless steel with an anti-corrosion treatment.
2. Weighing Module: Each silo is equipped with an independent weighing module, typically using high-precision strain gauge sensors. The system uses a “one silo, one weigher” configuration, with each weighing module operating independently without interference.
3. Feeding Device: Responsible for conveying materials from the silo to the weighing equipment. Different types of feeders can be flexibly configured according to different material characteristics:

1)Screw feeder: Suitable for free-flowing granular materials

2)Vibrating feeder with stirring function: Suitable for easily agglomerated powdery materials

3)Belt feeder: Suitable for high-flow continuous batching

4. Control System: The “brain” of the system, usually based on a PLC or microcomputer. It is responsible for analyzing sensor data and outputting control commands to achieve fully automated operation. The system can store hundreds of recipe parameters and has functions such as fault self-diagnosis, audible and visual alarms, and data logging.

Working Principle

The entire system operates under two logics: static batch batching and dynamic continuous batching. Both follow an independent metering logic with one weigher per hopper:

(I) Static Hopper Type (Compound Fertilizer/Water-soluble Fertilizer)

1. The PLC retrieves the target formula and sequentially starts the vibration breaking and coarse feeding mechanisms of the corresponding raw material hoppers;
2. Material falls into the dedicated weighing hopper of this hopper, coarsely feeding until 90% of the target weight is reached, then switching to fine screw/fine vibration micro-feeding;
3. The weighing sensor provides real-time weight feedback, compensating for the inertia of the falling material in advance. Once the set ratio is reached, the feeding in this hopper stops;
4. After all raw materials are weighed individually, the discharge doors of each weighing hopper are opened uniformly, and the material is collected and sent to the mixer for the next batch cycle. (II) Dynamic Belt Belt Type (Large-Scale Organic Fertilizer Production)
5. Each silo’s belt scale monitors the instantaneous flow rate in real time; the PLC compares the flow rate with the formula settings and automatically adjusts the motor frequency converter.
6. If the flow rate is too high, the speed is automatically reduced; if the flow rate is too low, the speed is increased, continuously and dynamically correcting the flow.
7. Materials from each silo synchronously fall onto the bottom collection belt and are continuously fed into the mixer, achieving 24-hour uninterrupted batching.

Applicable Raw Materials:

1. Powdered Raw Materials: Humic acid powder, chicken manure organic fertilizer powder, urea powder, monoammonium phosphate, potassium fertilizer powder, microbial inoculum powder, bentonite coating powder;
2. Granular Raw Materials: Urea granules, NPK compound fertilizer, BB fertilizer granules, fermented and decomposed organic granules, oilseed cake fragments;
3. Prohibited Materials: Moisture content > 15%, highly sticky slurry, ultra-long wound fibers, large hard lumps > 15mm (easily clog the feeding mechanism).

Production capacity range

Matching accuracy: Static ≤ ±0.2%, dynamic belt conveyor ≤ ±1%, the number of silos can be increased or decreased as needed.

Equipment Applications in Production Lines

1. Core Position in Fertilizer Production Lines

The single-silo, single-weighing batching system is the core equipment at the front end of the fertilizer production line, located after raw material input and before mixing/granulation.

Complete Processing Flow:

Raw Material Input → Single-Silo, Single-Weighing Automatic Batching → Mixing and Stirring → Granulation → Drying → Cooling → Screening → Packaging

2. Application in Organic Fertilizer Production

Organic fertilizer raw materials come from a wide range of sources, including agricultural waste such as livestock and poultry manure and straw, as well as industrial by-products such as humic acid and amino acids. This system can flexibly configure the feeding device according to the characteristics of different raw materials to ensure stable batching. Actual testing shows that the system can control the batching accuracy of organic fertilizer raw materials in different forms, such as granular and powdered forms, within ±0.2%, far exceeding the industry average of ±1%.

3. Application in BB Fertilizer/Compound Fertilizer Production

In BB fertilizer and compound fertilizer production, this system is commonly used in NPK fertilizer mixing, DAP mixing, and other scenarios. Compared to traditional semi-automatic batching lines, this system can increase the batching rate per unit time by over 30%, and raise the equipment’s effective operating rate from 75% to over 90%.

4. Flexible Switching Between Multiple Formulas The system can store hundreds of formula parameters, enabling rapid recall and modification of formulas. Production formulas can be adjusted at any time according to the fertilization needs of different crops and soil types. Batching accuracy can reach ±0.5%, and control accuracy ±1%.

Standard Operation and Full-Cycle Maintenance

(I) Standard Start-up and Shutdown Procedures

Start-up

1. Check that there is no fertilizer buildup in the vibration motors, feeding mechanisms, and weighing sensors of each bin, and that the dust removal fan is functioning normally;
2. Start the entire system under no-load conditions, and perform independent zero-point calibration of each weighing unit on the touchscreen;
3. Retrieve the corresponding fertilizer formula, conduct a no-load test run of a whole batch, and formally feed the fertilizer after confirming that the accuracy meets the standards.

Shutdown

1. First, stop the front-end feeding elevator, and wait until all materials in each bin and weighing unit are emptied;
2. Sequentially shut down the feeding, vibration, dust removal, and collection conveyor equipment;
3. Clean the surface of each bin’s weighing hopper and belt to remove any residual fertilizer, preventing clumping and corrosion of the sensors.

(II) Graded Maintenance Standards

1. Daily Inspection: Zero-point calibration of each bin’s weighing system, cleaning of clumps at the discharge port, and checking for misalignment of the vibrating motor and belts;
2. Weekly Maintenance: Lubrication of the screw/belt drive bearings, and cleaning of the dust collector filter bags;
3. Quarterly Maintenance: Replacement of the reducer gear oil, and inspection of the load cell wiring and damping pads for aging;
4. Annual Overhaul: Disassembly and thorough cleaning of the feeding mechanisms and weighing units of each bin, and calibration of the entire metering system’s accuracy.

(III) List of Vulnerable Parts

Weighing sensors, screw blades, belts, vibrating motors, dust collector filter bags, cylinder seals, and drive V-belts.

Target Customers for this Equipment:

1. Organic Fertilizer Manufacturers: The diverse types and varying proportions of raw materials are typical characteristics of organic fertilizer production. The independent compartment design of the single-compartment, single-weighing system ensures that the feeding and weighing processes of each raw material do not interfere with each other, making it particularly suitable for the complex batching requirements of organic fertilizer production.
2. BB Fertilizer/Blended Fertilizer Manufacturers: BB fertilizer production requires high precision in batching, necessitating the precise mixing of multiple raw materials. This system effectively ensures that the nitrogen, phosphorus, potassium, and trace element content of each batch of fertilizer meets the formula requirements.
3. Compound Fertilizer/Blended Fertilizer Manufacturers: Companies requiring automated batching of multiple raw materials.
4. Companies Building or Expanding Fertilizer Production Lines: Fertilizer production projects requiring a modern batching system. The system’s fully automated control enables seamless integration of production processes.
5. Small and Medium-Sized Fertilizer Plants Seeking Quality Upgrades: For companies transitioning from manual to automated batching, the single-compartment, single-weighing system is a cost-effective, entry-level automation solution.

Comprehensive Technical Features of the Equipment:

1. Independent weighing in each bin, eliminating cross-weighing interference and achieving industry-leading precision in fertilizer nutrient ratio proportions;
2. Modular and freely expandable, with 2-12 bins that can be assembled as needed, suitable for small plants and large-scale bases;
3. Fault isolation design, ensuring continuous production of the entire batching line is unaffected by a single bin failure, minimizing downtime losses;
4. Full coverage of both dry and wet materials, with screw feed for powders and vibratory/belt feed for granules, and a built-in arch-breaking system to prevent organic fertilizer bridging;
5. Convenient material changes with no cross-contamination, as each bin is completely independent, allowing for fertilizer formula changes without emptying the entire equipment;
6. Automated and digitalized, with independent bin control, complete functions including formula storage, batching records, and out-of-tolerance alarms;
7. Environmentally friendly, sealed dust removal system, with independent dust extraction ports for each bin, preventing dust leakage during powder fertilizer production.