Production line and factory setup overview
A small/medium moulded-fibre line converting sorted local wastepaper into protective apple, pear or tomato trays through contaminant removal, hydropulping, screening, refining and consistency control, vacuum forming on a dedicated fruit-pocket mould, wet transfer, controlled drying, optional hot pressing, nesting, compression testing and dry packing. Fruit trays require their own mould and bruise-protection trials; an egg-tray mould is not interchangeable.
Recommended lowest-entry line configuration Launch one tray matched to one confirmed fruit carton and one local crop. Screen a 500-1,000 tray/h reciprocating or compact rotary former with pulper, screen, chests, vacuum/air package and one aluminium fruit-tray mould. Use covered rack drying only after seasonal capacity trials; otherwise size a compact dryer to the wet output. Include carton-fit, stacking, vibration and fruit-bruising acceptance tests.
Production process and implementation sequence
- Wastepaper sorting and contaminant removal
- Hydropulping, screening and refining
- Consistency and additive control
- Vacuum forming on fruit-pocket mould
- Wet transfer and water recovery
- Controlled rack or compact drying
- Optional hot pressing and nesting
- Carton fit, compression, vibration and packing release
Products, capacity and market fit
- Afghan apple, pear and tomato packers need low-cost protective inserts for road transport.
- Sorted local wastepaper can replace imported plastic or foam trays.
- One crop, carton and pocket geometry keep tooling risk low.
- Drying and loaded transport performance determine saleable output.
- Apple or pear moulded-pulp tray - Buyer fruit diameter, pocket depth, carton fit, dry mass, moisture and compression - Orchards, packhouses, cold stores and exporters
- Tomato or stone-fruit tray - Separate validated pocket geometry, ventilation and bruise limit - Fresh-produce packers after dedicated trials
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Sorting table, hydropulper and screen | Prepares clean recycled fibre | 70-120 kg/h paper basis |
| Pulp chests, refiner and dosing | Controls furnish and consistency | Closed water loop |
| Vacuum fruit-tray former | Forms dedicated protective pockets | 500-1,000 trays/h |
| Fruit-tray aluminium mould set | Defines carton and fruit fit | One launch crop/size |
| Vacuum pump and compressed-air system | Forms and transfers wet trays | Matched duty and standby |
| Rack or compact dryer | Reaches safe storage moisture | Seasonal output matched |
| Optional hot press and stacker | Improves dimensions and nesting | Buyer-led option |
| Compression and transport test tools | Validates loaded packaging | Actual fruit and carton |
Raw materials, utilities and factory requirements
- Sorted local wastepaper with controlled plastic, metal and sand
- Clean makeup water and approved strength or sizing aids
- Drying fuel where forced drying is installed
- Straps, cartons, pallets, mould mesh and critical spares
- Three-phase power, vacuum and compressed air
- Reliable water with settling and high-recycle loop
- Covered dirty-paper and clean dry-product zones
- Drying yard or insulated dryer with safe fuel system
- Reject, sludge, drainage, odour and fire-control plan
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| Pulping, screening, chests and pumps | US$9k-23k | Local wastepaper preparation |
| Former, vacuum, air and one fruit mould | US$15k-38k | 500-1,000 trays/h |
| Rack/compact dryer, test and packing | US$9k-28k | Climate-dependent scope |
| Water loop, freight, installation and spares | US$9k-24k | Local tanks and civil interfaces |
| Indicative installed low-entry total | US$42k-113k | Building and wastepaper stock excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.