A Closer Look to Plastic Egg Tray Manufacturing Process

The main material used in egg tray has usually been foam, but new technology has brought upgrade it into plastic egg tray manufacturing process. These newer materials make it easier to store eggs and protect them from damage during shipping. By understanding this, distributors can find good manufacturers to take advantage of the growing market while it’s still new.

1. Market Potential

Foam egg trays are widely used for transporting eggs because eggshells are delicate and porous. While plastic egg trays were mainly designed for refrigeration, this is starting to change. Nowadays, plastic trays are also being used for shipping over long distances, thanks to improvements in technology.

The global egg tray market was worth USD 4,140 million in 2021 and is projected to grow to USD 6,353.60 million by 2029, with an annual growth rate of 5.50% from 2022 to 2029. The rising popularity of packaging solutions in developed countries like the United States and Germany, along with an increasing need for safe transportation, is boosting the demand for egg trays.

However, this is the general growth rate of egg trays, in fact for plastic products the number is increasing very rapidly.

2. Raw Materials

The main raw materials used are:

• PVC (polyvinyl chloride), polypropylene (PP), and polystyrene (PS). PVC is often chosen because it is easy to mold and inexpensive. It is made from a vinyl chloride monomer and appears as a white powder. In some factories, they often use PET plastic.
• Pigments, both organic and inorganic, are added as powders for color.
• Fillers, like talc and calcium carbonate, are also used in powder form.

3. Plastic Egg Tray Manufacturing Process

And here is the complete and specific process of how plastic egg tray is produced:

3.1. Raw Material Procurement

The plastic egg tray manufacturing process starts with sourcing raw materials like PP or PVC, polypropylene, and pigments. The quality of these materials is crucial, as they directly impact the durability and appearance of the trays. Therefore, materials should be sourced from reliable suppliers to ensure consistency and quality. 

The primary raw materials include:

• PVC (Polyvinyl Chloride): 70-80% of the mixture.
• Pigments: 2-5% for coloring.
• Fillers: Talc and calcium carbonate, about 10-15%.

However, each factory will have different types and a specific ratio of materials, which is also their competitive advantage, and of course, this information is confidential. Therefore, we will only provide estimated figures to help you easily understand the materials used.

3.2. Mixing Process

The raw materials are mixed together in specific ratios. This typically involves blending around 70-80% PVC with the appropriate amount of pigments and fillers to achieve the desired characteristics.

• Equipment: A high-capacity mixer blends the materials. And when it comes to mixing machines, a notable mention by manufacturers is the Plastic Mixer from Wensui Intelligent Equipment Inc.
• Ratio: Typically, 75% PVC, 3% pigments, and 15% fillers.
• Duration: Mixing takes about 10-15 minutes to ensure an even blend.

3.3. Injection Molding Process

The mixed materials are then fed into an injection molding machine. This no.3 plastic egg tray manufacturing process can be completed in about 20-30 seconds per cycle, depending on the complexity of the tray design.

• Machine Setup: Injection molding machines are set to operate at 180-200°C (356-392°F).
• Cycle Time: Each molding cycle lasts approximately 20-30 seconds, producing one or multiple trays at a time.
• Production Rate: A machine can produce around 1,000 trays per hour, depending on the design.

3.4. Resin Poured into Hopper

The resin mixture is poured into a hopper, where it is prepared for the next step in plastic egg tray manufacturing process. This step ensures a consistent flow of material into the injection molding machine.

• Hopper Capacity: The hopper holds enough resin for continuous operation, typically around 50-100 kg.
• Feeding Process: Automated systems ensure a steady flow of resin to minimize downtime.

3.5. Mixing & Melting of Resin

3.6. Cooling

Once the resin is injected into the mold, it cools and solidifies. This cooling phase generally lasts 10-15 minutes, ensuring that the trays maintain their shape and strength.

During this time, the liquid resin solidifies, taking on the shape of the mold and ensuring that the trays maintain their structural integrity and strength. Effective cooling is critical, as it not only affects the dimensional accuracy of the trays but also their overall durability.

3.7. Packaging & Storage

Once the egg trays have cooled and solidified, they are carefully packaged for storage and distribution. This final step involves stacking the trays methodically and wrapping them securely to prevent damage during transit.

Typically, the packaging process is conducted in batches of 100-200 trays per package, ensuring efficient handling and transport. Proper packaging is essential to maintain the quality of the trays, enabling them to reach retailers and consumers in excellent condition while also facilitating easier storage and inventory management.

4. FAQs

Are plastic egg trays more environmentally friendly than egg trays made from foam?

Indeed, plastic egg trays can be better for the environment than foam trays if they are made from recyclable materials. Foam trays often end up in landfills and take a long time to break down, while many plastic trays can be recycled, which helps reduce waste. However, the environmental impact also depends on how they are made.

What are the signs of a disreputable manufacturer that is not worth working with?

Here are some signs to look out for:

• Lack of transparency: If they won’t share details about how they make their products.
• Poor reviews: Many negative comments from past customers.
• Quality issues: Frequent reports of damaged or low-quality products.
• No certifications: Missing important safety or industry certifications.
• Bad communication: Hard to contact or slow to respond.

How should I choose an egg tray for my modern kitchen?

When selecting an egg tray for your kitchen, consider the following:

• Material: Choose between plastic or other materials based on durability and recyclability.
• Design: Look for a design that fits your kitchen aesthetic and is functional for storage.
• Capacity: Decide how many eggs you typically store and choose a tray that accommodates that amount.
• Ease of cleaning: Opt for materials that are easy to clean and maintain.
• Safety features: Ensure the tray protects the eggs from breakage and is made from food-safe materials.

In conclusion, the plastic egg tray manufacturing process is crucial for distributors looking for trustworthy factories. By understanding each step—from raw materials to packaging—distributors can identify reputable manufacturers that produce high-quality trays. This knowledge helps them make informed choices and establish strong partnerships with reliable factories.