Cement Woven Bag Washing Production Line

Product Overview

The cement woven bag washing production line is an integrated crushing–deinking–desanding–washing system specifically designed for PP woven bags and ton bags. It can thoroughly remove various impurities such as ink, cement clumps, and labels from the surface of woven bags, producing clean shredded material that seamlessly connects to subsequent pelletizing processes. This production line offers a processing capacity ranging from 600 to 1800 kg/h, with an ink removal rate of ≥92%, a sand removal rate of ≥95%, and a moisture content of ≤4% after squeezing. It can be customized according to customer production requirements and supports optional hot-washing units, meeting the washing needs of both lightly soiled and heavily soiled materials. It is a core auxiliary equipment for woven bag recycling and processing.

Technical Principles and Process Flow

In response to the characteristics of woven bags—high ink content, high sand content, and laminated surfaces—the production line employs a complete process comprising “shredding + intensive friction deinking + flotation separation + multi-stage rinsing + squeezing.” Each step is closely linked, ensuring efficient washing of soiled woven bags:

1. Whole-Bag Shredding: Bundles or individual 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 apart the originally tight weave structure while releasing embedded sand, cement clumps, and other contaminants, thus laying the groundwork for subsequent washing stages.

2. Intensive Friction Deinking and Washing: The shredded material enters a horizontal intensive friction washer, where high-speed wear-resistant blades cause vigorous collisions and self-friction. Combined with room-temperature or heated wash water, this process powerfully strips away surface printing ink, residual cement, and laminating adhesive layers. The detached ink and fine sand are discharged through the equipment’s screen along with wastewater. For materials with heavy ink and laminating adhesives, an optional hot-washing module operating at 80–95°C can be added, using environmentally friendly detergents to achieve even deeper washing.

3. Flotation Separation and Impurity Removal: After deinking, the material flows into a flotation washing tank. Lightweight impurities such as paper labels, plastic laminates, and light debris float to the surface and are discharged through the overflow outlet, while heavier sand and metal fragments settle at the bottom and can be periodically removed. Inside the tank, a screw conveyor performs preliminary rinsing, further eliminating surface residues.

4. Secondary Clean Water Rinsing: Following flotation separation, the material enters a secondary clean-water tank, where residual washing agents and fine particles are further removed in a clean-water environment, significantly enhancing the material’s cleanliness and ensuring that the produced shredded material meets the quality standards required for subsequent pelletizing.

5. Spiral Squeezing and Dewatering: The cleaned material is fed into a spiral squeezing machine, which physically presses out moisture. The machine’s wear-resistant stainless-steel screen simultaneously filters out any remaining fine residue, ultimately yielding dry material with a moisture content of ≤4%, ready to be directly fed into pelletizing equipment for processing.

6. Water Recycling Treatment: The production line is equipped with a three-stage sedimentation tank and filtration system. Washed wastewater undergoes sedimentation and filtration before being recycled, effectively reducing water consumption during production and complying with eco-friendly manufacturing standards.

Core Performance Parameters

1. Processing Capacity: 600–1800 kg/h
2. Ink Removal Rate: ≥92%
3. Sand Removal Rate: ≥95%
4. Moisture Content After Squeezing: ≤4%
5. Optional Hot-Washing Module Temperature: 80–95°C
6. Wash Water Recycling Rate: Over 85%

Key Product Advantages

1. Outstanding Deinking and Desanding Performance: Utilizing a high-speed intensive friction washing process, it delivers excellent results against heavy ink, cement clumps, and sand impurities on woven bags, achieving an ink removal rate of ≥92% and a sand removal rate of ≥95%, effectively resolving issues of incomplete washing for soiled woven bags.

2. Customizable Hot-Washing Unit: Supports optional hot-washing modules operating at 80–95°C, combined with eco-friendly detergents, enabling deep treatment of woven bag materials with heavy ink and laminating adhesives, catering to both lightly soiled and heavily soiled materials, and adapting to different types of recyclable waste.

3. Long Lifespan of Wear-Resistant Components: The wear-resistant blades used in the equipment are made of alloy materials, doubling their service life compared to conventional parts, while reducing the cost of consumables by 45%, significantly lowering daily maintenance expenses and minimizing production downtime.

4. Simultaneous Flotation Separation and Impurity Removal: The flotation washing tank enables simultaneous removal of light and heavy impurities, with lightweight labels and laminates exiting through one outlet and heavier sand and metal fragments through another, eliminating the need for additional sorting steps, thereby improving washing efficiency while ensuring material purity.

5. Water Recycling System Saves Water and Protects the Environment: Equipped with a three-stage sedimentation tank and filtration system, the production line achieves a wash water recycling rate of over 85%, reducing water consumption per ton of material by 75%. This not only lowers production water costs but also complies with eco-friendly manufacturing standards, reducing wastewater discharge.

6. Seamless Integration with Pelletizing Lines: The final dry material has a moisture content of ≤4%, making it ready to be directly fed into pelletizing equipment without additional dehydration or preprocessing steps, achieving seamless integration between washing and pelletizing and boosting overall production efficiency.

Core Value of the Product

1. Enhances the Quality of Recycled Pellets: With a comprehensive ink and sand removal rate exceeding 93%, it effectively prevents blackening and quality defects caused by ink residues, resulting in higher-quality recycled pellets suitable for more high-end applications.

2. Reduces Losses in Pelletizing Production: The cleaned material significantly reduces wear on pelletizing screws caused by sand and debris, while also cutting the frequency of screen changes by 70%, thereby decreasing material loss during screen replacement and improving pelletizing efficiency.

3. Lowers Overall Production Costs: The alloy wear-resistant blades double the service life of components, reducing consumable costs by 45%; the wash water recycling rate exceeds 85%, cutting water consumption per ton by 75%; and with only 2–3 operators needed per line, labor costs drop by 60%, comprehensively reducing production costs across equipment wear, water usage, and labor.

4. Ensures Eco-Friendly Compliance: The water recycling system dramatically reduces wastewater discharge, meeting environmental standards and helping companies avoid compliance risks while achieving sustainable recycling operations.

Target Customer Groups

This production line primarily serves customers such as woven bag recycling enterprises, cement/grain packaging plants, recycling centers, and large-scale PP recycled pellet factories, providing them with efficient, environmentally friendly solutions for washing woven bag waste and helping businesses improve the efficiency and quality of their recycling operations.

Application Scenarios

This production line is suitable for pre-treating various types of soiled woven waste, including cement woven bags, laminated ton bags, grain woven bags, bulk space bags, and snake-skin mesh bags. Whether the material carries heavy ink, cement clumps, or contains sand and label impurities, it can achieve efficient washing, providing high-quality raw materials for subsequent pelletizing production.

Solving Industry Pain Points

1. Addresses the issue of severe screw wear caused by sand embedded in woven bags: By releasing internal sand through whole-bag shredding and then thoroughly removing heavy impurities via flotation separation, the likelihood of sand entering the pelletizing stage is greatly reduced, lessening screw wear and extending equipment lifespan.

2. Solves the problem of blackened and substandard recycled pellets caused by ink residues: Using an intensive friction deinking process, combined with an optional hot-washing module, the ink removal rate reaches ≥92%, effectively clearing surface ink residues and improving the appearance and quality of recycled pellets.

3. Tackles frequent screen clogging and low production efficiency caused by dirty materials: With highly purified material after washing and extremely low impurity levels, the frequency of screen changes in the pelletizing stage drops by 70%, reducing downtime for screen replacements and boosting overall production efficiency.

4. Resolves the challenges of manual washing—high water and labor consumption, coupled with uncertain cleanliness: The production line achieves fully automated washing, requiring only 2–3 operators per line, significantly reducing labor input; meanwhile, its multi-stage washing process ensures material cleanliness, with a wash water recycling rate exceeding 85%, addressing the pain points of excessive water use and unstable cleanliness associated with manual washing.

Frequently Asked Questions (FAQ)

Q1: What types of woven bags can this production line handle?
A: This production line is suitable for cement woven bags, laminated ton bags, grain woven bags, bulk space bags, snake-skin mesh bags, and other types of soiled woven waste. Whether the material carries ink, cement clumps, or contains sand and label impurities, it can achieve effective washing.

Q2: What is the production line’s processing capacity range? Can the capacity be customized?
A: The standard processing capacity of the production line is 600–1800 kg/h, and it also supports customization based on customer production needs. Equipment configuration can be adjusted according to actual production scale to meet diverse capacity requirements.

Q3: Does the production line have special treatment options for heavily ink-stained woven bags?
A: Yes, the production line can be optionally equipped with a hot-washing module operating at 80–95°C, supplemented by eco-friendly detergents, enabling deep treatment of woven bag materials with heavy ink and laminating adhesives, ensuring that ink removal meets standard requirements.

Q4: How does the production line manage water consumption?
A: The production line is equipped with a three-stage sedimentation tank and filtration system, achieving a wash water recycling rate of over 85%, reducing water consumption per ton by 75%, thereby significantly lowering water usage during production and complying with eco-friendly manufacturing standards.

Q5: Can the cleaned material be directly used for pelletizing?
A: Yes, after spiral squeezing and dewatering, the material has a moisture content of ≤4% and high cleanliness with extremely low impurity levels, allowing it to seamlessly connect to subsequent pelletizing lines for direct pelletizing processing.