#6 Now you are ready to fill the machines feed hopper with media if not already filled. (Emptying the media from the machine and blowing the media out of the nooks and
crannys with an air hose when machine is not in use will DRASTICALLY increase
machine life!!!!!!)
#7 Finally, turn the main power switch on and place an empty container on the stopped
belt. Turn the soil delivery on and when soil begins to deliver to the belt you can slowly
accelerate the belt speed. To set the desired filling rate please adjust the height of the
hopper discharge gate to regulate soil delivery to the containers properly at the chosen
filling belt speed. Regulating this soil delivery is most always done with a height
adjustable discharge gate and sometimes is tuned more precisely with a variable speed
controlled soil delivery system. If your soil system is variable speed this option can be
used as well to properly regulate delivery. Proper Regulation means that the containers
are filled properly and the soil being returned through the machine is at a minimum!!!
WHEN FILLING POTS, BASKETS OR BOWLS IN A SINGLE FILE LINE
#1b Follow the same steps as above disregarding step #2. This device is typically not
used while filling single file containers and may need to be removed from above the
filling belt and stored for this application. There may also be a removable chute that
will need to be installed for this application in order to regulate the soil fall to a more
narrow drop thus reducing the amount of returned soil and optimizing the rate of fill.
Q: What do I do if my flat filler damages containers or turns them over when filling?
A: Usually this is due to improper Flat Filler adjustment, very coarse soil mix or flimsy containers.
#1 Review Set-Up Procedure Above And Insure Moving Parts of Flat Filler Are Not
Contacting Containers And Causing The Problem. Watch them run through empty
as well as while being filled very closely to determine if user adjustment is not to
blame.
#2 Inspect Soil Mix to rule out sticks, debris or large bark being the culprit
#3 Ensure that your containers are not collapsing before they are moved away from
their belt position by any machine or soil issues. If so, buy better plastic.
#4 Also inspect the containers transition from the filling belt to the take-off point. Does
the container dip at this transition and cause the problem? If so, add a bridge or
an additional roller to the take off point. (A powered roller take-off will cure this too.)
#5 Last, inspect to see if regulating the amount of soil delivery or changing the position
on the belt that the container rides on will help the situation by making these
adjustments and running a trial.
#6 If all of the above is ruled out or if one of the above reasons is to blame but can't be
overcome then hold down rails can be utilized to cure the issue. Their a little
cumbersome but they usually work very well.
Q: How can I improve the longevity of my Flat Filler and its soil delivery system?
A: Proper Maintenance, Regular Clean-Up, Dry Storage And Available Upgrades Can Make
The Difference Of A Few Yr Lifespan To A Few Decade Lifespan!!!
#1 Ideally, clean out the soil completely after every use! At the very least, clean the
soil out when the machine will not be used again the next morning!!! At the end of
use, either open the discharge door on the bottom rear of the Flat Filler Hopper or use
a makeshift chute to slide the media out of a belt hopper type machine on the ground
by running the soil system independantly. This process is much easier and more
effective by using an airhose to help the soil system empty entirely. Water retaining
media and fertilizers are the number 1 killer of Flat Fillers!!!!! Get it out after use!!!!
#2 Visually inspect Soil Chain Tension, Conveyor Belt tracking, Soil Chain & Sprocket
Condition, Belt Condition, Bearing Condition, Metal Condition, Adjustment Function
And overall machine on a weekly basis. Multiple times a day if there is a repetative
problem or a recent repair.
#3 Grease every greasable bearing after every 200 Hrs of Flat Filler use or every month,
whichever is more often. Refer to manufacturer for specific schedules but this is usual
good practice. Only 1 pump from grease gun each time, each bearing!!! Don't grease
untill you see grease unless that mistake has been made on that particular bearing
previously. MORE IS NOT BETTER!!! You jeopordize the seal and you let dirt in!!!
#4 Remove gaurds, lube roller chains and tension them if necessary every 600 Hrs or 3
months. (You should be to move most chain a little between sprockets but it should
have some resistance to a one finger lift and push) (This DOES NOT refer to the soil
chain on drag chain style Flat Fillers!!!)
#5 Keep indoors or under roof all the time or as often as possible if used as portable
unit!!!
#6 Stainless Steel units and units with Stainless Steel used in wear areas are available
on request. Stainless increases the price considerably but it also increases the life
expectancy indefinitely. (Rebuilt units with Stainless Replacement Panels are also
available.)
#7 Repainting the steel, that comes into direct contact with the growing media, with
a high zinc content coating or with other high quality rust preventative coatings will
significantly increase life as well. (Wire brush and thoroughly clean all steel prior to
applying any new coating! Prep should be the majority of the job!)
Q: What should I consider when purchasing a new, or new to me, Flat Filler?
A: There are several factors to consider in choosing the ideal Flat Filler for your business.
#1 The footprint of the compared machines. (How much floor area it requires)
If the unit is portable and will be used that way, will it fit through doorways, etc.?
#2 The media loading height of the Flat Filler. Will it work in your application?
(Consider bag loading, Bale Processor loading, Overhead or Incline Conveyor loading,
etc.) (An additional conveyor purchase or a loading mezzanine can usually address
any loading scenario, but all factors should be considered in making this decision.
#3 The actual production rates the Flat Filler will produce in your application. Container
and Tray sizes will provide different production rates on same machine due to the
different amounts of media the containers each hold. If machine is used with Seeder
or Transplanter or any supplemental machine that automatically controls the Filler
it will impact those numbers and certain supplemental machines may benefit from
higher Flat Filler production capabilities.
#4 Where is the Flat Filler manufactured? Are parts readily available in your area by
anyone other than the distributor of the machine? Will that manufacturer be around
in ten years? What outlets will you have if the distributor fails?
#5 Is the Flat Filler manufactured for longevity using materials/ coatings to resist rust
and withstand the materials that will be used in it? Question material thickness and
specifics regarding primers and protective coatings.
#6 Direction of container flow as opposed to media loading point. Will this configuration
be ideal for your production area/s? Most machines are available as Right to Left as
well as Left to Right units but must be ordered that way to begin with!
#7 Price! What will the return on investment be? Do your production needs justify a $10k
Flat And Pot Filler or a $30,000 unit? Does the amount of change-over your
application requires justify extra expense of higher-end adjustment mechanisms?
Large farms with fast-paced production at high numbers should purchase a hopper
over filling conveyor design machine. (They require less maintenance when
maintained properly.)
SOIL MIXING QUESTIONS AND ANSWERS:
Q: What Factors Should We Consider When Purchasing Soil Mixing Machinery.
A: There are several factors to consider when purchasing Soil Mixing Equipment.
#1 How many yards of mix will your business require within an hour, a day, a week?
#2 According to your mix volume needs should you consider Batch Mixing And/Or
Continuous Soil Mixing Equipment? Any Volume requirements over 30 Yds. Per
Hour will leave no choice other than continuous flow mixing without pre-mixing
and stock piling. Either way a Batch Mixer will require loading with pre-measured
ingredients and running the machine from 3-20 minutes dependant on mixer size and
manufacturer. Then dispensing mix and repeating the process. Continuous Soil
Mixing will require keeping each ingredients feed hopper filled and calibrating for
particular mix percentages for it to do the rest at a continuous pace. These systems
are tailored to the output volume and the ingredients used and are available as
fairly simple mechanical systems all the way to touch screen controlled with recipe
management software.
#3 If choosing a Batch Mixer it comes down to preferred manufacturer, mixer hopper
size, price and support. (Drag chain hopper mixers are not mixers and do not work!)
Keep it indoors if at all possible and don't forget an incline conveyor and possibly
overhead delivery conveyors to support your mix transfer needs.
#4 If choosing continuous soil mixing then your list of factors to consider is much
longer but must be used to provide the proper system for the facility.
A: We are un-matched in this arena but regardless of manufacturer there is a
great deal of information that the buyer and builder must share to get this
right. Each individual hopper should be sized to support its feed rate and
tailored to consistently feed the specific ingredient it will dispense. Mix belt
And Hopper Belt Widths should support the maximum output volume
required without any spill over. Control System and mix change over
steps should support number of mix changes and change over time
specified. System configuration should reflect specific facility and
production logistics considering material storage, flow, loader size,
mix dispensing points, etc. Consider material and coatings used to promote
the systems longevity, stainless steel is by far the longest lasting system
but is also by far the most expensive. (Don't buy a mild steel system that
is painted without primer!!!)
Please check back soon!!! This page is a work in progress and will grow quickly!!!