Grain Woven Bag Washing Line

Product Overview

The grain woven bag washing line is an integrated production line designed specifically for PP woven bags and ton bags, featuring crushing, deinking, sand removal, and washing functions. It can thoroughly remove various impurities such as ink, cement clumps, and labels from the surface of woven bags, ultimately producing clean shredded material that seamlessly connects to subsequent pelletizing processes. This equipment supports customization based on customer production requirements, delivering outstanding performance in vigorous friction-based deinking and sand removal. It handles standard soiled woven bags and, with optional hot-washing units, can also process heavily contaminated materials. Equipped with a water circulation system, it balances washing effectiveness with environmental protection and energy efficiency, making it a core auxiliary device in the field of recycled plastic processing.

Technical Principle and Process Flow

In response to the characteristics of woven bags—high ink content, significant sand presence, and laminated surfaces—the grain woven bag washing line employs a comprehensive process comprising “shredding + vigorous friction deinking + flotation separation + multi-stage rinsing + dewatering,” enabling end-to-end treatment from whole bags to clean, dry material:

1. Whole-Bag Shredding Stage: 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. This not only breaks down the woven structure but also releases heavy impurities like embedded sand and cement clumps, laying the groundwork for subsequent washing stages.

2. Vigorous 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. Combined with room-temperature or heated wash water, this process powerfully strips away surface printing ink, residual cement, and laminating adhesive layers. Detached ink and fine sand are discharged through screens along with wastewater. For heavily inked or laminated materials, an optional 80–95°C hot-washing module can be added, using eco-friendly detergents for deep treatment to ensure complete removal of contaminants.

3. Flotation Separation and Impurity Removal: After friction washing, the material flows into a flotation rinse tank, leveraging differences in impurity density to achieve separation. Lightweight paper labels, plastic laminates, and light residues 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. Within the tank, a screw conveyor performs preliminary rinsing, further eliminating surface residue.

4. Secondary Clean Water Rinsing: Following flotation separation, the material moves to a secondary clean-water tank, where it undergoes another thorough rinse in fresh water to remove residual washing agents and fine particles, further enhancing cleanliness and ensuring raw material quality for downstream pelletizing.

5. Spiral Dewatering: The cleaned material is then fed into a spiral dewatering machine, which physically squeezes out moisture. Simultaneously, a wear-resistant stainless steel screen filters out remaining fine debris, yielding ultra-low-moisture, clean dry material ready for direct feeding into pelletizing equipment.

6. Water Circulation Support System: The production line is equipped with a three-stage sedimentation tank and filtration system. Wash water, after settling and filtration, is recycled and reused, significantly reducing water consumption during production—conserving resources while minimizing wastewater discharge, thus meeting environmentally friendly production standards.

Performance Data

1. Processing Capacity: 600–1800 kg/h
2. Ink Removal Rate: ≥92%
3. Sand Removal Rate: ≥95%
4. Moisture Content After Dewatering: ≤4%

Core Advantages

1. Outstanding Deinking and Sand Removal Performance: Utilizing a high-speed friction washing process, it efficiently removes surface ink, residual cement, and embedded sand, achieving ideal washing results even for heavily soiled woven bags, ensuring that the resulting shredded material meets pelletizing quality standards.

2. Customizable Hot-Washing Unit: The line supports optional 80–95°C hot-washing modules, allowing flexible adjustment of the washing process according to material contamination levels, effectively addressing both ordinary soiled materials and those heavily stained with ink or laminated, broadening its applicability.

3. Long Lifespan of Wear-Resistant Components: Key parts of the equipment are crafted from wear-resistant materials—for example, the friction washer’s blades are made of alloy wear-resistant material, doubling their service life compared to standard blades, while reducing consumable costs by 45%, significantly lowering maintenance expenses and downtime.

4. Simultaneous Flotation Separation of Light and Heavy Impurities: By leveraging the density-based separation principle of the flotation rinse tank, it simultaneously removes lightweight labels and laminates as well as heavy sand and metal fragments, eliminating the need for additional separate impurity-removal equipment, simplifying the process flow and boosting processing efficiency.

5. Water-Circulation System Saves Water and Protects the Environment: The accompanying three-stage sedimentation and filtration system enables recycling of wash water, achieving a reuse rate exceeding 85% and reducing water consumption per ton by 75%, thereby cutting production water costs and aligning with green manufacturing policies.

6. Seamless Integration with Pelletizing Lines: With a final dry material moisture content of ≤4%, it can be directly fed into pelletizing equipment without additional dehydration or pre-processing steps, realizing seamless integration between washing and pelletizing and enhancing overall production efficiency.

Core Product Value

1. Enhances Quality of Recycled Pellets: With a combined ink and sand removal rate exceeding 93%, it effectively resolves issues of blackened pellets caused by ink residue and poor product appearance, producing uniformly colored, low-impurity recycled pellets suitable for manufacturing higher-quality plastic products.

2. Reduces Losses in Pelletizing Production: The high cleanliness of washed material lowers the frequency of screen changes in the pelletizing stage by 70%, decreasing raw material loss and downtime during screen replacement, improving continuous operation efficiency and reducing overall production costs.

3. Significantly Cuts Production Costs: Alloy wear-resistant blades double the service life, reducing consumable costs by 45%; with a water-recycling rate exceeding 85% and a 75% reduction in water usage per ton, labor costs drop by 60%—cutting expenses across equipment wear, water use, and manpower.

4. Meets Environmental Protection Standards: The water-circulation system minimizes wastewater discharge, complying with environmental regulations, helping companies avoid compliance risks while enhancing their green production image.

Target Customer Base

The target customers for the grain woven bag washing line include various enterprises involved in recycled plastic recovery and processing—such as woven bag recycling firms, cement and grain packaging plants, resource recycling centers, and large-scale PP recycled pellet factories—all of which generate substantial quantities of used woven bags and have stringent requirements for the quality and efficiency of recycled raw materials.

Application Scenarios

This equipment is suitable for pre-treating all types of soiled woven waste, including cement woven bags, laminated ton bags, grain woven bags, bulk space bags, snake-skin mesh bags, and more. Whether industrial packaging containing embedded sand or cement clumps, or food packaging bearing printed ink, this production line can deliver efficient washing, providing high-quality raw materials for subsequent pelletizing processes.

Solutions to Industry Pain Points

1. Solves the Problem of Sand Embedded in Woven Bags Causing Screw Wear: The line’s whole-bag shredding step releases internal sand, while the subsequent flotation separation completely removes heavy sand, ensuring that materials entering the pelletizing equipment are free of hard impurities, greatly reducing screw wear and extending the lifespan of pelletizing machinery.

2. Addresses Blackened Recycled Pellets Caused by Ink Residue: The powerful friction deinking process, combined with an optional hot-washing module, achieves an ink removal rate of ≥92%, effectively stripping away surface printing ink and preventing residual ink from affecting pellet color and quality, resulting in uniformly colored, low-impurity pellets.

3. Tackles Frequent Screen Clogging and Replacement During Pelletizing: Through multi-stage washing and impurity removal, material cleanliness is significantly improved, substantially reducing impurity content in the pelletizing stage, cutting screen-change frequency by 70% and shortening downtime for screen replacements, thereby enhancing continuous operation efficiency of pelletizing lines.

4. Alleviates Issues of High Labor Costs, Water Consumption, and Insufficient Cleanliness in Manual Washing: The production line automates the entire washing process, requiring only 2–3 operators per line, dramatically reducing labor costs compared to manual washing. Meanwhile, the water-circulation system drastically cuts water usage, while maintaining stable washing performance and far surpassing manual methods in terms of cleanliness, ensuring consistent quality of recycled raw materials.

Frequently Asked Questions (FAQ)

Q1: What is the processing capacity range of the grain woven bag washing line?
A: The line’s processing capacity ranges from 600 to 1800 kg/h, customizable according to customer production needs to meet the demands of businesses of varying scales.

Q2: Can the line handle laminated ton bags?
A: Yes. To address the characteristics of laminated ton bags, the line offers an optional 80–95°C hot-washing module, supplemented by eco-friendly detergents for deep treatment, effectively removing laminating adhesive layers and ensuring material cleanliness meets required standards.

Q3: What is the water-recycling rate of the line?
A: Equipped with a three-stage sedimentation tank and filtration system, the line achieves a wash-water recycling rate exceeding 85%, reducing water consumption per ton by 75%, significantly conserving resources and cutting production water costs.

Q4: What is the moisture content of washed material? Can it be directly fed into pelletizing?
A: After dewatering by the spiral dewatering machine, the material’s moisture content drops to ≤4%, making it suitable for direct feeding into pelletizing equipment without additional dehydration steps, thus achieving seamless integration between washing and pelletizing.

Q5: How long do the line’s consumable parts last? Are maintenance costs high?
A: Key consumable parts, such as the friction washer blades, are made of alloy wear-resistant material, doubling their service life and reducing consumable costs by 45%, significantly lowering maintenance expenses and downtime.