Innovation in Action: How PDS IG and
Insul-lite Turned a Space Challenge
into a Success Story
When Insul-lite decided to invest in a new automated IG line, they knew space was going to be their biggest obstacle. The company was moving into a new facility to accommodate growth—but the building’s rectangular layout wasn’t ideal for the straight-line design of most IG systems.
“We found a great building, but the line we initially looked at from PDS wouldn’t fit,” said Troy Layton, General Manager, Insul-lite. “We brainstormed with the PDS team, and we came up with a creative solution. The line now goes three-quarters down our floor, then makes a turn using a custom flipper they built. It was seamless—and something they’d never done before. It makes better use of our space and allows us to produce more efficiently than we thought possible.”
That innovative spirit defines the partnership between Insul-lite and PDS IG. Rather than compromise production goals or remove features like protective film application, the PDS IG engineering team developed an L-shaped line that maintained full functionality while maximizing the
available floorplan.
Most IG lines run straight,” explained Mike Rapp, President of Sales, PDS IG. “But we wanted Insul-lite to have everything they needed. So, our flipper design turns and flips the glass 90 degrees, allowing both film applicators to be used without losing any
capability. It also improves cleanup for installers because protective film is applied before the secondary seal.”
The results speak for themselves. Since installation, Insul-lite’s line has surpassed performance expectations, delivering smooth operation and high-quality output.
“We saw PDS as a partner from the start—and that’s continued,” Layton said. “Their support has been phenomenal. If we need help, they’re just a phone call away, and if something needs hands-on attention, they’re on-site within a day.”
That level of responsiveness is backed by a service contract and ongoing communication. PDS IG technicians visit twice a year for preventative maintenance, and the teams hold regular calls to ensure everything runs at peak performance.
System Highlights & Performance Advantages
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Industry-leading spacer durability for long-lasting IG performance and reliability.
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Exceptional thermal efficiency, improving energy performance and helping reduce heat loss.
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Can meet customer needs with ability to produce dual panes, traditional triple panes, AND single spacer triple panes.
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Protective film application that significantly reduces handling damage and product returns.
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High-efficiency inline gas filling process for consistent, reliable gas retention.
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Engineered flexibility to adapt to challenging building layouts without sacrificing production capacity.
For both companies, the collaboration is proof that when customer commitment meets engineering ingenuity, challenges become opportunities — and innovation leads the way.