INCITEC PIVOT FERTILISERS, Australia / Fertiliser

CHALLENGE

Incitec Pivot needed to upgrade its fertiliser bagging systems to increase efficiency, reduce corrosion risks, and handle varying densities of products while complying with industry regulations.

SOLUTION

Concetti supplied automated bagging, filling, and palletising lines with corrosion-resistant designs, boosting production and ensuring long-term durability for fertiliser packaging.

INCITEC PIVOT FERTILISERS

Concetti Revolutionizes Fertiliser Packaging for Incitec Pivot with Advanced Automation

Case Study:
Incitec Pivot Fertilisers (IPF) aimed to modernize its packaging operations for fertilisers, ensuring better efficiency and tackling corrosion challenges. After considering global suppliers, Concetti was chosen to deliver a comprehensive solution at their Gibson Island and Kooragang Island facilities. Concetti’s advanced systems include a gravity-fed net weighing system (NET/G), STARPACK bagging machines, and high-level push-type palletisers. The new equipment significantly boosted productivity, increasing the bagging rate from 3,500 bags per day to 1,200 bags per hour at Kooragang Island. The machines are built with anti-corrosive and anti-abrasive materials to handle the harsh fertiliser environment.

Technical Solution:
Concetti provided two complete automated systems at IPF’s facilities, each featuring:

Gravity-fed net weighing systems (NET/G): Ensures accurate product dosing for varied fertiliser densities.
Concetti STARPACK Bagging Machines: Robust machines for efficient, high-speed bagging, capable of handling 20-25 kg woven PP bags with gussets or pillow types.
High-Level Push Type Palletisers: Automated systems for quick palletising of bags.
Corrosion-Resistant Construction: Extensive use of stainless steel and anti-corrosive paints ensures long-lasting operation in challenging environments.
Hooding & Stabilizing System: Applied to full pallets for secure transportation and storage.
Customization for Fertiliser Characteristics: Adapted to handle the specific needs of varying fertiliser products, ensuring high-quality packaging and seamless production.

These innovations increased the packaging rate significantly and ensured consistent product quality, even in coastal and humid environments where corrosion is a major risk.

Strengths & Benefits:

Increased Efficiency: Bagging rate increased from 3,500 bags/day to 1,200 bags/hour.
Corrosion Resistance: Anti-corrosive materials and designs ensure long-term durability.
Customizable Solutions: Tailored to meet the specific characteristics of different fertilisers.
Easy Maintenance: Access doors and cleaning systems make routine maintenance easier.
Regulatory Compliance: Flexibility for integrating label applicators and ink-jet coders to meet traceability requirements.
Reliable Production: Continuous operation with minimal downtime.

Conclusion:
Concetti’s tailored packaging systems have dramatically improved IPF's fertiliser packaging operations, increasing production rates while safeguarding equipment longevity and meeting regulatory needs. The upgrade is a major boost for customers along Australia’s east coast.

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