Project Background & Existing Challenges

Demand for cookie trays was growing in the Indian market. As the customer’s order volume increased, its existing locally made semi-automatic equipment began to hit production bottlenecks:

• Manual sheet cutting limited production efficiency and made it difficult to handle large-volume orders.
• The ceramic heating system required more than 25 kW of power, putting additional pressure on production costs due to high local electricity prices.
• Cutting and sorting relied heavily on manual labor and also occupied considerable workshop space.

Project Timeline

Customized Solution

• Compact Integrated Design: Heating, forming, cutting, and stacking are integrated into one automated system with a compact footprint, making the thermoformer suitable for upgrading the customer’s existing workshop.
• Chain-Free Feeding with Cookie-Tray Mold: The chain-free feeding system is combined with a mold designed specifically for cookie tray production, reducing PET sheet waste.
• Fully Automatic Forming, Cutting & Stacking: The complete forming, cutting, and stacking process is automated, replacing manual cutting and sorting while increasing production-line output.

Project Outcome

After introducing the new equipment, it reduced electricity costs, material waste, and labor costs while improving overall production efficiency. The upgraded production line enables the customer to handle larger-volume orders.