Maximum Efficiency and Increased Quality Time

Transcription

1 SYSTEMS Automatic Roll-fed Machines for Forming/Punching Tools RDM 54K RDM 70K RDM 78K IC-RDM 54Kc IC-RDM 70Kc IC-RDM 75Kc IC-RDM 76K Maximum Efficiency and Increased Quality Time

2 ILLIG we simply include more for you Welcome to the world of ILLIG with main emphasis on high-performance lines and molds for thermoforming of plastics as well as technical solutions for the packaging industry. As one of the world s leading provider in this sector we are in demand everywhere where the economic production of sophisticated parts of uniformly high quality is required. Benefit from our over seven decades experience, the unique know-how and the complete product and service range of ILLIG just like numerous satisfied customers in more than 80 countries. We offer experience and competence as well as practical technical solutions from one single source - everything you need to reliably meet even most difficult challenges in the thermoforming and packaging sector. The systematic path to success with ILLIG. Thermoforming Packaging Technology Molds ILLIG synonym for most economic production of high-quality cups, trays and other parts. Worldwide. 2-3 Content: Welcome at ILLIG ILLIG Intelligent Control Concept IC Generation RDM-Kc Cleantivity Reliable Handling RDM-K Thermoformer RDM 54K und IC-RDM 54Kc RDM 70K und IC-RDM 70Kc IC-RDM 75Kc IC-RDM 76K RDM 78K Molds ILLIG Systems

3 ILLIG Intelligent Control Con cept The user benefits from the ILLIG IC - Intelligent Control Concept. The combination of high productivity, reproducibility and machine availability can be utilized to the full extent. Machine operation is considerably simplified at the same time. The Intelligent Control Concept includes several compatible modules. 1. ThermoLine-Control. Operation, control and storage of all individual machines of one line interlinked by Profibus. All data is storable and repeatable. All other machines can be operated and controlled by the thermoformer s operating panel. Error display/error analysis for all individual machines on one screen. 2. Dynamic process optimization. Automatic optimization of the possible number of cycles not subject to operator s skills. All opti mization parameters are automatically adapted. Highest produc tion performance, absolutely reliable. 3. Compensation of ambient influences during process. Automatic adaption of the heater setting values with changed ambient influences (Initial temperature of material roll, ambient temperature and temperature of machine stand). Levels of development 1 st Generation Pneumatic machine 2 nd Generation Servo driven machine 3 rd Generation Process optimized machine 4. Faster mold change. Guided and safe mold change thanks to different technical levels. For faster perfect mold change which is not subject to operator s skills. IC - The next Level ILLIG Intelligent Control Concept 5. Self-adaptive start-up (sas-up ). Start-up operation with reduced cycle speed (Forming time, table speed and valve switching like in production). Especially with new molds or after mold changes with reduced material consumption until optimum product quality is achieved. Machines equipped with the ILLIG Intelligent Control Concept are marked with the addition IC. The IC concept raises thermoforming to a new, higher level. 6. ILLIG NetService. ILLIG Heilbronn Service Department can get remote access to machine. Fast error diagnosis, minimum machine standstill times, on site service calls are not required. 4-5 This is how you benefit from ILLIG IC Market requirements Consequence Reproducibility Quality control Availability Conversion times Maintenance Productivity Increased performance Energy efficiency Process control Guided processes Process skills Operator has to deal with increasing complexity Technology Drive technology / Sensor system / Computer performance / Visualization technology Realization ILLIG Intelligent Control Concept PROFIT

4 ILLIG c Generation enhanced efficiency Fast product changes Higher output GUIDED MOLD CHANGE + + Precise guiding + + Semi-automatically + + Manually Benefit: Perfect operator support regardless of level of expertise. CALCULATION OF BASIC SETTING + + Calculation of all setting parameters + + Convenient transfer of values at the touch of a button Benefit: Stackable products starting with the first part. PROCESS DATA VISUALIZATION EVERYTHING AT A GLANCE + + Visualization of process data, such as forming pressure, downholder pressure, position main drive, as well as position pre-stretcher and valve switching time. FAST BUILD-UP OF FORMING PRESSURE + + Faster pressure build-up due to large tube cross section (mains pressure in forming air tank and not set forming pressure) + + Pressure sensor close to interface to upper tool + + Faster forming and better part quality + + Higher cycle speed by earlier cooling process Benefit: Fastest forming air technology on the market with pioneering part quality. OPTIMIZED EJECTOR MOVEMENT + + In the beginning ejector works with full cross section and controlled power + + During the movement it is decelerated and braked Benefit: A dynamic ejector movement with highest force for demolding of undercuts. Less load thanks to smooth sequencing and also less wear of molds and forming machine. Benefit: Perfect process optimization possible without additional measuring technology and costs. This results in increased cycle speed and improved quality. 6-7

5 RDM-K automatic roll-fed machines of the c Generation serial peak performance Higher part quality Low costs PERFECTION IN MATERIAL TRANSPORT + + Longitudinal material spreading by divided transport + + Longitudinal spreading can be infinitely set + + No waves in material, no material stretching + + Return movement possible + + Optimum part weight (reduction of cup weight) + + Optimum adaptation to all types of material + + New piercing without particles PROCESS CONTROL + + Real control by keeping the parameters on a constant level + + Automatic adaptation of radiation heater + + Compensation of processing and switching times + + Adaptation in real time + + Detection of wearing of single components Upper and lower heaters are equipped with longitudinal row control. By switching off the cross rows of heater elements on the feed side, the effective heater length can be adjusted to the material feed. Reduction of heating up time by 50% and energy saving by up to 33% thanks to HTSs heater elements. HEATER, GEOMETRY, DRIVE AND MONITORING % energy saving by HTSs heater elements + + Improved drive movement and load relief on cam rollers + + Increased service life of lower table by reduction of vibrations + + Less tool wearing by play-free rigidity of planetary gear + + Monitoring function for quality control, maintenance cycles, increase of cycle speeds as well as extension of service lives of machine and mold 8-9 For decades the demands for high part quality and reproducibility of packs have been closely connected with the forming/punching technology developed into an industrial standard by ILLIG. Picture right: 33% energy saving by HTSs heater elements

6 Cleantivity technology of cl eanliness Clean production with increased quality time. Numerous technical innovations were realized on IC-RDM-K machines to achieve this. Cleantivity was derived from Cleanliness and Productivity. Machine stand Machine stand with drip protection towards material. Condensation water Formation of condensation water is prevented by temperature control of the cooling water used in the machine for servo motors, material transport and thermo camera. Lubricant supply Lubricant is applied to the relevant lubrication spots of the material transport. This way lubricant consumption is optimized. Drip protection sheet towards material It is the intent to extend the operating time, running time and, in the end, the quality time of the thermoforming machine in order to achieve a high line output of high-quality formed parts. Food grade lubricants New food grade lubricants in accordance with DIN EN ISO and DIN EN ISO These H1 lubricants were developed for machine and lines in the food industry. Material transport A much better, new piercing method prevents formation of material particles on the piercing spots which might cause soiling of the formed parts (pictures below) Piercing, old version New piercing version without formation of particles

7 Designed for reliable handling Conventional stacking systems reached their limits due to the yet unrivalled cycle speeds and the corresponding increased output. The stacking device also had to be developed further in order to ensure reliable handling of the increased output. The newly developed stacking solutions ensure reliable handling of the enormous cup output and allow moreover an individual adaptation of the stacking device to the respective production process. PH turning head system with double function, it can be swiveled by180 degrees. The parts can cool down for one cycle after removal from the mold before being placed in the stacking cage Stacking today: Reliable and flexible Processing of large amounts of parts becomes child s play with the new stacking devices. Even cups with a tendency to de-nest in stacks or curved, short cups can thus be forwarded reliably to the downstream equipment. There the stacks of counted cups are packed into transport units. A further benefit provided by the stacking device is the wear-resistant design of all components. Soiling of cups by foreign particles is prevented and also strictest requirements of the food industry are met. Benefits: Reliable processing Reliable handling of large amounts Also ideal for critical cup shapes Perfectly suited for food industry Efficient by individual adaptation to automation level, output and further processing Can be used as optional extra for operating RDM-K thermoformers RDM-K stacking machines: PH 54c PH 70c PH 75c PH 76 PH 78 STPM 75b STP 75b STPL 75b SZA 73c

8 Automatic pressure forming machines RDM 54K and IC-RDM 54Kc Product Material Ø (mm) No. of cavities Output/h Yogurt cup PS 1,5 mm Yogurt cup PS 1,7 mm Drinking cup PP 0,8 mm Drinking cup PP 1,6 mm Vending cups PS 0,8 mm RDM 54K Product Material Ø (mm) No. of cavities Output/h Yogurt cup PS 1,5 mm Yogurt cup PS 1,7 mm Drinking cup PP 0,8 mm Drinking cup PP 1,6 mm Vending cups PS 0,8 mm IC-RDM 54Kc Automatic pressure forming machines RDM 54K IC-RDM 54Kc for forming areas up to 520 x 300 mm Forming area up to depth of draw 125 mm max. 520 x 300 Forming area from depth of draw 126 onward mm max. 520 x 260 Part height negative mm max. 185 Part height positive mm max. 15 Material width mm max. 545 Index length mm max. 350 Mold closing force kn max. 230 Number of dry cycles min-1 max. 34 RDM 54K Number of dry cycles min-1 max. 54 RDM 54K IC-RDM 54Kc APET cup Cup with metal lid Cup round for Cola CFB cup Cup round Cup round for soft ice cream Cup for soups Cup transparent with area Cup transparent with false bottom Deli cup Double chamber square Double chamber transparent Double chamber rectangular Ice cream cup with lid Cup for soft ice cream with lid Espresso capsule Deli cup transparent Applications RDM 54K IC-RDM 54Kc Flat rim fruit tray rectangular Yogurt cup Yogurt cup with false bottom Coffee cup for vending machines Coffee capsule Cup transparent Cup rectangular Eurotub - Margarine tub Margarine Eurotub Rectangular cup with contour Rectangular cup with round sealing rim Soft drink cup Plate with contour Pet food square Tray 4-up Drinking cup transparent Flat rim meat tray rectangular IC-RDM 54Kc

9 Automatic pressure forming machines RDM 70K and IC-RDM 70Kc Product Material Ø (mm) No. of cavities Output/h Yogurt cup PS 1,5 mm Yogurt cup PS 1,7 mm Drinking cup PP 0,8 mm Drinking cup PP 1,6 mm Vending cups PS 0,8 mm RDM 70K Product Material Ø (mm) No. of cavities Output/h Yogurt cup PS 1,5 mm Yogurt cup PS 1,7 mm Drinking cup PP 0,8 mm Drinking cup PP 1,6 mm Vending cups PS 0,8 mm IC-RDM 70Kc Automatic pressure forming machines RDM 70K IC-RDM 70Kc for forming areas up to 680 x 300 mm Forming area up to depth of draw 125 mm max. 680 x 300 Forming area from depth of draw 126 onward mm max. 680 x 260 Part height negative mm max. 185 Part height positive mm max. 15 Material width mm max. 730 Index length mm max. 350 Mold closing force kn max. 320 Dry cycles min-1 max. 32 RDM 70K Dry cycles min-1 max. 50 IC-RDM 70Kc RDM 70K IC-RDM 70Kc APET cup Cup with metal lid Cup round for Cola CFB cup Cup round Cup round for soft ice cream Cup for soups Cup transparent with area Cup transparent with false bottom Deli cup Double chamber square Double chamber transparent Double chamber rectangular Ice cream cup with lid Cup for soft ice cream with lid Espresso capsule Deli cup transparent Flat rim meat tray rectangular Applications RDM 70K IC-RDM 70Kc Flat rim fruit tray rectangular Yogurt cup Yogurt cup with false bottom Coffee cup for vending machines Coffee capsule Cup transparent Margarine tub Margarine Eurotub Rectangular cup with contour Rectangular cup with round sealing rim Soft drink cup Plate with contour Pet food square Tray 4-up Cup transparent IML cup rectangular - IML cup round - IML cup oval -

10 Automatic pressure forming machine IC-RDM 75Kc Product Material Ø (mm) No. of cavities Output/h Yogurt cup PS 1,5 mm Yogurt cup PS 1,7 mm Drinking cup PP 0,8 mm Drinking cup PP 1,6 mm Vending cups PS 0,8 mm IC-RDM 75Kc Automatic pressure forming machine IC-RDM 75Kc for forming areas up to 735 x 465 mm IC-RDM 75Kc Applications APET cup IC-RDM 75Kc Cup with metal lid Espresso capsule Cup round for Cola Yogurt cup CFB cup Yogurt cup with false bottom Cup round Coffee cup for vending machines Cup round for soft ice cream Coffee capsule Cup for soups Cup transparent Forming area depth of draw 150 mm max. 735 x 465 Cup transparent with area Margarine tub Part height negative mm max. 185 Cup transparent with false bottom Deli cup Margarine Eurotub Rectangular cup with contour Part height positive mm max. 15 Double chamber square Rectangular cup with round sealing rim Material width mm max. 850 Double chamber transparent Double chamber rectangular Soft drink cup Pet food square Index length mm max. 500 Ice cream cup with lid Drinking cup transparent Mold closing force kn max. 600 Cup for soft ice cream with lid Espresso capsule Water cup Plant pots round Dry cycles min-1 max. 42 Deli cup transparent Plant pots rectangular Flat rim meat tray rectangular Coffee capsule with hole

11 Automatic pressure forming machine IC-RDM 76K Product Material Ø (mm) No. of cavities Output/h Yogurt cup PS 1,5 mm Drinking cup PP 0,8 mm Drinking cup PP 1,5 mm Vending cups PS 0,8 mm IC-RDM 76K Automatic pressure forming machine IC-RDM 76K for forming areas up to 760 x 540 mm Applications IC-RDM 76K IC-RDM 76K APET cup Flat rim fruit tray rectangular Cup with metal lid Yogurt cup Cup round for Cola Coffee cup for vending machines Cup round Coffee capsule Cup round for soft ice cream Cup transparent Forming area depth of draw 150 mm max. 760 x 540 Cup for soups Cup transparent with area Margarine tub Margarine Eurotub Part height negative mm max. 150 Part height positive mm max. 15 Deli cup Double chamber square Double chamber transparent Rectangular cup with contour Rectangular cup with round sealing rim Soft drink cup Material width mm max. 850 Index length mm max. 565 Double chamber rectangular Ice cream cup with lid Cup for soft ice cream with lid Plate with contour Pet food square Tray 4-up Mold closing force kn max. 600 Dry cycles min-1 max. 42 Espresso capsule Deli salad transparent Flat rim meat tray rectangular Drinking cup transparent Deli salad transparent

12 Automatic pressure forming machine RDM 78K Product Material Ø (mm) No. of cavities Output/h Yogurt cup PS Yogurt cup PS Drinking cup PP Drinking cup PP Vending cups PS RDM 78K Automatic pressure forming machine RDM 78K for forming areas up to 760 x 420 mm Applications RDM 78K RDM 78K APET cup Espresso capsule Cup with metal lid Yogurt cup Forming area depth of draw 150 mm max. 760 x 420 Cup round for Cola Coffee cup for vending machines Part height negative mm max. 130 Cup round Cup round for soft ice cream Coffee capsule Cup transparent Part height positive mm max. 15 Cup for soups Margarine tub Material width mm max. 810 Cup transparent with area Deli cup Margarine Eurotub Rectangular cup with contour Index length mm max. 430 Double chamber square Rectangular cup with round sealing rim Mold closing force kn max. 550 Double chamber transparent Double chamber rectangular Soft drink cup Pet food square Dry cycles min-1 max. 57 Ice cream cup with lid Drinking cup transparent Cup for soft ice cream with lid Water cup

13 ILLIG mold technology your individual success system all from one single source ILLIG a perfect match Our system solutions allow simple and quick integration in the most diverse production lines. Even interlinkage in highly complex plants, linked from material manufacture through to completely decorated cups, is a standard task for us which we manage successfully on a daily basis. Quality and efficiency demands on formed parts will still be increasing in the future. Our automatic roll-fed machines are a central element for long-term competitive production. The second element, which is also important, is the mold. And for this topic ILLIG also offers future-oriented high-tech products: First-class, highly productive molds, suited to exhaust the potentials of our machines to the full extent. Integrated development and perfect coordination of both components result in a production system which can hardly be surpassed in terms of efficiency, productivity and reliability called the ILLIG success system ILLIG brand mold innovations: Often copied still unequaled ILLIG possess comprehensive experience in realizing revolutionary machine technology - best requirement for the development of corresponding molds. When we launch new machine concepts, we also offer suitable forming and punching tools. Tested on the original machines, tailor-made for your individual requirements developed and manufactured by ILLIG. Benefits: Optimum processing quality: Thanks to unique technical details Efficient and reliable operation: Thanks to minimum standstill times, low maintenance effort and long service lives Future-proof: Thanks to unique performance data Exclusively available at ILLIG clever details with maximum customer benefit. IC thermoforming stands for utmost product quality with high efficiency at the same time. With respect to molds, these requirements were met by the following innovations: Controllable cooling circuits for constant mold temperature, consistently good results are ensured Reduced forming air consumption and symmetry of all medi allows short mold filling times and identical part quality in all cavities Quick-change technology for shortest format changeover times Regrinding elements Lower mold weight, prerequisite for use of all machine potentials Separate mold cooling on forming station

14 ILLIG a complete spectrum to meet your requirements Thanks to innovative power, high quality standards and a complete orientation to our customers needs and requirements, ILLIG has become the market and technology leader in the sector of thermoforming and packaging technology. We drive progress significantly further onward and today we offer you the most extensive range of state-of-the-art machines and the appropriate molds. At ILLIG you really do receive everything from one source. Innovative whole solutions for the most diverse industries and applications, exactly adjusted to your individual tasks. Everything you need for sustainable and successful production and a permanent competitive edge. Excellent performance you can rely on us The ILLIG range of services comprises development, design, manufacture, assembly and commissioning of complex production lines and individual components. We are an owner-operated company with about 750 employees, own subsidiaries and representative offices in over 80 countries and present in all markets. We are your competent and reliable partner. The name stands for superior technology of excellent quality and a comprehensive, global service. Whatever you want you ll find it at ILLIG ILLIG offers you not only machines for the most diverse applications, but also corresponding accessories and molds. This way you can utilize the substantial potentials of our lines to the full extent and the high availability and productivity are ensured over the long term. Synergies that pay off definitely. Our range of products is completed by a comprehensive range of molds. Specifically coordinated with our machines, designed and manufactured in the ILLIG mold shop. Our products and our skills Thermoforming Systems Sheet processing machines Automatic roll-fed machines for forming/punching operation Automatic roll-fed machines, separate forming and punching Packaging Systems Skin and blister packaging machines Form, fill and seal lines Molds 26-27

15 ILLIG evolution of thermofor ming Today: Customers all over the world manufacture sophisticated and high-precision parts and packages for brand products. ILLIG stands for pioneering inventions and innovations. We actively invest in the research and development of new technology and work together with leading research institutes. Using the latest hardware and software tools our highly specialized engineers are developing forward-looking solutions. Solutions that offer decisive advantages to our customers, such as higher quality products produced in less time and at reduced costs - innovations that make our customers even more successful. ILLIG has been setting technological milestones for decades 1946 On May 27 Adolf Illig founds a maintenance and repair workshop in the garage of his parents home Development of pre-heaters with heated aluminum rollers for continuous PP heating Type UA 100: Construction of the first ILLIG vacuum forming machine RDM 50K first larger automatic thermoforming machine with tilt technology. It sets the new standard for hygiene conditions in the packaging industry Introduction of R 650: World s first roll-fed automatic vacuum forming machine for producing lids from preprinted material First software program to automate basic settings of vacuum forming machines First high-speed pneumatic forming and punching machine. Beginning of market-proven RDM series First In-Mold Labeling production line for applying PP labels to PP margarine tubs New RDM series machines introduced. Founding of ILLIG tool and mold shop complements product range for the production of cups and lids Fully aseptic form, fill and seal lines with a capacity of 700,000 yogurt cups per day First packaging machine line that integrates forming, filling and sealing. First piston dosing machine for pasty ingredients Development of innovative molds for forming and punching technology that set new standards in precision, temperature control and service life RDM 78K, ILLIG s first 3rd generation machine line in operation Premiere of In-Mold-Labeling for form, fill and seal lines Conversion of ILLIG high-performance thermoformers to 3rd generation technology Presentation of BF 70 first bottle former worldwide of its kind ready for serial production ILLIG designers achieve quantum leap in thermoforming with IC machines (ILLIG Intelligent Control Concept). Today ILLIG s IML-T decoration technology prevails among customers. In-Mold-Labeling lines conquer the market. In the past: The know-how from the repair shop and dryer production could be optimally used when the first ILLIG vacuum machine, type UA 100, was built..

16 Welcome at ILLIG ILLIG Intelligent Control Concept IC Generation RDM-Kc Cleantivity Reliable Handling RDM-K Molds ILLIG Systems The success system for your successful production Today ILLIG offers the IC-RDM-K line technology, the most flexible introductory program of state-of-the-art automatic roll fed machines, for separate forming and punching, worldwide. In this product group you obtain everything from one source: Innovative whole solutions for most diverse industries and applications, perfectly suitable for your individual requirements. Simplified operation Better cleanliness Mechanical improvement => => => ILLIG IC for higher availability Perfect for food sector Higher availability of processes IC-RDM-K. Everything you need for long-term successful production and a permanent competitive advantage. Worldwide Kontaktdaten ILLIG Maschinenbau GmbH & Co. KG Robert-Bosch-Str Heilbronn Deutschland Telefon: Fax: info@illig.de Web:

17 ILLIG systems for thermoforming and packaging technology Sheet processing machines Automatic roll-fed thermoformers for forming/punching tools Automatic roll-fed thermoformers, separate forming and punching Skin and blister packaging machines Form, fill and seal lines Mold shop en - Subject to change SYSTEMS ILLIG Maschinenbau GmbH & Co. KG Robert-Bosch-Strasse Heilbronn I Germany Tel Fax info@illig.de