A Reverse Blending based supply chain for mass customization of green fertilizers

Reverse Blending is a new product design and manufacturing approach based on finding the optimal chemical composition of a very small number of semi-finished common products (composites) whose possible blends may satisfy a wide variety of green fertilizers. As these fertilizers are adapted to the ecological requirements of crops and soils, Reverse Blending allows for both efficient and sustainable agriculture. Its implementation involves a supply chain redesign that calls for a shift from sequential batch production of different products to a hybrid system consisting of: i) make-to-stock of the composites within the chemical plant and ii) make-to-order of customized fertilizers within small blending units to be located near the farmer. This mass customization system brings new opportunities not yet exploited in the context of continuous production (granules, liquids ...). This paper aims to highlight these opportunities and demonstrate the managerial and logistical consequences of a Reverse Blending based mass customization through several analysis studies.