Smallholder maize systems in South Asia face challenges of low productivity, inefficient fertilizer use, and rising environmental footprints. Decision-support tools (DST) such as Nutrient Expert® (NE®), built on 4R nutrient stewardship principles, offer promise for achieving sustainable intensification (SI), yet their performance across diverse farm types remains poorly understood. This study assessed NE®-guided fertilization against farmer fertilizer practices (FFP) across 112 farms in four agro-climatic zones of southern West Bengal, India. Farm typologies were delineated using principal component and cluster analysis, resulting in seven distinct farm types (FT) reflecting socio-economic and biophysical heterogeneity. Paired on-farm trials compared NE® and FFP for multiple indicators, including yield, economics, energy use, and greenhouse gas (GHG) emissions. Results show that NE® reduced N, P, and K use by 66 %, 93 %, and 56 %, respectively, while increasing yields across all farm types, with the highest gains in FT-4 (71.1 %), FT-2 (63.0 %), and FT-7 (60.3 %). Gross return above fertilizer cost (GRF) improved in nearly all cases, with FT-2 achieving a 90 % gain. Energy productivity and net energy gain increased in most farm types, while yield-scaled GHG emissions declined in 88.4 % of farms. However, benefits were uneven: FT-3 and FT-5, constrained by setting higher yield targets, coupled with poor resource endowment and weak yield response, showed limited improvements. Thin-plate spline regression further identified farm-type–specific sustainability frontiers, indicating untapped potential for SI beyond current NE® yield targets. Overall, the findings demonstrate the utility of NE® in tailoring realistic yield targets for DST and nutrient management across heterogeneous farm systems, while also highlighting the importance of typology-based scaling strategies.
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