High-Rigidity Deep-Draw Forming | Integrated Automated Mass Production Solution
As market demand for large-size, deep-draw aluminum foil containers continues to grow across the food delivery, ready-to-eat meal and airline catering sectors, traditional small-to-medium tonnage stamping lines face widespread bottlenecks: insufficient stamping rigidity, low yield in deep-draw forming, limited capacity scalability and high labor dependency — making it difficult to fulfill high-quality, large-volume orders.
The AF-80AT fully automatic aluminum foil container production line is a turnkey manufacturing solution. Built around an 80-ton high-precision open-type press, it integrates a servo feeding system, multi-channel automatic stacking unit and scrap recycling & baling system to deliver fully automated production from mother roll loading to finished product stacking and discharge. Controlled by a unified PLC system with precisely synchronized process cycles, it eliminates common issues of fragmented equipment combinations such as coordination lag and poor parameter compatibility. With high operational stability and low failure rates, the entire line can be attended and packaged by a single operator, significantly reducing labor costs and management overhead.
Core Line Units: Modular Integrated Design with Fully Coordinated Processes
The complete production line consists of four core units. Each unit can be debugged and maintained independently, while operating in sync via the central control system to adapt to production requirements of different capacities and product specifications.
1. 80-Ton High-Precision Open-Type Punch Press
High-rigidity frame + Grade 1 accuracy ensures premium deep-draw forming quality
As the power core of the line, this press features an integral cast steel frame, a motor-gear-crankshaft drive system and symmetrical six-sided copper guide rails, achieving JIS Grade 1 stamping accuracy. With 800kN nominal force and sufficient nominal force stroke, it delivers consistent pressure required for deep-draw forming, effectively eliminating industry pain points such as incomplete forming, sidewall wrinkling and bottom cracking common with smaller-tonnage equipment, and significantly improving product consistency and production yield.
Key Performance Parameters
- 800kN (80-ton) nominal force with 4.5mm nominal force stroke, delivering strong stamping rigidity and excellent eccentric load resistance for various deep-cavity, large-size aluminum foil container forming
- 260mm slide stroke (customizable), 550mm maximum die height (customizable), compatible with forming dies of different depths
- 50–78 strokes per minute (customizable), allowing flexible stamping rhythm adjustment based on forming difficulty to balance quality and efficiency
- 650mm throat depth (customizable), 1000×1300mm table size (customizable), providing ample space for large-die installation and maintenance
Global Brand Configuration for Long-Term Reliability
Core components are selected from industry-leading brands, effectively increasing mean time between failures (MTBF) and reducing long-term maintenance costs:
- Electrical System: SIEMENS (Germany) main motor, OMRON (Japan) secondary-drop protection device for precise control and sufficient safety redundancy
- Pneumatic System: TACO (Japan) duplex solenoid valve, AirTac air treatment units and automation solenoid valves for fast response and excellent sealing performance
- Sealing & Lubrication: Taiwan Halsen seals paired with concentrated oil lubrication system to continuously reduce mechanical wear and extend service life
- Safety Protection: KingAir (Taiwan) hydraulic overload protection device combined with dry pneumatic friction clutch, responding instantaneously to overload conditions to protect equipment and dies
- Optimized Design: Upsized balance cylinder and frequency converter for enhanced operational smoothness; wet stamping process significantly reduces production noise and improves workshop working environment
2. SL1200 Servo Aluminum Foil Feeder
Closed-loop tension control for high-precision thin-foil conveying
The feeding unit adopts a servo drive system with fully automatic tension control, stably handling thinner gauge aluminum foil materials. It delivers slip-free, deviation-free conveying, effectively reducing material wrinkling and edge damage, and improving material utilization.
- Supports raw materials up to 1200mm in width and 800mm in maximum unwinding diameter, enabling large-roll production and reducing roll-change downtime
- Steplessly adjustable feeding length from 1mm to 9999mm with ±0.1mm feeding accuracy for precise positioning and minimal trim scrap
- Feeding speed up to 0–150m/min, dynamically synchronized with the press stamping rhythm
- 250mm lateral and height adjustment stroke for wide die compatibility; embossing roller optional for textured product production
3. Multi-Channel Automatic Stacking Unit
Contactless collection balancing efficiency and food safety compliance
Paired with a four-channel automatic stacker, it realizes fully unmanned operation including automatic counting, anti-collision conveying, neat stacking and full-stack discharge, completely solving issues of low manual collection efficiency, product deformation & scratching, and food hygiene risks from hand contact.
- Wide size compatibility: minimum 120×100×120mm, maximum 360×250×120mm (customizable)
- Maximum stacking speed of 65 pieces per minute per channel, perfectly matching press capacity with no collection bottleneck
- Flexible conveyor belt height adjustment for quick die changeover and line commissioning
- Neatly stacked products with scratch-free surfaces, eliminating secondary contamination from manual contact and complying with food packaging safety and hygiene standards
4. Automatic Scrap Recycling & Baling System
Closed-loop clean production with enhanced scrap residual value
Aluminum foil trimmings generated from stamping are automatically sucked through a negative-pressure fan to the baling unit and hydraulically compacted into high-density bales. This system prevents scrap buildup and equipment jamming to ensure continuous production, while keeping the workshop clean. Compacted scrap greatly reduces storage and transportation costs and increases recycling value.
Key Technical Specifications
| Item | Specification |
|---|---|
| Punch Press Nominal Force | 800kN (80 tons) |
| Slide Stroke Frequency | 50–78 strokes/min (customizable) |
| Slide Stroke Length | 260mm (customizable) |
| Maximum Die Height | 550mm (customizable) |
| Throat Depth | 650mm (customizable) |
| Table Size (Left-Right × Front-Back) | 1000×1300mm (customizable) |
| Maximum Raw Material Width | 1200mm |
| Feeding Accuracy | ±0.1mm |
| Stacking Speed (Per Channel) | Max. 65 pieces/min |
| Required Air Pressure | 0.6MPa |
| Main Motor Power | 11kW |
| Punch Accuracy Class | JIS Grade 1 |
Core Solution Values: Comprehensive Efficiency Gains from Capacity to Quality
1. Superior Deep-Draw Yield with High-Rigidity Large-Tonnage Stamping
The 800kN nominal force, combined with the integral cast steel frame and high-precision guide rails, delivers strong stamping rigidity and excellent eccentric load resistance. It consistently forms deep-cavity, large-size aluminum foil containers with uniform wall thickness and full contours, effectively reducing defect rates from drawing cracks and wrinkling — especially suitable for high-value deep tray and deep lunch box production.
2. Full-Process Automation Reduces Labor & Management Costs
Controlled by a unified intelligent system, the entire line automates all processes from feeding, stamping, stacking to scrap handling. A single operator can attend the line and handle finished product packaging, significantly reducing staffing requirements, labor costs and personnel management expenses.
3. Global Core Component Selection Ensures Long-Term Continuous Production Stability
Core components including electrical, pneumatic, sealing and safety protection parts are sourced from established industry brands. Combined with high-standard machining and assembly processes, the equipment delivers long MTBF and simple daily maintenance, supporting 7×24 continuous mass production to meet large-order delivery requirements.
4. Low-Noise Clean Production Meets Modern Factory Standards
The wet stamping process effectively reduces production noise. Together with the fully enclosed scrap recycling system, it maintains a clean and quiet workshop environment, meets green factory and clean production requirements, and helps enterprises improve on-site management standards.
5. Highly Customizable Configuration for Flexible Product Portfolio
Core parameters such as slide stroke, die height, throat depth and table size can be customized to product requirements, enabling quick adaptation to aluminum foil containers of different specifications and shapes. This helps enterprises flexibly adjust product mix and respond quickly to changing market demands.
6. Multiple Safety Protection Mechanisms Minimize Production Risks
Equipped with hydraulic overload protection, secondary-drop protection and other safety devices that respond instantaneously under abnormal conditions, it effectively protects equipment, precision dies and operators, reducing the risk of production accidents and equipment damage.
Ideal Applications
- Large-size takeaway aluminum foil lunch boxes, high-capacity takeaway containers
- Deep-draw aluminum foil lunch boxes, baking trays
- Standard aluminum foil containers for airline catering and railway meals
- Special aluminum foil packaging for ready-to-eat meals
- Household aluminum foil baking trays, multi-compartment lunch boxes
Whether you are building a new intelligent aluminum foil container production line, upgrading existing capacity, or expanding into high-value large-size deep-draw products, the AF-80AT fully automatic aluminum foil container production line provides a stable, efficient and cost-effective mass production solution, helping you build dual advantages in capacity and quality in the competitive aluminum foil packaging market.
