Raw material level troubleshooting: First, check whether the particle size and specific gravity of each raw material are matched. Urea has a bulk density of approximately 1.33 g/cm³, and potassium chloride approximately 1.98 g/cm³. When the specific gravity difference between the two is too large, direct mixing can easily lead to particle separation due to their different physical properties. If the particle size difference of the raw materials exceeds 1 mm, the raw materials need to be sieved to ensure that the particle size distribution of each component is similar (SGN index matching), reducing the risk of segregation from the source.

Equipment level troubleshooting: Check the wear of the mixing blades. When the blade wear exceeds 5mm, the stirring driving force decreases, and the material cannot be fully convectively mixed. The machine must be stopped to inspect the blades; severely worn blades should be replaced or repaired promptly. Simultaneously measure the gap between the blades and the housing—the design value is typically 5-8mm; if it shrinks to 2mm after wear, material is prone to jamming.

Operational level troubleshooting: Check if the mixing time is sufficient (normally 35 minutes). Ensure the feeding sequence follows the principle of "heavy before light, large before small"—first add the heavier main material (such as ammonium phosphate), then the lighter auxiliary materials, and finally the trace additives. If the above checks are satisfactory, the mixing time can be extended to 58 minutes via PLC. Sampling and testing confirm that uniformity meets standards before resuming mass production. Establishing a daily residue cleaning and bolt tightening inspection system can prevent 80% of common failures.