The number of operators for a compound fertilizer production line with an annual output of 100000 tons depends on the level of automation and production shifts. The conventional configuration is 12-25 people, and production lines with high automation can compress to 8-12 people.

Core influencing factors

Automation level: equipped with automatic batching, automatic packaging, and palletizing robots in the production line, significantly reducing the demand for manual labor; The semi-automatic production line that relies on manual batching and manual palletizing requires an increase in manpower.

Production shift: According to the common "three shift" (24-hour continuous production) configuration in the industry, if it is "two shift" or single shift production, the number of people can be reduced by 30% -50% accordingly.

Process complexity: The traditional drum/disc granulation process is easy to operate and requires less manual labor; High tower granulation requires additional monitoring of the melting and spraying processes, and 1-2 technical personnel need to be added.

Details of personnel with different configurations (taking three shifts as an example)

1. Automated production line (12-15 people)

Central control room operators: 3 people (1 person per shift, monitoring the equipment operation and parameter adjustment of the entire production line).

On site inspectors: 6 people (2 people per shift, responsible for raw material feeding, equipment inspection, and abnormal handling).

Packaging/palletizing post: 3 people (1 person per shift, in coordination with automatic packaging machines and palletizing robots, responsible for replenishing bags, sewing and reviewing packages).

Maintenance/Electrician: 2 people (on duty in shifts, responsible for daily equipment maintenance and emergency troubleshooting, part-time available).

2. Semi automatic production line (18-25 people)

Ingredient post: 6 people (2 people per shift, manually assisting in ingredient preparation and monitoring of raw material transportation).

Granulation/Drying Post: 6 people (2 people per shift, monitoring granulation and drying equipment, adjusting material humidity and temperature).

Screening/Coating Post: 3 people (1 person per shift, responsible for screening and grading, and adding coating agents).

Packaging/palletizing post: 6 people (2 people per shift, manually assisted bagging and palletizing, increased to 3 people per shift when there is no palletizing robot).

Maintenance/Electrician: 2 people (full-time, responsible for equipment maintenance and fault repair).

Suggestions for personnel optimization

Merge positions: Allow inspectors to perform simple operations in screening and coating processes, reducing the number of dedicated positions.

Skill training: Cultivate versatile operators who can take care of multiple aspects such as central control and inspection, reducing personnel redundancy.

Outsourcing assistance: Outsourcing heavy physical labor such as raw material handling and finished product stacking to reduce the number of fixed employees.