In commercial egg production, efficiency is key. However, even the fastest systems can struggle when it comes to protecting the eggs. Once the eggs leave the layer house, they enter a delicate stage in the supply chain. Any vibration, bump, or misaligned tray can lead to costly breakage.
The DuraPlas Egg Transport System provides a practical solution, designed for modern poultry operations. Made from injection-molded plastic, this product reduces cracks, contamination, and inefficiency through a streamlined design.
The Challenge: Mixed Egg Sizes and Fragile Cargo
In large poultry houses, it's common for eggs of different sizes to roll off the same conveyor belt. Large, extra-large, and jumbo eggs often share a collection line, but not every tray can handle this size variation. When heavier eggs are placed in trays that are too small or too flexible, they can create pressure that builds unevenly. This imbalance can result in hairline cracks, bruising, or crushed shells before the eggs even leave the farm.
The issue gets worse when the stacks of trays grow taller. Trays that bend slightly under weight can cause the load to shift, transferring stress from one tray to another and increasing the likelihood of damage. For operations that handle thousands of eggs daily, these small problems result in waste and lost profits.
DuraPlas engineers looked for a solution to this problem by asking how one system could safely handle every egg size in production. They found the answer by using consistent cell shapes, strong materials, and a modular design.
Engineered for Real-World Demands
The DuraPlas Egg Transport System is built around three interlocking parts that function as one: a pallet base, dividers, and 30-cell egg trays. Together, they form a cohesive transport unit capable of carrying up to 12,960 eggs per pallet, depending on configuration.
The pallet base is the primary support structure. It has a Flow-Thru design that allows automated cleaning systems to easily access every surface. This design prevents egg residue and bacteria from accumulating, a common issue in traditional closed pallets. The dividers give extra strength, enabling up to five pallets to be stacked for improved stability and even weight distribution. The 30-cell trays hold the eggs, with each cell able to support eggs weighing up to 90 grams or about jumbo size, while still accommodating smaller eggs.
The system works because it's modular. Every piece is injection-molded to ensure consistent sizes, which keeps stacks uniform and compatible across different loads. This reliability allows safe scaling, whether shipping a few pallets locally or filling a container for export.
Designed for Automation and Compatibility
Automation has changed how egg processing facilities operate. Now, machines like conveyors, graders, and washers handle tasks that were once performed by hand. DuraPlas designed its trays, dividers, and pallets to work well with automated systems. Each item is strong and, most importantly, maintains its shape, so it can withstand mechanical use without causing delays from jamming or misalignment.
DuraPlas made sure its products were compatible with several transportation systems. Producers can adopt them without needing to replace their old equipment. This backward compatibility allows operations to modernize step by step instead of changing everything at once.
For producers, this approach leads to less disruption, fewer equipment changes, and easier integration with existing workflows.
Built To Last, Easy To Clean
The DuraPlas system features a smooth, non-porous plastic surface that doesn't absorb moisture or bacteria, reducing cleaning time and chemical use. Its Flow-Thru pallet feet allow for effective high-pressure washing, minimizing contamination risks and enhancing hygiene. The durable plastic components resist cracking, chipping, or warping, and the trays can be stacked six high without issue. Weighing between 150 and 210 pounds when empty, the system remains stable when loaded yet is easy to move, allowing producers to invest in a reliable system that lasts through thousands of cycles with minimal wear.
Uniform Protection for Every Egg
One major inefficiency in egg production is the need to sort eggs by size before they are transported. The DuraPlas 30-cell tray solves this problem by holding medium to jumbo eggs in a single design. Its flexible shape gently supports heavier eggs while protecting smaller ones.
This flexibility makes logistics easier for farms. Instead of storing different tray types or adjusting sorting lines, producers can use one standard unit. This results in faster processing, reduced handling, and fewer opportunities for mistakes or damage. By tackling the mixed-size issue, DuraPlas helps producers focus on increasing output instead of dealing with workarounds.
Efficiency Beyond the Barn
The DuraPlas system offers several benefits that go beyond just the production floor. One major advantage is freight optimization, which is key to making a profit. The system's consistent sizing helps maximize shipments. The pallets fit perfectly in 20-foot, 40-foot, and 53-foot containers, making it easier to plan loads and minimize wasted space.
The system is also efficient when not in use. Empty trays nest neatly, and dividers and pallets stack flat for easy storage. This efficiency leads to lower warehousing costs and simplifies inventory management between production cycles. Every design choice—from weight to shape—prioritizes practical performance over unnecessary features.
Simple by Design, Powerful in Impact
The DuraPlas Egg Transport System is strong because of its precision. It improves egg handling without making it overly complicated.
By reducing breakage and bruising of different egg sizes, the system helps protect revenue. Its non-porous surface makes cleaning faster, boosting biosecurity and saving labor time. The standard design keeps automation lines running smoothly, and the use of tough materials lowers overall costs by extending the system's lifespan and reducing the need for replacements.
In an industry with tight profit margins, these small improvements provide a real edge over competitors.
