PP Woven Bags & Raffia Recycling Line
This system processes post-consumer PP woven sacks, raffia tape/yarn, and FIBC scrap with heavy sand, ink, and residual organics. It integrates controlled feeding, low-speed shredding, wet granulation, intensive washing, and staged drying to deliver PP flakes conditioned for extrusion. Optional pelletizing completes the recycling loop.
- Feedstock: PP woven sacks, raffia (tape/yarn), and FIBC scrap
- Cleaning stages: friction washing + rinsing/separation (hot wash optional)
- Residual moisture: typically < 3% with thermal drying (feedstock dependent)
- Typical throughput: 300–1500 kg/h (configuration dependent)
Decision Drivers
Primary selection factors determine module choice, utilities sizing, and output consistency.
Contamination Tolerance
Handles sand/grit, paper fibers, ink, light oils, and residual organics typical in post-consumer sacks and raffia.
Flake Size Control
Primary shredding and wet granulation establish a stable flake size window for washing efficiency and downstream extrusion feeding.
Moisture Targets
Dewatering and thermal drying achieve a defined residual moisture target for extrusion stability and optional pelletizing.
Wear and Service Access
Rotor/knife design, screen strategy, and bearing protection withstand abrasive contamination and ensure predictable maintenance intervals.
Water Loop and Energy Load
Washing loop and heating configuration balance cleaning performance with utilities demand based on the contamination profile.
Automation and Safety Interlocks
Line-level control logic supports steady throughput with overload protection, interlocks, and module-by-module permissives.
Supported Feedstock Forms
Processes typical incoming materials listed below (share photos/samples and contamination details for configuration selection).
PP Woven Bags
Cement bags, fertilizer sacks, rice bags, and other printed woven sacks.
PP Non-Woven
Non-woven fabric scraps and bags (PP), with optional deeper washing.
PP Raffia (Tape/Yarn)
Raffia strips, tapes, and yarn waste from weaving and packaging operations.
White Meltblown Fabric
White meltblown non-woven fabric scrap from filtration and hygiene production.
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Jumbo Bags (FIBC)
Bulk bags and big bags, including dusty or sand-contaminated material.
PP Offcuts & Grass Backing
Weaving offcuts and artificial grass backing scrap.
Process Flow
Follows a sequence from size reduction through washing and staged drying. Final configuration depends on contamination profile, target flake size, and downstream extrusion requirements.
Feeding & Pre-Sorting
Meters feeding with optional metal detection or manual pre-sorting to reduce tramp contaminants.
Shredding
Opens woven structures and stabilizes downstream cutting via low-speed, high-torque size reduction.
Wet Granulation
Cuts to a defined flake size range using water-assisted granulation for improved washing and rinsing efficiency.
Friction Washing
Removes sand/dust, loosened ink, and attached fibers from PP flakes via high-shear scrubbing.
Rinsing & Separation
Separates heavy contaminants and improves PP purity through rinse and density-based separation.
Dewatering & Drying
Mechanically dewaters followed by thermal drying (and optional squeezer) to meet a moisture target for extrusion.
Pelletizing (Optional)
Converts conditioned flakes to pellets when storage, dosing, or downstream feeding requires it.
Utilities and Footprint
Reference utilities and layout envelope by capacity tier (final sizing depends on contamination level and selected modules).
| Capacity (kg/h) | Install Power (kW) | Typical Layout Area (m²) | Operators / Shift | Compressed Air (MPa) | Process Water (m³/h) |
|---|---|---|---|---|---|
| 300 | 150 | 350 | 4 | 0.6-0.8 | 3 |
| 500 | 230 | 460 | 6 | 0.6-0.8 | 4 |
| 1000 | 430 | 500 | 6 | 0.6-0.8 | 5 |
Note: Values are indicative. Final utilities depend on contamination profile, hot washing/heating selection, and drying configuration.
Utilities guidance: electrical supply is specified by voltage/Hz and start method; water demand depends on open vs closed loop design and hot washing/heating selection.
Key Modules
Belt Conveyor Specifications
- Frame: Carbon steel or SS304 (options)
- Belt Type: PVC/PU (application dependent)
- With belt tensioning device and receiving hopper
- Belt Width & Length: Sized to throughput and layout
- Transporting raw materials into the system.
Single-Shaft Shredder Specifications
- Rotor Speed: 60–100 RPM (typical)
- Knife Material: D2 or alloy tool steel (application dependent)
- Screen Size: 40–100 mm (set by downstream cutting and washing)
- Hydraulic Pusher: Yes (for stable feeding under load)
- Motor Power: Sized by capacity and feedstock (typ. 30–200 kW)
- Opens woven structures and reduces bulk volume.
- Stabilizes downstream cutting and washing consistency.
- Reduces bridging and improves feeding control.
Wet Plastic Granulator Specifications
- Rotor Speed: 400–600 RPM (typical)
- Blade Material: D2 tool steel (common)
- Knife Arrangement: V-cut or scissor-cut (by material behavior)
- Screen Filter Size: 20–60 mm (typical for PP woven/raffia lines)
- Produces flakes sized for washing and rinsing efficiency.
- Reduces dust carryover by wet cutting and immediate rinsing.
- Improves feeding stability for dewatering and drying stages.
Friction Washer Specifications
- Rotor Speed: 500-600 RPM
- Water System: Top inlet, bottom outlet
- Operation: Continuous
- Cleaning Method: High-speed friction
- Removes sand/dust and loosened ink/fiber contamination.
- Transfers material between stages with controlled residence time.
- Reduces abrasive carryover into dewatering and drying.
Floating Separation Tank Specifications
- Interior Width: 1000mm - 1800mm
- Total Length: 4 - 7 meters
- Interior Material: Type 304 Stainless Steel
- Exterior Frame: Carbon Steel
- Paddle Motors: 1.5KW × 2 (frequency control)
- Geometry configured for stable separation and rinsing.
- Sectioned design supports staged rinsing and contamination management.
- Water loop can be configured for open or closed operation.
Hot Washer Specifications
- Operation Mode: Continuous or batch (by contamination)
- Heating Options: Electric, steam, or boiler integration (site dependent)
- Washing Method: Heated wash with optional chemical dosing
- Use Case: Ink, oils, glue, and heavy organics (when required)
- Improves removal of oils, glue, and stubborn organics when specified.
- Heating and chemistry are configured by cleanliness target and utilities.
- Integrated into the wash loop with controlled temperature and residence time.
Centrifugal Dryer Specifications
- Rotation Speed: ~1,000 RPM (typical)
- Moisture Reduction: Often ~20–30% (feedstock dependent)
- Main Components: Rotor with paddles, mesh screen tunnel
- Configuration: Sized by throughput and inlet water load
- Reduces thermal drying load by removing free water mechanically.
- Continuous operation for stable line throughput.
- Configured with wear protection for abrasive fines.
Thermal Pipe Dryer Specifications
- Drying Method: Hot air conveying with cyclone separation
- Heat Input: Electric or thermal integration (site dependent)
- Pipe Material: SS304 (common) with abrasion options
- Configuration: Single or multi-stage (by capacity and target moisture)
- Controls: Temperature and airflow control for stable drying
- Continuous drying for stable extrusion preparation.
- Cyclone separation helps manage fines and lightweight contamination.
- Configured to meet a defined residual moisture target.
- Scalable with multiple stages for higher throughput.
Film Squeezer Specifications
- Moisture Reduction: Typically reduces moisture from ~10–35% down to ~1–8% (inlet dependent)
- Mechanism: Screw-type compression and heating/friction densifying
- Output Capacity: 300–1500 kg/h (matched to line throughput)
- Energy Consumption: Sized by capacity and densifying requirement
- Reduces moisture and increases bulk density for feeding stability.
- Improves dosing consistency to extrusion/pelletizing.
- Optional stage selected when thermal drying alone is not optimal.
Water Ring Pelletizing System (Optional)
- Pellet Type: Water-ring cut, uniform granules
- Typical Inputs: Clean PP flakes from woven bags, raffia, and FIBC scrap
- Customization: Die face, filtration, and automation options
- Pelletizes conditioned PP flakes with stable die-face cutting.
- Improves handling and dosing versus loose flakes.
- Filtration and automation options are selected by pellet quality target.
Field Performance Notes
Representative operating observations (anonymized). Results depend on feedstock and configuration.
Printed cement sacks with heavy sand load: hot wash and higher friction-wash intensity reduced abrasive carryover into drying and improved flake cleanliness.
Raffia tape/yarn scrap with light organics: controlled granulation improved rinse efficiency and stabilized downstream feeding for extrusion preparation.
Mixed woven + FIBC scrap: selected dewatering + thermal drying stages achieved moisture target based on the inlet water load (squeezer optional).
Technical FAQs
Decision-oriented answers for selecting modules, utilities, and output targets.
What PP materials can this line process?
Processes PP woven sacks, raffia (tape/yarn), FIBC scrap, and PP non-woven. Specify washing intensity and hot washing (if required) for BOPP-laminated woven bags to match ink/adhesive contamination.
What output and moisture level can I expect?
Throughput ranges from 300–1500 kg/h depending on module selection and contamination load. Residual moisture relies on dewatering and drying stages; thermal drying commonly achieves < 3% when required for stable extrusion (feedstock dependent).
Do I need hot washing for printed cement bags or oily contamination?
Specify hot washing when ink, oils, glue, or heavy organics must be reduced to meet an output cleanliness target. Friction washing + rinsing suffices for light dust/sand loads. Heating method and chemistry depend on site utilities and the contamination profile.
Can this line produce PP pellets directly?
Yes—add extrusion/pelletizing. Select a squeezer to reduce moisture and increase bulk density before extrusion if inlet water load is high or pelletizing stability is critical. Filtration depends on the pellet quality target.
Can you customize the layout and automation level?
Yes. We configure layout, module selection, and control logic around capacity, contamination, available utilities, and footprint. Typical automation includes interlocks, overload protection, and module-by-module permissives; specify higher automation levels in the RFQ.
RFQ Requirements
Provide the minimum inputs below so we can size modules, utilities, and layout for your PP woven/raffia stream.
- Feedstock type(s): woven sacks, raffia (tape/yarn), FIBC, BOPP-laminated (yes/no)
- Contamination: sand/dust %, ink/adhesive, oils/organics, moisture at inlet
- Target throughput (kg/h) and operating hours per day
- Target output: flake size range and cleanliness/moisture requirement for extrusion
- Utilities available: voltage/Hz, heating source, water loop preference (open/closed)
- Space constraints: available length/width, elevation limits, material handling constraints
- Automation level and commissioning preference (remote/on-site)