automatic roll-fed machines, separate forming and punching

SYSTEMS

RV ThermoformerHigh Quality andLow Mold Costs

Automatic roll-fed machines, separate forming and punching RV 53 | RV 53d IC-Technology | RV 74d IC-Technology

www.meg

aplas

tgmbh

.com

2 - 3

ILLIG – there’s simply more in it for you!

Content:

Welcome to ILLIG ..............................................................................2-3ILLIG IC Intelligent Control Concept .................................................4-5RV Thermoforming systems ..........................................................6-15Molds ..............................................................................................16-17RV Technology ...............................................................................18-21

RV 53 / RV 53dRV 74d

ILLIG Systems ................................................................................22-27

ThermoformingPackaging Technology

Molds

Welcome to the world of ILLIG. Our passion is high-performance thermoforming ma-chines 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 sa-tisfied customers from more than 80 countries across the globe.

Our extensive experience and know-how go hand in hand to develop feasible solu-tions – 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. ILLIG – Synonym for most economical produc-tion of high-quality trays, cups and other parts. Worldwide.

Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

www.meg

aplas

tgmbh

.com

4 - 5

ILLIG – Intelligent Control Conce pt

Market requirements

Process control Guided processes Process skills

Operator has to deal with increasing complexity

ILLIG Intelligent Control Concept

Drive technology / Sensor system / Computer performance / Visualization technology

Reproducibility

Quality control Increased performanceEnergy efficiency

Conversion timesMaintenance

Availability Productivity

Consequence

Realization

Technology

P R O F I T

This is how you

benefit from

ILLIG IC

The user benefits from the IC – ILLIG Intelligent Control Concept. He can utilize the com-bination 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.

IC - The next LevelILLIG Intelligent Control Concept

Levels of development

3rd GenerationProcess optimized machine

2nd GenerationServo driven machine

1st GenerationPneumatic machine

1. ThermoLine-Control®. Operation, control and storage of all individual machines of one line interlinked by Profibus. All data is stora- ble 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 thepossible number of cycles not subject to operator’s skills. All optimization parameters are automatically adapted. Highest production performance, absolutely reliable.

3. Compensation of ambient influences during process. Automaticadaption of the heater setting values with changed ambient influences (Initial temperature of material roll, ambient temperature andtemperature of machine stand).

4. Faster mold change. Guided and safe mold change thanks todifferent technical levels. For faster perfect mold change which isnot subject to operator’s skills.

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 changeswith 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 machinestandstill times, service call on site not required.

Machines equipped with the „ILLIG Intelligent Control Concept”are marked with the addition „IC”.The IC concept raises thermoforming to a new, higher level.


www.meg

aplas

tgmbh

.com

6 - 7

RV-Thermoforming systems – automatic roll-fed machines, s eparate forming and punching

Economical and efficient, also for small batch sizes

Forming parts can be produced economically and efficiently, even in small batch sizes, using the RV vacuum forming technology in combination with molds of simple design. In positive forming the automatic pre-blowing me-thod allows a uniform wall thickness in high parts by pre-stretching the material.

The RV 53d und RV 74d generation -an innovative concept for vacuum forming supported by compressed air for higher performance and improved part quality

The RV-d series features a higher automation level and facilitated operation as well as convenient, rapid mold changes. Wall thickness is improved in high parts when produced in the positive forming method combined with automatic pre-blowing and pre-stretching of the material. Forming is performed by vacuum, supported by 3 bar compressed air.The total forming pressure is available within a very short time since forming air distan-ces were reduced. This equipment is suitable for the production of formings of superior quality and definition with higher output at the same time.

-1bar

P (t)

-1bar

P (t)

+ 3bar

Using the RV technology, uniform wall thickness is achieved by pre-blowing.

Part forming is carried out by vacuum.In the RV 53d and RV 74d series parts are formed by

vacuum, supported by 3 bar compressed air.

Perfect vacuum forming with small batch sizes.Tailored forming programs and fast format changes. Unique mold system and system of standard parts for building forming and punching tools as well as stacking devices.

RV 53 RV 53d

RV 74dRV 53d with hole punch press

RV 74d with hole punch press

RV 74d only forming STAL 90 horizontal punch press


www.meg

aplas

tgmbh

.com

8 - 9

RV 53 Thermoformer the standard for small batch si zesDigitalized sequencing allows practical operation.

RV 53 for economical batch sizes

RV machines feature simple tool technology for forming, punching and stacking of thermoformed parts. Using this technology vacuum forming can also be applied for the production of small batch sizes. The forming station is equipped with 4 independently working tool carriers. Forming tables and clamping frames are moved pneumatically. Subject to mold design and forming program, stro-kes of table and upper frame can be set.

Parameters for pre-blowing, suction and demolding can be digitally set on the central operating panel. These setting data can be saved and filed to ensure further repeatability. Up to 22 cycles can be achieved by using molds with direct or indirect cooling.

After forming the parts are punched in the punching station and transported to the stacking sta-tion suspended in the skeletal.

Proven machine program and simple mold technology

Mold change

The quick change system includes automatic setting of the material transport to mold width as well as quick clamping of forming and punching tools. Material index length, material transport acceleration, material transport speed, upper clamping frame stroke, pre-blowing, suction, table stroke, table speed and demolding air can be digitally set during machine operation. All mold and format parts can be changed from the operating side of the machine. Operation by touch screen.

Stacking station RV 53

Formed parts are stacked in upward direction into format-dependent stacking cages. The parts, suspended in the skeletal, are clam-ped in the stacking station and separated from the break-out plug. A further movement takes the formed parts into the stacking cage. Product stacks are formed using a counting device; subsequently they are moved to a discharge sheet by a pushing-out device.

The setting parameters of the stacking movements are entered on the operating panel. The stacking station can be moved in ope-rating direction in order to ensure precise stacking. Parts produced in small series are removed manually, automatic stacking is not required.

Samples of mold designs suitable for vacuum forming on RV machines.


www.meg

aplas

tgmbh

.com

10 - 11

RV 53d Thermoformer flexible and intelligentEconomical thermoforming of different batch sizes. Higher forming speed due to short forming air distances.

Formed parts attributed to pressure forming so far can be manufactured on these machi-nes in a cost-effective way.

Thermoforming with the RV-d series fea-tures improved performance, availability, flexibility and low format part costs. The core element of the innovative technology is a cost reduction of formed parts, also for smaller batch sizes.

Some of the major benefits of RV 53d are: Economical production of packaging artic-les made of all materials suitable for ther-moforming, simple operation, high output, fast mold change, and computer-aided ba-sic setting.

Versatility and high productivity

Innovative forming programs and optimized positioning of all elements involved in the forming process allow production of sophisti-cated part contours. Combined with tailored standard parts, inexpensive format sets are available which allow economical application of vacuum forming for small batch sizes as well. Based on newly developed standard parts customers benefit from for economical vacuum forming, also for small batch sizes. Short cycle times and a high automation level for forming, punching and stacking com-bined with a tried and tested quick-change mold technology ensure the demanded availability with high productivity at the same time.

Materials such as PS, PVC, PET and PP can be processed on RV machines. Materials at a range of 180 my up to 1.5 mm can be pro-cessed on RV 53d machines, as well as optionally up to 2 mm. The basic RV 53d machine is equipped with heating, forming and pun-ching station. The machine can be upgraded by adding a stacking device as well as a hole punch press.

Thanks to heating and material transport features PP can be processed without problem. Roll pre-heaters are available as additional modular elements for pre-heating. Shortest filling times for the individual cavities thus allow shortest cycle times with optimum part definition. Forming air and vacuum are available for upper and lower table with optional switching. Thanks to the pre-blowing device with pneumatic material pre-stretching a more uniform wall thickness is achieved in sophisticated parts manufactured by the positive forming. By using cooled molds up to 45 working cycles can be achieved with the RV 53d, subject to equipment level. PP is processed at 3 bar, with spreading and reinforced cooling performance.


www.meg

aplas

tgmbh

.com

12 - 13

RV 74d Thermoformer larger version intelligent and e fficient Thermoforming line for higher output. The RV 74d, featuring a larger forming area, pro-vides the same benefits for forming and punching as the RV 53d.Heating and forming station are basic ele-ments of the line. An individual thermo-forming system can be tailored by adding modular elements, such as hole punch press, steel rule punch press and stacking device.

Optimum thermoforming conditions by pilot heating technology

Upper and lower heater come as standard. The individual rows of heater elements can be pilot-controlled. Heater element rows which are not re-quired are automatically switched off, subject to index length and material width. The upper heater is equipped with longitudinal row control; the lower heater is equipped with cross row control. Optionally, a row of small heater elements is available on the mold side. Benefit: Cold influence is compen-sated.

A heating profile is calculated by the computer-aided basic setting in relati-on to the center row of heater elements. All thermoforming possibilities can be optimally utilized with this type of heater equipment.

Individual thermoforming system for your requirements

Longer service lives of steel rule dies thanks to higher flexural strength of the steel rule punch press. The steel rule punch press is equipped with movable upper and lower table. Higher cycle speeds are achieved by employing a servo drive. Based on this new drive technology, the punching tables can be moved by indexing or in various stages of creep speed. This is especially beneficial for adjustment of the steel rule dies. The play-free height adjustment of the upper bridge reduces the cutting shock and improves the service lives of the steel rule dies. The steel rule cutter can be moved in longitudinal and cross direction to achieve a uniform punching contour. The position is recalled by the computer-aided basic setting program.

Servo-driven material transport for precision positioning during high transport speeds

Width and index length setting of the material transport is carried out by the basic setting program. The servo positioning drive redu-ces index length tolerances to ± 0.2 mm. The spreading device moves apart the material transport in the area of the forming station, the material is stretched and thus webbing is prevented during the forming process. This is especially beneficial for PP processing. Material spreading in the RV 74d is carried out by servo motor. Spreading parameters are entered on the operating panel. Materials up to 2.5 mm can be processed.

Hole punch press

A hole punch press is available for the punching of bottoms and lids. Automatic positioning of the movable hole punch press by computer-aided basic setting.

Example RV 74d:The upper heater is equipped with longitudinal row control;

the lower heater is equipped with cross row control.Pilots


www.meg

aplas

tgmbh

.com

14 - 15

Cost-effective and versatile system solutions


Last but not least the part quality depends on the characteris-tics and the reliability of the individual production steps. ILLIG offers a broad and mature range of stacking system solutions, adjusted to the corresponding requirements.

Improved setting and operating convenience in RV 74d due to servo drives which are emplo-yed for the stacking movements. Distances of break-out plug and push-out device can be set very easily by using the teach-in method. The strokes set by the operator are converted by the machine control into setting values. These values can be stored. They reduce set-up times and result in higher efficiency.In the stacking variant for RV 74d where stacking is performed in downward direction, the break-out plugs push the formed part out of the web onto a stacking conveyor which de-scends cycle by cycle.

Descending distances can be programmed in different ways, thus causing formed parts to nest firmly or only slightly. When the set number is reached, the stacks of counted parts are transferred to the discharge conveyor and discharged from the machine.

The different stacking variants, among other things, also influence the forming process. This means better stacking, for example of hinged packs, thus 30 cycles/min are possible.

RV 74d stacking stationwith downward stacking(optionally RV 53d)

RV 74d stacking stationwith upward stacking

Stacking variants for all automation levels

Efficiency is based on the quality of the product stacks, cost-effective format parts, reliabili-ty as well as ergonomic end packaging. The concept of the stacking systems also meets the requirement for fast and simple change of format parts.

Additionally, the position of the stacking station is calculated by the basic setting program with respect to the index length.The position can be changed and stored during operation. Consequently, no setting work is required for repeat orders and a fast and reliable start-up is ensured.

www.meg

aplas

tgmbh

.com

16 - 17

Mold making manual – for your individual success sys tem

Requirements on formed parts in terms of quality and efficiency will continue to grow in the future as well. Our automatic roll-fed machines are an essential factor for long-term competitive production. The mold is the second, equally important component. ILLIG: provides trend-setting support also for this topic, so potentials of the RDKP machines can be utilized to the full extent – the ILLIG mold making manual.

Integrated development and perfect synchronization of both elements result in a production system of utmost flexibility, productivity and reliability.

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

I Optimum processing quality: Thanks to unique technical details. I Efficient and reliable operation: Thanks to minimum standstill

times, low maintenance effort and long service lives. I Future-proof: Thanks to unique performance data.

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 from ILLIG: Clever details with highest customer value

Customers can build their own molds in a cost-effective way by using the clearly arran-ged and user-friendly „Mold making manual“. An investment which will pay for itself fast and last but not least in the thermoforming of food packs.


www.meg

aplas

tgmbh

.com

18 - 19

Future-oriented system techn ology – noticeably short mold change times

Automatic roll-fed machine, separate forming and punching RV 53 Automatic roll-fed machine, separate forming and punching RV 53dApplicationsApplications

Forming area mm max. 500 x 350

Mold width between material transport

mm max. 516

Mold length in feed direction mm max. 366

Mold height on upper table mm max. 130

Mold height on lower table mm max. 50

Material width with mm max. 550

Index length mm max. 380

Part height above material level mm max. 100

Part height below material level mm max. 30

Cycle speed with process optimization 1/min. max. 22



mm max. 524








Forming pressure bar max. 3


RV 53 RV 53dHinged pack with euro hole ✔ ✔

Deli cup - ✔

Plant tray - ✔

Carrier pallet for work pieces ✔ ✔

Tray for chocolate marshmallows ✔ ✔

Blister ✔ ✔

Insert for chocolate candies ✔ ✔

Hinged pack for bakery products - ✔

Hinged pack for fruit salads ✔ ✔

Round tray with flat bottom ✔ ✔

Hinged packs with punched holes for fresh fruit - ✔

RV 53 RV 53dTray for vegetables ✔ ✔

Hinged pack for croissants - ✔

Hinged pack for felt pens ✔ ✔

Hinged pack for felt pens ✔ ✔

Tray for sweets ✔ ✔

Hinged pack for salad ✔ ✔

Tray for pharmaceutical products ✔ ✔

Tray for electronic components ✔ ✔

Corner protection - ✔

Hinged pack for cake ✔ ✔


www.meg

aplas

tgmbh

.com

20 - 21 Automatic roll-fed machine, separate forming and punching RV 74d Applications

RV 74dHinged pack with euro hole ✔

Deli cup ✔

Plant tray ✔

Carrier pallet for work pieces ✔

Tray for chocolate marshmallows ✔

Blister ✔

Insert for chocolate candies ✔

Hinged pack for bakery products ✔

Hinged pack for fruit salads ✔

Round tray with flat bottom ✔

Hinged packs with punched holes for fresh fruit ✔

RV 74dTray for vegetables ✔

Hinged pack for croissants ✔

Hinged pack for felt pens ✔

Hinged pack for felt pens ✔

Tray for sweets ✔

Hinged pack for salad ✔

Tray for pharmaceutical products ✔

Tray for electronic components ✔

Corner protection ✔

Hinged pack for cake ✔



mm max. 724








Forming pressure bar max. 3


Future-oriented system techn ology – impressive XL format


www.meg

aplas

tgmbh

.com

22 - 23

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, ma-nufacture, assembly and commissioning of complex production lines and individual components. We are an owner-operated company with about 750 employees, own subsidiaries and re-presentative offices in over 80 countries and present in all mar-kets. We are your competent and reliable partner. The name stands for superior technology of excellent quality and a com-prehensive, global service.

Whatever you want – you‘ll find it at ILLIG

ILLIG offers you not only machines for the most diver-se applications, but also corresponding accessories and molds. This way you can utilize the substantial potenti-als 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 I Sheet processing machines I Automatic roll-fed machines for

forming/punching operation I Automatic roll-fed machines,

separate forming and punching

Packaging Systems I Skin and blister packaging machines I Form, fill and seal lines

Molds


www.meg

aplas

tgmbh

.com

24 - 25

ILLIG stands for pioneering inventions and innovations. We actively invest in the research and development

of new technology and work together with lea-ding research institutes.

Using the latest hardware and software tools our highly specialized engineers are developing forward-looking so-lutions. Solutions that offer decisive advantages to our customers, such as higher quality products produced in less time and at reduced costs - inno-

vations that make our customers even more successful.

ILLIG – evolution of thermofor ming

ILLIG has been setting technological milestones for decades

1946On May 27 Adolf Illig founds a maintenance and repair workshop in the garage of his parents’ home.

1956Type UA 100: Construction of the first ILLIG vacuum forming machine.

1960Introduction of R 650: World’s first roll-fed automatic vacuum forming machine for produ-cing lids from pre-printed material.

1963First high-speed pneumatic forming and punching machine. Beginning of market-proven RDM series.

1964New RDM series machines introdu-ced. Founding of ILLIG tool and mold shop complements product range for the production of cups and lids.

1968First packaging machine line that integrates forming, filling and sealing. First piston dosing machine for pasty ingredients.

1984RDM 50K – first larger automatic thermoforming machine with tilt technology. It sets the new standard for hygiene conditions in the packaging industry.

1983Development of pre-heaters with heated aluminum rollers for conti-nuous PP heating.

1989First software program to automate basic settings of vacuum forming machines.

1993First In-Mold Labeling production line for applying PP labels to PP margarine tubs.

1994Fully aseptic form, fill and seal lines with a capacity of 700,000 yogurt cups per day.

1995Development of in-novative molds for forming and pun-ching technology that set new stan-dards in precision, temperature control and service life.

2005Premiere of In-Mold-Labeling for form, fill and seal lines.

2004RDM 78K, ILLIG’s first 3rd generation machine line in operation.

2006Conversion of ILLIG high-performance thermoformers to 3rd generation technology.

2008Presentation of BF 70 – first bottle former worldwide of its kind ready for serial production.

2013ILLIG designers achieve quantum leap in thermofor-ming with IC machi-nes (ILLIG Intelligent Control Concept).

TodayILLIG’s IML-T deco-ration technology prevails among customers. In-Mold-Labeling lines conquer the market.

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 know-how of the repair shop and dryer production.


www.meg

aplas

tgmbh

.com

26 - 27

The success system – for your successful productionILLIG IC-RV line technology - probably the most comprehensive program of state-of-the-art lines in the sector of automatic roll-fed machines for separate forming and punching.In this product group you obtain everything from one source: Innovative whole solu-tions for most diverse industries and applications, directly suitable for your individual requirements.

Simplified operation => ILLIG IC for higher availabilityBetter cleanliness => Perfect for food sectorMechanical improvement => Higher availability of processes

IC-RV: Everything you need for long-term successful production and a permanent competitive advantage. Worldwide.

Contact detailsILLIG Maschinenbau GmbH & Co. KGRobert-Bosch-Str. 1074081 HeilbronnGermanyPhone: 0049 7131 505 0Fax: 0049 7131 505 303E-Mail: [email protected]: www.illig.de


www.meg

aplas

tgmbh

.com

28 - MF

ILLIG Maschinenbau GmbH & Co. KGRobert-Bosch-Strasse 1074081 Heilbronn I Germany

Tel. +49 7131 505-0Fax +49 7131 505-303

E-Mail: [email protected]: www.illig.de

SYSTEMS

3122

.02.

2017

- en

- Su

bjec

t to

chan

ge

ILLIG systems for thermoformingand packaging technology

I Sheet processing machines I Automatic roll-fed thermoformers for

forming/punching tools I Automatic roll-fed thermoformers,

separate forming and punching I Skin and blister packaging machines I Form, fill and seal lines I Mold shop

www.meg

aplas

tgmbh

.com

automatic roll-fed machines, separate forming and punching

Documents