Egg tray production process includes pulp making system, pulp molding system, drying system, and packing system. It explains how to make egg trays from waste paper. Below is a video of a 7-year-old egg tray production line at Beston factory. More than that, Beston also offers quality equipment and various egg tray making solutions. If you are planning to start an egg tray manufacturing business, please feel free to contact us!
Review of Egg Tray Production Process
As mentioned, the egg tray making process includes pulp making, pulp molding, egg tray drying, and packing systems. Let’s review step by step.
Step 1. Pulp Making
Through the egg tray machine video, you may find the egg tray making process start from pulp making system, which makes waste paper into pulp.
Step 2. Pulp Molding
The molding system is where the trays are formed as expected shape, such as egg trays, egg cartons, apple trays, etc.
Step 3. Drying
The trays after demolding are with about 30% water. So you need to dry and solidify them. You can choose to dry naturally under the sun or in the bricking room.
Step 4. Packing
After drying the trays, you need to pack them up for sale or use.
Main Equipment of Egg Tray Production Process
1. Pulp Making System
The main equipment involved includes hydraulic pulper, pulp refiner, pulp and water pumps. Also, you need water and pulp pools. In general, only one worker is needed to put the waste paper and water into the hydraulic pulper by a ratio of 1:3. Then the paper pulp will be pumped into the refiner and be fixed more evenly. If you want to change the color, you can add coloring agents here. This part is mainly driven by electricity. If you have limited space, Beston also offers integrated pulping system, which puts the hydraulic pulper, pulp refiner, pulp and water pools together.
2. Pulp Molding System
The main equipment is the pulp molding machine. Except that, it also includes vacuum pump, air compressor, negative pressure tank, etc. When the prepared pulp will be transferred to the pulp molding system through the pump, it will be shaped on the forming molds with the help of the vacuum pump. When the forming molds rotate to the transfer mold, the wet trays will be moved using the air compressor. Then the transfer mold will send the trays to the drying system. It seems difficult, but in fact, Beston pulp forming part is fully automatic. Below is a video for your reference.
|Production Capacity (piece/h)||1,000||1,500||2,000||2,500||3,000-4,000||4,000-5,000||5,000-6,000|
|Mould Quantity (piece)||3||4||12||16||32||40||60|
|Total Power (kW)||34||41.2||53.7||57||90||150||153|
|Electricity Consumption (kW/h)||23.8||28.84||37.59||39.9||63||105||107.1|
|Materials Consumption (kg/h)||Paper||85||102||170||212||298||425||459|
3. Drying System
Beston offers three options, namely, natural drying, brick drying line, and metal dryer. Natural drying means to dry the trays naturally, which usually takes 2-3 hours. In comparison, the brick and metal drying systems are heated by fuel, so it can greatly reduce the drying time to 20 munites. Let’s review the pros and cons of the different drying systems.
|Natural Drying||1. Low investment cost
2. Few construction works
|1. Need large space and labor input
2. Only suitable for small-scale investors
|Brick Drying Line||1. Effective and quick
2. Moderate cost
3. Easy to operate
|1. Only single-layer design, so it needs at least 40 meters in length
2. More construction works are needed
|Metal Dryer||1. Easy to transport and install
2. High drying efficiency
3. Multilayer design to reduce the floor space
2. Limits in heating fuel (wood and coal are not available)
Step 4. Packing System
Some choose to pack manually. While an automatic packing system consists of a hot press machine, a packer, and a counter. We use a hot press to make the surface smooth. For the fully automatic egg tray machine, it can count the trays as the preset number. Then pack them up for sale. Below is a video for your reference.
FAQ of Egg Tray Production Process
Q 1. How many workers to operate the egg tray production line?
A: Generally, 3-6 workers. One is for feeding. If you have a big egg tray plant, you can have a loader for help. During the molding process, you can have a worker to clean the molds or you can employ an automatic cleaning device. Then you need one or two workers to transfer the wet trays for drying. If you use a conveyor belt, there is no worker needed. After drying, there are one or two workers to pack the trays up. If you are in the areas with high wages, you can consider having an automatic egg tray machine.
Q 2. How to make good quality egg trays?
A: Firstly, use more quality materials, such as old books, newspapers instead of old cartons and corrugated paper. Secondly, the ratio of pulp is 1 paper into 3 water. You can add some additives. But more importantly, to mix the pulp evenly. We advise hiring experienced workers to make pulp. Thirdly, to choose quality equipment, which is essential for making quality egg trays.
Q 3. Does it pollute during the egg tray making process?
No, the whole egg tray production process is pollution-free. There is no waste water and gas produced. All the water will be recycled. And the egg tray machine recycles waste paper to pulp molded products, which is degradable.
Q 4. How long does an egg tray production process last?
A: For the automatic line, it takes about 30 minutes from pulp making to packing. While for natural drying, it needs 2-3 hours to dry the trays. In terms of the molding system, it just needs a few minutes.
Knowing more about the egg tray manufacturing process will help you to choose the suitable machine. If you have any questions about the egg tray production line, please contact us. Beston Machinery has 70+ successful cases all over the world, as well as experienced engineers to serve you. And we offer online installation service to make sure your machine will be put into use without delay even under the influence of COVID-19. Welcome to contact us for details!