Customer Background
The client is an organic fertilizer manufacturer located on Java Island, Indonesia. The company specializes in producing granular organic fertilizers and soil conditioners using local agricultural by-products such as coconut husk powder, palm residue, and compost materials.
Their products are supplied to agricultural plantations across Southeast Asia and also exported to overseas markets.
With increasing order volumes, the customer’s previous manual batching combined with a simple drum mixer could no longer ensure stable batch consistency or meet growing production demands. An automated upgrade became necessary.
Core Technical Requirements
The customer outlined several clear production requirements:
- Two dry granular materials must be automatically dosed in fixed proportions (main material + micronutrient additive).
- A high-viscosity organic fermentation liquid must be sprayed during mixing.
- The liquid has poor flowability, and conventional pumps easily clog.
- The mixing process must preserve granule integrity and avoid particle breakage.
- Single batch capacity approximately 400 kg.
- Equipment must be easy to clean and suitable for tropical high-humidity environments.
- Operation should be simple so local workers can quickly learn and manage the system.
Customized Engineering Solution
Based on the customer’s process flow, environmental conditions, and material characteristics, we designed and manufactured a fully automated proportioning and mixing production line.
1. Dual Hopper Proportional Feeding System (Elevated Platform Design)
The system includes one large hopper and one smaller hopper installed on a reinforced elevated platform.
- Timed proportional discharge ensures stable recipe accuracy.
- Materials flow by gravity directly into the drum mixer.
- The platform structure is equipped with safety railings and anti-slip steps.
- Strong structural design suitable for continuous industrial operation.
This configuration guarantees stable formulation ratios while minimizing manual intervention and reducing human error.
2. Drum Mixing Machine
A rolling drum mixer was selected to achieve gentle and uniform mixing.
- Forward rotation for mixing.
- Reverse rotation for discharge.
- Tumbling motion protects granule integrity.
- High mixing uniformity without excessive powder formation.
This design is particularly suitable for granular organic fertilizers and soil conditioners.
3. Stainless Steel Reactor Tank + Peristaltic Pump Spraying System
To address the high-viscosity fermentation liquid, we implemented a specialized spraying system.
- Stainless steel liquid storage tank for durability and hygiene.
- Peristaltic pump selected to prevent clogging issues common with conventional pumps.
- Internal spray pipeline installed inside the drum mixer.
- Liquid spraying synchronized with mixing operation.
This system ensures uniform coating of the granules while maintaining stable liquid delivery.
Project Results
After installation and commissioning, the production line achieved the following improvements:
- Stable and precise dry material proportioning.
- Uniform spraying of high-viscosity fermentation liquid.
- Improved batch-to-batch consistency.
- Approximately 40% reduction in manual labor.
- Increased daily production capacity.
- More standardized and organized production environment.
The customer successfully upgraded from semi-manual production to an automated batch-controlled manufacturing system, significantly improving efficiency and product quality.