CASE STUDY: Automatic fertilizer packaging at Agroracio

Assignment: fully automatic fertilizer packaging

Agroracio defined clear requirements:

• significant increase in speed and smoothness of operation
• minimum operator intervention
• guaranteed dosing accuracy meeting audit controls
• high reliability and stability without interruption of production
• compatibility with the existing conveyor for filling the hopper
• simple maintenance, quick and easy cleaning, minimal downtime
• easy operation
• hygiene and safety - surfaces suitable for contact with fertilizer, safe for the operator
• ergonomic working environment (inserting buckets, lids, removing finished packages)
• filling of different bucket volumes and different weights.

A conventional line was not enough. A new type of equipment was constructed.

We considered customizing existing technologies, but it was not possible to achieve the required capacity or dosing accuracy. Therefore, the decision was made: NOMATECH will design and manufacture a completely new type of filling line suitable for the properties of fertilizers - specifically their moisture, abrasiveness and corrosiveness.

Development and production: a year of work from the first sketch to the prototype

NOMATECH's goal was to design a solution based on accurate weighing, reliable packaging handling and a robust structure that can handle the most demanding operations. Our designer David Šebesta, who was responsible for the technical solution participated in the design, and project manager Nikola Belžíková, who supervised the smooth running of the entire project, .

LUNA-B Filling Station

The LUNA-B filling station is a fully automated device designed for precise filling of large-volume containers, such as buckets or barrels. The station works with a preset dose and is supplemented with a suitable type of dosing device depending on the nature of the product. In this case, it was a RACKET LW2 linear scale.

How the entire cycle proceeds:

1. Empty containers are automatically removed from the magazine.
2. Containers are transported to the filling point by a roller conveyor.
3. Containers are filled with the required amount of fertilizer and moved to the lid application station.
4. The lids are automatically placed on the container and pressed firmly.
5. The finished package continues along the conveyor for further manipulation.

The LUNA-B filling station allows for quick conversion to other packaging formats and in the standard configuration can handle up to 15 packages per minute, with the possibility of expanding with other automation elements.

The development and production of the LUNA-B filling station took twelve months.

At each stage of construction, the compatibility of the product (fertilizer) with the machine components was tested. After the main parts were manufactured, the fertilizer was analyzed - in particular its moisture content, corrosion risks and handling behavior. Based on this data, we selected:

• the final suitable surface treatment of the materials
• type of seals
• construction modifications for long-term durability.

The parts coming into contact with the product were made of stainless steel, the other structural elements of standard steel. The line also includes a dosing system designed for precise weighing without deviations.

The result is a robust, stable and fully automated LUNA-B filling station that worked without the need for further modifications from the very beginning. This is exceptional when developing a completely new technology.

Evaluation of AGRORACIA

"We rate the cooperation with NOMATECH at a high level. We always had professional, clear and prompt communication from the sales manager, the designer provided technical solutions exactly according to our requirements, and the production and assembly department did quality work with an emphasis on detail and functionality.
We also appreciate the approach of director Petr Houdek, who helped us set up processes and strengthened our trust in long-term cooperation. The service was fast, reliable and always available, which contributed to the trouble-free launch of the line."

Ing. Tomáš Boroš, Agroracio

Future: potential for expansion

Agroracio is considering expanding the line in the future, depending on the market situation.

However, the installed technology allows for the expansion of the line with additional automation elements at any time in the future.

If a machine from the catalog does not exist, NOMATECH will do everything to satisfy the customer. It will design and manufacture a new type of equipment.

This project is a typical example of what sets NOMATECH apart: we not only manufacture machines for automatic packaging - we can design them from scratch according to the specific needs of the customer.

Agroracio is currently working with a line developed to suit their product. It replaced a physically unsustainable process, significantly increased capacity, accuracy and stability, and minimized dependence on manual labor.

Do you want to speed up packaging, relieve employees, and achieve stable production?

We will design a technology that can handle even a demanding product and take your production to the next level.

Just get in touch.