rdm k 3 generation thermoformersillig.de/uploads/tx_illig/rdm_70k_3g_en.pdf · high-tech solutions...

RDM K

3rd GenerationThermoformers

ILLIG, system supplier of ther-moforming lines, set two goals for the further development of RDM-K automatic pressure forming machines for the production of products for various applications, predomi-nantly cups of all shapes and sizes in high quantities. With these so-called 3rd Genera-tion Thermoformers increase in output and improvement of product quality are both achieved at the same time.

Millions of thermoformed cups are produced. Current developments in machine and tool technology open up a clear increase in productivity and product quality for this mass-produced article. In spite of or even with less forming air consumption automatic thermoformers achieve an increase in cycle speed in a clear tow-digit percentage range, at the same time product quality is raised to a level previously unequaled.

Thermoforming newly specified

Automatic roll-fed machine for forming/punching tools


Material saving and improved Quality

Equal treatment principle appliedAchieve more with less forming air

Warm water for better coolingMore efficient material use

Quality parametersWeight of formed part - important feature

Benefi ts of decoration technologyfor In-Mold Labeling in thermoforming

Process optimization by different stacking system variants

Everything from one sourceHigh-Tech solutions for thermoforming

3rd generation tool technology

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ENERGY CONSUMPTION

MATERIAL CONSUMPTION

PRODUCT QUALITY

LINEINVEST

SERVICE

APPLICATION TECHNOLOGY

PRODUCTIVITY

TOOL

RESOURCE-SAVINGRESOURCE-SAVING

PROFIT-OPTIMIZEDPROFIT-OPTIMIZED

Material saving

Automatic start FSS (forming,

punching and stacking)

It is intended that the first punched-out products meet all quality requirements and can be stacked right away as good parts. The sometimes difficult hand-ling of reject parts is prevented and consequently there is one less source of problems.

First of all the pre-stretchers are placed on the material for a number of cycles which has to be defined and this way they are heated up. There is no punching during the start-up cycles.The pre-stretchers only move a short stroke which is sufficient to bring them to operation temperature but it is short enough not to cause any problems with skeletal guiding.Moreover, downholders and cutting elements are also brought to operation tempera-ture during the start-up cycles. Thus the production parameters are in the correct range.This way correctly formed parts are produced already with the first punching and stacking stroke which can be stacked right away.

Better reproducibility within smaller weight range of cups makes reduction of initial material thickness possible.

Material from bead on stak-king rim can be saved.

Due to this RDM-K techno-logy all thermoformable materials can be processed e.g.: PS, PP, PET, EPS and EPP.

Improved Quality

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Material abuts on wall of forming part at a higher tempe-rature level thus better defini-tion and Improvement of part quality.

A further benefit is the funda-mental reduction of thermal stress. This way a consistent sealing rim inclination is achieved with higher cycle speed or a reduced sealing rim inclination with consistent cycle speed (with directly cooled downholder and downholder lifting).

Higher cooling-down speed of part due to increased amount of transported heat. Consequently better control and better reproducibility of solidification process.

Process-optimized material stretching on cup wall

No bead on stacking edge

Increase in top load but still same initial thickness

Increased rigidity (with iden-

tical material thickness) due

to downholder lifting

Reduction of logistics costs

(with downholder lifting)

Reduction of stacking distance while maintaining original product design

Increase in number of products per stack in box (e.g. previously 100 pieces; new 110 pieces

Reduction of machine

standstill times

Extension of maintenance intervals

Longer service lives of components used

Easier preventive mainte-nance

Better accessibility of wear and tear parts

Reduction of stacking distance










directly on the pre-stretchers. An own switching valve is allo-cated to every cavity in order to enable selective control of the synchronous generation of forming air. This controlled reproducibility has a direct effect on the quality of the ther-moformed cups.

Equal treatment of all cavities in a multi-cavity tool is a demand in thermoforming to maintain criteria reproducible from cycle to cycle such as weight, side wall thickness, rigidity (so-called top load) etc., with are decisive for the quality of the thermo-formed cups throughout all tool cavities. When analyzing the practice so far it was found that especially application of forming air would still improve the process. State-of-the-art for the so far for current 2nd Gene-ration machines and tooling were valves which centrally ensured generation of forming air pressure in all cavities. In the first development step towards 3rd Generation Ther-moformers valves integrated laterally on the tool were applied. Each one of these valves controlled the genera-tion of forming air pressure only for one complete row of cavities. This already resulted in an improvement compared

to previous generations. But still, using the row-controlled forming air supply, a absolutely synchronous treatment of all cavities is not ensured. More-over, forming of the material and clinging to the cooled tool wall (and thus onset of cooling effect) is performed from cavity to cavity within a certain time frame.

In the now realized 3rd Gene-ration of machines and tooling forming air is supplied sepa-rately to every cavity, directly above the pre-stretches (Fig. 1). So the pressure air is available

Equal treatmentprinciple applied

Fig. 1A switching valve

on every cavity ensurescontrolled

supply of forming airwith high repeat accuracy.

Forming

air

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A further innovation is for the benefit of improvement of part quality and also cycle time reduction: Cup forming with reduced forming air volume. Compared to standard tools so far, 3rd Generation RDM-K tools work with a forming air volume reduced by up to 50 % per cavity. This decrease in volume considerably increases the dynamics in generation of forming pressure (Fig. 2). Product forming in the cavi-ties is not only considerably faster but also there is higher definition due to the reduced

Achieve more with less forming air

forming air volume. Thanks to the time advantage compared to the standard so far, the mate-rial abuts on the cavity wall at higher temperature and thus in a more plastic condition.

Fig. 2Compared to the standard so far (case A) reduced forming air volume (case B) results in considerably higher dynamic gene-

ration of decrease of forming air pressure – higher cycle speeds are achieved by the saving in time.

Time saving










The saving in time resulting from reduced forming air volume coupled with the new individual cavity control can be directly utilized for an increase in cycle speed. This increase in productivity is supported by a an optimized new tool cooling system. Up to four cooling circuits are now available in the forming tool. They can be individually controlled and separately supply upper tool part, downholders now directly cooled, lower tool part and ejectors. The tools are equipped with cooling channels close to the cavities' contours with cross sections dimensioned accor-dingly to ensure heat dissipa-tion from cavities is performed as quickly as possible during

high cycle speeds. Lowering the cooling agent's temperature is not required, quite the contrary. When in the past cooling water temperature of 12 °C was required, tools for 3rd Genera-tion RDM-K automatic pressure forming machines can now be cooled with water of 16 °C to 18 °C. A further major benefit of the increased temperature of the cooling water: There is much less risk of condensation water formation on the tool with increasing atmospheric humidity

Warm water for better cooling

Directly cooled downholder for improved cooling of cup rim

Cooling water inlet tempe-rature 16°C - 18°C

Constant volume flow (RDM 70K)

Up to 4 cooling circuits in forming tool

Benefits:

A further innovation also contri-butes to an increase in quality and productivity. The pressure level control of the downhol-ders, adapted to the respective phase in the thermoforming process. The full downholder force is not applied directly by placing the downholders (closing of tool). The maximum force only starts with applica-tion of main pressure and is decreased at the end of the forming process. By applying the full closing force right away a bead formed so far on the upper cup rim due to the embossing processed triggered by this. Systematic research revealed that this bead depot of approx. 10 % of the part weight can be set in motion by varying the down-holder pressing force. With the

More efficientmaterial use

new downholder pressure level control optimally adjusted to the chronological sequence of the forming process, this material depot can be drawn completely into the side wall during stretching. The result of the new process control is a very uniform wall thickness distribution.

The pressure air control of the cooled downholders adjusted to the thermoforming process prevents bead development on the upper

cup rim – and the shorter duration of main pressure at the same time extends service life of machines and tools.

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Pre-cooling(Pre-pressure)

Punching(Punching pressure)

Cooling (Main pressure)

Without downholder pressure level control there is always unavoidable formation of a bead on the upper cup rim. (1) – Variation of contact pressure can cause the bead material to move (2) – optimum adjustment of down-holder pressure levels finally results in a uniform wall thickness distribution (3).

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Quality parameters relevant for thermoformed cups are combined in the picture (top load). In this respect innovations of machine and tooling result in uniformity and repeat accuracy of all cup geometries so far unachievable in thermoforming with multi-cavity tools.Examples for this are measuring values of a yoghurt cup mass-produced on the new RDM-K shown in table 2. These values show that in practice the speci-fied tolerances are far under-gone. For instance, tolerances for the sealing rim thickness specified in the tenths of a milli-meter range are now reflected in reality only in the range of some tens microns. This close range throughout all cavities of a multi-cavity tool also applies to further cup dimensions and cup weight.

This is how rigidity of the cup is increased by this "additional material". So a thinner material, lighter by approx. 10 % gram-mage, would now be sufficient to surely maintain the cup rigi-dity achieved so far. With the multi-cavity tools always used in cup production the downholder control ensures a controlled, uniform placement of the downholders throughout the

Q – Like qualityparameters

Thermoformed cups must meet several quality specifications, left: pressure test to judge cup rigidity (top load)

PS Yoghurt cup73 mm Ø; 1.25 mmWall thicknessIncrease: 63 %

EPS Drinking cup73 mm Ø; 0.8 mmWall thicknessIncrease: 48 %

PP Yoghurt cup 75 mm Ø; 1.15 mmWall thicknessIncrease: 28 %

EPP Drinking cup 75 mm Ø; 1.2 mmWall thicknessIncrease: 28 %

With the innovations of

the 3rd Generation RDM-K

automatic pressure forming

machines a considerable

increase in productivity

(higher cycle speeds) is

achieved, as shown by these

practical examples:

cavities defined with respect to time and also a pressure level control adjusted to the forming process. The downholders are directly cooled now, as already explained, to support short cycle times.

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Unit weight of cups, especially yoghurt cups, is a very impor-tant feature as these mass articles are ordered by weight. It is thus important for the pack manufacturer not to go beyond the minimum weight of a cup in serial production. He can now utilize the advantage of very high precision and repeat accuracy – i.e. the very narrow forming part tolerances that can be realized – in a value-adding way with thermofor-mers and tools of the current RDM-K generation. He can also use a lighter (thinner) material than the one used so far and still maintain the demanded minimum weight reliably. Or else: Tolerances used in present specifications might be much closer in the future.

A further very important feature, also for yoghurt cups, is the planeness of the sealing rim.

Weight of formed part - important feature

A maximum of 5° angle devia-tion is admissible, beyond that a cup in serial production cannot be sealed reliably any more. With the new thermoforming technology presented here the exceeding of limit values is no longer jeopardized, even with the now achievable, conside-rable higher cycle speeds accor-ding to table. The formings have much less tendency for devia-tion of the sealing rim angle due to the reproducible precise process control.

PS yoghurt cup mass-produced on new RDM-K: Range of measuring

values (number of random samples: 45 cups) is considerably closer than

demanded in specification










Cup decoration with ILLIG IML system (in-mold labeling system) by inserting pre-printedlabels from magazines directly into the forming tool. All label variants are feasible, from 2-sided label through to 5-sided full decoration.

Much more attractive decora-tion can be produced with this system. There are almost no limits with respect to container shapes. Perpendicular side walls, as required for banderoled cups, are no longer required.

Printed and suitbly pre-punchedlabels are inserted in magazines. The chutes are desi-gned for operation of several hours. A special retaining system allows reliable, indivi-dual label supply.

Benefits of decorationtechnology for In-Mold Labeling in thermoforming

Using IML you will achieve an excellent

photo-realistic quality for your product images.

Thanks to the compact design this system can also be used for FSL machines. When labels have been inserted into the forming tool (designed as tiling tool) the cup is formed into the cavity – as conventio-nally done in thermoforming, i.e. forming and decoration are effected in one step.

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The decoration impresses with excellent quality and high brilliance and can be produced in both methods, offset printing or gravure printing.

Not only the outside areas can be decorated but also the bottom. This option grows more and more important since the EAN code on the bottom is increasingly important.

The label improves side wall stability of the cup (rigi-dity) so the basic material thickness for the cup can be reduced.

Certain decorations can only be produced in the IML method due to the required print quality. Besides photo-realistic images more information can be accommodated on the pack by using smaller fonts.

Last but not least, in IML the cup decoration can be changed without interrup-tion of production.

Benefits for customer:

The share of decorated so-called "premium products"

will further increase in the food sector.

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Unique position with respect to haptics in cup design due to possibility to accentuate grooves in a brilliant way.










Last but not least the proper-ties of the product are subject to quality and reliability of the downstream equipment. ILLIG therefore offers a reliable range of stacking systems and down-stream equipment adjusted to:

automation level

output

further processing.

The corresponding stacking system variant is subject to the above. Safe and reliable product stacking is assured by employing the predominantly used servo drive technology suitable for synchronization and precision adjustment of the stacking movements.

Consequently, the stacking system can be adjusted to the output of the thermoformer at any cycle speed.

PH with turning device for

RDM K

The limitations of the stacking systems available on the market become obvious very quickly when cycle speeds over 35 cycles per minute are concerned and also with respect to their behavior during start-up of an inline system. Here, too, ILLIG had to open up a totally new path resulting in the develop-ment of PH with turning device.

The PH with turning device picks up the cups from the forming machine by means of arbors and forwards them to a stacking cage. The arbors are located on both sides of a low-vacuum suction box. There is sufficient vacuum to hold the products on the arbors. Linear and turning movements are synchronized with the drives for the table movements of the RDM-K by a virtual shaft.


Before the cups reach the stak-king cage the products remain on the format-dependent arbors for a longer cooling time due to the sequencing of the turning unit, this way deforma-tions are prevented.

Furthermore, the products are stacked by means of the stable product rim. Hygienic requirements are thus met and damage to the cup rim is prevented that might be caused by retaining systems.

Stacking devices were further developed to ensure reliable handling of the thermoformers' increased output. Even cup geometries which are difficult to keep together in a stack, i.e. curved, short cups. are forwarded automatically and reliably to the down-stream equipment for further processing, such as packing of counted cup stacks in transport units or – for in-line opera-tion – direct filling, sealing and packing.

Reliable and perfect handling

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Additional product handling, type PH

Machine operation

PH via Siemens Operator Panel

Printer interface (USB)

As additional device for existing RDM-K machines in operation including supply interface.

Cycle speeds are achieved with the stacking machine of up to 45 cycles/min. (cycle speed subject to product, type of material, tool and upstream/downstream equipment).

PH system withturning device










ILLIG, system supplier, delivers machines and tools for thermo-forming and packaging techno-logy from one source.

Types of machines:

The tasks we successfully cope with are numerous. New raw materials and changed con-sumer requirements must be considered. Moreover, ILLIG continuously observes the mar-ket and develops innovative solutions together with partner companies and research cen-ters. Higher cycle speeds and optimized forming processes are only feasible by applying innovative materials, manuf-acturing techniques, drive systems, electronic compon-ents, measuring methods, and integrated process control. At the same time new components must undergo a comprehensive quality control for improve-ment of ease of operation and maintenance, conversion times, service life and availability of the lines. Simulation, laboratory and endurance tests in prototy-ping at ILLILG serve to optimize all components at an early stage. In research, development and design approx. 100 staff

Everything from one source

members invent trend-setting solutions. Under consideration of numerous conditions decisive product advantages and better benefits are developed for cu-stomers.The thermoforming specialist can produce samples in the technical processing depart-ment with his laboratory ma-chines on one hand, but he can also test new developments

of material manufacturers in a comprehensive way. Last but not least the integra-tion potential of new develop-ments is checked together with the customer and also on site. This results in solutions for long-term and economic application of ILLIG systems and tooling.

ILLIG is the only manufacturer

offering the combination

of tools (forming air reduc-

tion) and machines (power

compensation).

Sheet processing machines

Automatic roll-fed machines for forming/punching tools

Automatic roll-fed machines separately forming and punching

Skin and blister packaging machines

Form, fill and seal lines

Mold and tool shop

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High-Tech solutions for thermoforming

Thanks to utilization of synergy effects and consistent modula-rization ILLIG offers a program which is unique all over the world. Customized lines can be manufactured within a very short time due to configura-ted modules. Tried and tested components result in economic batches in production and ensure high product quality as well as spare part supply at short notice for decades. We possess further expertise in heating of thermoplastic materials and processing tech-niques for forming by means of vacuum or pressure air. The products are decorated, automatically filled, sealed, punched or undergo finishing work. Special devices for loa-ding the machines or down-stream equipment for stacking and/or packing of formed parts are prerequisites for technically mature production lines.System solutions are a main concern at ILLIG today. Dif-

ferent expansion levels are generated from so-called basic machines by adding modules through to high-performance machines for multiple-shift operation. Smooth integration of ILLIG systems into produc-tion lines becomes obvious in many fully integrated lines, interlinked from material production through to the finally decorated cup. In prac-tical application this results in high-tech solutions providing highest availability rates. Brand products are produced daily worldwide on a constant level of quality with these systems.

Product quality

New thermoformed products

Output

Visualization of process data

Trend-setting with 3rd Generation Thermoformers

ILLIG sets the standard with respect to:










Comprehensive expertise from one single source at ILLIG based on integrated development of both components, machine and tools. In addition there are optimized process engineering methods for optimum use of the complete system.

Customer benefit:

Tool tests carried out on the original machine provide data suitable for practical operation and result in minimum commis-sioning times at customer. Our technological expertise is secured by decades-long expe-rience in designing forming/punching tools and based on a multitude of national and international industrial property rights.Most part contours of products can be realized by applying state-of-the-art production technologies, i.e. a broad range of marketing demands can be met.

Tool technology for forming/punching tools

less maintenance effort required for tool repairs

short standstill periods due to quick-change technology

optimum cutting results on product due to new cutting technology

longer lifetimes due to highly wear-resistant materials and new guiding elements.

Controllable cooling circuits

The temperature profile in the process is a decisive element for a very low number of rejects. With a newly developed cooling technology, at an inlet tempe-rature of 16 – 18 °C, the outlet temperature is monitored and, if required, the volume of cooling water is adapted.

This results in an almost constant tool temperature in all operating states, in fact, close to the manufacturing temperature of the tool. With up to 4 control circuits it is possible to meet requirements of sophisticated products without problem.

3rd generation tools are equipped with different features to achieve uniform product quality in all cavities. The features include:

Directly cooled downholder,

downholder lifting and down-

holder pressure levels

The quality of the products can be additionally affected by employing directly cooled downholders and the inno-vative downholder control. Forming of sealing rim, stacking edge as well as wall thickness distribution in the side wall can be affected in a reproducible way by interaction of pre-stretcher and forming air and by means of downholder lifting and pressure level.

repr

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Quick-change technology

The tool quick-change techno-logy helps to keep conversion times as short as possible during format changes. Quick-change systems are available for pre-stretchers, bottoms and forming inserts. The tool stays in the machine while these changes are carried out.

Complete forming/punching tools can be changed by one single operator using certain devices on the machine. Already during the tool installation the lines for forming air and water are fixed as a result. Existing tools can be used with suitable adapter sets.

Regrinding elements

The difference in height resul-ting form the ground punch can be offset by reworking the regrinding element. This way forming inserts no longer have to be adjusted in height.

Vacuum on forming insert

and ejector

The forming/punching tool can be equipped with a vacuum tension function to extend the effective cooling time. During the cooling time the cup is held by vacuum, heat transition is improved, cooling performance is optimized. Consequently the residual heat in the cup is reduced resulting in improved product quality.

Lightweight tools

In order to be able to benefit from the possibilities provided by the machine to the full extent, the machine technology with tilting mechanism calls for lighter tools made of high-strength aluminium. Cooling of the lower tool was considerably improved. By launching the currently largest tilting machine for forming/punching tools on the market, ILLIG also set the standard in tool making.

Reduced forming air

consumption and symmetry

of all media

A considerable reduction of mold filling times is achieved by innovative forming air valves and their arrangement on the tool.

A further major element is the symmetrical arrangement of all media (forming air, vacuum, venting, cooling) which consi-derably affects the uniform quality of the products formed in all cavities. Moreover, the quality of the products can be additionally improved by using directly cooled downholders with innovative downholder control.










ILLIG Maschinenbau GmbH & Co. KGRobert-Bosch-Strasse 1074081 Heilbronn/GermanyTelefon: +49(0)7131/505-0Telefax: +49(0)7131/505-303e-mail: [email protected]: www.illig.de

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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 linesProduced Tooling

for Thermoforming and Packaging Technology

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