Pulp egg tray and egg box production lines represent one of the most mature, cost-efficient, and environmentally responsible packaging solutions in today’s global market. With rising concerns about plastic pollution, escalating demand for recyclable packaging, and worldwide growth in the poultry and agricultural sectors, molded pulp egg trays and cartons have become a preferred choice for both producers and retailers.
This complete guide provides an in-depth explanation of raw materials, production technologies, machine configurations, workflow processes, automation options, and industry opportunities—offering manufacturers a thorough blueprint for planning, upgrading, or investing in a pulp egg tray or egg box production line.
1. Introduction to Pulp Egg Trays & Egg Boxes
Egg trays and egg boxes are protective packaging products made from recycled paper pulp. They are widely used to store, transport, and display eggs in supermarkets, farms, and distribution channels.
Key Advantages
- Eco-friendly & biodegradable
- Shock-absorbing protection
- Low production costs
- Strong market demand
- Suitable for global environmental regulations
Molded pulp packaging is produced through the process of pulping, forming, drying, and hot pressing. A single production line can manufacture a wide range of items, such as:
- 30-cell egg trays
- 12/6/10-egg cartons
- Fruit trays
- Cup trays
- Industrial protective packaging
However, egg tray and egg carton products remain the largest application worldwide, typically accounting for more than half of total molded pulp output.
2. Raw Materials for Pulp Egg Tray & Egg Box Production
The core raw material is waste paper, including:
- Old Corrugated Cardboard (OCC)
- Old Newspapers (ONP)
- Office waste paper
- Recycled egg trays or cartons
- Why Waste Paper Works Best
- Abundant and low-cost
- High fiber content and good bonding performance
- Fully recyclable and compostable
- Stable supply in all markets
Water and food-safe chemical additives (optional) may also be included:
- Waterproof agents
- Oil-resistant additives
- Color pigments
- Strengthening agents
Quality of raw materials directly affects product strength, forming stability, and consistency—making proper sorting and pulping essential.
3. Overview of the Production Line Workflow
A complete pulp egg tray and egg box production line typically includes the following stages:
(1) Pulping System
Waste paper is mixed with water inside hydrapulpers, refiners, and pulp storage tanks.
Breaking → Screening → Refining → Pulp storage
Target pulp consistency: 3–5%
(2) Forming System
- The pulp is vacuum-formed into shape using production molds.
Types of forming systems: - Rotary Drum Forming Machine (most common)
- Reciprocating Forming Machine
- Rotary Double-Rotation System (high capacity)
Vacuum suction removes excess water while forming precise cavities in the mold.
(3) Drying System
The wet trays are transferred to the drying line.
Drying methods include:
- Multi-layer metal drying tunnel (most popular)
- Brick drying chamber
- Natural sun drying (small-scale or low-investment)
Consistent drying is critical for product strength and dimensional accuracy.
(4) Hot Pressing (Optional for Egg Boxes)
Egg cartons typically undergo hot pressing to:
- Improve surface finish and accuracy
- Enhance stiffness
- Enable printing or labeling
This step creates a clean, high-value retail-grade appearance.
(5) Stacking & Packing
Automatic counters and stackers organize finished products.
Packing options:
- Manual baling
- Semi-automatic packing
- Fully automatic compression packing
Automation significantly improves labor efficiency and consistency.
4. Machine Types & Production Line Configurations
A. Manual Production Line
- Lowest investment
- Uses manual drying or basic equipment
- Suitable for small farms or low-output regions
B. Semi-Automatic Production Line
- Automated forming
- Manual or semi-automatic drying
- Ideal for small to medium enterprises
C. Fully Automatic Production Line
- Full automation from pulping to packing
- Multi-layer drying tunnel
- High-speed and continuous production
- Suitable for large factories or national distributors
D. Fully Automatic Egg Carton Production Line with Hot Press
- Includes precision hot pressing
- Adds printing/labeling systems
- Targets supermarket-grade retail packaging markets
5. Mold Types and Product Flexibility
Molds determine the shape, size, and quality of the final packaging.
Common mold sets include:
- 30-cell egg tray molds
- 6/10/12-egg box molds
- Duck egg tray molds
- Cup tray molds
- Fruit tray molds
- Industrial packaging molds
High-quality molds (aluminum + CNC machining) ensure:
- Accurate shape
- Long service life
- Smooth surface
- Faster forming speed
A single production line can produce multiple products by changing molds.
Conclusion
Pulp egg tray and egg box production lines represent one of the most profitable, sustainable, and scalable packaging industries available today. Their reliance on recycled paper, low production costs, and high global demand make them ideal for new investors, packaging companies, and poultry industry stakeholders.
Whether you are planning a small farm-based setup or a fully automated industrial factory, understanding the full production process—from raw materials to quality control—allows you to build a reliable, long-term, and environmentally responsible business.
