**Case Study in Packaging Industry: Intelligent Transformation of Fully Automatic Thermoforming Folding Machines**

Against the backdrop of the packaging industry's shift towards intelligent and efficient operations, numerous packaging enterprises have achieved innovative production models and enhanced market competitiveness through technological upgrades of fully automatic thermoforming folding machines. Companies have adopted diverse upgrade paths based on their production needs and existing equipment foundations, forming a series of replicable and scalable practical cases. This article introduces the technical upgrade solutions, implementation processes, and outcomes of fully automatic thermoforming folding machines, providing references for other enterprises.

**Case 1: Low-Cost Intelligent Upgrade for an SME Food Packaging Manufacturer**

**Company Profile**

A small-to-medium-sized food packaging enterprise (50 employees, annual output value of RMB 20 million) mainly producing thermoformed packaging trays for snacks such as potato chips and biscuits. Before the upgrade, the company used three semi-automatic thermoforming folding machines, requiring manual feeding, positioning, and defect sorting, with the following challenges:

- High labor costs (2 workers per production line, monthly labor cost of RMB 12,000)

- Low production efficiency (daily output of 8,000 pieces)

- High defect rate (approximately 6%)

Due to limited capital, the company opted to retrofit its existing equipment with intelligent solutions instead of investing in high-end smart machinery.

**Upgrade Solutions**

1. Installation of Automatic Feeding and Positioning System

   - Conveyor-belt automatic feeding devices installed at the material inlet

   - Paired with photoelectric sensors for precise positioning (error ±0.2mm)

   - Reduction of 1 operator per production line

2. Addition of Automatic Defect Detection Module

   - Industrial cameras installed for visual inspection

   - Real-time identification of folding accuracy and surface defects

   - Automatic rejection of defective products to improve yield

3. Optimization of Heating System

   - Replacement with energy-efficient heating elements

   - Equipped with intelligent temperature controllers (control accuracy ±1°C)

   - Power consumption reduced from 12kW to 8kW

**Implementation Process**

The upgrade was completed in two phases:

- Phase 1 (1 month): Retrofitting one machine for trial operation and parameter adjustment

- Phase 2 (2 months): Completing the remaining equipment modifications and conducting operator training

Total investment approximately RMB 80,000, with no disruption to normal production during the retrofitting period.

**Upgrade Outcomes**

1. Cost-Benefit Analysis

   - Monthly labor cost reduced from RMB 36,000 to RMB 18,000

   - Annual labor cost savings of RMB 216,000

   - Annual electricity savings of approximately RMB 36,000

2. Production Efficiency

   - Daily output increased from 8,000 to 15,000 pieces

   - Improvement rate of 87.5%

   - Order fulfillment cycle shortened by 42%

3. Quality Enhancement

   - Defect rate decreased from 6% to 1.5%

   - Annual reduction in raw material waste of approximately RMB 120,000

4. Return on Investment

   - Upgrade costs recovered within 4 months

   - Annual output value increased to RMB 28 million

   - Successful establishment of partnerships with 2 major food manufacturers

This case demonstrates a feasible path for SMEs to achieve intelligent equipment upgrades with limited investment, providing replicable experience for similar enterprises. Through targeted technological transformations, not only were specific production pain points addressed, but dual enhancements in economic benefits and market competitiveness were also realized.