illig Form Fill Seal Line - FSL 48

The new FSL 48 picks up from the proven FFS line technology embodied in the smaller FS 37 size model. Innovations introduced at the equipment and design level mainly reflect the demands of the dairy industry, where hygienic filling is a key theme. Accordingly, all components of this machine are made of stainless steel. Moreover, its multi-track filling unit (newly developed for the FSL 48 as well) is designed to provide CIP (cleaning in place) and SIP (sterilization in place), making the system generally suitable for aseptic filling.

Hygienic filling
The hygiene levels supported by this machine range from thermoforming with sterile air to a configuration with all-enclosed filling section (also available with CIP/SIP) and an optional sterilization of lid foil by UV irradiation. Where no central sterilization facility is available in-house, a so-called sterilization module can be optionally attached directly to the machine to generate sterile air and hot steam while also providing peroxide spraying for the filling tunnel. The system's filling and packaging performance reliably conforms to diverse standards up to VDMA Hygiene Class IV for hygienic filling machines. 

All stations on the FSL 48 feature state-of-the-art servomotors. A motion control system coordinates machine movements and displacement paths to provide high operating speeds. These controlled sequences result in a very smooth operation of the line, so that even highly liquid products can be filled into single-serve packs at rates exceeding 30 cycles/minute without product overspilling onto the sealing rim. 

Automatic repositioning systems at the form, seal and punch stations ensure uniform sealing rims on all containers.

The format surface area of the new FSL 48 has been enlarged from that of its FS 37 predecessor. With a size of 480 mm x 320 mm (or up to 350 mm in the case of non-decorated articles), it enables the output of one complete cycle – e.g., 12 standard curd cheese packs – to fit into a carton compatible with the Euro pallet module. The format surface area is adaptable to accommodate single or dual cups, or 4- or 6-cup trays. Thanks to the multi-track filling unit, cups can be filled with up to eight different products at the same time.

The new FSL 48 can process all customary sheet stock suitable for FFS lines, e.g., PS, PP, multilayer materials (e.g., PS/EVOH/PE), APET, and even stock made of PLA (polylactide) biopolymers. The same applies to the heat-sealable lid material.

IML: Brilliant decoration of diverse cup geometries
The in-mold labeling (IML) unit developed for the FSL 48 uses printed labels supplied from a magazine. These are placed into the mold cavity and become integral with the cup wall in the subsequent thermoforming cycle. The mold is of tilting design to allow outputs of up to 30 cycles/minute to be achieved despite this additional process step. The footprint of the IML device is not larger than that of a conventional banding unit. 

Since the IML decorating technology does not require vertical container walls, it provides the additional benefit of supporting a broad diversity of cup shapes. This ability to accommodate distinctive cup designs in conjunction with eye-catching labels goes a long way towards enhancing the product's POS appeal on the supermarket shelf.

The IML process opens up a broad range of cup decorating options – from one-sided, two-sided or three-sided (e.g., U-shaped) to four- or even five-sided (including bottom decoration, e.g., with an integrated bar code) designs – to combine high visual appeal with superior functionality. Depending on the cup material, the technology supports matching PP, PS or paper labels.

Upgradable into a full-size production line
Apart from the machine version with integrated IML unit (FSL 48 model), the basic machine is also available in its FS 48 standard form for thermoforming, filling and sealing single-serve packs or other non-decorated foodstuff containers. 

Any configuration of this FFS machine – whether FS 48 or FSL 48 – can be combined with a carton packer adapted to its output capacity. The packer, which is also servomotor-driven, features an automatic carton erector and can handle any kind of carton, from trays to open-top to wraparound types. 

For more details contact us:
Phone: +91 22 3296 4721/22/23
Fax:  + 91 22 2661 4494
Web: Illig

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