Form-Cut-Stack Machines.
Integrated roll-fed thermoforming lines that form, cut, and stack finished parts in a single continuous process. Designed for high-volume production of food packaging, trays, containers, and industrial packaging.
What is a form-cut-stack machine?
A form-cut-stack machine is an integrated thermoforming line that performs three operations in sequence: forming the heated plastic sheet into parts, cutting (punching) the formed parts from the web, and stacking the finished parts — all in one continuous, automated process.
Unlike standalone vacuum forming machines that produce one sheet at a time, form-cut-stack machines process continuous rolls of thermoplastic film. The roll is fed through infrared heaters, formed in a toggle press station, punched in a separate cutting station with up to 90 tonnes of force, and the finished parts are automatically stacked and counted. The skeleton (trim waste) is wound for recycling.
This integrated approach eliminates the need for separate trimming and stacking operations, reducing labor, floor space, and handling damage. Form-cut-stack machines are the standard for high-volume packaging production where consistency, speed, and automation are critical.
FCS Series — Form-Cut-Stack Line.
FCS-6090
Roll-fed continuous pressure forming machine with integrated forming and punching stations. Designed for high-volume thermoformed packaging production with servo-driven precision and up to 90 tonne punching force.
Key Specifications
How does the form-cut-stack process work?
The FCS process feeds a continuous roll of thermoplastic film through four stations in sequence: heating, forming, cutting, and stacking — producing finished, trimmed, and counted parts without manual handling.
Unwinding & Feeding
The thermoplastic roll is loaded onto the unwind station. Servo-driven spike chains grip the film edges and index it forward with ±0.3mm accuracy, ensuring precise registration at each station.
Heating
Sandwich infrared heaters (top and bottom) heat the film to forming temperature. Zone-controlled heating ensures uniform temperature across the full 600×900mm forming area.
Forming
A toggle press drives the mold into the heated film. Vacuum and/or compressed air shape the material against the mold. The toggle mechanism provides consistent forming force and speed across every cycle.
Cutting (Punching)
The formed web advances to the cutting station where a steel rule die or matched metal die punches out the finished parts with up to 90 tonnes of force. Clean, precise cuts with no secondary trimming required.
Stacking & Counting
Finished parts are automatically stacked, counted, and collected. The skeleton (trim waste) is wound onto a separate roll for recycling or granulation.
What applications use form-cut-stack machines?
Form-cut-stack machines are used for high-volume production of food packaging trays, disposable containers, lids, cups, blister packs, material handling trays, and any thin gauge thermoformed part produced in quantities exceeding 100,000 units per year.
Food Packaging
Trays, containers, lids, portion cups, and clamshell packaging for fresh produce, dairy, bakery, and prepared foods
Disposable Tableware
Cups, plates, bowls, and cutlery trays for food service, catering, and institutional use
Pharmaceutical Packaging
Blister packs, unit dose trays, and medical device packaging requiring consistent dimensions
Industrial Trays
Material handling trays, component packaging, and protective inserts for electronics and automotive parts
Agricultural Packaging
Seedling trays, nursery pots, and horticultural packaging produced in high volumes
Consumer Goods
Cosmetic packaging, toy packaging, and retail display trays with consistent quality
FCS Series vs AM Series — which machine do you need?
The FCS Series integrates forming and cutting in one line for maximum throughput. The AM Series is a standalone forming machine that requires a separate cutting station. Choose FCS for high-volume production; choose AM for flexibility and lower initial investment.
| Factor | FCS Series | AM Series |
|---|---|---|
| Forming Area | 600 × 900mm | 500 × 600mm |
| Integrated Cutting | Yes (up to 90 tonne) | No (separate station needed) |
| Integrated Stacking | Yes (automatic) | No |
| Forming Method | Toggle press | Standard press |
| Best For | High-volume packaging lines | Flexible production, lower volumes |
| Footprint | Larger (integrated line) | Compact (standalone) |
| Investment | Higher (complete line) | Lower (forming only) |
Need a High-Volume Packaging Line?
Tell us about your packaging application, material, production volume, and part dimensions. Our engineering team will recommend the right FCS or AM configuration.