Mesh Bag Recycling and Washing Production Line

Product Overview

The mesh bag recycling and washing production line is an integrated regeneration processing equipment specially designed for PP woven bags and ton bags. It integrates the entire process flow of crushing, deinking, sand removal, and washing, enabling thorough removal of printing ink on the surface of woven bags, internal cement clumps, attached labels, and various other impurities, ultimately producing clean shredded material that can be directly fed into subsequent pelletizing processes. This production line supports customization based on customer output requirements and boasts core advantages such as a wide processing capacity range, high impurity removal efficiency, and low operating costs, making it a professional auxiliary equipment in the field of recycled plastics processing.

Technical Principle 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 systematic process of “shredding + intensive friction deinking + flotation separation + multi-stage rinsing + dewatering,” with each step closely coordinated to achieve efficient and thorough washing:

1. Whole-Bag Shredding Step: 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-sized flakes. This not only breaks down the woven structure but also releases internally trapped sand, cement clumps, and prepares the material for subsequent impurity removal steps.

2. Intensive Friction Deinking and Washing: The flake-shaped 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 strips away surface printing ink, residual cement, and laminated adhesive layers. Detached ink and fine sand are discharged through a screen along with wastewater. For materials with heavy ink and laminated adhesives, an 80–95°C hot-washing module can be optionally used, supplemented by eco-friendly detergents for deep treatment, ensuring complete impurity removal.

3. Flotation Separation for Impurity Removal: After deinking, the material flows into a flotation washing tank, leveraging differences in specific gravity to separate impurities. Lightweight impurities such as paper labels, plastic laminates, and light debris float to the surface and are discharged through an overflow outlet, 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 reducing surface residue.

4. Secondary Clean Water Rinsing: Following flotation separation, the material enters a secondary clean-water tank for another round of rinsing, thoroughly removing residual washing agents and fine particulates, thereby further enhancing cleanliness to meet the high-purity requirements of subsequent pelletizing processes.

5. Spiral Dewatering: The cleaned material is fed into a spiral dewatering machine, where physical squeezing removes excess moisture. Simultaneously, the machine’s wear-resistant stainless steel screen filters out remaining fine residues, yielding dry material with extremely low moisture content that can be directly sent to pelletizing equipment for further processing.

6. Water Circulation Treatment System: The production line is equipped with a three-stage sedimentation tank and filtration system. Wastewater generated during the washing process undergoes sedimentation and filtration before being recycled, significantly reducing water consumption throughout the production cycle and meeting environmentally friendly production standards.

Core Performance Parameters

1. Processing Capacity: 600–1800 kg/h; production line specifications can be customized according to actual customer output needs.

2. Ink Removal Rate: ≥92%, effectively stripping away all types of printing ink from the surface of woven bags, thus preventing any adverse impact on the quality of regenerated pellets.

3. Sand Removal Rate: ≥95%, completely eliminating heavy impurities such as sand and cement clumps trapped inside woven bags.

4. Moisture Content After Dewatering: ≤4%; the low-moisture dry material can be directly fed into the pelletizing stage without additional drying.

Key Product Advantages

1. Outstanding Deinking and Sand Removal Performance: Designed specifically to address the high sand and ink content of woven bags, the friction deinking and flotation separation processes efficiently remove all kinds of impurities—even heavily soiled bags can yield clean shredded material, fully meeting the demands of pelletizing production.

2. Strong Customization Capability: Production line scale can be tailored to meet customers’ specific output requirements, with optional hot-washing units available to handle both ordinary and severely contaminated materials, providing flexible adaptation to diverse production scenarios.

3. Low Operating Costs: The equipment features long-lasting wear-resistant components; compared to similar machines, alloy wear-resistant blades last twice as long, while consumable parts costs have dropped by 45%, significantly reducing maintenance and replacement expenses.

4. Thorough Impurity Separation: By simultaneously removing both light and heavy impurities through flotation separation, there’s no need to install multiple separate impurity-removal devices, simplifying the production process while ensuring effective impurity removal and boosting productivity.

5. Water-Saving and Environmentally Friendly: The integrated water circulation system achieves a water reuse rate exceeding 85%, reducing water consumption per ton by 75%. This not only cuts down on water usage but also minimizes wastewater discharge, aligning with eco-friendly production standards.

6. Seamless Integration with Pelletizing Lines: The clean dry material produced can be directly fed into pelletizing equipment, eliminating the need for additional intermediate handling steps and achieving seamless connection between recycling/washing and pelletizing operations, thereby improving overall production efficiency.

Core Value of the Product

1. Enhanced Quality of Regenerated Pellets: With an overall impurity removal rate exceeding 93%, issues like blackening and poor appearance of regenerated pellets are completely resolved, allowing the produced pellets to meet high-quality standards and expand their application scope.

2. Reduced Losses in Pelletizing Production: Thorough impurity removal lowers the frequency of screen changes during pelletizing by 70%, minimizing production interruptions and raw material losses caused by clogged screens, thus improving the operational efficiency of pelletizing lines.

3. Significant Cost Reduction: Consumable parts costs have fallen by 45%, water consumption per ton has decreased by 75%, and only 2–3 operators are needed per line, cutting labor costs by 60%. Overall production expenses are reduced across multiple dimensions, including equipment consumables, water usage, and manpower.

4. Environmentally Compliant Production: The water circulation system dramatically reduces water consumption and wastewater discharge, meeting environmental policy requirements and helping companies achieve green, sustainable production while enhancing their corporate environmental image.

Target Customer Groups

This production line targets various enterprises involved in recycled plastics processing and related packaging industries, including woven bag recycling companies, cement/grain packaging plants, resource recycling centers, and large-scale PP pellet factories. It provides these businesses with professional solutions for recycling and washing woven bag waste, supporting their efforts toward efficient and environmentally friendly regenerative production.

Application Scenarios

This production line is suitable for pre-treating various types of dirty woven waste, including cement woven bags, laminated ton bags, grain woven bags, bulk space bags, snake-skin mesh bags, and more. Whether it’s industrial packaging containing sand or cement clumps, or food and grain packaging with printing ink and laminates, this line delivers efficient impurity removal and thorough washing, providing high-quality raw materials for subsequent pelletizing processes.

Solutions to Industry Pain Points

1. Addressing Severe Sand Contamination Causing Screw Wear: The production line releases sand through the shredding process and then uses flotation separation to thoroughly remove heavy sand, preventing it from entering pelletizing equipment and causing screw wear, thereby extending the service life of pelletizing machinery.

2. Solving Blackening and Poor Appearance of Regenerated Pellets Caused by Ink Residue: The intensive friction deinking process, combined with an optional hot-washing module, achieves an ink removal rate of ≥92%, completely eliminating surface printing ink on woven bags and ensuring the appearance and quality of regenerated pellets.

3. Tackling Frequent Screen Clogging and Low Efficiency in Pelletizing Due to Dirty Materials: The highly effective impurity removal capability significantly reduces impurity levels in the pelletizing process, lowering the frequency of screen changes by 70% and shortening production downtime, thus boosting overall production efficiency.

4. Mitigating High Labor Costs and Inconsistent washing Quality: The automated production line requires only 2–3 operators throughout the entire process, replacing traditional manual washing methods. Not only does this drastically cut labor costs, but standardized procedures also ensure consistent washing quality. Meanwhile, the water circulation system reduces water consumption per ton by 75%, resolving the issue of excessive water use in manual washing.

Frequently Asked Questions (FAQ)

Q1: What types of woven bag waste can this production line process?
A: It can handle cement woven bags, laminated ton bags, grain woven bags, bulk space bags, snake-skin mesh bags, and other heavily soiled woven waste—whether it’s industrial packaging with high sand content or food packaging with ink and laminates, all are compatible.

Q2: Can the production line’s processing capacity be adjusted?
A: Yes, this production line is custom-made and can be tailored to meet specific customer output requirements, with a processing capacity ranging from 600 to 1800 kg/h.

Q3: How effective is the treatment for heavily inked and laminated woven bags?
A: For such materials, an 80–95°C hot-washing module can be optionally added, along with eco-friendly detergents for deep treatment, effectively stripping away heavy ink and laminated adhesive layers and ensuring the final shredded material meets the cleanliness standards required for pelletizing.

Q4: Is the production line very water-intensive?
A: Not really. The line is equipped with a three-stage sedimentation tank and filtration system, achieving a water reuse rate of over 85% and reducing water consumption per ton by 75%, resulting in significant savings compared to traditional washing methods.

Q5: Can the produced shredded material be directly fed into the pelletizing stage?
A: Yes, after spiral dewatering, the material’s moisture content is ≤4%, eliminating the need for additional drying. It can seamlessly connect to the subsequent pelletizing line, boosting overall production efficiency.