Deinking and Washing Line for Laminated Woven Bags

Product Overview

The deinking and washing line for laminated woven bags is an integrated pre-processing equipment specially designed for PP woven bags and ton bags. It combines crushing, deinking, sand removal, and washing into a single process, effectively stripping away surface printing ink, internal cement clumps, labels, and other impurities, ultimately producing clean shredded material that can seamlessly connect to the subsequent pelletizing stage. The equipment supports customization based on customer production requirements, with processing capacities ranging from 600 to 1800 kg/h. It accommodates both ordinary heavily soiled woven bags and severely contaminated materials, making it an efficient and environmentally friendly core pre-processing solution in the recycled plastics industry.

Technical Principles and Process Flow

In response to the characteristics of woven bags—high ink content, high sand content, and laminated surfaces—the equipment employs a comprehensive process of “shredding + intensive friction deinking + flotation separation + multi-stage rinsing + dewatering,” with each step closely coordinated to achieve efficient washing:

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. This not only breaks down the original woven structure but also releases embedded sand, gravel, and cement clumps, reducing the burden on subsequent washing stages.

2. Intensive Friction Deinking: 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 removes surface printing ink, residual cement, and laminating adhesive layers. For materials with heavy ink and adhesive contamination, an optional 80–95°C hot-washing module can be used alongside eco-friendly detergents for deep treatment. Removed ink and fine sand are discharged through screens along with wastewater, completing preliminary impurity separation.

3. Flotation Separation: After deinking, the material flows into a flotation washing tank. Leveraging differences in material density, 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 for periodic removal. Within the tank, a screw conveyor performs primary rinsing, further eliminating adhering contaminants.

4. Secondary Clean Water Rinsing: Following flotation separation, the material enters a secondary clean-water tank, where it undergoes a second rinse in flowing clean water to thoroughly remove residual washing agents and fine particles, further enhancing cleanliness and ensuring compliance with quality standards for subsequent pelletization.

5. Spiral Dewatering: The cleaned material is fed into a spiral dewatering machine, where physical squeezing removes excess moisture. Simultaneously, a wear-resistant stainless steel screen filters out remaining fine residues, yielding dry material with a moisture content of ≤4%, ready for direct use in the pelletizing stage.

6. Water Recycling System: The equipment is equipped with a three-stage sedimentation and filtration system. Washed wastewater is treated through sedimentation and filtration before being recycled, significantly reducing water consumption during production and meeting environmental sustainability requirements.

Key Performance Data

1. Processing Capacity: 600–1800 kg/h; models can be customized according to actual customer production needs.
2. Ink Removal Rate: ≥92%, deeply removing printing ink to ensure high-quality recycled material.
3. Sand Removal Rate: ≥95%, completely eliminating sand and cement clumps embedded in woven bags.
4. Moisture Content After Dewatering: ≤4%; dry material can directly feed into pelletizing lines.
5. Water Recycling Rate: Over 85%, dramatically reducing water usage per ton of processed material.

Core Product Advantages

1. Outstanding Deinking and Sand Removal Performance: Utilizing a high-speed intensive friction washing process tailored to the high ink and sand content of woven bags, it effectively removes heavy contamination, addressing the insufficient cleanliness of conventional washing equipment.

2. Strong Customization Capability: Production line scale can be tailored to meet specific customer output requirements, with optional hot-washing units available to handle both ordinary and severely contaminated materials, adapting to diverse recycling scenarios.

3. Long Lifespan of Wear-Resistant Components: Key parts are made from alloy wear-resistant materials, doubling blade life and reducing consumable costs by 45%, significantly lowering maintenance expenses and downtime.

4. Simultaneous Flotation Separation: The flotation washing tank enables simultaneous separation of light and heavy impurities, efficiently removing paper labels, plastic laminates, sand, metal fragments, and other contaminants in one go, boosting washing efficiency and purity.

5. Water Recycling System: Saves water and protects the environment, with a three-stage sedimentation and filtration system achieving over 85% water recycling and reducing water consumption per ton by 75%, cutting production costs while meeting eco-friendly standards.

6. Seamless Integration with Pelletizing Lines: The final dry material has a moisture content of ≤4%, allowing direct connection to downstream pelletizing lines without additional dewatering, enhancing overall process continuity and efficiency.

Core Product Value

1. Enhances Recycled Material Quality: With a combined ink and sand removal rate exceeding 93%, it effectively resolves issues like blackened pellets and poor color consistency, producing clean shredded material suitable for manufacturing high-quality recycled plastic pellets and boosting market competitiveness.

2. Reduces Production Losses: The frequency of screen changes in the pelletizing stage drops by 70%, minimizing raw material waste and downtime during screen replacement, thereby improving pelletizing efficiency and lowering overall production costs.

3. Cuts Operating Costs: Alloy wear-resistant blades double service life, reducing consumable costs by 45%; high water recycling rates cut water usage per ton by 75%; and with only 2–3 operators required per line, labor costs drop by 60%, providing multi-faceted cost reductions for businesses.

4. Ensures Environmentally Compliant Production: The water recycling system drastically reduces water consumption, meeting environmental standards and helping companies avoid regulatory risks while complying with recycling regulations.

Target Customer Groups

This equipment primarily serves woven bag recycling enterprises, cement and grain packaging plants, recycling centers, and large-scale PP recycled pellet factories, offering them efficient and environmentally friendly solutions for washing and recycling woven bags, thereby helping businesses improve the efficiency and quality of their recycled plastic operations.

Application Scenarios

The equipment is suitable for pre-treating heavily soiled woven waste, including cement woven bags, laminated ton bags, grain woven bags, bulk space bags, snake-skin mesh bags, and more. Whether dealing with industrial packaging containing sand and cement or food and grain packaging with printed ink, it delivers efficient washing, providing high-quality clean raw materials for subsequent pelletizing production.

Solving Industry Pain Points

1. Addresses the issue of sand and gravel causing severe wear on granulation screws: By releasing sand through whole-bag shredding and thoroughly removing sand in later stages, the equipment prevents hard impurities from entering the granulation process and damaging granulation machinery, extending equipment lifespan.

2. Improves the problem of blackened pellets and poor color consistency caused by residual ink: The intensive friction deinking process achieves an ink removal rate of ≥92%, effectively enhancing the color and quality of recycled materials to meet the demands of high-quality recycled plastic production.

3. Solves the frequent screen clogging and low production efficiency associated with dirty materials: Clean shredded material significantly reduces impurity blockages during granulation, cutting screen-change frequency by 70% and increasing continuous operating time and production efficiency of granulation lines.

4. Replaces manual washing, addressing issues of high water and labor consumption and unreliable cleanliness: The automated integrated production line requires only 2–3 operators, delivering far higher washing efficiency than manual methods while maintaining stable, controllable cleanliness. Meanwhile, the water recycling system dramatically reduces water usage, saving both manpower and resources.

Frequently Asked Questions (FAQ)

Q1: What is the capacity range of this deinking and washing line for laminated woven bags?
A: The equipment’s processing capacity ranges from 600 to 1800 kg/h, and the production line size can be customized to suit customers’ actual output needs.
Q2: Can the equipment handle severely contaminated woven bags?
A: Yes, the equipment can be optionally equipped with an 80–95°C hot-washing module paired with eco-friendly detergents, enabling deep treatment of heavily inked and laminated contaminated woven bags to ensure effective washing.
Q3: What is the water recycling rate of the equipment?
A: Equipped with a three-stage sedimentation and filtration system, the equipment achieves a water recycling rate of over 85%, reducing water consumption per ton by 75% and significantly cutting production water costs.
Q4: Can the clean shredded material produced directly feed into the pelletizing line?
A: Yes, after spiral dewatering, the material’s moisture content is ≤4%, requiring no additional dehydration and ready for direct use in pelletizing, thus enhancing process continuity.
Q5: How long do the equipment’s consumable parts last?
A: Key components are made from alloy wear-resistant materials, doubling blade life and reducing consumable costs by 45%, effectively lowering maintenance expenses and downtime.