Coating and Blending Plant

Two process lines in one plant

For this project, a new production plant for seed coating, pelleting and seed mixtures was implemented. The plant consists of two independent but coordinated lines: a coating and pelleting line with two Niklas batch treating units, and a blending line with two blenders for different batch sizes and hourly capacities.

Both lines were planned into a new building. From intake, conveying, pelleting, blending and sampling through to packaging, the result is an integrated solution for the industrial processing of forage and cover crop seeds.

Insights

The coating and pelleting line is designed for the treatment of seed with liquid and powder components. The raw material is fed into the line via a big bag intake with downstream control screen and then transferred to the two Niklas W.N. 5/100 batch treating units. There, seed, liquid components and powder are precisely dosed and processed in a controlled batch process.

After a further control screening step to separate any agglomerates or fine particles, the final product is gently filled into boxes. This allows the complete process from raw material intake to treated finished product to be controlled and reproduced reliably.

In the second line, seed blends are produced. Individual components can be dosed via bag intake stations and box tippers. All intake hoppers are equipped with load cells allowing each component to be dosed accurately into the blenders according to the specified blending recipes.

For large batches and high throughput, our high-performance double-shaft horizontal blender Type RDM 8 with a volume of 8,000 liters is used. In addition, a smaller diagonal blender was integrated to allow flexible production of smaller batches or special mixtures. Both machines provide homogeneous and gentle blending. Discharge is designed for clean product handling with minimized residues.

After blending, the product is control-screened, sampled and transferred to the packaging line.

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Highlights

The special feature of this project lies in the combination of two complex production lines within one new plant concept.

The plant offers high flexibility in daily operation: larger batches can be processed via our high performance horizontal blender, while the smaller blender provides additional options for smaller lots or special blends. The intake of different containers and components was also designed accordingly.

The coating and pelleting line places high demands on dosing accuracy, recipe management and process control. Liquid and powder components must be applied evenly and processed reproducibly.

Machine positioning, platforms, conveying routes, pipework, aspiration system and operating areas were coordinated with the planned workflows. This created a modern production plant that combines two different process areas within one common plant layout.

From concept development, engineering, supply and installation coordination through to control system integration and commissioning, the project was implemented as a comprehensive plant solution.

Custom Solutions – end to end

Concept development and process design
Project planning and layout design
Mechanical and plant engineering
Delivery of machinery and plant components
Assembly and installation
Commissioning
Operator training
Service and support