IC-RDK 80 Maximum performance by ILLIG Intelligent Control Concept. Automatic roll-fed machine, separate forming and punching RDK 80 IC Technology

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1 SYSTEMS Automatic roll-fed machine, separate forming and punching RDK 80 IC Technology IC-RDK 80 Maximum performance by ILLIG Intelligent Control Concept

2 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept ILLIG there s simply more in Welcome to the world of ILLIG. Our passion is high-performance thermoforming machines and molds, as well as high-tech solutions for the packaging industry. We are a leading manufacturer of thermoforming machines and solutions, and the first choice when it comes to producing complex, high-quality thermoformed parts efficiently. Benefit from over seven decades of experience, industry-leading expertise and our comprehensive range of products and services, and join countless other satisfied customers from more than 80 countries across the globe. Our extensive experience and know-how go hand in hand to develop feasible solutions all from one single source. We offer everything you need to smoothly fulfill even the most demanding thermoforming and packaging projects. ILLIG - your systematic path to success. 2-3

3 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems it for you! ILLIG Synonym for most economical production of high-quality cups, trays and other parts. Worldwide. Thermoforming Packaging Technology Molds Content: Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept IC-RDK 80 Thermoforming System RDK Technology Steel rule cutting at its finest Stacking today Decoration unlimited IC-RDK 80 data Molds ILLIG Systems

4 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept IC-RDK 80 Thermoforming Sys success all along the line Loading AWK material roll stand 11 Skeletal granulator 2 STAL 90 punch and die press 12 ITG temperature control device 3 RO, ROK material roll stand 13 PC cooling device 4 VHW roll pre-heater 14 Extruder 5 IC-RDK 80 automatic forming machine 15 Stacking station with handling system 6 Hole punch press 16 FD 74 granules suction 7 Stand 17 Silo available on site 8 Steel rule punch press 18 9 Stacking, counting and pushing out device 19 FPTS 40 mold STB 10, STB 20, STB 40, STB 50 molds 10 Skeletal rewinding unit

5 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems tem Pre-heating 18 Forming/ punching Handling (Hole punching) Handling (Inserting) Separating 19 Handling (Stacking) Handling (Rewinding) Handling (Reducing) Handling (Cooling, temperature control) Handling (Suction) Molds Forming/punching operation Separate Forming and punching/ Forming/punching operation Separate Forming and punching/ with punch and die trimming tool ILLIG line competence

6 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept ILLIG Intelligent Control Conc The user benefits from the IC ILLIG Intelligent Control Concept. He can utilize the combination of high productivity, reproducibility and machine availability to the full extent. Machine operation is considerably simplified at the same time. The Intelligent Control Concept includes several compatible modules. 6-7 Machines equipped with the ILLIG Intelligent Control Concept are marked with the addition IC. The IC concept raises thermoforming to a new, higher level.

7 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems ept 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). 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. Levels of development 1 st Generation Pneumatic machine 2 nd Generation Servo driven machine 3 rd Generation Process optimized machine 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. 6. ILLIG NetService. ILLIG Heilbronn Service Department gets remote access to machine. Fast error diagnosis, minimum machine standstill times, service call on site not required. 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

8 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept IC-RDK 80 Thermoforming Syst separate forming and punching Flexibility The modular machine concept provides high flexibility for forming/punching operation as well as for separate forming and punching. 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. In addition, individual plants can be composed thanks to the line technology. Picture 1 IC-RDK 80 automatic pressure forming machine. Picture 2 IC-RDK 80 automatic pressure forming machine with steel rule punch press and skeletal granulator. Picture 3 IC-RDK 80 automatic pressure forming machine with hole punch press and steel rule punch press. 8-9 Picture 1 Parts can be produced without punching mismatch in the edge area by forming the heated material with pre-stretcher and pressure air and by punching the parts out of the web in that same cycle. This is an essential for automatic processing of parts. Fundamental RDM features could be transferred to the RDK technology, such as the high demands on forming/punching as well as findings resulting from high-speed thermoforming. High rigidity of the forming/punching station and maximum plane parallelism of the forming tables are basic requirements for forming/punching. Toggle levers, tables and guide pillars were optimized regarding maximum closing and punching forces to achieve ideal punching results. These forces are transmitted to the tables by double toggle levers and generated by servo motors with satellite roller screws.

9 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems em automatic roll-fed machine, & forming/punching operation Picture 2 Picture 3 Forces are transmitted centrally to the joint of the double toggle lever, so no cross forces act upon the pillar guidings of the forming tables. Thanks to variable setting options for table strokes and speeds coupled with separately driven upper and lower clamping frames, different forming programs are available. Thus all part variants can be smoothly realized. Optimum wall thickness distribution is achieved in the side wall of the product by the servo drive technology employed by ILLIG. The movements of forming table and pre-stretcher can thus be precisely synchronized. Thanks to better material distribution in the side wall of the product identical product stability can be achieved even when thinner basic material is used. Product quality is enhanced in terms of increased part rigidity as well as precise and plane sealing rims which are obtained by employing cooled downholders in the mold.

10 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept ILLIG k Generation the next dimension of producti TOP Mold cooling Separate mold cooling on forming station. Compensation Compensation of heating-up of machine and material inlet temperature. Reproducible heating process means constant forming temperature and constant product quality. Heater control The upper heater can be additionally controlled by a cross row of small heater elements on the mold side. Benefit: No heat loss between heater and cold mold. HTSs heater elements Benefits over FSR heater elements: Reduction of heating-up time by 50%, energy saving of up to approx. 33 %. Compared to HTS heater elements energy saving of up to approx. 8%. Dynamic process optimization Optimized drive technology and sequencing for forming, punching and stacking station. Calculated overlapping of machine sequencing. Motion control system. Spreading device Pneumatic spreading device in addition before forming station. Material transport guided parallel in forming station. Heater cover Water-cooled cover rail for exact representation of heating pattern

11 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems on reliability We give you the decisive reasons How do you promote your products? What sales arguments do you use to convince your customers? Perhaps with excellent stability and rigidity, impressive surface quality, unmatched functionality and minimum size tolerances at attractive costs? Not bad but it could be shorter. Simply say Produced with ILLIG - then your customer knows! Spreading device before forming station for perfect material handling. Mold cooling on forming station. Reinforced stacking with dynamic process optimization. Picture left: Adjustable, water-cooled heater cover (Picture: Parking position).

12 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept RDK 80k Generation peak p In ILLIG solutions synergies between customer benefit and development of thermoformers result in considerably higher output. Different process steps run during the actual forming process (movements of forming table, build up of forming pressure, punching, stacking, etc.). The precision of the process steps has an effect on the product s quality. Acceleration of individual process steps is utilized for further performance increases of the machine. Servo-driven material transport system for exact positioning during high transport speeds Width and index length of the material transport are set on the touch screen by using the computer-aided basic setting. The servo-mechanical positioning drive reduces index length tolerances to +/ 0.2 mm. In the area of the forming station the material transport is moved apart pneumatically by the spreading device. The material is stretched so webbing is prevented during the forming process. This is especially suitable for PP processing. The pneumatic chain tensioning system is supplied with adjustable pressure and keeps the transport chains separately under optimal tension. This way the play between the individual chain links and the tolerances occurring in an expanding chain can be offset Benefits: Chain tension no longer has to be checked and readjusted. Better transport accuracy and longer service life of chains since chain tension is always optimally set and identical for both chains. Reduction of wear and tear due to integrated cooling channels. Picture right: The upper and the lower heater are equipped with longitudinal row control. The effective heating length can be adapted to the index length by switching off cross rows of heater elements on the feed side. Reduction of heating time by 50% and energy saving of up to 33% thanks to HTSs heater elements.

13 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems erformance in series Optimum economical thermoforming by sustainable heating technology Upper heater and lower heater are part of the basic equipment. The individual rows of heater elements can be controlled by pilots. Rows of heater elements which are not needed are switched off automatically subject to index length and material width. In addition, the upper heater can be controlled by a cross row of small heater elements on the mold side. Heat loss between heater and cold mold is thus prevented. The heating time is reduced by approx. 50% by using HTSs heater elements. Another benefit is the energy saving potential of up to 33% compared to FSR standard heater elements. Four rows of heater elements can be switched off so the effective length of upper and lower heater can be adjusted to the transport step in an optimal way. Additionally, the heater length can be precisely adjusted to the index length by using water cooled heater covers. The control establishes a heating profile, subject to the rows of heater elements, by using the computer-aided basic setting. It is possible, for example, to increase or decrease the temperature level as a whole to achieve higher cycle speeds. Excessive sagging due to material overheating is detected by a light barrier. Upper and lower heater move back and the machine stops. It is therefore not possible for the material to fall into the lower heater. Thanks to this optimized heater equipment the entire thermoforming potential can be optimally utilized.

14 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept Top precision steel rule cutting at its finest Steel rule punch press and hole punch press Steel rule punch presses are employed for part and hole punching. They are equipped with movable upper and lower table. In automatic mode the station starts working as soon as the first parts are transported into the punch press. The whole station can be moved in longitudinal direction by servo drive. The correct position is determined by the computer-aided basic setting and stored. Precision corrections can be performed during operation. The toggle lever drive an essential component of the steel rule punch press is very rigid thanks to its mechanical force transmission. In the dynamic phase of closing and opening there is central force transmission into the double toggle lever joint which prevents development of transverse forces on the pillar guidings of the forming tables

15 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems The steel rule cutter is positioned by motor driven adjustment devices. They allow movements of the steel rule cutter in all degrees of freedom. The selected positions can be changed during operation and stored. The use of a steel rule die heating reduces cutting forces and extends the service life. Moreover cutting quality is increased and reproducibility of the formed parts is improved. Adjustment of cutting dies, height adjustment, floating cutter Production tolerances on the part result from the fact that the heated material is formed by pre-stretcher and pressure air and punched. In order to limit this tolerance range the punching tools are designed as so-called floating cutters. Cutting contours are supported in a freely movable way within the holding plate so the centering aids can center the cutting dies shortly before punching. This process is supported by the movement profile of the table drives since the speed is reduced in the decisive phase and thus there is sufficient time for the centering process. The benefits provided by heated dies are fully maintained in floating cutters as well.

16 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept Stacking today safe and flexib Last but not least product features are subject to the quality and reliability of the different production steps. ILLIG therefore offers a reliable range of stacking systems and downstream equipment for IC-RDK 80 machines adjusted to automation level, output and subsequent treatment. Safe and reliable product stacking is achieved at any speed by consistent use of servo drive technology. Stacking movements can be synchronized and precisely adjusted. Admissible depths of draw are considered in the layout of the stacking station. Positive and negative parts can be stacked. In automatic mode the stacking station starts working as soon as the first punched out cycle has been fed. In the standard version clamping mask and stacking chute are moved together simultaneously by a pneumatic cylinder and thus fix the skeletal. The formed parts are held in the skeletal by tiny holding studs. The format-dependent break-out unit removes the parts from the skeletal and places them in the stacking chute. After stacking of a certain number of parts in the stacking cage, the stacks are moved on a sheet or a conveyor by servo motor Stacking station with counting and servo-driven pushing-out device, parts are pushed on a sheet and/or a conveyor. Version with divided stacking cage for higher cycle speeds. Stacking station with handling system, stacks of counted cups are formed on a conveyor. A/B/C stacking is possible. Moreover, parts formed in W-configuration can be stacked. Change of format parts by quickchange technology allows shortest conversion times. Conventional stacking format parts can be used.

17 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems le Key benefits: Reinforced stacking. Smooth operation ensures reliable stacking. Better access to stacking station for maintenance work and mold installation/removal. Height of stacking stroke increased. Skeletal rewinding with diameter control unit and signal. Rewinding unit can be removed as a whole. Optionally the clamping mask can be driven by a servo motor. This results in reproducible, synchronous stacking movements regardless of part weight. Synchronized movements allow reliable stacking and thus an optimum stacking process. The setting parameters of the servo-driven stacking movements can be programmed and stored in the teach-in method. The push-out time of formed parts must be extended for high cycle speeds. For this purpose a fixed stacking cage is used in addition to the movable version. In conjunction with the servo driven clamping mask buffer stacks can be formed in the movable stacking chute. Consequently, formed parts can be pushed out regardless of cycle speed. Vacuum device on stacking station used to fix parts on break-out unit. Two vacuum circuits for alternating stacking. Parts might get detached from the breakout unit during break-out and stacking process and thus get out of place. In that case smooth part centering one into the other is quite unlikely which makes smooth stacking almost impossible. A vacuum device on the break-out unit holds the parts in place. The vacuum is generated by the central main vacuum pump and a vacuum tank.

18 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept Decoration unlimited with pre-printed materials Brilliant product quality with pre-printed materials A control device with photo cell is employed for processing pre-printed materials, e. g. for ready for sale lid production. Servo driven material transport and detector ensure precise positioning of the printed material in the mold. Depending on the application, the photo cell is located on the material transport in the center of the mold and/or on the feed side of the machine. The material must be equipped with print marks at intervals equivalent to the printing images. After reaching the set index length at high speed, the print mark is searched at an additional creep speed. As soon as the print mark is detected, the search run ends. The material is transported only further by the correctional value to ensure precise print positioning Different stacking system variants can be used for lid stacking. Lid mold, type FPTS 40. Positioning of pre-printed materials by photo cell.

19 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems RDK technology for benefits in lid production: Improved material distribution in the rim area by material drawn in from skeletal area. Less maintenance effort required for mold repairs. Short standstill times due to fast changes of steel rule dies. Optimum punching results on product due to new punching technology in the area of the holding studs. Longer lifetimes due to cutter length limitation on forming /punching tool.

20 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept IC-RDK 80 automatic roll-fed ma highest quality IC-RDK 80 automatic roll-fed machine, separate forming and punching & forming/punching operation Forming area in forming/punching operation mm max. 743 x 552 Forming area in forming operation mm max. 756 x 565 Mold width between material transport mm max. min. Mold length in feed direction mm. max. min Mold height on upper table mm. max. 230/370 Mold height on lower table mm max. 220 Material width with actuated clamping frame mm max. 805 Hinged pack with euro hole Deli cup Deli lid Plant tray Carrier pallet for work pieces Tray for chocolate marshmallows Blister Insert for chocolate candies Hinged pack for cookies Hinged pack for fruit salads Round tray with flat bottom Contour lid Hinged packs with punched holes for fresh fruit IC-RDK 80

21 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems chine Applications Lid for cheese Tray for vegetables Hinged pack for croissants Round lid with cross slot Hinged pack for felt pens Tray for sweets Hinged pack for salad Tray for pharmaceutical products Tray for electronic components Corner protection Menu tray with 3 compartments and sealable flat rim Tray with punched holes for vegetables Hinged pack for cake IC-RDK 80 Material width without/width actuated clamping frame mm max. min. Index length mm max. min. Part height above material level mm max. 120 Part height below material level mm. max. 120 Forming pressure bar 6 Cycle speed with process optimization 1/ min max. 55

22 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept ILLIG mold technology your individual success system all from one single source 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.

23 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems 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. 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 cycles for constant mold temperature, consistently good results are ensured. Reduced forming air consumption and symmetry of all media. allows short mold filling times and identical part quality in all cavities. Quick-change technology for shortest format changeover times. Regrinding elements. Minimum mold weight, prerequisite for use of all machine potentials. Separate mold cooling on forming station.

24 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept ILLIG a complete spectrum to Thanks to innovative power, high quality standards and a complete orientation to our customer s 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 the 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

25 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems meet your requirements 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 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 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.

26 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept ILLIG evolution of thermoform 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 Today: Customers all over the world manufacture sophisticated and high-precision parts and packages for brand products. Looking back: The first ILLIG UA 100 vacuum forming machine was built based upon the knowhow of the repair shop and dryer production.

27 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems ing 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 Type UA 100: Construction of the first ILLIG vacuum forming machine Introduction of R 650: World s first roll-fed automatic vacuum forming machine for producing lids from preprinted material First high-speed pneumatic forming and punching machine. Beginning of market-proven RDM series New RDM series machines introduced. Founding of ILLIG tool and mold shop complements product range for the production of cups and lids First packaging machine line that integrates forming, filling and sealing. First piston dosing machine for pasty ingredients First pre-heaters with heated aluminum rollers for continuous heating of PP RDM 50K first larger automatic thermoforming machine with tilt technology. It sets the new standard for hygiene conditions in the packaging industry First software program to automate basic settings of vacuum forming machines First In-Mold Labeling production line for applying PP labels to PP margarine tubs Fully aseptic form, fill and seal lines with a capacity of 700,000 yogurt cups per day New revolution of 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 market.

28 Welcome to ILLIG Survey Line Competence ILLIG IC Intelligent Control Concept The success system for your successful production Today ILLIG offers the IC-RDK 80 line technology, the most extensive scope of stateof-the-art lines in the sector of RDK forming/punching technology, worldwide. In this product group you obtain everything from one source: Innovative whole solutions for most diverse industries and applications, directly suitable for your individual requirements. Simplified operation => ILLIG IC for higher availability Better hygiene => Perfect for food sector Mechanical improvement => Higher availability of processes IC-RDK 80: Everything you need for long-term successful production and a permanent competitive advantage. Worldwide

29 IC-RDK 80 Thermoforming System RDK Technology Molds ILLIG Systems Contact details ILLIG Maschinenbau GmbH & Co. KG Robert-Bosch-Str Heilbronn Germany Phone: Fax: info@illig.de Web:

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32 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 Internet: