Turnkey Solution

Линия производства упаковки EPS — высокоплотные защитные вкладыши

Линия производства упаковки EPS на базе высокоплотных (30-50 кг/м³) машин фасонного формования и пресс-форм вкладышей под заказчика для упаковки электроники, бытовой техники, автокомпонентов и медицинского оборудования. Разработана для прочности на сжатие >100 кПа и подтверждена испытаниями на падение по ISTA 3A / ASTM D5276, производительность 3 000-15 000 вкладышей в день. Спроектирована и изготовлена на собственных заводах, ввод в эксплуатацию на объекте заказчика.

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3,000-15,000 inserts/day
Daily Output Range
30-50 kg/m³ (high)
Density Range
>100 kPa at 10% strain
Compression Strength
ISTA 3A / ASTM D5276
Drop-test Compliance

What Is a Линия производства упаковки EPS?

Линия производства упаковки EPS — это готовая установка, которая вспенивает сырые гранулы EPS и формует их паром в защитные упаковочные детали: высокоплотный предвспениватель, 6-8 силосов созревания, усиленные машины фасонного формования, пресс-формы вкладышей под заказчика и комплект коммуникаций (пар, охлаждающая вода, сжатый воздух, вакуум). Амортизирующие вкладыши формуются при плотности 30-50 кг/м³ — около 100 кПа сжатия при 30 кг/м³ и 200 кПа при 50 кг/м³ — за цикл 60-100 секунд, и одна линия выпускает от 3 000 до 15 000 вкладышей в день в зависимости от количества установленных формовочных машин. Формовочная машина в центре этой линии — упаковочная формовочная машина EPS — представляет собой усиленную машину фасонного формования: тот же цикл заполнения / пара / охлаждения / выброса, что и у стандартной машины EPS, но рассчитанную на паровую камеру 0,7-0,9 МПа вместо 0,4-0,6 МПа, поскольку вкладышам плотностью 30-50 кг/м³ со стенками 10-50 мм требуется больше энергии для спекания, чем рыбному ящику плотностью 16-22 кг/м³.

This Solution Solves

The real pain points operators in this industry face every day.

One failed drop test rejects the whole container

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.

Density drifts between shifts, so compression strength drifts with it

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.

Every account wants a different recipe, and the operator has to remember it

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.

Thick-wall inserts keep moving after they leave the mold

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.

How We Solve It

Specific technical answers ChinaEps engineers into this production line.

1
Challenge
The batch has to prove ISTA 3A / ASTM D5276 compliance before it ships
Our Answer
An in-line compression tester verifies >100 kPa at 10% strain during production, and the 4-machine layout adds a 10-30 m² on-site drop-test lab so the sample test happens before the container is loaded.
Differentiator
A test record per shipment, not one certificate per year.
2
Challenge
Holding density inside the 30-50 kg/m³ window batch after batch
Our Answer
Pre-expander steam pressure is controlled to the recipe rather than to the operator, and every batch is lot-coded through 6-8 aging silos with 24-48h aging before it reaches a molder.
Differentiator
Traceability per silo, from bead lot to finished insert.
3
Challenge
Switching between buyer-specific recipes without re-teaching the line
Our Answer
The PLC recipe library stores 100+ buyer recipes (density / cycle / steam time / cooling). The operator selects the buyer ID and the machine runs the locked recipe.
Differentiator
Recipe changeover is a selection, not a setup.
4
Challenge
Dimensional stability on 10-50 mm thick walls
Our Answer
A reinforced steam chest holds 0.7-0.9 MPa against a standard 0.4-0.6 MPa to fuse thick walls on a 60-100 second cycle, then 5-10 minutes of extended cooling before stacking.
Differentiator
Dimensions checked after cooling, not at the mold.

What This Line Produces

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

Production Flow

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

Step 1

EPS Raw Material

High-grade beads from supplier, traceability lot-coded.

Step 2

Pre-expander

High-density 30-50 kg/m³ pre-expansion for cushioning strength.

Step 3

Aging Silo

24-48h aging with batch traceability per customer order.

Step 4

Recipe Load by Customer

PLC loads buyer-specific recipe (density / cycle / steam-time).

Step 5

High-Density Molding

Reinforced SM-1200/1400 molds insert, 60-100s cycle for fusion.

Step 6

Extended Cooling

Thick-wall cooling 5-10 min for dimensional stability.

Step 7

Compression QC

On-line compression tester verifies >100 kPa at 10% strain.

Step 8

Pack + Drop-Test (Sample)

Sample drop-test per buyer batch, full lot shipped on pass.

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

  • · High-density pre-expansion 30-50 kg/m³ for cushioning strength
  • · Slower expansion = denser cell wall = higher compression resistance
  • · Steam-pressure tightly controlled for density consistency
  • · Multi-batch tracking per buyer drop-test specification
2. Aging Silo
ES-AUTO 6-8 silos

2. Aging Silo

  • · 6-8 silos for buyer-specific recipe management
  • · Aging 24-48h (longer than fish box, shorter than board)
  • · Per-customer density grade routing
  • · Drop-test batch traceability per silo
3. High-Density EPS Packaging Molding Machine
SM-1200 / 1400

3. High-Density EPS Packaging Molding Machine

  • · Reinforced steam chest for 30-50 kg/m³ density molding
  • · Cycle 60-100s for high-density bead fusion
  • · Heavy-duty clamping for thick wall (10-50mm) inserts
  • · Multi-cavity for high-throughput buyer-specific SKU
4. Custom Insert Molds
Per buyer drop-test

4. Custom Insert Molds

  • · Electronics insert (TV / monitor / laptop corners)
  • · Appliance insert (refrigerator / washing machine corner blocks)
  • · Automotive insert (bumper / dashboard packaging)
  • · Medical equipment custom geometry
Steam + Cooling + Air + Vacuum + Drop-test

5. Auxiliary Systems

  • · Steam system: 1-1.5T boiler for high-density load
  • · Cooling: extended for thick-wall stability
  • · Air: high pressure for clamping insert thickness
  • · Drop-test lab on-site for QC verification (optional)

Line Tier Options

Choose your production scale

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

Small Line

1 machine

3,000-5,000 inserts/day

  • Pre-expander 1
  • Aging Silos 6
  • Shape Molder 1
  • Insert Molds 4-8 sets
  • Auxiliary each 1 set
Most Common

Middle Line

2 machines

6,000-10,000 inserts/day

  • Pre-expander 1
  • Aging Silos 6-8
  • Shape Molders 2
  • Insert Molds 8-16 sets
  • Auto Conveying 1 set
  • Drop-test Lab recommended

Large Line

4 machines

12,000-15,000+ inserts/day

  • Pre-expander 1-2
  • Aging Silos 8-12
  • Shape Molders 3-4
  • Insert Molds 16-30 sets
  • Full Auto Conveying 1 set
  • Auto Demold + Stacking recommended
  • Drop-test Lab on-site

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 (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

Site preparation

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

Floor area
600-1,000 m²
Ceiling height
>= 6 m
Electrical
Three-phase 380V / 50Hz, 200+ kW
Steam supply
Local boiler 1-1.5 T
Cooling water
30-40 m³/h tower
Compressed air
6-7 m³/min compressor
Drop-test space
10-30 m² lab

Why ChinaEps for This Solution

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

High-Density 30-50 kg/m³ Engineering

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.

Per-Customer Batch Traceability

PLC silo routing + batch lot codes give per-shipment QC records. Critical for electronics / medical buyers who require traceability for liability.

Drop-Test Lab Integration

On-site ISTA / ASTM lab (Option 3) verifies every batch on-site before shipping. Reduces buyer return rate, increases per-shipment margin.

Reinforced Steam Chest

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

Steam · Air · Cooling Water

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

Steam Consumption (3-machine cushioning line)

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
Recommendation Recommended boiler: 1-1.5 T/h (higher per-cycle than fish box due to density). Use 0.8T for 1-2 machines, 1.5-2T for 4+ machines.

Compressed Air Consumption

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
Recommendation Recommended air compressor: 6-7 m³/min at 0.8 MPa. Air storage tank 2-3 m³. Air dryer essential.

Cooling Water Consumption

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
Recommendation Recommended cooling tower: 30-40 m³/h. Cooling water pumps: 2 pcs. Water pool: 15-20 m³.

Container Plan

20GP / 40HQ Loading Configurations

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

Option 1: 1 x 40HQ — Small Cushioning Line

1 high-density molder, daily output 3,000-5,000 inserts

40HQ Container #1

  • Pre-expander 1 set
  • Fluidized Dryer 1 set
  • Aging Silos 6 pcs
  • Conveying 1 set
  • SM-1200 High-Density 1 set
  • Insert Molds 4-8 sets
  • Vacuum + Pump 1 set
  • Cabinet 1 set
  • Spare 1 batch

Option 2: 2 x 40HQ — Middle Cushioning Line

2 molders + drop-test setup, daily output 6,000-10,000

40HQ #1 — Pre-expansion + Silos

  • Pre-expander 1 set
  • Fluidized Dryer 1 set
  • Aging Silos 6-8 pcs
  • Conveying 1 set
  • Cabinet 1 set

40HQ #2 — Molding + QC

  • SM-1200 High-Density 2 sets
  • Insert Molds 8-16 sets
  • Vacuum Tank+Pump 1 set
  • Compression Tester 1 set
  • Auto Stacker 1 set
  • Spare 1 batch
Recommended

Option 3: 4 x 40HQ — Recommended Multi-Customer Plant

4 molders + drop-test lab, daily output 12,000-15,000+

40HQ #1 — Pre-expansion

  • Pre-expander 1-2 sets
  • Fluidized Dryer 1 set
  • Aging Silos 8-12 pcs
  • Full Auto Conveying 1 set

40HQ #2 — Vacuum + Cooling System

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

40HQ #3 — Molding Group A

  • SM-1200 / 1400 2 sets
  • Insert Molds 8-16 sets

40HQ #4 — Molding Group B + QC Lab

  • SM-1200 / 1400 2 sets
  • Insert Molds 8-16 sets
  • Drop-Test Lab 1 set
  • Compression Tester 1 set
  • Spare 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

What is an EPS packaging production line?
It is the complete set of machines that turns raw EPS beads into finished protective packaging: pre-expander, aging silos, shape molder, the insert molds, and the steam / cooling / compressed-air / vacuum utilities behind them. The line is defined by the density it runs — 30-50 kg/m³ for industrial cushioning inserts — because density sets compression strength, and compression strength is what the buyer drop test measures.
What machines does an EPS packaging production line need?
Five subsystems are mandatory: a high-density pre-expander, 6-8 aging silos, a reinforced shape molder (SM-1200 / SM-1400), the buyer-specific insert molds, and the utility set (1-1.5 T steam boiler, 30-40 m³/h cooling tower, 6-7 m³/min air compressor, vacuum). The full turnkey configuration on this page lists 20 items, including compression tester, auto stacker, wrapper and waste crusher.
Which EPS packaging line do I need — industrial inserts, fish boxes, or fruit trays?
Pick by end product, because density and mold set differ. Industrial cushioning inserts for electronics, appliances, automotive and medical equipment run 30-50 kg/m³ on this line. Insulated seafood and ice boxes run far lighter on the EPS fish box production line. Ultra-light fruit trays and liners run multi-cavity molds with quick changeover on the fruit packaging line. The pre-expander, silos and utilities are shared engineering; the molder duty and molds are not.
Which molding machine makes EPS packaging?
A shape molding machine fitted with the buyer’s insert mold — SM-1200 (1,200 × 1,000 mm platen) or SM-1400 for larger inserts. For protective packaging it is specified differently from a standard EPS molder in three places: a reinforced steam chest holding 0.7-0.9 MPa against a standard 0.4-0.6 MPa, heavy-duty clamping for 10-50 mm wall sections, and a 60-100 second cycle instead of the 45-90 seconds a light box runs. Below roughly 30 kg/m³ a standard molder is adequate; at 30-50 kg/m³, which is where drop-test compression strength lives, it is not.
Do you manufacture the EPS packaging machines yourselves?
Yes. Eps Industry Engineering builds the pre-expander, the shape molders and the mold sets in its own plants — 10,000 m² across three sites in Jiangyin, Wenzhou and Dongguan — and integrates them with the silo, utility and handling equipment that completes the line. The management system is ISO 9001 certified and machines in the pre-expander and block cutting ranges carry CE certification issued by SGS. Ask for the certificate scope covering the specific model you are quoting, not a company-level statement.
Why high-density 30-50 kg/m³ vs fish box 16-22?
Cushioning protects expensive equipment in drop tests. Compression strength scales with density. 30 kg/m³ gives ~100 kPa, 40 kg/m³ gives ~150 kPa, 50 kg/m³ gives ~200 kPa. Buyer drop-test spec determines target.
Can your line meet ISTA / ASTM drop-test compliance?
Yes. Lot traceability + density consistency + on-site drop-test lab (Option 3) verify every batch meets ISTA 3A or ASTM D5276. We provide test certificates per shipment.
How is per-customer recipe managed?
PLC recipe library stores up to 100+ customer recipes (density / cycle / steam-time / cooling). Operator selects buyer ID, machine runs the locked recipe. No human error.
What is the cycle time for thick-wall inserts?
60-100 seconds. Thicker wall (>20mm) requires longer steam fusion. Optimization vs throughput is recipe-specific per buyer.
Do I need a separate boiler vs my existing fish box line?
If you already have 1T boiler, you can run small cushioning line on it. For 4-machine cushioning plant, 1.5T boiler is recommended.
How long does the line take to commission?
Equipment delivery 30-45 days + on-site installation 14-21 days. First product shipment typically 60-90 days after PO.

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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In-depth Guide

EPS Shape Molding Machine Buyer’s Guide

Machine-level selection behind this line — platen size against part dimensions, 45-90 second cycle windows, steam consumption per cycle, and where semi-automatic stops paying and full automation starts.

Read the complete guide

Related Production Lines

Diversify revenue with adjacent production capability — many customers operate multiple ChinaEps lines side-by-side.

EPS Fish Box Production Line

Insulated seafood and ice boxes are molded far lighter than industrial inserts — different mold set, different line sizing, cold-chain buyers.

Fruit Packaging EPS Tray Line

Ultra-light trays and liners on multi-cavity molds with 30-minute changeover, for exporters running 5-12 SKUs a day.

EPS Recycling Line

Edge trim and rejected inserts go back into the line as regrind instead of to landfill — the usual next purchase for a packaging plant.