A brand-new, fully integrated automated production solution for pulp tableware (compatible with the export‑grade dry‑press and wet‑press tableware lines, as well as integrated production of waist‑tray paper trays).

I. Program Positioning and Applicable Products

1. Applicable Categories

2. Core Advantages of the Solution (A completely new intelligent upgrade, distinct from traditional semi-automatic lines)

1. End-to-end unmanned integration : Pulping → Forming → Hot-press drying → Edge trimming → Stacking → Packaging → Palletizing—entirely automated with robotic arms and servo‑controlled coordination; a single production line requires only 2–3 on‑site operators.
2. Compatible with both dry and wet pressing processes. A single production line, with a quick mold change, can manufacture premium export tableware and cushioning paper trays, seamlessly accommodating your existing overseas tray‑box orders.
3. Energy-Saving and Consumption-Reducing Patent-Pending Hot-Pressing System : In-mold synchronous drying and shaping at 180–200°C eliminates the need for a long tunnel dryer, reducing energy consumption by 25%;
4. AI-powered intelligent management + end-to-end pest control system : Equipped with integrated workshop disinfection, warehouse pest control, and pre‑loading empty container disinfection procedures, it resolves your container‑related insect‑infestation complaints.
5. 100% recycling of wastewater and waste materials : Closed-loop reuse of production wastewater and automated pulp return from edge trimming ensure environmental compliance and hassle-free export clearance.
6. Data Cloud Platform : Production capacity, energy consumption, yield rates, and disinfection records are archived in real time, enabling the generation of audit‑ready traceability reports for overseas customers.

II. Fully Automated Process Flow (Brand-New Intelligent Line)

1. Pulping Section: Automatic pulping and refining of pulp boards, grinding, formulation of food-grade additives, and online automatic adjustment of consistency.
2. Forming Section: Fully servo‑controlled vacuum suction forming, with real-time correction of green body thickness and basis weight, and automatic rejection of defective parts.
3. Hot-press core section: 60–80 t servo‑boosted press, dual heating with thermal oil and steam, in‑mold one‑step dehydration and drying—no secondary tunnel drying required.
4. Post‑process integration: automatic trimming of flash and simultaneous return of scrap to the slurry tank; post‑stacking UV disinfection of finished products, eliminating insect eggs and flying insects at the source.
5. Packaging and warehousing automation: automatic bagging, inkjet coding, carton sealing, and stretch‑wrap sealing; AGV transport to a dedicated outbound finished‑goods warehouse.
6. Integrated pest‑control logistics system: automated mosquito‑killing and insect‑trapping sticky traps in warehouses, a PCO timed, area‑wide disinfection and pest‑control coordination program, and a standardized cleaning and disinfection procedure for empty shipping containers.

III. Complete Automated Equipment Configuration List (Delivered as a Brand-New, Fully Assembled System)

(1) Front-end fully automated pulping circulation system (zero external wastewater discharge)

1. Fully automatic pulp board refiner and high-consistency refiner;
2. Multi-stage slurry tank + online automatic concentration control system;
3. Water circulation filtration and recovery unit, steam–water separation device;
4. Automatic scrap‑return slurry conveyor (automatically returns edge trim and defective parts, with a utilization rate of 98%+).

(2) Core‑forming and hot‑pressing integrated machine (whole‑machine patent, suitable for both dry and wet pressing)

1. Vacuum slurry‑suction forming station: reciprocating slurry‑suction mold with intelligent vacuum‑negative‑pressure regulation.
2. Servo‑controlled hot‑press forming station: maximum pressure of 80 tons, temperature control within ±2°C, and in‑mold synchronous drying at 180–200°C.
3. Automatic edge trimming/punching station: trims edges in a single pass, with no manual edge finishing required.
4. Truss-type servo robot: Ensures no manual contact with wet blanks throughout the entire process, thereby minimizing contamination and the introduction of pest sources.
5. Configuration: high-pressure vacuum pump unit, air compressor, and thermal oil heating system.

(3) Post‑process fully automated finished‑product handling line (pest control and sterilization + automated packaging)

1. Finished-product automatic stacking and sorting machine;
2. UV ultraviolet disinfection tunnel (pre‑disinfection prior to product shipment, eliminating surface insect eggs and small insects);
3. Fully automatic inner-bag packaging machine and sealing machine;
4. Online inkjet printer (automatically prints batch numbers, production dates, and export markings);
5. Automatic flap‑folding and box‑sealing machine; complete wrapping‑film sealing equipment.

(4) Intelligent Warehousing and Logistics Automation (Addressing the Root Cause of Container Pests)

1. AGV automated transfer robots; finished products are stored in segregated zones (export and domestic sales kept separate).
2. Warehouse Intelligent Pest Control System: automatic mosquito-killing lamps, sticky insect trap monitoring, and timed, eco-friendly misting disinfection units.
3. Automatic disinfection station for export pallets (compatible with IPPC‑certified heat‑treated pallets for cleaning and disinfection);
4. Container empty‑box pre‑treatment workstation: an integrated system for high‑pressure cleaning, enclosed disinfection, and ventilation‑based static conditioning.

(5) Intelligent Central Control Cloud Management System

1. Centralized control cabinet for the entire system, with one-button start/stop and automatic fault alarm.
2. Cloud-based storage of production data: automatic archiving of capacity, energy consumption, yield, disinfection records, and warehouse inspection logs.
3. Mobile remote monitoring, supporting online traceability audits for overseas customers.
4. Automated generation of pest‑control records (which can serve as supporting documentation for foreign‑trade pest‑management corrective actions).

IV. Standard Solutions by Production Capacity (Select according to requirements; complete, brand-new units)

Option 1: A dedicated small‑scale foreign trade line (focusing on waist‑disc paper trays and medium‑to‑small batch tableware)

• Daily production capacity: 800–1,000 kg/24 h
• Host Model: SD-P22/TF-01C All-in-One Unit
• Required workshop space: ≥300㎡
• On-site personnel: 2–3 people (for inspection and mold changes only)
• Applicable: For your existing export waist‑plate orders, we can provide sample sets with a small selection of tableware and arrange for small‑batch shipments.
• Key highlights: Compact footprint, moderate investment, and comes with a complete set of finished-product disinfection and warehouse pest-control systems.

Option 2: Medium-Scale Fully Automated Production Line (Mainstay for Bulk Exports of Tableware and Paper Trays)

• Daily production capacity: 2,000–2,500 kg/24 h
• Host: Dual-station servo-integrated molding and hot-pressing line
• Workshop area: ≥600㎡
• On-duty personnel: 3 people
• Compatibility: Long-term, stable overseas orders; simultaneous production of multi-category meal trays and waist trays; ideal for factory capacity expansion.

Option 3: Complete Line for a Large-Scale Intelligent Unmanned Factory (Annual Capacity of 3,000 Tons or More)

• Multi‑host parallel operation + fully automated AGV‑based three‑dimensional warehousing;
• End-to-end, fully automated handling with no manual intervention, supported by a dedicated disinfection workshop and a container pre‑treatment area.
• Equipped with an on-site eco-friendly wastewater treatment plant and a third-party disinfection data integration system, we meet the factory‑audit requirements of major European and American clients.

V. Three Major Technological Innovations (Distinguishing It from Traditional, Outdated Equipment)

1. In-Mold Synchronous Drying Energy-Saving Technology

2. End-to-end integrated pest control design (specifically addressing your container‑borne insect issues)

1. Production side: UV disinfection of finished products to eliminate insect eggs on the product surface.
2. Warehouse Operations: Intelligent timed disinfection and sealed, partitioned storage to eliminate flying insects in the warehouse.
3. Logistics side: Pallet disinfection and standardized cleaning and disinfection of empty containers; the entire process is integrated into the equipment’s central control system, with disinfection records automatically generated for each container and readily accessible for customer verification.

3. Mold system with rapid switching between dry and wet pressing modes

VI. Environmental Protection and Export Compliance Assurance

1. The raw materials are plastic-free and fully biodegradable, meeting EU and U.S. FDA food-contact standards.
2. Production wastewater is recirculated in a closed-loop system, with fresh water consumption ≤ 0.3 m³/h and no external discharge of effluent.
3. Edge‑trim waste is 100% recycled into pulp, achieving zero solid waste discharge.
4. The complete equipment set comes with CE certification and a material test report confirming food-grade compliance.
5. Automatically generates disinfection and production records, which can be directly used for customer pest‑control remediation and factory audits.

VII. Investment Returns and Supporting Implementation Services

1. Payback Period

2. One-stop delivery service (a fully comprehensive, turnkey solution)

1. Factory floor layout planning and utility‑energy consumption estimation;
2. Complete equipment design, manufacturing, installation, and commissioning;
3. Custom mold manufacturing (universal molds for waist trays and various types of dinner plates);
4. Comprehensive training for operators covering all process steps (equipment operation, pest control, and preparation of foreign trade records).
5. Lifetime after-sales service, remote fault diagnosis, and annual equipment upgrades;
6. Complementary SOP documents for pest control and a corrective action report template (designed to directly address overseas customer complaints) are provided.

VIII. The solution addresses your core pain points.

1. Insect Issues in Foreign Trade Containers The complete production line integrates fully automated processes for disinfection, warehouse pest control, and pre‑treatment of empty containers, with all disinfection records automatically archived to ensure end-to-end traceability from the source.
2. Dry-pressed waist plates + mixed tableware production : A universal dry‑wet pressing machine that eliminates the need to run two separate production lines, thereby reducing equipment investment.
3. High labor costs : Fully robotic and AGV‑automated, with a 70% reduction in manpower;
4. Export factory inspections are difficult. : Cloud-platform data traceability, environmental compliance, and pest‑control standardization system—passed major‑client audits on the first attempt.