In 2024, Lane Machinery’s technical team went deep into a compound fertilizer plant in Java, Indonesia, which was facing a typical Southeast Asian production dilemma:
1. Complicated raw material characteristics: the local palm meal addition amount reaches 25% (standard formula ≤ 15%), resulting in frequent clogging of traditional granulators.
2. High temperature and high humidity environment: air humidity is always above 80%, and the drying energy consumption is 40% higher than the design value.
3. Unstable power supply: voltage fluctuation range ±25%, resulting in frequent downtime of the control system.
4. Shortage of labor skills: the average education level of operators is only 9 years, and the equipment needs to be highly automated.
After 72 hours of on-site data collection, key issues were identified:
5. Water content fluctuation of material in granulation section exceeds ± 2.8% (process requirement ≤ ± 1.5%)
6. The temperature control deviation of drying hot air is ±35℃.
7. The power consumption of tons of products reaches 89kWh (the benchmark value of the same kind of climate zone ≤ 65kWh)
1. Localization of raw materials:
2. Climate adaptation modification:
3. Electric power system reinforcement:
1. Tropical Intelligent Pelletizing System
Customized double-stage granulator
The front section adopts Φ2.4m mixing and granulating cylinder (rotational speed 8-15r/min adjustable)
The rear section is equipped with vibrating fluidized bed (amplitude 0.5-3mm stepless adjustment)
Innovation point of Compound Fertilizer Production Line Retrofit Solution:
Development of humidity compensation algorithm, when the environment RH>75% automatically increase the amount of binder injection by 1.2%.
Configuration of self-cleaning scraper system to solve the problem of high-fiber material adhesion
2. Energy intelligent management system in Compound Fertilizer Production Line Retrofit Solution
Implementation of “gas-electricity-heat” triple-supply transformation:
Utilizing exhaust gas waste heat to drive 20kW absorption refrigeration unit.
The annual power supply of the photovoltaic roof reaches 146MWh (meeting 15% of production power consumption).
Energy consumption index after renovation:
Comprehensive energy consumption of tons of products reduced from 1.8GJ to 1.2GJ
Peak time electricity consumption compressed from 62% to 38%.
3. Robust control system
Adoption of industrial grade wide temperature PLC (-20℃~70℃ stable operation)
Fault-tolerant design for key parameters:
Voltage fluctuation ± 25% can maintain speed deviation ≤ 1.5%
Local autonomous operation within 12 hours of network interruption
| Indicator | Before Renovation | After Renovation | Improvement |
|---|---|---|---|
| Annual Production Capacity | 68,000 tons | 92,000 tons | +35% |
| Equipment Failure Rate | 23 times/month | 4 times/month | -83% |
| Palm Kernel Meal Processing Limit | 18% | 28% | Breakthrough in raw material limitations |
| Operator Skill Requirements | Technical school + 3 years experience | Junior high + 3 days training | Lower labor threshold |
| ROI Period | – | 2.1 years | Including government subsidies |
Customer Feedback: “Lane Machinery Group’s compound fertilizer production line retrofit solution not only solved the equipment problem, but also helped us establish a standard for local raw material application, and now we can save $86,000 per month in raw material import cost.”
With the global fertilizer industry showing the three major trends of “diversification of raw materials, low-carbon production, and simplification of operation”, Lane Machinery will continue to innovate:
R&D of straw/seaweed and other non-traditional raw material processing technologies.
Promote the development of carbon footprint tracking system for equipment
To our global customers: We provide free remote production diagnostic service, by analyzing the 3-day production data (including power consumption, output, raw material ratio) you send, and issue a preliminary proposal for modification within 72 hours.
From palm plantations in Southeast Asia to phosphate mines in Africa, in addition to the compound fertilizer production line retrofit solution, Lane Machinery has always been committed to the deep integration of China’s smart manufacturing with local needs.
We not only provide equipment, but also sustainable capacity enhancement solutions to help our global customers gain competitive advantages in localized production.
