Fertilizer Blending Plant in Indonesia

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Construction content and scale

The main construction content of this fertilizer blending plant in Indonesia project is detailed in the table below.

Engineering category	Name of single engineering	Engineering content and scale
Main engineering	Production workshop	Steel structure building, building area 3024m², main production site.
Auxiliary engineering	Office building	Brick-concrete structure, 2 stories high, floor area/100m², building area 200m², used as office space.
	Staff lounge	Brick-tile structure, 1 story high, building area 200m².
Storage and transportation engineering	Finished product warehouse	Steel structure building, building area 2800m², product storage site.
	Raw material warehouse	Steel structure building, building area 5819m², storage place for raw and auxiliary materials.

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Main products and production capacity

After completion, this fertilizer blending plant in Indonesia project will achieve an annual production capacity of 25,000 tons of organic fertilizer (water content ≤30%).

Product name	Annual output	Packaging specifications	Remarks
Powdered organic fertilizer	12,500 t/a	50kg/bag	Moisture content ≤30%
Powdered biological organic fertilizer	12,500 t/a	50kg/bag	Moisture content ≤30%

Note:

In this fertilizer blending plant in Indonesia project, the raw and auxiliary materials and production processes required for the two products, powdered organic fertilizer and powdered bio-organic fertilizer, are the same, but the ratio of raw and auxiliary materials is different.

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Main raw and auxiliary materials

The main raw and auxiliary materials and energy consumption of this fertilizer blending plant in Indonesia project are shown in the table below.

No.	Name of raw and auxiliary materials	Annual usage	Source
1	Peat soil	15000t	Purchased
2	Tobacco stems	7500t	Purchased
3	Mushroom waste residue	2500t	Purchased
4	Water	126m³/a	Local water supply network
5	Electricity	300,000 kW ·h	Local power supply department

Note: The tobacco stems and mushroom waste residues used in this project are fermented clinkers, all from the project area.

(1) Peat soil:

Peat soil refers to soil in some river and lake sedimentary low plains and mountain valleys. Due to long-term water accumulation, aquatic vegetation is dense, and a large amount of incompletely decomposed plant residues accumulate and form a peat layer under hypoxic conditions.

(2) Tobacco stems:

Tobacco is a plant of the genus Nicotiana in the Solanaceae family. Tobacco stems are the coarse and hard veins of tobacco leaves, accounting for about 25%-30% of the leaf weight. Tobacco stems are rich in protein, sugar, lignin, cellulose, organic acid, pectin, etc. The nitrogen, phosphorus and potassium content is significantly higher than that of grain crop straw, making them a valuable biomass resource.

The purpose of using tobacco stems for biological fermentation to produce bio-organic fertilizer is to make full use of the unique physical and chemical properties of tobacco stem waste to produce high-fertility organic fertilizer at a low production cost and simple production process.

(3) Mushroom waste residue:

In places where mushrooms are grown, a large amount of discarded mushroom residue is produced every year. These mushroom residues are rich in crude protein, crude fat and nitrogen extracts, as well as minerals such as calcium, phosphorus, potassium and silicon.

They are very nutritious and can be used as a good medium for vegetable seedlings, soilless cultivation or flower cultivation. The nitrogen and phosphorus content of mushroom residues is high, so it is not suitable to be used directly as a matrix. It should be mixed with peat, garden soil or granular ore in a certain proportion to form a composite matrix for later use. The proportion of mushroom residues should not exceed 60% when mixing.

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Product Standards

The quality of organic fertilizers produced in this fertilizer blending plant in Indonesia project must meet the “Organic Fertilizer Standards”. The product standards are as follows:

Item		Indicators
Technical indicators	Organic matter mass fraction (on a dry basis), %	≥45
	Total nutrients (nitrogen + phosphorus pentoxide + potassium oxide) mass fraction (on a dry basis), %	≥5.0
	Water (fresh sample) mass fraction, %	≤30
	Acidity (pH)	5.5~8.5
Heavy metal limit index (mg/kg)	Total arsenic (As) (on a dry basis)	≤15
	Total mercury (Hg) (on a dry basis)	≤2
	Total lead (Pb) (on a dry basis)	≤50
	Total cadmium (Cd) (on a dry basis)	≤3
	Total chromium (Cr) (on a dry basis)	≤150
Ascaris egg mortality and fecal coliform count index meet the requirements of “Biological Organic Fertilizer”

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organic fertilizer manufacturing process design

The specific process flow adopted by this fertilizer blending plant in Indonesia project is as follows:

1. Peat soil, fermented tobacco stems and mushroom waste are added to the storage hopper in a certain proportion.
2. The raw and auxiliary materials with good proportions are conveyed from the storage hopper to the fertilizer crusher machine for crushing, and then screened and graded by the screening machine. The materials on the screen are returned to the crusher by the conveyor for further crushing, and the particle size of the powdered materials under the screen is 2-4mm;
3. The powdered materials under the screen are conveyed to the high-level storage hopper by the conveyor, and then conveyed to the automatic scale for bagging and weighing.
4. The finished products after bagging and weighing are conveyed to the bag sewing machine for packaging, and then stored for sale.

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Main fertilizer manufacturing machines

The main fertilizer making machines of this fertilizer blending plant in Indonesia project are detailed in the table below.

No.	Equipment Name	Model and Specifications	Power(kw)	QTY
1	Storage Hopper	4*2.6*1.55m	/	1
		2.22*2.22*2.35	/	1
2	Conveyor	B600*5300mm	5	1
		B600*8000mm	4	1
		B600*5000mm	3	1
		B500*4700mm	3	1
		B600* 14200mm	5	1
		B400*6000mm	4	1
		B1000*4200	7.5	1
3	fertilizer crusher machine	BSFS-110,10~15t/h	60	1
4	Fertilizer grinder (optional)	LR500-60,3～4t/h	30	1
5	Screening machine	1030-3S	1.5	1
6	Automatic fertilizer bagging machine	/	/	1
7	Bag sewing machine	/	0.92	1
8	Air compressor	/	1.5	1
9	Forklift	40 type	/	1
10	Forklift	3 tons	/	1

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The plant layout

The plant area of this fertilizer blending plant in Indonesia project is an irregular polygon. The southwest corner of the plant area is the employee lounge, the middle of the plant area is the production workshop, the south of the plant area is the finished product warehouse, the southeast is the office building and the plant gate No. 1, the north and east are the raw material warehouse, and the northeast corner is the plant gate No. 2.

The plan layout of this project has clear functions, is conducive to production and transportation, meets the process requirements, and the overall layout meets the fire protection and environmental protection requirements.

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What is the prospect of building a fertilizer mixing line in Indonesia?

The prospect of building a fertilizer blending plant in Indonesia is relatively optimistic. The following is a detailed analysis:

Policy support

• The government promotes agricultural development: The Indonesian government attaches great importance to agricultural development, and agriculture is one of the important pillars of the national economy. The government supports agricultural modernization through a number of policies, including providing subsidies, technical support and infrastructure construction.
• Fertilizer subsidy policy: The Indonesian government subsidizes fertilizers (including chemical fertilizers and organic fertilizers) to reduce farmers’ production costs. This provides a stable market demand for fertilizer mixing production lines.
• Environmental protection policy: With the increase in environmental awareness, the government encourages the use of environmentally friendly fertilizers to reduce the negative impact of chemical fertilizers on the environment. Fertilizer blending plant in Indonesia can produce customized environmentally friendly fertilizers, which is in line with policy directions.

Market demand growth

• The agricultural scale is huge: Indonesia is one of the largest agricultural countries in Southeast Asia, mainly planting crops such as rice, palm oil, rubber, and coffee. These crops have a huge demand for fertilizers, providing a broad market space for fertilizer mixing production lines.
• Increased demand for customized fertilizers: Different crops and soil types require fertilizers with different ratios. The fertilizer mixing production line can produce customized fertilizers according to customer needs to meet diverse market demands.
• Rising demand for organic fertilizers and compound fertilizers: With the development of sustainable agriculture, farmers’ demand for organic fertilizers and compound fertilizers has gradually increased. The fertilizer mixing production line can flexibly produce various types of fertilizers to meet market trends.

Trends in agricultural modernization

• Transition from traditional agriculture to modernization: Indonesia is promoting agricultural modernization to improve agricultural production efficiency and sustainability. The fertilizer mixing production line can support this transformation by providing efficient and environmentally friendly fertilizers.
• The rise of precision agriculture: Precision agriculture requires precise proportioning of fertilizers according to soil and crop needs. The fertilizer blending plant in Indonesia can meet the needs of precision agriculture and provide customized fertilizer solutions.

Raw material supply

• Abundant local raw materials: Indonesia has abundant fertilizer raw materials (such as urea, phosphate fertilizer, potash fertilizer) and organic fertilizer raw materials (such as livestock and poultry manure, crop waste). This provides sufficient raw material supply for the fertilizer mixing production line.
• Raw material cost advantage: The sufficient supply of local raw materials and low transportation costs help reduce production costs and improve market competitiveness.

Geographical advantages

• Southeast Asian market center: Indonesia is located in the center of Southeast Asia, with a superior geographical location, which is convenient for exporting fertilizers to neighboring countries such as Malaysia, the Philippines, Vietnam, etc.
• Large domestic market demand: Indonesia has a large domestic agricultural scale and a strong demand for fertilizers. The domestic market itself is a huge market.

Technical cooperation and innovation

• International cooperation opportunities: Indonesia is actively attracting foreign investment and technical cooperation, especially in the fields of agriculture and environmental protection. The construction of fertilizer blending plant in Indonesia can improve production efficiency and product quality with the help of international advanced technology and management experience.
• Technological innovation: By introducing advanced fertilizer mixing technology and equipment, high-quality and efficient fertilizer products can be produced to meet market demand.

Challenges and risks

• Fierce market competition: Indonesia’s fertilizer market is highly competitive, with many domestic and foreign companies. New entrants need to face the competitive pressure of existing companies.
• Infrastructure restrictions: The infrastructure (such as transportation and electricity) in some areas may not be perfect, which increases the difficulty of production and transportation.
• Insufficient awareness of farmers: Some farmers have a low awareness of customized fertilizers and new fertilizers, which may affect market promotion.

Development Suggestions

• Strengthen market promotion: Improve farmers’ awareness and acceptance of customized fertilizers and new fertilizers through demonstration projects, training and technology promotion.
• Strive for government support: Make full use of government subsidies, tax incentives and other policies to reduce investment and operating costs.
• International cooperation: Cooperate with international companies or research institutions to introduce advanced technology and management experience to improve production efficiency and product quality.
• Establish a stable raw material supply chain: Cooperate with local fertilizer and organic fertilizer suppliers to ensure a stable supply of raw materials.
• Focus on environmental protection and sustainable development: Integrate environmental protection concepts into production and marketing to enhance the market competitiveness of products.

Building a fertilizer plant project in Indonesia has broad prospects. Government policy support, large agricultural scale, abundant raw material resources and the need for agricultural modernization all provide favorable conditions for the development of fertilizer mixing production lines.

However, enterprises need to pay attention to challenges such as market competition, infrastructure and farmers’ awareness, and seize opportunities through technological innovation and market promotion. If these challenges can be effectively addressed, fertilizer mixing production lines will have great development potential in Indonesia.

If you are interested in building a fertilizer blending plant in Indonesia project, feel free to contact RICHI Machinery for technical support on fertilizer processing plant design, equipment configuration, production line layout, civil engineering solutions, etc.!