Hygiene Nonwoven Waste Granulator

Product Overview

The hygiene nonwoven waste granulator is a specialized granulation machine designed specifically for nonwoven recycling. It features a compacting and agglomeration feeding system that 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. It is suitable for recycling various types of nonwoven and meltblown fabric waste, including PP and PET, and can directly process whole bundles of nonwoven edge trimmings, eliminating the need for pre‑crushing. This enables efficient recovery and reuse of waste materials, helping companies reduce disposal costs and improve resource utilization.

Technical Principle

This equipment utilizes an integrated compacting unit combined with a single-screw extrusion process, featuring a dedicated treatment workflow tailored to the characteristics of fluffy nonwoven waste. First, the fluffy nonwoven waste is fed directly into the compactor chamber, where high-speed rotating blades shear and crush the material. Frictional heat generated during this process causes the material to self‑heat and contract, forming uniform agglomerates with a bulk density increased by 3–4 times. These agglomerates are then smoothly fed into the extrusion screw. In the extrusion stage, a low‑temperature, precisely controlled extrusion process is employed, strictly regulating processing temperatures to prevent 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 completes the final shaping, ensuring both the performance and purity of the finished pellets.

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: the compactor directly processes whole bundles of nonwoven edge trimmings
5. Pellet performance retention rate: ≥80%
6. Impurity content in pellets: ≤1%
7. Screw and barrel material: 38CrMoAlA, bimetallic alloy, nitrogen‑treated
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‑cutting 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

Core Advantages

1. Stable feeding without clogging: Equipped with a compacting and agglomeration feeding system, the machine ensures smooth, consistent feeding without bridging or slippage, effectively avoiding production fluctuations caused by conventional feeding methods and guaranteeing continuous operation.
2. Eliminates pre‑crushing step: The compactor can directly process entire bundles of nonwoven edge trimmings, removing the need for additional crushing equipment, simplifying the production process and saving on equipment investment and workshop space.
3. Low‑temperature process preserves material properties: By employing a low‑temperature, precisely controlled extrusion process, the machine minimizes fiber degradation at high temperatures, achieving a pellet performance retention rate of ≥80% and ensuring the value of recycled materials.
4. Compact structure and easy operation: With a streamlined design and minimal footprint, the equipment features simple operating procedures, reducing facility investment and personnel training costs.
5. High precision in impurity control: Following filtration, the finished pellets contain ≤1% impurities, ensuring the purity of recycled materials and meeting subsequent production quality requirements.

Core Product Value

1. Guaranteed high productivity: With a standard capacity ranging from 300 to 1500 kg/h, the machine can produce up to 36 tons of recycled pellets per day over a 24‑hour shift, fully meeting the needs of large‑scale waste recycling operations.
2. Significant cost reduction: Edge trimmings can be 100% reused on‑site, saving hundreds of thousands of yuan annually in waste disposal costs; recycled materials can be directly reintegrated into the production of lower‑grade nonwovens and injection‑molded products, cutting raw material costs by 25% and substantially lowering overall production and operating expenses.
3. Enhanced resource utilization: Transforming nonwoven waste—previously destined only for incineration or landfill—into reusable granular feedstock reduces resource wastage and supports environmentally friendly manufacturing practices.
4. Customizable adaptation: As a tailor‑made product, it can be precisely configured to meet specific production volumes and processing requirements, perfectly aligning with each company’s scale and operational needs.

Target Customer Groups

Nonwoven fabric manufacturers, mask production facilities, geotextile companies, hygiene product factories, and textile waste recycling enterprises—all generate substantial quantities of nonwoven edge trimmings or waste daily and have an urgent need for effective recycling and reuse. This equipment helps these businesses achieve resource circularity while reducing production costs.

Application Scenarios

This equipment is suitable for recycling and granulating various types of nonwoven waste, including PP spunbond nonwovens, PET needle‑punched nonwovens, meltblown fabric edge trimmings, geotextile waste, hygiene nonwovens, and mask waste. It enables on‑site processing of waste within enterprise premises, converting discarded materials into reusable recycled pellets for use in producing lower‑grade nonwovens, injection‑molded products, and other applications.

Solutions to Industry Pain Points

1. Solving the challenge of feeding fluffy materials: Addressing the issues of bridging, slippage, and unstable output commonly encountered when handling fluffy nonwovens, the machine’s compacting and agglomeration feeding system compresses fluffy materials into uniform pellets, increasing bulk density by 3–4 times and ensuring smooth, stable feeding to maintain consistent production.
2. Improving poor performance of recycled materials: Conventional high‑temperature processing often leads to severe fiber degradation and inferior recycled material quality. This equipment adopts a low‑temperature, precision temperature‑controlled extrusion process, preventing high‑temperature degradation and achieving a pellet performance retention rate of ≥80%, thereby enhancing the usability of recycled materials.
3. Reducing waste disposal costs: Traditionally, nonwoven fabric edge trimmings could only be disposed of through incineration or landfill, resulting in high disposal expenses and significant resource waste. This equipment enables 100% on‑site reuse of waste, saving tens of thousands of yuan annually in disposal costs while transforming waste into usable raw materials and minimizing resource consumption.

Frequently Asked Questions (FAQ)

Q1: What types of materials can this granulator process?
A: The equipment is compatible with various PP/PET nonwovens and meltblown fabric waste, including PP spunbond nonwovens, PET needle‑punched nonwovens, meltblown fabric edge trimmings, geotextile waste, hygiene nonwovens, mask waste, and more.
Q2: Does the equipment require a pre‑crushing step?
A: No, the built‑in compactor can directly process whole bundles of nonwoven edge trimmings, eliminating the need for pre‑crushing and simplifying the production process.
Q3: What is the performance of the finished pellets?
A: Thanks to the low‑temperature, precision temperature‑controlled extrusion process, the finished pellets maintain a performance retention rate of ≥80% and have an impurity content of ≤1%, making them suitable for direct reuse in producing lower‑grade nonwovens and injection‑molded products.
Q4: What are the delivery and warranty periods?
A: Delivery takes 70–80 working days, and the warranty lasts 13 months from the bill of lading date.
Q5: Can the equipment be customized according to enterprise needs?
A: Yes, this is a custom‑made product with no fixed price. It can be tailored to meet specific production volume requirements, precisely matching each company’s scale and operational needs.