Project Background & Existing Challenges

As demand for egg trays continued to rise in Iran, product specifications and styles were changing more frequently. The customer’s existing semi-automatic equipment provided limited automation, while upgrading the production line posed several practical challenges:

• Operators were accustomed to conventional blister forming machines. Switching to a completely different system would require additional training and could interrupt production.
• The customer already owned more than 200 sets of molds, creating a risk that a new machine would make the existing tooling unusable.
• Product specifications changed frequently. Higher-investment positive/negative-pressure three-station machines were not well suited to the customer’s requirement to continue using locally made molds.

Project Timeline

• 2018: The customer began discussing its equipment requirements with Amtop.
• 2019: The customer purchased the first machine for trial production. After successful production validation, they continued placing repeat orders.
• To date: Five forming machines have been purchased to support the upgrade of the customer’s older production lines.

Customized Solution

• Familiar Operating Principle for a Smooth Upgrade: The vacuum forming machine retains a similar operating approach to the customer’s conventional blister forming equipment, allowing operators to quickly become familiar with the new system while reducing training requirements and production downtime.
• High Mold Compatibility with Support for Locally Made Molds: The equipment accommodates the customer’s self-developed and locally manufactured egg tray molds, helping preserve the value of its existing mold inventory.
• 3-Station Cyclic Operation: The three-station system supports continuous production with a relatively straightforward maintenance approach, balancing mass-production capability with operating and maintenance costs.

Project Outcome

The customer upgraded its production line while keeping established operator working practices largely unchanged. The new equipment also made it easier to meet demand for egg trays in different specifications. With a total of five machines installed, the customer increased production capacity and expanded its egg tray range.