PP Woven Bag Recycling and Washing Line

Product Overview

The PP woven bag recycling and washing line is an integrated processing system specially designed for various types of PP packaging waste, such as PP woven bags and ton bags. It combines crushing, deinking, sand removal, washing, and dewatering processes into a single workflow, effectively removing surface printing inks, cement clumps, paper labels, laminated adhesive layers, and other contaminants. The final output is high-purity PP shredded material that meets cleanliness standards and can seamlessly connect to downstream pelletizing operations. The equipment can be customized according to customer production requirements, offering broad processing capacity, high impurity removal rates, water conservation, and environmental friendliness—making it an essential supporting system for recycling enterprises, packaging plants, and recycled pellet manufacturers.

Technical Principles and Process Flow

In response to the characteristics of PP woven bags—high ink adhesion, high sand content, and laminated surfaces—the washing line employs a closed-loop process featuring “shredding + intensive friction deinking + flotation separation + multi-stage rinsing + squeezing.” This ensures that the material’s cleanliness meets pelletizing requirements. The specific process flow is as follows:
1. Whole-Bag Shredding: Bundles or individual PP woven bags and ton bags are fed by a feeder into a twin-shaft shredder, where they are coarsely shredded into 5–10 cm pieces, breaking up tightly woven structures while releasing embedded heavy impurities such as sand and cement clumps, thus laying the groundwork for subsequent washing stages.
2. Intensive Friction Deinking and Washing: The shredded material enters a horizontal high-speed friction washer, where rapidly rotating wear-resistant blades cause intense collisions and self-friction, aided by immersion in ambient-temperature or heated wash water, effectively stripping away stubborn surface contaminants like printing inks, residual cement, and laminated adhesive layers. For heavily soiled materials, a custom 80–95°C hot-washing module can be added, paired with eco-friendly detergents, to achieve deep treatment of severe ink and adhesive residues. Removed ink and fine sand are discharged through the equipment’s screening system along with wastewater.
3. Flotation Separation and Impurity Removal: After friction washing, the material flows into a flotation rinse tank, leveraging density differences among impurities: paper labels, plastic laminates, and light debris—having lower densities than water—float to the surface and are discharged via overflow; heavier sand, metal fragments, and other dense impurities settle at the bottom and can be periodically removed. A spiral mechanism within the tank simultaneously performs preliminary rinsing, further eliminating surface residues and remaining washing agents.
4. Secondary Clean Water Rinsing: Following flotation separation, the material moves to a secondary clean-water tank, where it undergoes additional rinsing in flowing clean water to thoroughly remove residual washing agents and fine particles, significantly enhancing material cleanliness and ensuring product quality in downstream pelletizing stages.
5. Spiral Squeezing and Dewatering: The cleaned material is fed into a spiral squeeze dryer, which physically presses out moisture. The machine’s wear-resistant stainless steel screen simultaneously filters out any remaining fine residue, producing dry material with a moisture content of ≤4%, ready for direct use in pelletizing equipment.
6. Water Recycling System: The production line is equipped with a three-stage sedimentation and filtration system, allowing washed wastewater to be settled and filtered before being reused, dramatically reducing overall water consumption and enabling an environmentally friendly, water-saving production model.

Performance Data

1. Processing Capacity: 600–1,800 kg/h, with customizable configurations tailored to specific customer throughput needs.
2. Ink Removal Rate: ≥92%; for heavily soiled materials, adding a hot-washing module can further enhance removal efficiency.
3. Sand Removal Rate: ≥95%, effectively eliminating sand, cement clumps, and other embedded impurities.
4. Post-Squeeze Moisture Content: ≤4%, meeting the dry-material requirements for direct pelletization.
5. Wash Water Recycling Rate: Over 85%, substantially reducing water usage per ton of processed material.

Core Advantages

1. Outstanding Deinking and Sand Removal Performance: Utilizing a high-speed friction washing process specifically engineered to address the high ink and sand content of PP woven bags, this system deeply removes stubborn contaminants, solving the problem of incomplete impurity removal found in conventional equipment and meeting the demands of heavily soiled woven bags.
2. Customizable Configurations: Customers can tailor the system to their specific contamination levels, incorporating hot-washing units to handle both ordinary and severely contaminated materials, while adjusting production capacity based on throughput needs to suit businesses of varying scales.
3. Long Lifespan of Wear Parts and Low Maintenance Costs: Key components are made from alloy wear-resistant materials, doubling the service life of wear parts and reducing procurement costs by 45%, thereby decreasing downtime for maintenance and lowering long-term operating expenses.
4. Simultaneous Light and Heavy Impurity Separation: By exploiting density differences, the system separates light and heavy impurities concurrently, eliminating the need for additional multi-stage purification equipment, simplifying the process and boosting impurity removal efficiency.
5. Water Recycling System for Conservation and Environmental Protection: Equipped with a three-stage sedimentation and filtration system, the washing water is recycled at a rate exceeding 85%, cutting water consumption per ton by 75% and aligning with eco-friendly production standards while reducing water costs.
6. Seamless Integration with Pelletizing Lines: With a final dry material moisture content of ≤4%, the output can be directly fed into pelletizing equipment without additional dehydration, achieving seamless integration between recycling/washing and pelletizing operations and improving overall production efficiency.

Core Product Value

1. High Impurity Removal Ensures Quality of Recycled Pellets: With a combined ink and sand removal rate exceeding 93%, the system effectively prevents blackening and quality defects caused by residual ink, enhancing the market competitiveness of recycled pellets.
2. Reduced Operating Costs in Pelletizing: Thorough impurity removal lowers the frequency of screen changes during pelletizing by 70%, minimizing downtime and filter wear, thereby increasing production efficiency and reducing consumable costs.
3. Significant Reduction in Energy and Labor Costs: With over 85% of wash water recycled and water consumption per ton reduced by 75%, the system requires only 2–3 operators per line, cutting labor costs by 60% and compressing overall operating expenses.
4. Extended Service Life of Subsequent Equipment: By completely removing sand and other abrasive impurities, the system prevents sand-related wear on pelletizing equipment screws, prolonging equipment lifespan and reducing repair and replacement costs.

Target Customer Groups

PP woven bag recycling companies, cement packaging plants, grain packaging facilities, resource recovery centers, large-scale PP recycled pellet factories, and any manufacturing enterprise requiring treatment of PP packaging waste.

Application Scenarios

This equipment is suitable for pre-treating all types of contaminated PP woven waste, including cement woven bags, laminated ton bags, grain woven bags, bulk space bags, snake-skin mesh bags, and more. Configurations can be adjusted according to different levels of contamination, ensuring that the resulting clean shredded material meets the requirements of downstream pelletizing operations and helping enterprises achieve resource-based recycling and reuse of PP packaging waste.

Solutions to Industry Pain Points

1. Addressing Severe Sand Contamination Causing Screw Wear: Through shredding to release embedded sand, followed by flotation separation to thoroughly remove heavy sand impurities, the system prevents sand from entering pelletizing equipment and causing screw wear, thereby extending equipment lifespan.
2. Solving Blackening and Quality Defects Caused by Residual Ink: Employing an intensive friction deinking process with an ink removal rate of ≥92%, complemented by optional hot-washing modules to further enhance removal efficiency, ensuring the appearance and quality of recycled pellets.
3. Tackling Frequent Screen Clogging and Low Production Efficiency: By deeply removing impurities, the system reduces the likelihood of screen blockages during pelletizing, cutting screen-change frequency by 70% and increasing continuous operation time and production efficiency of pelletizing lines.
4. Mitigating the Drawbacks of Manual Washing—High Water and Labor Consumption, Uncertain Cleanliness: Featuring a fully automated, integrated production line that requires only 2–3 operators per shift, significantly reducing labor input; meanwhile, multi-stage washing and impurity removal processes ensure stable compliance with cleanliness standards, while the accompanying water-recycling system drastically cuts water usage, resolving many issues associated with manual washing.

Common Questions (FAQ)

Q1: What types of materials can this PP woven bag recycling and washing line process?
A: Designed specifically for PP woven bags, the equipment handles cement woven bags, laminated ton bags, grain woven bags, bulk space bags, snake-skin mesh bags, and other contaminated PP woven wastes. Customized hot-washing modules can be added to suit different degrees of contamination.
Q2: What is the equipment’s processing capacity range? Can it be customized?
A: The standard processing capacity ranges from 600 to 1,800 kg/h, but the production line configuration can be tailored to meet specific customer throughput needs, accommodating businesses of varying sizes.
Q3: How effective is the equipment at removing impurities?
A: The equipment achieves an ink removal rate of ≥92%, a sand removal rate of ≥95%, and a combined ink-and-sand removal rate exceeding 93%, effectively guaranteeing the cleanliness of the output material and meeting downstream pelletizing requirements.
Q4: How does the equipment conserve water?
A: Equipped with a three-stage sedimentation and filtration system, the production line recycles over 85% of wash water, reducing water consumption per ton by 75% and significantly lowering production water costs, aligning with eco-friendly production standards.
Q5: Can the equipment directly interface with downstream pelletizing lines?
A: Yes, the final dry material produced has a moisture content of ≤4%, requiring no additional dehydration and able to be fed directly into pelletizing equipment, achieving seamless integration between recycling/washing and pelletizing operations.