Shredding and recycling nonwovens and PP nonwovens with WEIMA shredders
Nonwovens are lightweight, bulky and often extremely tear-resistant – properties that make them particularly challenging to shred. WEIMA shredders process nonwovens reliably and in a controlled manner for subsequent recycling steps. Whether edge trim, rolls or bales, the material is shredded to a defined, conveyable size and optimally prepared for further processing such as sorting, washing, densifying, extrusion or regranulation.
Applications: Shredding nonwoven fabric with WEIMA
What is nonwoven?
A nonwoven is a textile material that has been bonded together in some way – but is neither woven nor knitted. Instead, individual fibres and filaments are laid out to form a loose layer and then bonded together, for example by pressure, heat, water jets, needles or binding agents. When it comes to recycling, the key factor is how clean and free from contamination the material stream is. Typical materials include polyester (PET), polypropylene (PP), viscose, cellulose and natural fibres. Depending on how it is manufactured, non-woven fabric can be very soft, strong, absorbent, filtering, sound-absorbing or thermally insulating.
How is nonwoven made?
Nonwoven are produced in three basic steps:
1. Preparing and laying the fibres
Fibres or filaments made from, for example, PET, PP, viscose or cellulose are laid out to form a loose web.
2. Bonding the nonwoven
The fibres are bonded together mechanically, thermally, chemically or using water jets. Typical processes include needle-punch, spunlace, spunbond and meltblown.
3. Finishing and converting
The nonwoven fabric can then be coated, embossed, cut to size or further processed as roll goods.
Where is the nonwoven used?
One major area of application for nonwoven fabrics is hygiene, which includes, for example, nappies, feminine hygiene products and incontinence products. Other typical applications include the textiles sector, care wipes, wet wipes, medical drapes, masks, protective clothing, air filters, building insulation, car interiors, carpet backing, agricultural nonwovens and cable sheathing.
WEIMA solutions for shredding nonwoven fabrics
F-rotor for films, fibres and flexible nonwoven fabrics
With nonwoven fabrics, the cutting geometry is key to ensuring a stable process. The WEIMA F-rotor has been developed for flexible materials such as filaments, tapes, ropes, cords and films. Thanks to the special blade spacing and cutting geometry, the materials are prevented from becoming entangled, which could otherwise lead to melting and blockages due to friction. The blades engage fully with the counter-blade and, together with a narrow cutting gap, ensure controlled feed and rapid, efficient shredding.
Europe produces around 3 million tonnes, or more than 80 billion square metres, of nonwoven fabrics annually.
How nonwoven recycling works
Nonwoven fabrics are no longer a niche product; they are found in numerous industrial applications – from filtration and construction products through to geotextiles and vehicle interiors. According to EDANA, more than 1.9 million tonnes were produced in the 27 EU countries alone in 2025.
This wide range of applications goes hand in hand with an equally diverse array of materials and properties. Consequently, the importance of suitable solutions for returning production residues and end-of-life nonwovens to the recycling loop is also growing.
FAQ about nonwoven recycling
A nonwoven fabric is a textile material consisting of fibres bonded together. Unlike traditional textiles, nonwoven fabrics are neither woven nor knitted. Instead, individual fibres and filaments are arranged in a loose layer and then bonded together, for example by means of pressure or a binding agent.
Yes, non-woven fabric can be recyclable, but not all types of non-woven fabric are equally easy to recycle. Non-woven fabric made from PP or PET is generally easy to recycle mechanically. The same applies to non-woven fabric made from natural fibres or cellulose. It becomes more difficult with blended non-woven fabric.
Mixed polymers, coatings, adhesives or fillers can alter the material properties of the recycled material and make processing more difficult. The more homogeneous and well-understood the input stream is, the easier it is to control the recycling process.
Key factors are a suitable cutting geometry, controlled feed and a correctly adjusted cutting gap. The WEIMA F-rotor is specially designed for flexible materials and reduces wrapping, as well as the resulting friction and blockages.
Not usually. The majority of production waste is clean and does not require washing prior to initial shredding. Washing may be necessary for post-consumer or agricultural nonwoven fabrics. Whether washing takes place before or after shredding depends on the level of contamination, the plant design and the target quality.
Depending on the material, this is followed by sorting, metal separation, washing, drying, compaction, fine grinding and/or extrusion. In mechanical PP recycling, the processed material is typically melted down, filtered and pelletised into regranulate.
Only to a limited extent. Due to its low bulk density and voluminous structure, non-woven fabric is often pre-shredded. This enables a more uniform feed and a more stable extrusion process.
Single-shaft shredders from the WLK and W5 series are particularly suitable for nonwoven fabrics, although the four-shaft shredders from the ZM series are also a good choice. The appropriate machine and cutting geometry depend on the form of the material, the throughput and the desired output size.