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Fertilizer Plant

NPK Fertilizer and Manure Production Plant Automation Solution

Altus technology was implemented to deliver a high-connectivity, dynamic automation solution for the production of NPK (nitrogen, phosphorus, and potassium) fertilizers and organic manure.

The system supports integrated process control, enhancing operational efficiency, product consistency, and production reliability throughout the manufacturing cycle.

Tailored solution for fertilizer and manure production

Developed by one of Altus’ certified system integrators, the NPK (nitrogen, phosphorus, and potassium) fertilizer plant operates using Nexto Xpress (XP) PLC technology.

The solution supervises critical production stages, including dosing, material handling, and raw material mixing processes. The system manages scales, humidity sensors, motors, conveyors, gates, cylinders, and electropneumatic valves, ensuring precise process coordination and high operational performance throughout fertilizer and manure production.

Multiprotocol system

Support for multiple communication protocols was a key factor in selecting the Xpress PLC for this project

Enhanced precision

The Altus-powered solution significantly improved the precision of material mixing processes

High connectivity

The ability to seamlessly integrate with major cloud hosting services was another standout feature of the Xpress PLC

Quick decision making

The PLC’s seamless communication with field devices enhances decision-making speed for the management team

Performance and connectivity with Xpress PLC

The developed application uses the XP340 PLC as a key component, the most complete model in the NX Series, with an XP300 PLC acting as an I/O expansion, increasing the number of communication points and allowing the PLC to interact with more devices.

In this setup, communication between PLCs is handled via CANopen, while the XP340 connects to field devices using the RS-485 serial port and MODBUS RTU protocol. In some cases, the solution is enhanced with an X2 Series HMI for recipe input and production control.

Cloud-ready multiprotocol communication

In addition to the field operations, the solution integrates a cloud platform for data storage and processing, along with a SCADA system to oversee production processes.

To send operating data to the cloud platform, the XP Series PLC uses the MQTT communication protocol, while communication with the supervisory system is done via OPC DA. In turn, the supervisory software can also query the cloud database using the MQTT protocol.

The difference in the Altus experience

What sets Altus apart, besides our prompt and dynamic customer support, is the exceptional connectivity and cost-effectiveness of the Xpress PLCs.

This new system architecture enhanced the precision of raw material mixing and sped up communication between the PLC and field devices, enabling faster decision-making by the management team and reducing operational costs.