Client: EC Grow, Inc.  — Eau Claire, Wisconsin

Industry: Fertilizer /  Salt

Application: Stockpile loading of bulk fertilizer and deicing salt in a bagging facility

Material: Granular and pelletized fertilizer, blended fertilizers, and deicing salts

EC Grow, Inc. is one of the Midwest's largest blenders of turf and ornamental fertilizer and deicing products, supplying private-label bagged fertilizer and ice melt to retailers including Bomgaars and Menards. To support continued growth in its retail business, EC Grow brought a new East Plant online in early 2024 in Eau Claire, Wisconsin. The facility uses Vortex Open/Stockpile Loading Spouts to load granular fertilizer and deicing salt into open storage with controlled drop height and reduced dust emissions.

The Challenge: Controlling Dust at the Point of Loading

EC Grow's East Plant handles a wide range of dry bulk materials in support of its bagging operation — granular fertilizer, coated prills, finished blends, and multiple grades of deicing salt. All of these share the same fundamental challenge: when granular product free-falls from a fixed inlet into an open pile, fines become airborne and escape into the surrounding building.

Uncontrolled dust creates real day-to-day issues. It degrades indoor air quality and adds to house keeping demands. As a pile draws down, drop height grows, so dust generation and particle attrition tend to be worst when the pile is lowest. Every pound of fines lost to the air is product that never makes it into the customer's bag.

The Vortex Solution: Telescoping Loading Spouts

Working with EC Grow's project team, Vortex supplied Open/Stockpile Loading Spouts mounted along the elevated service catwalk that runs the length of the building. Engineered specifically for placing dry bulk solids into open piles, each spout's flexible inner sleeve and outer dust shroud extend downward as the pile grows and retract as it draws down — holding a consistently short drop into the cone of material rather than a ten- or fifteen-foot freefall onto bare concrete.

For an operation loading both fertilizer and salt under one roof, the design delivers several specific benefits:

•      Reduced dust emissions — the dual-sleeve design allows for capturing fines inside the spout and vents displaced air through an integrated dust collection path, keeping airborne dust out of the building and out of the operator's breathing zone.

•      Less product attrition — the short drop height protects fragile coated prills from breaking and keeps salt particles intact for cleaner downstream bagging.

•      Material versatility — the same spout model handles EC Grow's full product range, from low-density urea-based fertilizer to abrasive sodium chloride and dense calcium-chloride-treated ice melt.

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Results: Cleaner Loading, Less Lost Product

Since the East Plant came online in early 2024, the spouts have handled EC Grow's full lineup of bagged fertilizer and ice melt products, holding a consistent short drop across every loading cycle.

Plant personnel report a markedly cleaner working environment compared to traditional open loading. Dust is contained at the point of discharge rather than drifting through the building, reducing housekeeping demands and improving air quality. Fines staying with the material also means less product lost to the air.

Engineered Loading Solutions for Dry Bulk Operations

Vortex engineers and supplies Open/Stockpile Loading Spouts, along with truck, rail, ship, and barge loading solutions, for fertilizer producers, deicing salt processors, and other dry bulk operations worldwide. Contact Us or Request a Quote to learn how Vortex can engineer a loading solution for your application.

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