There was plenty of news in thermoforming at K 2007 as with continuous roll-fed packaging systems having greater output, enhanced cooling, reduced air consumption and more automation.

Germany's Illig introduced, what it claims is the industry's fastest machine: its largest continuous in-line machine - the RDK 90, with a forming area of 840 x 670 mm. The machine uses special steel-rule die-cutting technology and offers the option to trim inside or outside the tool. The machine produces 4x6 mm PET trays in a 20-cavity mold at 55 cycles/min, and has been developed to compete in high-volume packaging applications in USA. Special automation equipment is an important feature of this system. A five-axis robot from Kuka Robotics that unloads stacks of finished product is claimed to be more versatile than a typical pick-and-place robot. The machine also can change tools in about 20 min.

Italy's Meico displayedthe FT700 : its tilt-mold, trim-in-place unit with 40 ton clamp, and a forming area of 705 x 400 mm and a special method for closing and tilting the mold. The pivot system uses four servo-driven cams and levers that tilt the mold 70° for better stacking. Claimed benefits include precision, repeatability and controlled force distribution during platen movements and cutting. A servomotor also actuates plug movement. High-speed movements result in a dry cycle of 41 shots/min. A 32-cavity mold reportedly can produce 7-oz PP drink cups at 80,000/hr. The machine has a smaller footprint than competitive models due to the shorter stacking system. Its fixed circular stacking channels are also said to be simpler to use than a moveable stacking system.

With a forming area of 850 x 750 mm, the GLE 9000 HS from Italy's Amut SpA is said to be the fastest high-capacity in-line extrusion/forming system in Europe. The electric-powered unit makes 200 ml HIPS cups at 200,000/hr in a 99-cavity mold, anda dry cycles 45 shots/min. The system produces two-colour sheet with up to four layers. An innovative rim roller handles 220,000 cups/hr. Meanwhile,
Tthe new-generation F87 in-line extrusion/forming line from Italy's OMV runs a 72-cavity mold to make 200 ml PP drink cups at 130,000/hr. It is reportedly the only system that can form containers up to 20 cm deep.