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ILLIG – we simply include more for you

Content:

Welcome at ILLIG ..............................................................................2-3ILLIG Intelligent Control Concept IC .................................................4-5Generation RDM-Kc ..........................................................................6-9Cleantivity® .....................................................................................10-11Reliable Handling ..........................................................................12-13RDM-K Thermoformer ..................................................................14-23

RDM 54K und IC-RDM 54KcRDM 70K und IC-RDM 70KcIC-RDM 75KcIC-RDM 76KRDM 78K

Molds ..............................................................................................24-25ILLIG Systems ................................................................................26-31

ThermoformingPackaging Technology

Molds

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ILLIG – synonym for most economic production of high-quality cups, trays and other parts. Worldwide.

Welcome at ILLIG ILLIG Intelligent Control Concept IC Generation RDM-Kc Cleantivity Reliable Handling RDM-K Molds ILLIG Systems

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 custo-mers 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.

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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.

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

This is how you

benefit from

ILLIG IC

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

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 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.

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 can get remote access to machine. Fast error diagnosis, minimum machi-ne standstill times, on site service calls are not required.

ILLIG c Generation – enhanced efficiency

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Fast product changes Higher outputGUIDED 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.

Benefit: Perfect process optimization possible without additional measuring technology and costs. This results in increased cycle speed and improved quality.

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.


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RDM-K automatic roll-fed ma chines of the c Generation – serial peak performance

Picture right:33% energy saving by HTSs heater elements

For decades the demands for high part quality and reproducibility of packs have been closely connected with the forming/punching tech-nology developed into an industrial standard by ILLIG.

Higher part quality Low costsPERFECTION 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

HEATER, GEOMETRY, DRIVE AND MONITORING + 33% 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

Upper and lower heaters are equipped with longitudinal row control. By swit-ching 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.


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Cleantivity® – technology of cl eanliness

Clean production with increased quality time. Numerous technical innovations were realized on IC-RDM-K machines to achieve this.

Machine standMachine stand with drip protection towards material.

Condensation waterFormation 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 supplyLubricant is applied to the relevant lubrication spots of the material transport. This way lubri-cant consumption is optimized.

Food grade lubricantsNew food grade lubricants in accordance with DIN EN ISO 14159 and DIN EN ISO 21469. These H1 lubricants were developed for machine and lines in the food industry.

Material transportA much better, new piercing method prevents formation of material particles on the piercing spots which might cause soiling of the formed parts (pictures below).

Cleantivity® was derived from „Cleanliness“ and „Productivity“.

It is the intent to extend the operating time, run-ning 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.

Drip protection sheet towards material

Piercing, old version New piercing version without formation of particles


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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 hand-ling of the enormous cup output and allow moreover an indi-vidual adaptation of the stacking device to the respective pro-duction process.

RDM-K stacking machines:PH 54c | PH 70c | PH 75c | PH 76 | PH 78STPM 75b | STP 75b | STPL 75bSZA 73c

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 stric-test requirements of the food industry are met.

Benefits:

I Reliable processing I Reliable handling of large amounts I Also ideal for „critical“ cup shapes I Perfectly suited for food industry I Efficient by individual adaptation to

automation level, output and further processing I Can be used as optional extra for operating

RDM-K thermoformers

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.


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Automatic pressure forming machines RDM 54K and IC-RDM 54Kc

Number of dry cycles min-1 max. 34

Number of dry cycles min-1 max. 54

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

Automatic pressure forming machines RDM 54K | IC-RDM 54Kcfor forming areas up to 520 x 300 mm

Product Material Ø (mm) No. of cavities Output/h

Yogurt cup PS 1,5 mm 75 18 41040


Drinking cup PP 0,8 mm 73 18 51840


Vending cups PS 0,8 mm 70 24 72000







Applications

RDM 54K IC-RDM 54KcAPET 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 ✔ ✔

RDM 54K IC-RDM 54KcFlat 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 ✔ ✔

RDM 54K

RDM 54K

IC-RDM 54Kc

IC-RDM 54Kc


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Automatic pressure forming machines RDM 70K and IC-RDM 70Kc

Automatic pressure forming machines RDM 70K | IC-RDM 70Kcfor forming areas up to 680 x 300 mm

RDM 70K IC-RDM 70KcAPET 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 ✔ ✔

RDM 70K IC-RDM 70KcFlat rim fruit tray rectangular ✔ ✔

Yogurt cup ✔ ✔

Yogurt cup with false bottom ✔ ✔

Coffee cup for vending machines ✔ ✔

Coffee capsule ✔ ✔


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 ✔ ✔


IML cup rectangular - ✔

IML cup round - ✔

IML cup oval - ✔













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






RDM 70K

IC-RDM 70Kc

Applications


Dry cycles min-1 max. 32


RDM 70K

IC-RDM 70Kc

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Automatic pressure forming machine IC-RDM 75Kc

Automatic pressure forming machine IC-RDM 75Kcfor forming areas up to 735 x 465 mm







Forming area depth of draw 150 mm max. 735 x 465







IC-RDM 75KcEspresso capsule ✔

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 ✔

Pet food square ✔

Drinking cup transparent ✔

Water cup ✔

Plant pots round ✔

Plant pots rectangular ✔

Coffee capsule with hole ✔

IC-RDM 75Kc

Applications


IC-RDM 75KcAPET 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 ✔

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Automatic pressure forming machine IC-RDM 76K

Automatic pressure forming machine IC-RDM 76Kfor forming areas up to 760 x 540 mm


Yogurt cup PS 1,5 mm 75 60 104400




IC-RDM 76KAPET cup ✔



Cup round ✔


Cup for soups ✔


Deli cup ✔






Espresso capsule ✔

Deli salad transparent ✔

Flat rim meat tray rectangular ✔

IC-RDM 76KFlat rim fruit tray rectangular ✔

Yogurt cup ✔


Coffee capsule ✔

Cup transparent ✔

Margarine tub ✔




Soft drink cup ✔

Plate with contour ✔

Pet food square ✔

Tray 4-up ✔


Deli salad transparent ✔








IC-RDM 76K

Applications


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Automatic pressure forming machineRDM 78K

Automatic pressure forming machine RDM 78Kfor forming areas up to 760 x 420 mm


Yogurt cup PS 75 45 89100

Yogurt cup PS 95 32 57600

Drinking cup PP 73 45 113400

Drinking cup PP 95 32 59520

Vending cups PS 70 55 141900

RDM 78KAPET cup ✔



Cup round ✔


Cup for soups ✔


Deli cup ✔






RDM 78KEspresso capsule ✔

Yogurt cup ✔


Coffee capsule ✔

Cup transparent ✔

Margarine tub ✔




Soft drink cup ✔

Pet food square ✔


Water cup ✔








RDM 78K

Applications


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ILLIG mold technology – your individual success systemall 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 suc-cessfully on a daily basis.

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

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:

I Controllable cooling circuits for constant mold temperature, consistently good results are ensured I Reduced forming air consumption and symmetry of all medi allows short

mold filling times and identical part quality in all cavities I Quick-change technology for shortest format changeover times I Regrinding elements I Lower mold weight, prerequisite for use of all machine potentials I Separate mold cooling on forming station

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 pro-duction system which can hardly be surpassed in terms of efficiency, productivity and reliability – called the ILLIG success system.


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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

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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

Today:Customers all over the world manufacture sophisticated and high-precision parts and packages for brand products.

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. .

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.

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


The success system – for your successful productionToday ILLIG offers the IC-RDM-K line technology, the most flexible introductory pro-gram of state-of-the-art automatic roll fed machines, for separate forming and pun-ching, worldwide. In this product group you obtain everything from one source: Innovative whole solu-tions for most diverse industries and applications, perfectly suitable for your individual requirements.

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

IC-RDM-K. Everything you need for long-term successful production and a perma-nent competitive advantage. Worldwide.

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

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

[email protected]

SYSTEMS

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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

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