ILLIG - Soft, Thermoformed Air Ducts

Soft, Thermoformed Air Ducts :

Spanish Automotive Supplier Puts Third ILLIG Twinsheet Line in Operation

Heilbronn, July 2016. – A Spanish worldwide operating automotive supplier already put the third ILLIG UAR 155g thermoformer in operation at the beginning of this year. Air ducts are manufactured on this machine in the twinsheet method out of cross-linked PE foams (XLPE). They are suitable for air-conditioning of vehicle interiors. The automotive supplier, domiciled in the North of Spain in the Basque province of Álava, is specialized in the production of seals and sound-reducing components made of foams. The extremely lightweight ducts for guiding hot and cold air, manufactured in the thermoforming method, meet the demands of the automotive sector especially well. Compared to blow-molded, hard PP ducts still frequently used they provide clear benefits thanks to their positive properties.

In twinsheet thermoforming of XLPE foams two materials heated up to forming temperature are formed into half shells in the mold, supported by vacuum, and at the same time they are welded together on the outer contour. With the system developed by ILLIG; the formed parts are punched directly in the mold after the end of the cooling time. The upper mold part is equipped with extendible serrated knives. The lower mold part is equipped with grooves in which the knives immerse during punching. The punched out parts are held by holding bridges and moved out of the forming station in this way. Outside the thermoforming machine only the connection areas of the air ducts have to be cut – just like blow-molded hard ducts.

Beneficial properties – customized thermoforming technology

A duct made of XLPE foam (density approx. 70 to 80 kg/m³, subject to application) is not only substantially more lightweight than a duct made of solid PP (density about 0.9 g/cm³ or 900 kg/m³), among other properties, it also possesses substantially lower heat conductivity and better acoustic dampening behavior thanks to its structure.

In this way the foam’s lower heat conductivity and heat capacity minimizes development of condensation water in the air duct after switching off the air conditioning system. High elasticity and good resilience of the ducts provide further benefits, such as ease of assembly and reduction of squeaking and rattling sounds even with only smallest installation space available.

For air duct thermoforming XLPE (thickness 3 to 4 mm) is supplied by two material roll stands and each material is heated up in the forming station to a surface temperature of max. 200 C. Subsequently the heater moves out of the forming station very fast – movement time less than 3 s – in order to minimize cooling of the material up to the start of the forming process. Consequently, the servo drives for the upper and lower mold table are designed especially for very fast movement speeds of up to 500 mm/s, even for molds with a weight of up to 1 t per mold table.

A further benefit provided by thermoforming with ILLIG technology compared to extrusion blow molding: Several parts of even different sizes and geometries can be manufactured at the same time on the large-area mold (the UAR 155g features a forming area of max. 1.450 mm x 1.200 mm). This means a short cycle time per air duct. Thus air ducts made of foam are competitive with PP blow-molded hard ducts also in terms of costs – manufacturing costs per duct are comparable.

illig Invitation - Interpack 2014, Hall 6 - Booth E02

We will welcome you at Illig Hall 6, Booth E02

World Premiere of ILLIG FSL 48 – A New Standard for FFS Lines

Experience the new FSL48

The newly designed FSL 48 form, fill and seal line, tailored to meet the demands of the food industry, and especially the dairy industry, will be the core element of ILLIG's trade fair appearance at this year's Interpack, Düsseldorf, May 8 to 14. As of now an IML (in-mold labeling) station is integrated in an FFS line and employed to decorate packs in a brilliant way directly in the thermoforming process. Most conventional cup geometries which can be produced on form, fill and seal lines can be realized.

Filling and labeling – whatever fruit flavor is desired. The ILLIG multi-lane filler sets the standard for form, fill and seal lines. Now, several flavors can be filled in one machine format using the same or different labels. In all production phases the most demanding hygiene conditions for food packs are met. Different flavors can be filled at the same time by the line with one machine format, such as strawberry, orange, banana, cherry. Trade and consumers find their 4, 6 or 8 favorite flavors in crates or boxes at a glance, subject to the format layout of the ILLIG FSL 48. Manual re-sorting is no longer required.

In addition to this core element ILLIG will present economical solutions for blister packs at the Interpack stand which add to product protection, transport protection and also eye-catching presentation of products at the point of sale (POS).

We will be glad to meet you at Illig Hall 6, Booth E02

For Further Information 

Contact Us:

illig@hi-techi.com
+91 22 3296 4721 / 22 / 23

Happy Diwali

Thank You For Visiting Us @ K2013

illig Invitation K-2013

The IC-Thermoformer – A New Machine Generation which Thinks and Controls

Experience the new thermoformer IC-RDM 54K and IC-RDKP 72 as line.
ILLIG consistently pursue the strategy of increase in efficiency in thermoforming by employing the IC technology. This new control concept is designed for the current machine generation featuring servo driven motions in all sections of the machine. High dynamics can be achieved in the forming process using this drive concept and the process-controlled machine sequencing which can be realized with it. This results in high productivity of the thermoforming line with high quality of the formed parts at the same time. ILLIG Intelligent Control Concept now provides the possibility to the user to utilize the capacity to the full extent with only low operating effort required. The IC concept includes compatible control modules for the dynamic optimization of all processes, from simplification of machine operation and accelerated commissioning of new tools through to process control in order to eliminate environmental influences and also to improve process stability and product quality.


The Intelligent Control Concept includes several compatible modules:ThermoLineControl®
Dynamic process optimization
Compensation of ambient influences during process
Faster mold change
sas-up® (self-adaptive start-up phase)
ILLIG NetService (troubleshooting and remote diagnosis)

        

Two automatic roll-fed thermoforming lines with machines and molds of the RDKP and RDM-K series, equipped with the new IC technology, will be presented at the K stand under production conditions. RDM-K machines are specifically designed for serial production of cups of various shapes and sizes out of thermoplastic material. Roll-fed thermoformers of the RDKP series produce trays and hinged packs, used e.g. for protection of food articles during transport and presentation on the supermarket shelf. On the stand APET cups will be produced on an IC-RDM 54K machine, forming area 520 x 300 mm². The machine is equipped with an 18-up tool, i.e. more than 50,000 cups are produced per hour. Hinged packs are produced on an IC-RDKP 72 machine (forming area max 756 x 535 mm²) out of PP on a 6-up tool.

We are looking forward to welcoming you..

Visit illig at K2013

Hall 3 - Stand A52

For Further Information 
Contact Us:
illig@hi-techi.com
+91 22 3296 4721 / 22 / 23

ILLIG's new FSL 48 – Redefining the Standards

ILLIG's new FSL 48 – Redefining the Standards in hygienic decorative packaging of dairy products
The new FSL 48 – hygienic & decorative filling and packaging of dairy productsThe hygiene levels supported by the new FSL 48 range from thermoforming IML-decorated cups with sterile air through a configuration with an all-enclosed filling section to the optional sterilization of lid foil by UV irradiation. Moreover, the machine's newly developed multi-track filling unit is designed to provide CIP (cleaning in place) and SIP (sterilization in place), making it generally suitable for aseptic filling. Thus, the FSL 48 delivers filling and packaging capabilities which reliably conform to diverse standards up to VDMA Hygiene Class IV for hygienic filling equipment. Thanks to the multi-track filling unit, cups can be filled with up to eight different product varieties 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) organic polymers. The same applies to the heat-sealable lid material.

The new forming, filling and sealing machine FSL 48 is cut out for the task of hygienic filling and packaging of dairy products – including, e.g., product families of differently flavored varieties – in thermoformed IML-decorated cups.

The format surface area of 480 mm x 320 mm (or up to 350 mm in the case of non-decorated articles) makes it possible to accommodate the output of one complete cycle – e.g., 12 standard curd cheese packs – in a carton compatible with the Euro pallet module following sealing and separation of the cups from the web. This format size is adaptable to obtain single or dual cups, or 4- or 6-cup trays. The machine's controlled, exclusively servomotor-driven movements result in a very smooth operation, 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. 

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 matching 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.

IML: Brilliant custom decoration of a broad diversity of cup geometriesThe IML unit developed for the FSL 48 uses printed pre-cut labels supplied from a storage magazine. These labels are placed in the mold cavity and become integral with the cup wall in the subsequent thermoforming cycle. Since the IML process does not require vertical container walls, this decorating method provides the additional benefit of supporting a broad diversity of cup shapes for improved visual impact on the supermarket shelf. Indeed, IML 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 a bottom decoration, e.g., with an integral 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. The IML unit is integrated directly into the molding station and requires no more floorspace than a conventional banding unit.

The IML unit of the FSL 48 machine withdraws labels printed in brilliant photo quality from a storage unit and transfers them into a mold cavity. Diverse cup geometries are supported. Even the bottom of the cup may be used – e.g., to apply a large and easy-to-read bar code without interfering with product design.

Another advantage of the IML technology employed consists in the fact that each mold cavity can accommodate a differently printed label. Such versatility is helpful in filling and packing product families, which is basically made possible by the multi-track filler configuration. Product changes too are quick and easy to implement with this technology.

Inserting the labels into the mold adds an additional operating step to the thermoforming workflow. In the interests of attaining maximum productivity (i.e., high cycle rates) despite this requirement, the label is inserted concurrently with the ongoing molding step outside the closed mold. To this end, the lower part of the mold is in the shape of a fourfold cube which rotates through 90 deg. in every cycle. Each printed label is inserted and fixed in the cavity with the lower mold part awaiting its next 90-deg. turn into the molding position. At the rate of 30 cycles/minute that can thus be achieved, and with the useful sheet stock area sized to yield, e.g., 12 standard curd cheese packs, the machine will thus deliver 21,600 single-serve packs per hour – hygienically filled and sealed into a custom-designed container of high decorative appeal for sustainable presentation on the POS shelf.

Visit illig at K2013

Hall 3 - Stand A52

Click Here to RSVP

For Further Information 
Contact Us:
illig@hi-techi.com
+91 22 3296 4721 / 22 / 23

Presenting Illig Innovative Varioboxx

The Innovative Varioboxx – Lightweight & Clearly Arranged, Insert Thermoformed

Heilbronn/Germany, April 2013. – For Michael Däbritz, Managing Director of Varioplast Konrad Däbritz GmbH located in the Swabian Ötisheim, there is no better KLT box for transportation and storage of small parts than the so-called Varioboxx. And this is not only due to the fact that the company working with main focus as injection molding specialist in the automotive industry developed this pack and also produce it themselves. “Simply by the facts our Varioboxx differs from standard, typical KLT boxes. It is significantly lighter, thus environmentally friendlier and also cheaper. Thanks to its transparency the content can be checked at a glance“, says Michael Däbritz.

The components of the Varioboxx are manufactured in two different processes. The open carrier box only consisting of frames and ribs and providing the required stability is injection molded as standard part. The transparent inserts serving as receptacles for parts can be individually designed and are suited to be placed into the carrier box. These inserts as well as the dust-tight lid are manufactured by thermoforming. For manufacturing these parts Varioplast expanded their machinery by a state-of-the-art UA 100g sheet processing machine. Originally developed for their own needs, third parties can now purchase the meanwhile patented Varioboxx from Varioplast. It is available in three sizes.

The transparent inserts of variable design suitable for the Varioboxx are now produced
by Varioplast on a servo driven state-of-the-art ILLIG UA 100g thermoformer.

New Box Concept to Improve Handling and Ecobalance
Besides the improved function, the ecological benefit is an equally important aspect for Michael Däbritz – and the related economic savings potential as well. “The Varioboxx, designed e.g. as 1/4 Euro pallet size, only weighs 1.5 kg including insert and lid. Compared to the solid, completely injection molded version about 2 kg of CO2 are saved already during manufacturing of the box as a result of the lower weight. And a truck saves approx. 2 l of diesel per 100 km due to the reduced loading weight. For every truck drive this means a reduction of about 5 kg of CO2 emissions over a 100 km distance“, he calculates. 

The Varioboxx concept is a combination of standard and special pack. The carrier box is the standard element, a robust injection molded part of the size of 1/4 or 1/8 Euro pallet, optimized in terms of carrying capacity, weight and stackability. The box is suitable for block storage thanks to the frame's provably high load bearing capacity. It is available in individual coloring and also in a recyclate version. The transparent inserts, suited to be placed into the carrier box, can be individually designed for optimum synchronization of volume utilization and support of the products stored and transported in these boxes. The inserts can be manufactured as thermoformed articles in a flexible and cost effective way, just like the dust-proof lid of the box. “Using our new ILLIG UA 100g we can now utilize all benefits provided by a high-speed thermoformer. Thanks to the related short conversion times and the high process consistency we can now even produce inserts for individual applications in small to medium batch sizes economically and of high product quality“, says Michael Däbritz. There are also two ILLIG thermoformers of previous design available in the company's thermoforming department.

Meanwhile many customers – especially renowned system suppliers of automotive manufacturers – supplied with parts and equipment groups by Varioplast are exclusively using the Varioboxx as reusable transport box. In-house, in Ötisheim, only the Varioboxx is employed, e.g. for part storage at assembly areas.

The content is directly visible and optimally protected for transport. But still the
box is very lightweight, as demonstrated by Michael Däbritz, presenting this
Varioboxx loaded with components.

High Performance Thermoforming TechnologyThe process-controlled machines of the UA series from Heilbronn provide new impetus for the production of thermoformed products in terms of productivity (cycle speed), product quality and operating convenience. Machine size UA 100g, as used by Varioplast, is designed for thermoforming material from sheet and roll stock, featuring a forming area of up to 960 mm x 660 mm. The innovations developed by ILLIG and realized in this machine generation comprise machine loading, continue along the process chain with heating up the material to forming temperature and the actual thermoforming with all stages from pre-forming through to demolding of the product. Objective of all measures taken is always to attain a maximally realizable output with uncompromisingly high product quality and facilitated machine operation at the same time.

Examples of such developments, often patented, are e.g. reliable sheet destacking, compensation of outside influences during heating and reduction of temperature loss of heated material until forming, prevention of chill marks, achieving a uniform wall thickness distribution during forming as well as reduction of cooling time. The "Auto" operation page featuring all important functions of a screen page or the new optimization aid for setting the forming pressure in the course of forming in conjunction with a new, frequency-controlled vacuum pump are further elements to enhance operating convenience.

The modern series of ILLIG UA sheet processing machines provides a multitude of machine types and equipment variants featuring different forming areas. These machines combine high precision and repeat accuracy with high productivity, product quality and operating efficiency.

Visit illig at K2013

Hall 3 - Stand A52

Click Here to RSVP

For Further Information Contact Us:
illig@hi-techi.com
+91 22 3296 4721 / 22 / 23

IC-Thermoformer – A New Machine Generation which Thinks and Controls

The IC-Thermoformer – A New Machine Generation which Thinks and Controls
Heilbronn/Germany, August 2013. – At this year's K Trade Fair, Düsseldorf, October 16 to 23, ILLIG will present thermoforming of tomorrow on automatic roll-fed machines equipped with the innovative, so-called IC technology. Machines equipped with the “ILLIG Intelligent Control Concept” are marked with the addition “IC”. The IC concept raises thermoforming to a new, higher level. The dynamic process optimization, one element of this concept, allows for the first time to utilize the optimum of a thermoforming line provided by today's machine technology, i.e. servo motor drives employed in all sections of the machine, fast and with only low operating effort required.


Two automatic roll-fed thermoforming lines with machines and molds of the RDKP and RDM-K series, equipped with the new IC technology, will be presented at the K stand under production conditions. RDM-K machines are specifically designed for serial production of cups of various shapes and sizes out of thermoplastic material. Roll-fed thermoformers of the RDKP series produce trays and hinged packs, used e.g. for protection of food articles during transport and presentation on the supermarket shelf. On the stand APET cups will be produced on an IC-RDM 54K machine, forming area 520 x 300 mm². The machine is equipped with an 18-up tool, i.e. more than 50,000 cups are produced per hour. Hinged packs are produced on an IC-RDKP 72 machine (forming area max 756 x 535 mm²) out of PP on a 6-up tool.


Capacity of servo-driven thermoformers utilized to full extent with ILLIG IC

ILLIG consistently pursue the strategy of increase in efficiency in thermoforming by employing the IC technology. This new control concept is designed for the current machine generation featuring servo driven motions in all sections of the machine. High dynamics can be achieved in the forming process using this drive concept and the process-controlled machine sequencing which can be realized with it. This results in high productivity of the thermoforming line with high quality of the formed parts at the same time. ILLIG Intelligent Control Concept now provides the possibility to the user to utilize the capacity to the full extent with only low operating effort required. The IC concept includes compatible control modules for the dynamic optimization of all processes, from simplification of machine operation and accelerated commissioning of new tools through to process control in order to eliminate environmental influences and also to improve process stability and product quality.


One of the modules, ThermoLineControl, is employed to call up and program all machine components of the production line centrally on the forming station. Various, structured support functions are available for process optimization and reduction of tool installation times. A further component is the so-called dynamic process optimization. The machine operator does not have to possess specialist knowledge about the interdependence of optimization parameters. This interdependence is considered by the control for every station of the line. A change of setting data is followed by recalculation and immediate adaptation of the cycle speed.


For an increase in process reliability the effects of changing environmental influences – e.g. temperature drift within the material due to heating up of material stand with progressing production time - are offset by employing a compensation control. Moreover, the use of the sas-up® (self-adaptive start-up) module for commissioning of new tools, a start-up operation with reduced cycle speed and process-optimized setting data, results in a considerable reduction of material consumption during start-up. The Intelligent Control Concept (ILLIG IC) is completed by integration of a production line in the ILLIG NetService. Thus ILLIG service engineers can look into all components of the line, diagnose errors and correct setting-related malfunctions quickly.


ILLIG is a global leading supplier of high-performance production lines and molds for thermoforming plastic materials as well as of solutions for the packaging industry. The company's product and services portfolio comprises the development, design, fabrication, installation and start-up of complex manufacturing lines and individual components. With branch establishments and agencies in over 80 countries, ILLIG is locally present in all markets around the globe. For more than 65 years, this owner-managed enterprise has been serving its worldwide clientele as a reliable partner in cost-efficient thermoplastic molding of sophisticated precision parts backed by innovative technology of unsurpassed quality and a comprehensive worldwide after-sales support.

For Further Information 

Contact Us:

illig@hi-techi.com
+91 22 3296 4721 / 22 / 23

illig Open House - 9-10 May, 2012

The Exhibition 2012

Experience brand new technologies and benefits by innovative solutions for automatic roll-fed machines concerning processing, quality and control concepts.

Experience the thermoforming machines like the models RV 53d, RDK 80 of the latest design and RDK 90 line interlinked with RS 96 granulator. Experience also two customers’ lines a RDK 54 and a RDK 80 for lid production.

Out of product range forming/punching tools our 3^rd Generation RDM 70K with stacking device PH 70 is shown as well as customer’s 3 ^rd Generation line RDM 75K and product handling PH 75 and the granulator RS 90. Another exhibit is the 3^rdGeneration line RDM 75K and product handling PH 75, rimming device BAG 50b, roller pre-heater VHW 90/4b and RS 90. A 2 ^nd Generation machine RDM 70K and SZA 73 latch stacking device with a tool for yogurt cups completes the machine demonstration in this product range.

Demonstrated are high-performance thermoforming machines and new developments. Thermoforming with ILLIG Intelligent Control Concept IC, realized by ILLIG.

• ThermoLineControl for lines with administration of setting data
• Process control to eliminate environmental influences
• Dynamic optimization of machine sequencing for all devices
• Operator controlled tool change
• Error diagnosis / remote control

For Registration - Contact Us

Phone: +91 22 3296 4721/22/23

Fax:  + 91 22 2661 4494

Email: Illig@Hi-Techi.com 

Web: Illig

illig Form Fill Seal Line - FSL 48

Presenting the Illig FSL48

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
Email: Illig@Hi-Techi.com 

Web: Illig