Automatic pressureforming machinesRDM 50 K, RDM 54 K,RDM 70 K, RDM 75 K

How to achieve formings ofsuperior quality.

Based on customer require-ments, ILLIG manufacturestechnically sophisticated andeconomical productionsystems providing optimumsolutions for products. Theconsistent use of thermofor-ming and the expansion of itsapplications require con-sider ation of:

product design

material selection

material production

forming

stacking

handling

printing and packing

The ILLIG RDM-K production system,setting the standard for an innovative,user-friendly thermoforming concept.

automation/finishing work

Flexible equipment variants result ineconomical production sequencing.

The performance of a pro-duction system essentiallydepends on the availability ofall individual elements. ILLIGoffers independent elementsand linkage kits suitable fordifferent production require-ments and performancelevels.

performance range

RDM-K system technology

high-performance thermoforming

operating concepts

optimizing of process

stacking concepts

tool technology

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automatic forming/punching machine RDM 54 K

RDM-K machines with for-ming/punching technologystand for: precise mechanicaldrive systems, high quality ofthermoformed articles, per-formance and reliability. Thecustomer can select from acomprehensive group of product ranges with variousforming areas and differentequipment levels.

The forming device with thecam-controlled toggle leversystem ensures high formingand punching forces. Theforming table movements arenot limited to upward and

downward direction. After theforming process it is tilted inthe feed direction through anangle of 80°. From this posi-tion the ejectors push thecups into the stacking de-vice. The tilting movement ofthe forming table permitscontrolled discharging andstacking of the thermoformedarticles even if multiple-rowtools are employed.

Free potentials can be bestutilized by optimizing themachine’s sequencing duringthe forming and movementphase resulting in higher

cycle speeds and optimumsequencing. Hygienic condi -tions for the production offood packs are improved byusing non-lubricated air forcylinders and seals.

Specifications with regard totool changing were consider edin the RDM-K concept. More -over, the accessibility of allmachine elements for serviceand maintenance was im-proved.

New ideas create new markets. Precisionand flexibility being essential requisites.

RDM 70 K line with stacking device ÜG 75,interlinked with a granulator RS 75b

Our concept for success:flexibility and high availability.

forming and punching

At ILLIG, basic research isused to gather all parametersessential for thermoforming.Supported by calculationprograms, optimizing of themachines can be achievedby overlapping mechanicaland electronic drive systems.

Consistent operator guidan-ce is the key to practical util -ization of the complex pro-cess as well as the variableover-crossing effects of indi-vidual process sections. Inthe department for appliedtechnology, developmentsare tested under conditionssimilar to actual productionand adjusted for applicationin the customer’s machine.All types of machines areavailable at any time for presentation and customertesting.

Solutions found in the de -velopment and design stagetake into account the futureapplication range of themachine. State-of-the-arttechnologies are testedaiming at a reduction of en ergy consumption as wellas service and maintenanceefforts and checked for being

economical. Innovative pro-ducts and tool designs aredeveloped together with newmachines or processengineering elements. Theoverall concept of the ma -chines is always taken intoconsideration.

Theoretically found perform -ance data are transferredinto simple operation con-cepts in practice. Consistentoperator guidance on thescreen, computer-aidedbasic setting and optimizingof machine operation resultin an increase of perform -ance as well as improvedproduct quality.

Experience and requirementsof our customers are alsoincorporated in all new ILLIGdevelopments. The resultingtried and tested serial ma -chines and custom-madesolu tions ensure economicalproduction.

tilting

stacking

transparent PP cups

RDM-K technology, based on researchand development.

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performance range

RDM-K system technology

high-performance thermoforming

operating concepts

optimizing of process

stacking concepts

tool technology

Market advantages by matching different performancelevels with suitable technology.

ILLIG – competence andinnovative power.

To achieve optimum produc-tion, every molded articlecalls for a specific solution.Know-how and innovativetechnology are required forplanning complete machinelines, from material pre-heating through to cup dec -oration, stacking, counting,feeding and packing intosealed plastic bags.

For decades, our machinesand process engineeringaspects have been contin -u ally setting the standardfor flexible and economicalsolutions.

Product-oriented high-per form ance lines can beassembled from com-prehensive standardequipment. These custom-made production systemsresult in competitiveadvant ages especially whennarrow deadlines and highquality demands areconcerned.

Since all components aretested and delivered fromone source, smooth oper -a tion is ensured even for complex machine lines.

Performance and speed ofthe modular parts must besynchronized within thew holesystem as much as possible.Sensors or bus systems areemployed for con necting thevarious functions.

The thermoformer’s skeletalwaste is led directly into anoise-reduced granulator.Various arrangements arepossible, such as linear or90° arrangement behind themachine. Noise-reducedskeletal feed and automaticthreading systems areavailable.

The regrind can either befilled into bags or conveyedto existing silos. In case ofextruder linkage, the skeletalgranulator is integrated in thein-line process and theregrind is conveyed back tothe extruder.

RDM 75 K in-line system with stacking deviceand interlinked with a granulator

RDM-K System

The speeds of the down-stream equipment are adjusted to the performancecapacity of the formingmachine.

granulator unreelingdevice

stackingdevice

rimmingdevice

roll pre-heater

sleevewrapper

cartonpacker

extrusionI/OI/O

I/O I/O

forming station RDM 75K with 40-cavity forming/punching tool

In-line production standsfor cost-effective produc-tion of large quantities ofcups in multiple-shift oper -ation.

High availability of individualmachine components is anessential factor for in-lineoperation. Reliability is abasic element.

Reliability and economy arebenefits for our customers.Especially with PP proces-sing, where the heat of theextruder within the materialcan be used in the formingprocess thereby reducingthe heat requirement in theforming machine. One of themain advantages of this working method is the factthat the extruded mate rialcan be fed directly into theforming machine and theregrind can be processed inthe extruder right away.

The thermoformer is linkedwith an extruder by a linkagekit. The material reaches theforming machine by bufferloop, between continuousand discontinuous process.The production capacity ofthe forming machine is adap-ted to the material quantitywhich is produced. Moreover,with this linkage kit just oneoperator can start the machine.

PP samples

High-performance thermoforming – high performanceand consistent product quality.

conveying of granu-late from silo

extrudingcooling/smoothing heating

forming/punching

stacking

skeletalgranulator

return conveying of material

performance range

RDM-K system technology

high-performance thermoforming

operating concepts

optimizing of process

stacking concepts

tool technology

6 7

Easy operation and computer-aided basic setting arebased on research and development.

The digitalized machine featurespractical operation and computer-aided basic setting.

Process engineering andapplication technology inconjunction with comprehen-sive material knowledgeresult in an optimum machineprogram incorporating theparameters for forming,punching and stacking.

Optimum setting data andprocess times for new toolscan be calculated dependingon material, part geometryand tool design. In all ILLIGmachines, calculation is carried out supported bycomputer-aided basic setting

and in conjunction withservo-motor drives.

The RDM-K sets a new stand -ard regarding facilitated oper- ation. A total reproduc ibilityof production data is a majorelement for maximum avail-ability especially for highautomation levels and fre-quent product changes. Allrelevant process data areentered on the operationpanel and displayed as setpoint/actual comparison.

The optimized data can bestored and they are available

right away for repeat orders.All major operation data arecontinuously available tocheck the ongoing produc-tion.

simulation – optimum wall thicknessdistribution

operating panel with PLC unit

strokes

pressures

speeds

temperatures

HD drive

servo-motor drivenmaterialtransport

servo-motordriven plugassist

bussystems

computer-aidedbasic setting

I /O

I /O

I /O

Consistent product quality – essential requisitefor industrial production.

heater setting

forming program

operating panel OP 37 and PLC unit

digital setting and storageof machine parameters,hence reproducible form -ing process

servo-motor drivenmaterial transport andcentral width adjust-ment

optimum material heating

large forming air tankswith digital setting ofpressure for quicker for-ming

HD drive combined withregulation of main drive

Siemens S7 control withscreen operating panelOP 37

plug assist data

Optimum machine equipmentis the basis.

consistent product quality byoptimum machine equipment

performance range

RDM-K system technology

high-performance thermoforming

operating concepts

optimizing of process

stacking concepts

tool technology

8 9

The required performance, part quality andavailability can only be achieved by optimizingthe thermoforming process.

Development of machine and tool from one source results in optimized thermoforming process.

improved distribution of forming airfor better contour definition

This process consists of amultitude of detail solutionsincluding the whole sequen-cing as well as the tool tech-nology.

Reproducible material heat -ing as a function of theindex length is a requisite forhigh part quality. ILLIG usesceramic IR elements withexact temperature regulation(+/– 1°C regulation accu-racy).

All RDM-K machines areequipped with upper andlower heating. The upper

heater is regulated in longi -tudinal rows, the lower heaterfeatures full area control bypilots.

The servo-motor driventransport drive ensure exact positioning at high

transport speeds and re -duces index length toleranceto +/– 0.1 mm. Exact settingof the transport system re -duces material consumption.

For PP processing, the ma -terial transport is pneumati-cally moved apart by thespread ing device. The ma -

terial is tensioned, thus preventing webbing duringthe forming process. A cen-tral width adjustment makesoperation easy.

course of speedpneumaticplug assistservo-motor drivenplug assist

Heater equipment of RDM-K machines. Upper heater with longi -tudinal row control. Lower heaterwith full area control.

The thermoforming process can be optimizedby using customer-specific equipment.

The servo-motor drivenplug assist ensures evenmaterial distribution in thecup. The basic material thick -ness can be reduced by upto 15 % without jeopardizingthe stability of the formedpart. Side wall marks arereduced, especially in crystalclear materials such as PPand APET. There is an im-provement of the products’optical quality and printingon high-performance machines will show bestresults.

consistent speed

digital setting of start,return movement andspeed of plug assist

energy costs saving ofapprox. 75 % comparedto pneumatic plug assist

New forming air valves areused for improving the con-tour definition. The fastestpossible mold filling is achieved in combination withthe large pressure air tank.The forming pressure remainson a constant level. This re sults in higher output capa-city.

an increase in availability

digital feed-back controlof all process parameters

recording of operationdata and diagnostic aid

minimized service andmaintenance efforts

reduction of energy con-sumption

increase in cycle speeds

reduction of start-upwaste

optimized overall processfrom raw material throughto packing and includingtool change

Benefits : Customer-specific equip-ment results in :

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performance range

RDM-K system technology

high-performance thermoforming

operating concepts

optimizing of process

stacking concepts

tool technology

Stacking matched with the performance of formingmachines by using various stacking systems and resultingin economical production.

Flexible equipment variants for economicalsequencing and safe production.

Product properties essentiallydepend on the quality andreliability of the downstreamequipment.

We therefore offer a reliablerange of stacking systemsand downstream equipmentadjusted to:

automation level

output capacity

further processing

stacking device SUG 73, SUG 75,can be linked with downstreamequipment

Based on the above is thefunction principle of thestacking system where theoutput capacity of the for-ming machine is consideredand also subsequent produc-tion steps. ILLIG offers differ -ent stacking systems. Therange covers manual cupremoval through to fully auto-matic stacking systems withloading devices for down-stream equipment.

stacking deviceSE 73, SZA 73, SZSfor manual cupremoval

The cups are positioneddirectly into the recesses ofthe stacking pallets. They arestacked into stacking cagesin sequence. This way cupdeformations are preventedand cooling is improved.Now the cup stacks can ei -ther be removed manually orthey can be automaticallyseparated. Horizontal or ver-tical discharge is possible.With horizontal cup dis-charge the stacks form acontinuous column whichcan be led into a printingmachine or, if drinking cuplines are concerned, into arimming device.The stacking system can besupplied with a hole punch

Flexible equipment variants for economical productionsequencing. All individual components decisive for theprocess are ILLIG-produced.

stacking device STP 75 for single row cupdischarge or STPM 75 for manual cup removal

vertical cup discharge

transposing, stacking and transferdevice with hole punch unit PLS 75b

stacking device STPV 75 forvertical cup discharge

unit for the production ofproducts which require holepunching in the bottom, suchas plant pots.

performance range

RDM-K system technology

high-performance thermoforming

operating concepts

optimizing of process

stacking concepts

tool technology

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Development of machine and tooling from onesource means in practice high-tech equipmentof highest availability.

ILLIG tool technology, precisionfor long service lives.

3-zone cooling

As early as in the planningstage, tool design know-howis integrated in the wholeconcept.

Additional equipment can beused, such as servo-motordriven plug assists for evenmaterial pre-stretching, de -vices for hollow bottom and

inverted-bottom tools, ordirectly cooled high-pressuredownholders for embossingof sealing rims.

Systems to monitor the tooltemperature or an exceedingof the punching force helpprevent damage to the pro-duction system.

The tool can be exchangedcompletely, or just theforming inserts.

The tool quick-change tech-nology helps to keep con -version times as short as pos -sible. Mechanical devicesenable only one operating

person to exchange the form-ing tool.

The tool is installed and byfixing it, connections for forming air and water areestab lished at the sametime.

standardized construction

product development

quality

low wear and tear

long service lives

commercial efficiency

servicing, maintenance

production quality

availability

optimum utilizationof forming area

optimum production system

technology

Forming inserts, ejector bottoms and pre-stretchingplugs can be exchanged if contours differ but punchingdiameters are the same.

The tool remains in themachine, consequently theset-up time is considerablyreduced. Tool costs are alsoreduced since only one basictool is required for severalforming inserts.

The arrangement of coolingconnections as well as theflow rate of the coolant arealso major elements. A uni-form cooling of all cavities inthe tool and therefore a con-trolled expansion can beachieved by applying certainmeasures.

Sufficient corrosion protec-tion of the tools is veryimportant to maintain theirquality level. Some examplesare: the use of corrosion-proof tool steels, optimumwater qualities and closed-loop cooling circuits as well

as the use of galvanic cor -rosion protection in the tool.

Cooling time is a decisivefactor for the duration of theprocess and consequentlyfor the cycle speed of themachine.

With increasing materialthickness, more heat will haveto be dissipated in the shor-test possible time. Thereforethe punches are equippedwith a cooling jacket whichprovides the necessary cool-ing.

For an extension of the effec-tive cooling time, the forming/punching tool can be equipped with a vacuumclamping. Thanks to thisvacuum clamp ing, the cup isheld during the cooling time.This improves the passage ofheat, i.e. the cooling capacity.

Various cooling circuits forintensive cooling of criticalareas of the forming toolresult in an increase in outputcapacity of up to 20 %.

The extremely low quota ofrejects can also be attributedto the temperature profile inthe process. Upper and lowertool halves must be preciselytemperature-controlled. Thehigh precision of the toolparts is being monitored bystate-of-the-art measuringtechnology. Consequently,punches and die plates can

separate cooling circuits forupper and lower tool

quick-change technology for plugassists, bottoms and forming inserts

be exchanged, and alsopunches can be interchangedwithin the cavities.

Moreover, the forming toolsat ILLIG are tested on originalmachines to stand the prac-tical test. The customerreceives optimum settingdata together with the toolresulting in shortest possiblestart-up times. This way thestated performance andquality specifications will bemet.

temperature control

production parameters

cycle speed

quick-change technology

tool change

conversion

process parameters

computer-aidedbasic setting

start-up

ejector bottom withengraving

forming insertmenu tray

performance range

RDM-K system technology

high-performance thermoforming

operating concepts

optimizing of process

stacking concepts

tool technology

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for Thermoforming and Packaging Technology

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

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