Automation Upgrade Plan for The Large Bag Packaging Workshop of A Russian Fertilizer Plant.

Automation Upgrade for a Russian Fertilizer Plant's Bulk Bag Packaging Workshop

We recently undertook an automation upgrade project for the bulk bag packaging workshop of a Russian fertilizer plant. The challenge involved integrating three production lines (named Line 1, Line 2, and Line 3) which package large bags of product, requiring their outputs to be consolidated and palletized. The robotic pick-up stations for these lines are designated as A, B, and C, respectively.

The operational complexity was significant. The three lines may work simultaneously, in pairs, or individually. They could be producing identical products or different ones. Each line handles over 10 different product types, which must be palletized onto two possible pallet sizes in four different stack heights, resulting in more than 50 distinct palletizing patterns.

To address this, our structural, software, and project engineers engaged in intensive brainstorming for over 10 days. The solution was to distill the requirements into 9 operational modes, selectable via the PLC, successfully meeting all client specifications.

Compared to building a new production line, upgrading and renovating an existing factory is more than ten times more difficult. This is because all our design plans must accommodate the factory's existing equipment and space constraints.

The video demonstration shows Line 1's 25kg bags being picked at Station B, then palletized, stretch-wrapped, and finally delivered to the forklift pickup station.

A note on testing: To simulate real production conditions, our workshop team filled 50 bags with sand. Each test run required manually lifting these heavy bags—weighing around 30kg—onto the conveyor belt hundreds of times. For engineers not accustomed to manual labor, this was an exceptionally demanding task, repeated through countless test cycles.

**On a lighter note:** During sandbag testing, we encountered some unevenly filled bags (approx. 28kg to 32kg) due to the sand's poor flowability and high density, leading to minor stack inconsistencies in the video. This issue does not occur with standardized 25kg, 30kg, or 50kg fertilizer bags.

The system has now passed two rounds of factory acceptance tests and subsequent improvements. A final pre-shipment inspection is scheduled shortly, with the goal of dispatching the equipment before the Chinese New Year.

Stay tuned to our website for upcoming videos from the final on-site commissioning and acceptance at the client's plant!

MIGRAND Machinery

Ava Duan

Mobile/Wechat/Whatsapp: 0086-13706885851

Email: sales@grand-packing.com