An EPS packaging production line built on high-density (30-50 kg/m³) shape molders and per-buyer insert molds for electronics, appliance, automotive and medical equipment packaging. Engineered for >100 kPa compression strength and ISTA 3A / ASTM D5276 drop-test evidence, at 3,000-15,000 inserts per day. Designed and built in our own plants, and commissioned on site.
An EPS packaging production line is a turnkey plant that expands raw EPS beads and steam-molds them into protective packaging parts: a high-density pre-expander, 6-8 aging silos, reinforced shape molders, the buyer-specific insert molds, and the utility set (steam, cooling water, compressed air, vacuum). Cushioning inserts are molded at 30-50 kg/m³ — around 100 kPa compression at 30 kg/m³ and 200 kPa at 50 kg/m³ — on a 60-100 second cycle, and one line runs 3,000 to 15,000 inserts per day depending on how many molders you install. The molding machine at the centre of this line — an EPS packaging molding machine — is a reinforced shape molder: same fill / steam / cool / eject cycle as a standard EPS molder, but built for a 0.7-0.9 MPa steam chest instead of 0.4-0.6 MPa, because 30-50 kg/m³ inserts with 10-50 mm walls need more energy to fuse than a 16-22 kg/m³ fish box.
The real pain points operators in this industry face every day.
Electronics and appliance buyers test a sample against ISTA 3A or ASTM D5276 on arrival. A single fail sends the full shipment back, and the cost lands on the packaging supplier, not on the brand.
Compression strength tracks density: about 100 kPa at 30 kg/m³ and 200 kPa at 50 kg/m³. A pre-expander run on operator feel makes parts that pass on Monday and fail on Friday.
A plant serving industrial accounts juggles a different density, cycle time and steam time per buyer. Recipes kept on paper are the single largest source of scrapped batches.
Walls of 10-50 mm shrink for hours after demolding. Parts measured at the machine pass; the same parts fail the buyer incoming check two days later.
Specific technical answers ChinaEps engineers into this production line.
End products this turnkey line is engineered to manufacture.
TV / monitor corner inserts
Laptop / tablet packaging
Refrigerator / washing machine corner blocks
Air-conditioner packaging
Automotive bumper / dashboard inserts
Medical equipment custom geometry
Industrial machinery packaging
OEM cushioning to customer drawings
From raw material to finished product — six stages, fully integrated.
High-grade beads from supplier, traceability lot-coded.
High-density 30-50 kg/m³ pre-expansion for cushioning strength.
24-48h aging with batch traceability per customer order.
PLC loads buyer-specific recipe (density / cycle / steam-time).
Reinforced SM-1200/1400 molds insert, 60-100s cycle for fusion.
Thick-wall cooling 5-10 min for dimensional stability.
On-line compression tester verifies >100 kPa at 10% strain.
Sample drop-test per buyer batch, full lot shipped on pass.
Line Composition
The full production line is composed of these core subsystems — each one engineered as a self-contained module.
Line Tier Options
Pick a tier that matches your daily output target — equipment scales accordingly.
3,000-5,000 inserts/day
6,000-10,000 inserts/day
12,000-15,000+ inserts/day
Full Equipment List
Every machine in the turnkey package — main equipment, auxiliary systems, and optional upgrades.
| No. | Equipment | Qty | Function |
|---|---|---|---|
| 1 | EPS Pre-expander (high-density) | 1 set | High-density bead 30-50 kg/m³ |
| 2 | Fluidized Bed Dryer | 1 set | Bead drying |
| 3 | Multi-grade Aging Silo | 1 set | Customer-specific recipe storage |
| 4 | Automatic Conveying System | 1 set | Bead transfer |
| 5 | SM-1200 High-Density Molder | 1 set | Reinforced steam chest forming |
| 6 | SM-1400 Heavy-Duty Molder | 1 set | Large insert forming |
| 7 | Custom Insert Molds | 1 set | Per buyer drop-test spec |
| 8 | Heavy-duty Vacuum System | 1 set | Thick-wall demold |
| 9 | Extended Cooling Conveyor | 1 set | Thick-wall stability cooling |
| 10 | Steam Boiler | 1 set | 1-1.5T high-density steam supply |
| 11 | Cooling Tower | 1 set | 30-40 m³/h |
| 12 | Air Compressor | 1 set | 5-7 m³/min for heavy clamping |
| 13 | Insert Compression Tester | 1 set | On-line QC verification |
| 14 | Drop-Test Lab Equipment | 1 set | ISTA / ASTM verification (optional) |
| 15 | Auto Stacker | 1 set | Insert handling |
| 16 | Heat Sealing Wrapper | 1 set | Anti-static + cushion sealing |
| 17 | SPLB-1200 Pallet Wrap | 1 set | Bulk shipment |
| 18 | Waste Crusher | 1 set | Edge reject recycling |
| 19 | Central Control + Traceability | 1 set | Lot tracking per buyer batch |
| 20 | Steam / Air / Water Pipeline | 1 set | Heavy utility distribution |
Workshop Requirements
Before equipment arrival, the buyer needs to prepare the following on-site infrastructure.
Engineering specifically tuned for this application — not a generic line.
Cushioning compression strength is determined by density. We tune pre-expander + cycle for 30-50 kg/m³ — far higher than fish box, matching ISTA 3A / ASTM D5276 drop-test specs.
PLC silo routing + batch lot codes give per-shipment QC records. Critical for electronics / medical buyers who require traceability for liability.
On-site ISTA / ASTM lab (Option 3) verifies every batch on-site before shipping. Reduces buyer return rate, increases per-shipment margin.
High-density requires higher steam pressure + longer hold. Our SM-1200/1400 reinforced chest handles 0.7-0.9 MPa vs standard 0.4-0.6 MPa.
Utility Consumption Calc
Per-equipment + total demand for sizing your boiler, compressor, and cooling tower.
| Equipment | Per Unit | Qty | Total |
|---|---|---|---|
| EPS Pre-expander (high-density) | 150-250 kg/h | 1 | 150-250 kg/h |
| High-density Molders | 120-180 kg/h | 3 | 360-540 kg/h |
| Pipeline loss (≈10%) | - | - | 50-80 kg/h |
| Total Steam Demand | - | - | 560-870 kg/h |
| Equipment | Per Unit | Qty | Total |
|---|---|---|---|
| Pre-expander pneumatics | 0.3-0.4 m³/min | 1 | 0.3-0.4 m³/min |
| Molder clamping (heavy) | 0.6-1.0 m³/min | 3 | 1.8-3.0 m³/min |
| Auto conveying + stacker | 0.5-1.0 m³/min | 1 | 0.5-1.0 m³/min |
| Compression test pneumatics | 0.2-0.4 m³/min | - | 0.2-0.4 m³/min |
| Total Air Demand | - | - | 2.8-4.8 m³/min |
| Equipment | Per Unit | Qty | Total |
|---|---|---|---|
| High-density molders | 4-6 m³/h | 3 | 12-18 m³/h |
| Extended cooling conveyor | 3-5 m³/h | 1 | 3-5 m³/h |
| Pre-expander cooling | 1-2 m³/h | 1 | 1-2 m³/h |
| Total Circulating Water | - | - | 16-25 m³/h |
| Actual Make-up Water (8h) | - | - | 12-20 m³/day |
Container Plan
Pre-engineered container loading for your line size — daily output 800-30,000+ pieces.
1 high-density molder, daily output 3,000-5,000 inserts
40HQ Container #1
2 molders + drop-test setup, daily output 6,000-10,000
40HQ #1 — Pre-expansion + Silos
40HQ #2 — Molding + QC
4 molders + drop-test lab, daily output 12,000-15,000+
40HQ #1 — Pre-expansion
40HQ #2 — Vacuum + Cooling System
40HQ #3 — Molding Group A
40HQ #4 — Molding Group B + QC Lab
Local-purchase recommendation: Steam boiler, air compressor, cooling tower, and water tank are not shipped from China — local purchase saves freight, matches local voltage / certifications, and reduces total project cost by 15-25%.
Share your capacity targets, product specs, and budget — our engineers design the optimal line for your factory.
Diversify revenue with adjacent production capability — many customers operate multiple ChinaEps lines side-by-side.
Insulated seafood and ice boxes are molded far lighter than industrial inserts — different mold set, different line sizing, cold-chain buyers.
Ultra-light trays and liners on multi-cavity molds with 30-minute changeover, for exporters running 5-12 SKUs a day.
Edge trim and rejected inserts go back into the line as regrind instead of to landfill — the usual next purchase for a packaging plant.
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