Needle-Punched Nonwoven Granulator

Product Overview

The needle-punched nonwoven granulator is a specialized granulation machine designed specifically for recycling nonwoven waste. Equipped with a densifier–pellet feeding system, it effectively addresses industry challenges such as bridging and slippage when processing fluffy nonwovens. The equipment employs a low-temperature, precision temperature-controlled extrusion process, which maximizes the preservation of the core properties of nonwoven materials, making it suitable for recycling and granulating various types of nonwoven fabrics and meltblown fabric waste, including PP and PET. This machine can directly process whole bales of nonwoven edge trimmings, eliminating the need for pre‑crushing. With its compact design, small footprint, and user‑friendly operation, it helps nonwoven manufacturers achieve 100% in‑plant reuse of waste, significantly reducing raw material costs and waste disposal expenses.

Technical Principle

The needle‑punched nonwoven granulator integrates a densifier and a single‑screw extrusion process to efficiently recycle fluffy nonwoven waste into granules. First, fluffy nonwoven waste is fed directly into the densifier chamber, where high‑speed rotating and stationary blades shear and crush the material. Frictional heat generated during this process causes the material to self‑heat, shrink, and compact into uniform pellets. Once the bulk density increases by 3–4 times, the material is smoothly fed into the extrusion screw, fundamentally preventing bridging and slippage issues common with conventional feeding methods. In the extrusion stage, the machine utilizes a low‑temperature, precisely controlled extrusion process to strictly regulate processing temperatures, thereby avoiding high‑temperature degradation of fibers. Simultaneously, a vacuum degassing system removes oils and moisture from the material. After filtration to remove impurities, water‑cooled pelletizing forms the final product—high‑performance recycled granules with low impurity content.

Performance Parameters

1. Standard capacity: 300–1500 kg/h
2. Compatible materials: Various PP/PET nonwovens and meltblown fabric waste
3. Main motor power: 30–315 kW
4. Feeding method: Densifier directly processes whole bales of nonwoven edge trimmings
5. Recycled granule performance retention rate: ≥80%
6. Granule impurity content: ≤1%
7. Screw and barrel material: 38CrMoAlA, bimetallic, nitrided treatment
8. Heating method: Electric heating, electromagnetic heating
9. Heater materials: Cast aluminum, cast copper, mica, ceramic heaters
10. Motor brands: Siemens, ABB, Weg, or leading domestic brands
11. Pelletizing methods: Die‑face pelletizing, strand‑cut pelletizing
12. Bearing brands: NSK, SKF, INA, FAG, or top domestic brands
13. Inverter brands: ABB, FUJI, Delta, Siemens
14. Delivery time: 70–80 working days
15. Warranty period: 13 months from the bill of lading date
16. Trademark/brand: PURUI
17. Country of origin: NANTONG

Core Advantages

1. Stable feeding without clogging: Equipped with a densifier–pellet feeding system, the machine ensures smooth, stable feeding without bridging or slippage, effectively preventing production fluctuations and guaranteeing continuous operation.
2. Eliminates pre‑processing steps: Can directly handle whole bales of nonwoven edge trimmings, removing the need for additional pre‑crushing, simplifying the production process and saving on equipment investment and labor costs.
3. Low‑temperature process preserves material properties: Utilizing a low‑temperature, precisely controlled extrusion process, the machine strictly manages processing temperatures, minimizing fiber degradation at high temperatures. The resulting granules maintain a performance retention rate of ≥80%, ensuring superior quality of recycled materials.
4. Compact and easy to operate: With a streamlined overall structure, minimal floor space, and straightforward operating procedures, the machine requires no complex professional training, enabling quick adoption and reducing maintenance complexity.
5. Strict impurity control: Through an advanced filtration system, the finished granules maintain an impurity content of ≤1%, enhancing purity and meeting stringent quality requirements for subsequent reuse.

Core Value of the Product

1. High capacity and efficient recycling: With a standard capacity ranging from 300 to 1500 kg/h, the machine can produce up to 36 tons of recycled granules per day, enabling rapid large‑scale recovery of nonwoven waste.
2. Significant cost reduction and efficiency gains: Helps companies achieve 100% in‑plant reuse of production scrap, saving hundreds of thousands of yuan annually in waste disposal costs. Recycled materials can be directly reused in low‑end nonwoven products and injection‑molded items, cutting raw material costs by 25% and substantially lowering overall production expenses.
3. Outstanding environmental value: Replaces traditional waste incineration and landfill practices, reducing resource waste and environmental pollution, supporting green manufacturing and compliance with environmental policies.
4. Stable and reliable quality: Backed by mature technology and components from leading brands, the machine operates stably, producing uniformly consistent granules that provide dependable support for production needs.

Target Customer Base

The primary target customers for this equipment include nonwoven fabric manufacturers, mask production facilities, geotextile companies, hygiene product factories, and textile waste recycling enterprises—businesses that routinely generate substantial amounts of nonwoven edge trimmings and waste and urgently require efficient, high‑quality waste‑recycling solutions.

Application Scenarios

The needle‑punched nonwoven granulator is primarily used for recycling and granulating various types of nonwoven waste, covering PP spunbond nonwovens, PET needle‑punched nonwovens, meltblown fabric scraps, geotextile waste, sanitary nonwovens, mask waste, and more. Whether it’s in‑plant reuse of production scrap or centralized processing by specialized waste‑recycling firms, this machine delivers stable, efficient granulation solutions, transforming discarded nonwovens into reusable recycled granules and promoting resource circularity.

Solutions to Industry Pain Points

1. Solves feeding challenges: Addressing the issue of fluffy nonwoven materials easily causing bridging, slippage, and significant production fluctuations, the machine’s densifier–pellet feeding system compacts fluffy materials into high‑density pellets, ensuring uniform, stable feeding and completely resolving production variability.
2. Improves recycled material quality: To counteract severe fiber degradation caused by traditional high‑temperature processing, the machine adopts a low‑temperature, precision temperature‑controlled extrusion process, preventing high‑temperature damage to fibers. The resulting granules maintain a performance retention rate of ≥80%, greatly enhancing the quality of recycled materials.
3. Reduces waste disposal costs: Tackling the problem of high disposal costs and resource waste associated with burning or landfilling production scraps, the machine enables 100% recycling and granulation of waste, turning it into usable recycled raw materials. This not only eliminates hefty waste‑disposal fees but also substitutes part of virgin raw materials, lowering procurement costs for businesses.

Frequently Asked Questions (FAQ)

Q1: What types of materials can this needle‑punched nonwoven granulator process?
A: The machine is compatible with various PP/PET nonwovens and meltblown fabric waste, including PP spunbond nonwovens, PET needle‑punched nonwovens, meltblown fabric scraps, geotextile waste, sanitary nonwovens, mask waste, and more.
Q2: Does the machine require pre‑crushing?
A: No, the machine’s built‑in densifier can directly process whole bales of nonwoven edge trimmings, eliminating the need for pre‑crushing and simplifying the production workflow.
Q3: What is the quality of the finished recycled granules?
A: Using a low‑temperature, precision temperature‑controlled extrusion process, the machine achieves a performance retention rate of ≥80% and an impurity content of ≤1%. The granules can be directly reused in low‑end nonwoven products and injection‑molded items.
Q4: What are the delivery and warranty periods?
A: The delivery time is 70–80 working days, and the warranty lasts 13 months from the bill of lading date.
Q5: What is the machine’s capacity range?
A: The standard capacity ranges from 300 to 1500 kg/h, with a maximum daily output of up to 36 tons under 24‑hour operation. Customized models can be tailored to meet specific customer production needs.