Turnkey Solution

Fruit Packaging EPS Tray Line — Multi-Cavity Mold System

Multi-cavity SM-1200/1400 shape molders + buyer-specific mold library (apple tray / mango box / grape liner / OEM design) produce 800-1,500 trays/h at 14-18 kg/m³ ultra-light density. Designed for fruit exporters running 5-12 SKUs per day with 30-minute mold changeover.

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8,000-30,000 trays
Daily Output Range
14-18 kg/m³ (ultra-light)
Density Range
35-60s (multi-cavity)
Cycle Time
5-12 SKUs/day
SKU Switching

What This Line Produces

End products this turnkey line is engineered to manufacture.

Apple trays (24/30/48 count)

Mango shipper boxes

Grape clamshell liners

Strawberry trays

Pear / peach trays

Avocado boxes

OEM custom fruit packaging

Mixed-fruit gift box inserts

Production Flow

From raw material to finished product — six stages, fully integrated.

Step 1

EPS Raw Material

Raw EPS resin beads from supplier.

Step 2

Pre-expander

Ultra-light 14-18 kg/m³ density (lower than fish box).

Step 3

Aging Silo

4-12h aging cycle for thin-wall stability.

Step 4

Recipe Selection

PLC loads SKU recipe by fruit type (apple / mango / grape).

Step 5

Multi-Cavity Molding

SM-1200/1400 with 4-12 cavity tray mold, 35-60s cycle.

Step 6

Vacuum Demold + Inspection

Fast vacuum demold + optical reject for thin walls.

Step 7

Auto Stacking + SKU Sort

Stacker sorts by SKU for parallel SKU production.

Step 8

Wrap + Warehouse

SPLB-1200 wraps SKU-specific pallets.

Line Composition

Production line subsystems

The full production line is composed of these core subsystems — each one engineered as a self-contained module.

1. EPS Pre-expander
SPJY-1400

1. EPS Pre-expander

  • · Pre-foam beads to ultra-light 14-18 kg/m³ density
  • · Lower density = lower fruit weight gain in transit
  • · Steam-pressure controlled batch operation
  • · Optimized for thin-wall fruit tray production
2. Aging Silo
ES-AUTO 4-6 silos

2. Aging Silo

  • · 4-6 silos to support multi-SKU recipe management
  • · Faster aging cycle 4-12h for thin-wall products
  • · PLC routing prevents grade contamination
  • · Multi-density grade support
3. Multi-Cavity Shape Molder
SM-1200 / 1400

3. Multi-Cavity Shape Molder

  • · SM-1200: 4-8 cavity for apple trays / single mango box
  • · SM-1400: 6-12 cavity for grape liner / multi-fruit tray
  • · Cycle time 35-60s for fruit-grade thin walls
  • · Quick mold change ~30 min for SKU switching
4. Fruit Tray Molds (Library)
Custom multi-cavity

4. Fruit Tray Molds (Library)

  • · Apple tray (24/30/48 count)
  • · Mango shipper box (4/6/8 fruit)
  • · Grape liner (clamshell-compatible)
  • · OEM custom — fruit-specific cavity design
Steam + Cooling + Air + Vacuum

5. Auxiliary Systems

  • · Steam system: boiler + manifold + thin-wall pressure control
  • · Cooling system: vacuum + cooling tower for fast demold
  • · Compressed air system: pneumatic SKU switching
  • · Vacuum + auto stacker for fragile thin-wall trays

Line Tier Options

Choose your production scale

Pick a tier that matches your daily output target — equipment scales accordingly.

Small Line

1 machine

8,000-12,000 trays/day

  • Pre-expander 1
  • Aging Silos 4
  • Multi-cavity Molder 1
  • Tray Molds 3-5 sets
  • Vacuum + Auxiliary each 1 set
Most Common

Middle Line

2 machines

15,000-20,000 trays/day

  • Pre-expander 1
  • Aging Silos 5-6
  • Multi-cavity Molders 2
  • Tray Molds 6-10 sets
  • Auto Conveying 1 set
  • Quick Mold Change recommended

Large Line

4 machines

25,000-30,000+ trays/day

  • Pre-expander 1-2
  • Aging Silos 6-8
  • Multi-cavity Molders 3-4
  • Tray Molds 10-20 sets
  • Full Auto Conveying 1 set
  • Auto Demold + Stacking recommended

Full Equipment List

Complete configuration (20 items)

Every machine in the turnkey package — main equipment, auxiliary systems, and optional upgrades.

No. Equipment Qty Function
1 EPS Pre-expander 1 set Pre-foam beads, density control
2 Fluidized Bed Dryer 1 set Dry pre-expanded beads
3 Aging Silo 1 set Aging for thin-wall stability
4 Multi-cavity Recipe System 1 set PLC SKU recipe library
5 Automatic Conveying System 1 set Bead transfer to molders
6 SM-1200 Multi-cavity Molder 1 set Fruit tray forming
7 SM-1400 Multi-cavity Molder 1 set Large tray / shipper box forming
8 Custom Fruit Tray Molds 1 set Per fruit SKU
9 Quick Mold Change System 1 set 30-min SKU switching
10 Vacuum System 1 set Fast demold for thin walls
11 Steam Boiler 1 set Steam supply
12 Cooling Tower 1 set Circulating water cooling
13 Air Compressor 1 set Pneumatic SKU control
14 Auto Stacker 1 set Fragile tray handling
15 Tray Inspection System 1 set Optical reject
16 SPLB-1200 Wrapping Machine 1 set Pallet wrap
17 EPS Crusher (Recycling) 1 set Reject tray reuse
18 Dust Collection System 1 set Workshop cleanliness
19 Central Control Cabinet 1 set Line PLC management
20 Steam / Air / Water Pipeline 1 set Utility distribution

Workshop Requirements

Site preparation

Before equipment arrival, the buyer needs to prepare the following on-site infrastructure.

Floor area
350-500 m²
Ceiling height
≥ 5.5 m
Electrical
Three-phase 380V / 50Hz
Steam supply
Local boiler 0.8-1 T
Cooling water
Local cooling system
Compressed air
Local 5-6 m³/min compressor

Why ChinaEps for This Solution

Engineering specifically tuned for this application — not a generic line.

Multi-Cavity Mold Library + Quick Change

Mold library 5-12 SKUs + 30-minute changeover lets you run apple in morning, mango in afternoon — match fluctuating buyer orders without per-SKU dedicated lines.

Ultra-Light 14-18 kg/m³ Density

Lower than standard EPS to keep tray weight low — shipping cost saved on every pallet. Critical for fruit margins on long-haul export.

Thin-Wall Molding Expertise

Multi-cavity thin-wall (3-5mm) requires precise vacuum + steam timing — our SM-1200 is tuned for this; generic shape molders crush thin walls.

Local Boiler Recommendation

Steam load lower than fish box — we recommend 0.8-1T boiler with local purchase, saves 15-25% project cost.

Utility Consumption Calc

Steam · Air · Cooling Water

Per-equipment + total demand for sizing your boiler, compressor, and cooling tower.

Steam Consumption (4-machine fruit line)

Equipment Per Unit Qty Total
EPS Pre-expander 80-150 kg/h 1 80-150 kg/h
Multi-cavity Molders 60-100 kg/h 4 240-400 kg/h
Pipeline loss (≈10%) - - 32-55 kg/h
Total Steam Demand - - 352-605 kg/h
Recommendation Recommended boiler: 0.8-1 ton/h (thin-wall lower demand vs fish box). For 1-2 machines use 0.5T; for 5-8 machines use 1.2-1.5T.

Compressed Air Consumption

Equipment Per Unit Qty Total
Pre-expander pneumatics 0.2-0.3 m³/min 1 0.2-0.3 m³/min
Multi-cavity SKU switching 0.4-0.7 m³/min 4 1.6-2.8 m³/min
Auto conveying + stacker 0.5-1.0 m³/min 1 0.5-1.0 m³/min
Quick mold change pneumatics 0.3-0.5 m³/min - 0.3-0.5 m³/min
Total Air Demand - - 2.6-4.6 m³/min
Recommendation Recommended air compressor: 5-6 m³/min at 0.7 MPa (higher than fish box due to multi-SKU pneumatic load). Air storage tank 2 m³. Air dryer essential for SKU sensors.

Cooling Water Consumption

Equipment Per Unit Qty Total
Multi-cavity molders 2-4 m³/h 4 8-16 m³/h
Vacuum system cooling 3-5 m³/h 1 3-5 m³/h
Pre-expander cooling 1-2 m³/h 1 1-2 m³/h
Total Circulating Water - - 12-23 m³/h
Actual Make-up Water (8h) - - 8-18 m³/day
Recommendation Recommended cooling tower: 25-30 m³/h. Cooling water pumps: 2 pcs. Water pool: 8-15 m³.

Container Plan

20GP / 40HQ Loading Configurations

Pre-engineered container loading for your line size — daily output 800-30,000+ pieces.

Option 1: 1 × 20GP — Small Line

1 multi-cavity machine, daily output 8,000-12,000 trays

20GP Container #1

  • EPS Pre-expander 1 set
  • Fluidized Bed Dryer 1 set
  • Aging Silos 4 pcs
  • Conveying System 1 set
  • SM-1200 Multi-cavity 1 set
  • Fruit Tray Molds 3-5 sets
  • Vacuum System 1 set
  • Control Cabinet 1 set
  • Spare Parts 1 batch

Option 2: 2 × 40HQ — Middle Line

2 machines, daily output 15,000-20,000 trays

40HQ #1

  • EPS Pre-expander 1 set
  • Fluidized Dryer 1 set
  • Aging Silos 5-6 pcs
  • Conveying 1 set
  • Vacuum Tank+Pump 1 set
  • Electrical Cabinet 1 set

40HQ #2

  • SM-1200 Multi-cavity 2 sets
  • Fruit Tray Molds 6-10 sets
  • Quick Mold Change 1 set
  • Pipes/Valves 1 batch
  • Spare Parts 1 batch
Recommended

Option 3: 4 × 40HQ — Large Multi-SKU Plant

4 machines, daily output 25,000-30,000+ trays

40HQ #1 — Pre-expansion

  • Pre-expander 1-2 sets
  • Fluidized Dryer 1 set
  • Aging Silos 6-8 pcs
  • Conveying full auto
  • Cyclone 1 set

40HQ #2 — Vacuum + Cooling

  • Vacuum Tank 1 set
  • Vacuum Pump 2 sets
  • Cooling Tank 1 set
  • Cooling Pump 2 sets
  • Cabinet 1 set

40HQ #3 — Molding Group A

  • SM-1200 / 1400 Multi-cavity 2 sets
  • Fruit Tray Molds 5-10 sets

40HQ #4 — Molding Group B + Mold Library

  • SM-1200 / 1400 Multi-cavity 2 sets
  • Fruit Tray Molds 5-10 sets
  • Quick Mold Change Carts 2 sets
  • Spare Parts 1 batch

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%.

Frequently Asked Questions

How many SKUs can one machine produce per day?
With quick-change mold system, 5-12 SKUs per machine per day. Each SKU change takes ~30 minutes. Most fruit packers run 3-5 SKUs in morning shift + 3-5 in afternoon.
Why ultra-light 14-18 kg/m³ density?
Fruit trays carry their own weight + fruit weight + 5-8 stacking layers. Lower density (14-18 kg/m³) cuts tray cost 20-30% vs standard 18-22 kg/m³, while still meeting compression load. Higher fruit margin.
Can the molds be customized for my specific fruit?
Yes. Custom mold design takes 4-6 weeks including 3D CAD + mold flow simulation. We support apple / mango / grape / strawberry / pear / avocado + any custom cavity layout.
What is the cycle time per tray?
35-60 seconds per cycle depending on cavity count + wall thickness. With 6-cavity molds, that means 200-300 trays per cycle — 800-1,500 trays/h per machine.
Do I need different machines for different fruits?
No. One SM-1200 (or SM-1400 for larger) handles all fruit SKUs via mold change. Only specialty large boxes (>1400mm) need dedicated SM-1700/1800.
What container plan fits 25,000 trays/day?
4 × 40HQ. Container 1 = pre-expansion, Container 2 = vacuum cooling, Container 3+4 = 4 multi-cavity molders + tray molds + spare parts.

Tell Us Your Production Goals

Share your capacity targets, product specs, and budget — our engineers design the optimal line for your factory.

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