New Granulator Converts Nonwoven Waste to Recycled Plastics

The global challenge of efficiently recycling disposable nonwoven fabrics, polyester fibers, nylon fibers and similar materials may have found its solution. These once-valuable production materials often become difficult-to-process waste after single use, presenting both environmental and economic concerns.

Innovation Meets Efficiency: The Two-Stage Nonwoven Plastic Pelletizer

A specialized two-stage plastic pelletizer has been developed specifically to address the recycling challenges of nonwoven materials, polyester fibers, and nylon fibers. This integrated system combines feeding, crushing, conveying, degassing, filtering, and pelletizing into a single continuous process, transforming waste materials into high-quality recycled plastic pellets with unprecedented efficiency.

The system eliminates the need for multiple separate processing stages, significantly reducing labor requirements, processing time, and facility space while maintaining output quality.

Core Technology: Dual-Stage Extrusion for Superior Results

At the heart of the system lies an advanced two-stage extrusion process. Operators can select between vented or non-vented extruders based on material characteristics. The dual-stage design provides enhanced removal of moisture and volatile components (such as inks) while improving material plasticization and homogeneity—critical factors for producing premium-grade recycled pellets.

Breakthrough Filtration: Continuous Operation, Maximum Output

The system incorporates an innovative dual-position plate-type screen changer that delivers three key advantages:

• Zero-downtime screen changes: Enables filter replacement during operation, eliminating production interruptions
• Expanded filtration area: Provides significantly greater surface area than conventional filters, reducing change frequency while improving filtration quality
• Dual-flow design: Maintains continuous material flow during screen changes, maximizing throughput and minimizing waste

Precision Pelletizing: Cold-Strand Cutting for Consistent Quality

The pelletizing unit employs a proven cold-strand cutting system featuring efficient water cooling, powerful air drying, and precision cutting. Extruded plastic strands undergo complete cooling before surface moisture removal and final cutting into uniform pellets. This process ensures dimensional consistency and surface finish quality ideal for subsequent manufacturing processes.

Flexible Feeding Options for Diverse Material Types

The system offers two adaptable feeding solutions to accommodate various waste forms:

1. Belt conveyor unit: Handles bulk materials with amp-based feed rate control for automated operation
2. Optional nip roller assembly: Works with the belt conveyor to process entire rolls of film material, ideal for high-volume operations

Advanced Processing Systems Ensure Optimal Extrusion

Precision temperature control and a cutting/compaction system maintain semi-molten plastic at ideal conditions for stable, uniform extrusion. This prevents feed inconsistencies that could compromise output quality.

Dual-Vent Design for Material Purification

Two strategically placed vent ports effectively remove inks, moisture and other volatiles—particularly valuable when processing printed nonwovens or high-moisture content materials. This significantly enhances pellet purity and physical properties for superior end-product performance.

Technical Specifications and Model Options

The system is available in multiple configurations to meet varying production needs:

PTCS 3-in-1 Plastic Recycling System (Universal Model)

Beyond specialized nonwoven models, a comprehensive 3-in-1 recycling system is available, incorporating:

• Conveyor belt
• Crusher chamber
• Primary and secondary extruders
• Pelletizing unit
• Water cooling system
• Drying unit
• Storage silo
• Vent system
• Filtration system

Material compatibility: Processes HDPE, LDPE, LLDPE, PP, BOPP, CPP, OPP, PET and other plastics

Customization options: Available for screw diameter (80-185mm), L/D ratio (30/1 to 36/1), screw material (38CrMoAl or bimetallic), vent configuration (dual, single, or none), and voltage requirements (adaptable to regional standards)

Performance-Enhancing Options

• Metal detection systems for impurity removal
• Nip roller assemblies for roll material processing
• Precision additive dosing systems for product customization
• Centrifugal dewatering systems for enhanced pellet drying

Implementation and Support

Custom systems require 50-70 days for production. Comprehensive support includes one-year warranty and optional on-site installation/operator training by experienced engineers to ensure rapid, stable production line implementation.

The technology has demonstrated global success, producing recycled pellets suitable for film blowing, pipe extrusion, and various plastic product manufacturing—contributing to sustainable material cycles while delivering economic value across packaging, agricultural, and industrial applications.