Big Bag Crushing and Washing Line

Product Overview

The big bag crushing and washing line is an integrated production line specially designed for PP woven bags and big bags, combining crushing, de-inking, sand removal, and washing. It can thoroughly remove various contaminants such as ink, cement clumps, and label residues from the material surface, producing clean shredded material that seamlessly connects to subsequent pelletizing processes. As a customized product, this line has no fixed price; it is tailor-made according to the customer’s production capacity requirements and can flexibly adapt to different scales of recycled plastic processing scenarios.

Technical Principles and Process Flow

In response to the characteristics of woven bags—high ink content, high sand content, and laminated surfaces—the line employs a complete process of “shredding + intensive friction de-inking + flotation separation + multi-stage rinsing + dewatering,” with each stage closely coordinated to achieve efficient and thorough washing of contaminated woven waste:
1. Whole-Bag Shredding Stage: Bundles or individual big bags are fed by a feeder into a twin-shaft shredder, where they are coarsely shredded into 5–10 cm pieces, breaking up the originally tight weave structure while releasing heavy impurities such as embedded sand and cement clumps, thus preparing the material for the next washing stage.
2. Intensive Friction De-inking and Washing: The shredded material enters a horizontal intensive friction washer, where high-speed wear-resistant blades cause vigorous collisions and self-friction between particles. Combined with room-temperature or heated wash water, this process powerfully removes stubborn contaminants like printing ink, cement residue, and laminating adhesive layers from the material surface. Released ink and fine sand are discharged through a screen along with wastewater, completing preliminary contamination separation. For materials with severe ink or laminating adhesive issues, an optional 80–95°C hot-washing module can be added, using eco-friendly detergents for deep treatment to ensure maximum contaminant removal.
3. Flotation Separation and Impurity Removal: After friction washing, the material flows into a flotation rinse tank. Leveraging differences in specific gravity, lightweight impurities such as paper labels, plastic laminates, and light debris float to the surface and are discharged via overflow outlets, while heavier sand and metal fragments settle at the bottom and can be periodically removed. Inside the tank, a screw conveyor simultaneously performs primary rinsing, further reducing residual surface contaminants.
4. Secondary Clean Water Rinsing: The material then enters a secondary clean-water tank, where it undergoes a second rinse in flowing clean water to remove residual washing agents and fine particulates, further enhancing cleanliness and ensuring the quality of pellets produced later.
5. Spiral Dewatering: The cleaned material is fed into a spiral dewatering machine, where physical squeezing achieves dehydration. At the same time, a wear-resistant stainless steel screen filters out any remaining fine residue, yielding dry material with low moisture content that directly meets the feed requirements of pelletizing operations.
6. Water Recycling Treatment: The production line is equipped with a three-stage sedimentation tank and filtration system. Wastewater generated during the washing process is settled and filtered before being recycled, significantly reducing water consumption and meeting environmentally friendly production standards.

Core Performance Parameters

1. Processing Capacity: 600–1800 kg/h, customizable based on actual customer production needs
2. Ink Removal Rate: ≥92%, effectively stripping printing ink from woven bag surfaces and preventing blackening of recycled pellets
3. Sand and Mud Removal Rate: ≥95%, completely eliminating embedded sand, cement clumps, and other impurities
4. Moisture Content After Dewatering: ≤4%, allowing the dried material to be directly fed into pelletizing without additional drying

Key Product Advantages

1. Outstanding De-inking and Sand Removal Performance: Designed specifically to handle woven bags with high sand and ink content, this line combines intensive friction with flotation separation to efficiently treat heavily contaminated bags, ensuring material cleanliness meets pelletizing requirements.
2. Strong Customization Capability: With an optional hot-washing unit, the line can handle both standard contaminated woven bags and more challenging materials with severe ink or laminating adhesive issues, meeting diverse customer needs.
3. Long Lifespan of Wear-Resistant Components: Key parts are made from wear-resistant materials; alloy wear-resistant blades last twice as long as conventional products, while component costs are reduced by 45%, significantly lowering long-term maintenance expenses.
4. Simultaneous Removal of Light and Heavy Impurities: Using flotation separation, both floating light impurities and settled heavy impurities are removed concurrently, eliminating the need for separate de-impurity steps and boosting overall production efficiency.
5. Water Recycling System Saves Water and Protects the Environment: Equipped with a three-stage sedimentation and filtration system, the line achieves over 85% water recycling, reducing water consumption per ton by 75%, thereby cutting production water costs and complying with eco-friendly production standards.
6. Seamless Integration with Pelletizing Lines: The clean, dry material produced can be directly fed into pelletizing equipment without intermediate transfer or secondary processing, achieving seamless connection between crushing/washing and pelletizing and improving the overall continuity of the production process.

Core Value of the Product

1. Efficient and Thorough washing: With a combined ink and sand removal rate exceeding 93%, this line effectively addresses issues like blackened recycled pellets and poor product quality, enhancing the overall quality of recycled plastics.
2. Cost Reduction and Efficiency Gains: In the pelletizing stage, mesh-changing frequency is reduced by 70%, minimizing downtime and increasing production efficiency; alloy wear-resistant blades last twice as long, cutting component costs by 45% and lowering equipment maintenance expenses.
3. Energy and Resource Conservation: With over 85% water recycling and a 75% reduction in water consumption per ton, production water costs are significantly lowered, while labor costs drop by 60% thanks to the line’s minimal staffing requirements, reducing manpower input.
4. Customized Adaptability: Tailored to meet specific customer production needs, the line also offers an optional hot-washing module, accommodating varying degrees of contamination in woven bag materials and serving diverse scales and requirements of recycled plastic processing.

Target Customer Groups

The target customer base for the big bag crushing and washing line includes various enterprises involved in recycled plastic processing, such as woven bag recycling companies, cement/grain packaging plants, recycling resource centers, and large-scale PP pellet factories. These businesses all face substantial amounts of woven bag waste that require effective treatment, and this production line helps them achieve efficient recovery and reuse, enhancing both economic and environmental benefits.

Application Scenarios

This production line is suitable for pre-treating various types of contaminated woven waste, including cement-woven bags, laminated big bags, grain-woven bags, bulk space bags, and snake-skin mesh bags. Whether industrial packaging woven bags contain cement clumps or sand, or food packaging woven bags bear printing ink or laminates, this line can effectively clean them, transforming them into clean shredded material ready for pelletizing.

Solving Industry Pain Points

1. Addressing Severe Sand Contamination Causing Screw Wear: Through whole-bag shredding and flotation separation, heavy impurities such as sand and cement clumps are thoroughly removed, preventing these hard particles from entering pelletizing equipment and causing screw wear, thereby extending the service life of pelletizing machinery.
2. Solving Blackened Recycled Pellets and Poor Quality Caused by Ink Residue: With intensive friction de-inking, the ink removal rate reaches ≥92%, effectively stripping printing ink from woven bag surfaces and ensuring uniform color in recycled pellets, thus improving product quality.
3. Reducing Frequent Mesh Changes and Low Production Efficiency Caused by Dirty Material: After processing by this line, material cleanliness is greatly improved, reducing mesh-changing frequency in the pelletizing stage by 70% and shortening downtime for mesh changes, thereby boosting overall production efficiency.
4. Alleviating Labor-Intensive Manual washing and Unreliable Cleanliness: This line automates the entire washing process, requiring only 2–3 operators per shift, dramatically reducing manpower compared to manual washing; meanwhile, its water-recycling system saves water and ensures stable washing results, effectively guaranteeing material cleanliness.

Common Questions FAQ

Q1: What is the processing capacity range of the big bag crushing and washing line?
A: The line’s processing capacity ranges from 600 to 1800 kg/h, and as a customized product, it can also be adjusted according to the customer’s actual production needs.
Q2: Can the line handle woven bags with severe ink and laminating adhesive?
A: Yes, the line can be equipped with an optional 80–95°C hot-washing module and eco-friendly detergents to deeply treat woven bags containing heavy ink or laminating adhesive, ensuring effective contaminant removal.
Q3: What is the water-recycling rate of the line?
A: The line is fitted with a three-stage sedimentation and filtration system, achieving a water-recycling rate of over 85%, reducing water consumption per ton by 75%, making it highly water-efficient and environmentally friendly.
Q4: Can the produced material be directly fed into the pelletizing stage?
A: Yes, after spiral dewatering, the material’s moisture content is ≤4%, qualifying it as clean, dry material that can seamlessly connect to subsequent pelletizing lines without additional drying.
Q5: How long do the line’s wear-resistant components last?
A: Key wear-resistant components, such as alloy wear-resistant blades, have a lifespan twice as long as conventional products, while component costs are reduced by 45%, effectively lowering long-term equipment maintenance expenses.