Page1of the Press Release: ILLIG at K 2010
ThermoLineControl – the new control concept for thermoforming environments
ILLIG ThermoLineControl – a convenient touchscreen-based line management system providingextensive, structured operator support features for process optimizationandreduced set-up times.
Hall 3, Stand A52
ILLIG at K 2010
ILLIG ThermoLineControl – the new control concept for thermoforming environments
Heilbronn / Germany,27 October 2010 – A this year's "K" trade fair, the performance of ILLIG's current 3rd generation thermoformers is demonstrated under 'real-life' production conditions by a thermoforming system built around a combination molding/punching-action RDK 90 machine.Thisconfigurationboasts the new ILLIG ThermoLineControl system, an equipment management and MMI tool implemented for the first time in this form, which enables the operator to control all components of the production line (all the way to the run-out product handling system) centrally from the forming station. Moreover, it featuresa wealth of structured support functions which allow users to accelerate the run-up to stable thermoformingconditions after each change to new product.
Compared to theirpredecessors, these 3rd generation RDK (combined molding and punching) and RDKP (separate molding and punching) thermoformers have well over 30% shorter operatingcycles. Much of this performance gainis owed to theconsistent use of servomotor drives for all motion sequences– an actuating technologythat saves energy whilealso ensuring high speeds and precision. Furthermore, these drive systems provide an elevated positioning accuracy and repeatability which permitsmaximized overlap between machine operations, thus saving valuable process time. Cycle durations can thus be reduced substantially, and the output of thermoformed products is boosted accordingly. An optimized mold technology featuring contour-following coolant passages adds to these 3rd generation improvements.
At this year's "K", exhibits a the ILLIG booth will include an RDK 90– the largest automatic pressure forming machine in the line-up, providing a 900 mm processable stock width and 700 mm feed length. This unit is shown making APET trays (of the type sold millions of times over as sales and keep-fresh packaging for meat, vegetables, fruit, etc.)in a 16-cavity mold at a rate of 55 cycles/minute. For reliable processing of this high output– more than 50,000 trays per hour – the RDK-90 line includes a double handling system tending to the removal and stacking of finished products.
ThermoLineControl– a control system geared for high productivity
At the control and MMI level, these productivity improvements are supported by the newly developed ThermoLineControl system which provides an extensive array of operator assistance features. Thesebegin with the definition of a basic start-up setting for running the machine up to capacity after a product or mold change. Once the user has entered the material type, stock thickness and a few other product and mold data, the software will automatically determine a basic setting including the cycle rate and matching stock heating program. The line is then ready for production, its parameters adapted for optimum product quality.
Over and above this computer-assisted basic set-up and optimization of the thermoforming process,the control system provides continuous monitoring – with clear graphic visualization – of all machine operating sequences, plus the ability to store all settings and production parameters in memory. This capability eliminates the laborious manual documentation routines formerly widespread in industrial thermoforming. For all molds used and all products ever made on a given thermoformer, the relevant data recordscan be stored in the new information and recipe management system featuring convenient search options so that all data can be instantly retrieved and used in production.
Reduced set-up times – faster return to productivity
Beyond thesecomprehensive thermoformer control functions, ILLIG's ThermoLineControl system – designed specifically for production lines – incorporatesmany other efficiency-boosting improvements. As demonstrated on an RDK-90 line at the "K" trade show, it allows all operations of the individual machines making up the production line to be centrally managed, optimized and process-controlled via the MMI station on the thermoformer. As a necessary precondition for this capability, all add-on and supplementary equipment on the line – from the roll stand to the standalone cooling unit through to product handling system – come with matching interfaces as standard.
Apart from providing enhanced operator convenience, this control capability will save much set-up time during format or mold changes. Assisted by the thermoformer's mold quick-change system, formerly non-productive periods are thus converted into precious value-adding time.
Moreover, the new ThermoLineControl system makes fault analysis and troubleshooting tasks easier, faster and, above all, more focused. On production lines remotely monitored via the Internet using ILLIG's Net Service, technicians working from Heilbronncan examine line components, diagnose faults and provide quick remedieswhere a malfunction is due to incorrect settings.
In all, the high cycle speeds and significantly reduced set-up times of ILLIG's 3rd generation thermoformers provide processors with clearly improved plant availability rates and hence, superior productivity. As a result,the new-generation ThermoLineControl system developed and progressed to the marketability stage for the RDK 90 has nowbecome available for all 3rd generation roll-fed automatic thermoforming machines made by ILLIG. This also applies to the RDM-K series of automatic thermoformers typically used to make cup-shaped articles for various foodstuff processing applications with the aid of multicavity molds.
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 60 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.
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Further information:
Wolfgang Konrad, Marketing and Advertising Manager
ILLIG Maschinenbau GmbH & Co. KG, Robert-Bosch-Str. 10, D-74081 Heilbronn / Germany
Phone:+49 (0) 71 31 / 5 05– 2 36, Fax: - 12 36, E-mail:
Editorial contact and voucher copies:
Dr. Georg Krassowski, Konsens PR GmbH & Co. KG,
Hans-Kudlich-Str. 25, D-64823 Groß-Umstadt / Germany –
Phone.: +49 (0) 60 78 / 93 63 - 0, Fax: - 20, E-mail:
Dear colleagues,
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Traditional „manual documentation“ routinesbecome a thing of the past. The new ThermoLineControl system stores information in its data record management system and provides various argument-based search and retrieval optionsfor a speedy relaunch of production.
With ThermoLineControl, all machine components of the production line – such as the roll stand (AWK) and roll preheating system (VWH) - can be centrally accessed and programmed at the forming station (RDK), e.g., in the case of a format or mold change. The conventional set-up process (bottom left) is reduced to a minimum of steps (bottom right).
Illustrations: ILLIG
ILLIG Maschinenbau GmbH Co. KG, Robert-Bosch-Straße 10, D-74081Heilbronn / Germany
Phone: +49 (0) 71 31 / 505 - 0, Fax: - 3 03, E-mail: –