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.
Machinecraft FCS Series — Enclosed Form-Cut-Stack Line
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 60 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 — Inside the Machine.
FCS Series — Full Machine (Doors Closed)
Machinecraft FCS Series form-cut-stack machine — full front view with enclosed safety panels and HMI touchscreen
FCS Series — Form-Cut-Stack Line.
FCS Series — Internal View
Roll-fed continuous pressure forming machine with integrated forming, punching, and stacking stations. Available in Eco (pneumatic), Pro (servo), and XL (high-speed servo) variants. Servo-driven spike chain indexing with ±0.3mm accuracy.
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. 3-4 pitch zone-controlled heating ensures uniform temperature across the full forming area. Light sensor detects sheet sag for safety.
Forming
A toggle press drives the mold into the heated film. Vacuum and/or compressed air (up to 6 bar) shape the material against the mold. Spring-type sheet clamping and pressure plug assist for fine detail reproduction.
Cutting (Punching)
The formed web advances to the cutting station where a steel rule die punches out the finished parts with up to 60 tonnes of force. Motorized XY fine alignment ensures equal trim on all sides. Heated punching option available for PET.
Stacking & Counting
Finished parts are automatically picked by a servo-driven robotic arm, stacked, and counted. Up/Down or A/B stacking options. The skeleton (trim waste) is wound onto a separate roll for recycling or granulation.
Complete Production Line Output
Finished thermoformed containers stacked on the output conveyor. Skeleton waste is wound below for recycling.
Roll stand for continuous sheet feeding. Supports various roll widths and diameters.
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 | 600×500 to 800×600mm | 500 × 600mm |
| Integrated Cutting | Yes (up to 60 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) |
Frequently Asked Questions
What materials can the FCS Series process?
The FCS Series processes HIPS, ABS, PET, rPET, PP, PS, PVC, and PLA in roll form. Sheet thickness range is 0.5–2.0mm. The machine handles both transparent and opaque materials.
What is the maximum cycle speed?
The FCS 6050 Eco achieves up to 25 cycles/min. The servo-driven S FCS 8060 Pro/XL achieves up to 40 cycles/min depending on part depth and material.
Can the FCS machine do pressure forming?
Yes. The FCS Series supports both vacuum forming and pressure forming up to 6 bar. Pressure plug assist is available for deep draws and fine detail reproduction.
What is the punching force?
The FCS 6050 Eco uses pneumatic punching. The S FCS 8060 Pro/XL uses servo-driven punching with up to 60 tonnes of force, suitable for cutting PET and multi-layer materials.
Does the machine include automatic stacking?
Yes. A servo + pneumatic robotic arm picks finished parts and stacks them automatically. Up/Down and A/B stacking modes are available. Count setting is programmable via the HMI touchscreen.
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.