Additional units, system components

Additional units, system components

Improved process safety in thermoforming and packaging technology due to additional elements and system components bus systems consistent product quality and higher output by optimized machine equipment Increasing demands with respect to thermoformed products call more and more for high process safety. The use of system components is re commended for optimum use of thermoforming applications within the machines ca pa bilities. For decades ILLIG has been offering components for flexible production and high availability at the same time. Chillers and temperature con trol devices are employed to keep temperatures of machines and tooling on constant levels. ILLIG machine lines are completed by upstream equipment such as pre-heaters or downstream skeletal granulators with devices for conveying granulate, bagging units or conveyors for in-line systems. Keeping temperatures on certain levels affects thermoforming as a whole. This means individual temperature control or cooling circuits cannot be regarded as separate issues. Energy consumption is improved by using various cooling and temperature control devices and also there is reduced wear and tear of high-preci - sion tool parts as well as an increase in cycle speed. More over, start-up waste is reduced.

system technology roll pre-heaters heating, cooling, temperature controlling skeletal granulators applications SMSH suction device TR trimming saw ITS temperature control sys. ITG temperature controller PC water chiller SMSH suction device FD conveyor RS granulator VHW roll pre-heater PC water chiller SMSH suction device FD conveyor RS granulator VHW roll pre-heater PC water chiller PC water chiller PC water chiller Optimum production of dif - ferent types of articles calls for individual solutions. ILLIG offers useful equipment, tech nologies and system components to meet these requirements. machines is improved and the concept of preventive maintenance is expanded. Increased performance is ultimately achieved thanks to better process control. With a view to future applications complete machine lines can be operated thanks to linkage kits. Technological developments increasingly call for Profibus connections between individual system components. Process supervision of the whole system is thus possible. Central data management to ensure continuous production monitoring as well as quality improvement. This way service of the 2 3

Better forming results and even material heating VHW 91/2 roll pre-heater ILLIG pre-heating technology ideal for PP processing ILLIG was prompted to fur - ther develop the pre-heating technology due to the specific demands made on thermoforming when processing thermoplastic materials, especially PP. Initially developed for processing thick materials it soon became obvious that higher output rates as well as improved quality can also be achieved for thin materials when using a roll pre-heater. Best forming results and low energy consumption at the same time are some of the benefits provided by the ILLIG pre-heating technology. The heating rolls are located in a fully insulated cabinet. For this reason energy consumption is kept low level and the material will not cool down in contact-free space. Even material heating and very low start-up waste can only be achieved by contact heating. Systems with one or two heating rolls are avail - able, subject to the material thickness processed. In machines equipped with one heating roll, materials of up to 1.0 mm can be evenly heated. Two-roll equipped pre-heaters are recommend - ed for materials up to 1.8 mm or 2.5 mm. Designed as independent units the pre-heaters can be easily integrated into existing thermoforming arrangements. In VHW 60b, 90b and 91 roll pre-heating systems heat transmission is gentle due to maximum material wrapping angles around the heating rolls. Arrangement of drives and control units outside the heating area to prevent influence by heat radiation.

system technology roll pre-heaters heating, cooling, temperature controlling skeletal granulators applications VHW 90/2b roll pre-heater control by compensating roller with or without Profibus connection control by light barrier with Profibus connection Better forming results with ILLIG roll pre-heaters permanent, wave-free and even clinging of material to heating rolls due to integrated material brake optimum heat transfer through the whole material cross section by contact heating maximum material wraparound length and/or heat - ing length resulting in higher cycle speeds of thermoformer uniform, even material heating due to maximum number of heating rods free expansion of material in longitudinal and cross direction thus less sagging in thermoformer and more uniform wall thickness in formed parts simple temperature setting by internal regulation of roll temperatures individual temperature setting for heating rolls and convection heater no material overheating during machine stops no sticking of material due to Teflon-coated surface of heating rolls heating roll drive with frequency converter for continuous unreeling of material minimum wear and tear of material transport in thermoformer since piercing is easier due to heated material low start-up waste Setting and control of continuous draw-off speed is performed optionally: by Profibus connection with set-up thermoformer independently, subject to amount of material drawn off by the downstream thermoformer by Profibus connection with set-up thermoformer and/or independently, subject to amount of material drawn off by the down - stream thermoformer ILLIG VHW 60b and VHW 90b and VHW 91/2 roll pre-heaters VHW 91/2 is especially used for thicker materials and higher pre-heating performance Additional benefits: predominantly used for pro cessing materials of up to 2.5 mm thickness two-roll system with pneumatically operated support for swivelling movement for easier material thread - ing 4 5

The comprehensive delivery program of thermoforming machines is completed by chillers and temperature control units ILLIG temperature control technology heating and cooling for optimum forming results and reproducible forming process ILLIG ITG 600 temperature controller Optimized and reproducible production data are the basis for thermoformed parts of superior quality. A consistent temperature profile of all components involved in the process is a prerequisite. ILLIG offers chillers and temperature control units for this purpose. ILLIG chillers The chillers are mainly used for cooling of molds, clamping frames and transport devices of thermoforming machines. Moreover, these chillers can be operated in combination with tempera - ture controllers. This way a closed temperature control/ cooling circuit is formed ensuring constant tool oper - ating temperatures. Operation costs are consid - erably reduced due to these devices since no fresh water is required for cooling. Calcifying of the cooling lines in machine and tooling is prevented thanks to the closed cooling circuit. Calcified cooling lines result in a decrease of cycle speeds and they also cause considerable damage to production equipment. ILLIG temperature controllers Exact temperature control of the forming tools is a major element to achieve consist - ent forming results with regard to wall thickness distribution and definition. Superior forming results are achieved by the high pump capacity which causes fast circulation of the temperature control agent, i.e. water. Better heat transition is a major advantage in temperature control when using water as circulating agent instead of oil (for temperatures up to + 140 C). Thanks to the higher efficiency operation temperatures are reached very fast. All devices are equipped with automatic venting, level monitoring and water refill. They are filled directly from the water supply system. Moreover, there is an automatic evacuation system to empty tools and tubes before a tool change. Benefits: compact, modular devices extremely functional when exposed to high ambient temperatures highly functional and safe operation reduced energy consumption optimum ease of service several sizes to cover different requirements

system technology roll pre-heaters heating, cooling, temperature controlling skeletal granulators applications ITS temperature control modules tool cooling with ILLIG PC water chiller heat up tool with ILLIG ITG 600 temperature controller temperature control of tool with ITG 600 temperature controller and cold water The devices can be used with ILLIG automatic sheet and roll processing machines 1 ILLIG ITS temperature control system The temperature control system is very suitable to indi - vidually regulate the temper - atures of machine / tool components in different temperature circuits. This way it is possible to cool down the holding frame in UA machines and to heat up the clamping frame at the same time. Subject to the tool size, there can be either one or two temperature-control circuits. Thanks to its modular design, the number of temperaturecontrol circuits in the temper - ature-control system can be adapted to the relevant machine equipment. Operation via forming ma - chine is optionally possible with a Profibus connection. Minimum temperature differ - ences between inlet and outlet are required in upper and lower tool to extend tool lives and/or to increase production speeds of RDM ma chines. Fully automatic regulation of temperature and flow volume Temperature and volume flow control in all operation mo des (upper and lower tool) is carried out fully automatically. A separate cooling circuit for ejectors and, if required, downholders is also available with direct connection to customer s cooling system. The inlet temperature during production (14 20 C) makes it possible to operate the tool close to its manufacturing temperature. The high inlet temperature thus also results in energy savings since the cooling water does not have to be cooled to such an extent any more. This fact can already be considered in the design stage of the central cooling systems. Tool cooling is not subject to pressure fluctua - tions in customer s cooling system. Additional functions are also available, such as: monitoring of pressure and temperature of customer s cooling system integrated filter for cus - tomer s cooling system display of cooling water outlet temperatures and monitoring of limit values on screen operating panel 2 3 4 example for ILLIG ITS temperature control system 1 mold is heated with two temper - ature control circuits switched in a parallel way 2 cooled holding frame 3 temperature-controlled clamping frame 4 temperature-controlled prestretcher 6 7

ILLIG granulators downstream equipment suitable for all roll-fed thermoformers Comprehensive modular elements for interlinked processing ILLIG granulators are specifically equipped to suit thermoforming requirements. Res pective interlinkage kits ensure optimum synchronization of mechanical interfaces in individual roll-fed thermoformers and interfaces of the control system. If cycle speeds of the thermoformer differ, the draw-in speed of the skeletal is adapted accordingly. Consequently, the resulting granulate is of uniform size which is important for recycling. The grinding element located in the sound-insulated hous - ing can be moved out for maintenance or used as substitute granulator for pro - cessing different grades. A swivelling roll draw-in element provides easy access to the machine for cleaning purposes or to exchange the screen. Different granulate sizes can thus be generated. Interlinkage with thermo - former For machines of the RDM series, the granulator is deliv - ered with skeletal draw-in feature and high version of sound insulation housing. The skeletal can be led above the stacking unit either in a linear way or at a 90 degree diversion besides the stacking unit. For the RDK and RDKP series there is a compact version which can be integrated into the machine as optional extra. Various components for granulate suction With the SMSH suction device the granulate can be conveyed directly from the granulator into bags. grinding element of a granulator The FD 74 conveying blower is either used to further process granulate within inline systems or to transport granulate into silos.

system technology roll pre-heaters heating, cooling, temperature controlling skeletal granulators applications Granulators for uncontaminated granulate different linkage kits and installation variants are available versions adapted to different thermoformers optimum sound insulation due to closed construction sound-reduced skeletal feed automatic synchronization of skeletal draw-in to speed of thermoformer good accessibility to thread skeletal skeletal forwarding devices improve access for removal of formings as well as tool change ease of maintenance since grinding element can be removed from sound insulation housing no time-consuming, complicated change of skeletal required 8 9

Optimized production due to peripherals. Higher availability by integration of all parameters relevant to the process. Applications and process engineering Different requirements have to be met with respect to con trol and regulation of temperatures, strokes and speeds as a result of diverse applications in the thermo - forming and packaging technology. The parameters are influenced by material, environmental influences and operation conditions but there are also influences with - in the production system due to the succession of continuous and discontinuous methods of operation. The complexity of the process shows that a production system can only be used to its full extent if all individual process steps are linked. However, high demands have to be met in the thermoform - ing process regarding heating and cooling technology. The narrow tolerances within the forming tools call for ex - ternal balancing of tempera - ture fluctuations during oper - ation. Constant temperature conditions must be achieved while considering all elements affecting the process. Hea t - ing/cooling systems reflect data in accordance with the requirements of practical operation. Different heating/cooling circuits are required within a production system, subject to the requirements. This way constant operation conditions are achieved and consequently consistent product quality. Processing of materials with - out contamination is a major element in the application of system components in thermoforming. Direct interlinkage of thermoformer and skeletal granulator prevents contamination of the granu - late. Moreover, even material draw-off is ensured regardless of material thickness and skeletal temperatures. Addi - tionally, good accessibility is ensured to change the form - ing tools. Data management The integrated signal transfer within a machine line results in costs savings, increased efficiency and transparency of the process. This can be employed in high-efficiency lines with high demands regarding quality and productivity. The production process can be measured and is repro - ducible thus providing proof for quality control purposes.

system technology roll pre-heaters heating, cooling, temperature controlling skeletal granulators applications Benefits: improved quality management by uniform administration of setting data uniform documentation of setting data facilitates quality assurance higher flexibility and efficiency by standardized change of setting data, product changes can be performed much faster and safer the pilot function of the thermoformer is main - tained, i.e. changes per - formed on the thermo - former automatically will cause adaptation of all system components increased availability by guided error analysis in all system components support of preventive maintenance 10 11

ILLIG Maschinenbau GmbH & Co. KG Robert-Bosch-Strasse 10 74081 Heilbronn/Germany Telefon: +49(0)7131/ 505-0 Telefax: +49(0)7131/ 505-303 e-mail: info@illig.de Internet: www.illig.de 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 Produced Tooling 8000.08.2005 - e -, Subject to change.