SYSTEMS

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Automatic roll-fed machines, separate forming and punching
RV 53 | RV 53d IC-Technology | RV 74d IC-Technology

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RV Thermoformer
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High Quality and

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Low Mold Costs

 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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ILLIG – there’s simply more in it for you!

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Welcome to the world of ILLIG. Our passion is high-performance thermoforming ma-

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chines and molds, as well as high-tech solutions for the packaging industry.

We are a leading manufacturer of thermoforming machines and solutions, and the

first choice when it comes to producing complex, high-quality thermoformed parts

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efficiently. Benefit from over seven decades of experience, industry-leading expertise
and our comprehensive range of products and services, and join countless other sa-
tisfied customers from more than 80 countries across the globe.

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Our extensive experience and know-how go hand in hand to develop feasible solu-
tions – all from one single source. We offer everything you need to smoothly fulfill

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even the most demanding thermoforming and packaging projects.

ILLIG - your systematic path to success. ILLIG – Synonym for most economical produc-
Thermoforming

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tion of high-quality trays, cups and other parts.
Worldwide. Packaging Technology

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Content:
Welcome to ILLIG...............................................................................2-3
ILLIG IC Intelligent Control Concept..................................................4-5
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RV Thermoforming systems...........................................................6-15
Molds...............................................................................................16-17
RV Technology................................................................................18-21
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RV 53 / RV 53d
RV 74d
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ILLIG Systems.................................................................................22-27
 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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ILLIG – Intelligent Control Conce pt

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The user benefits from the IC – ILLIG Intelligent Control Concept. He can utilize the com- 1. ThermoLine-Control®. Operation, control and storage of all indiv-
Levels of development

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idual machines of one line interlinked by Profibus. All data is stora-
bination of high productivity, reproducibility and machine availability to the full extent. ble and repeatable. All other machines can be operated and con-
Machine operation is considerably simplified at the same time. The Intelligent Control trolled by the thermoformer’s operating panel. Error display/error 1st Generation
analysis for all individual machines on one screen. Pneumatic machine
Concept includes several compatible modules.
2. Dynamic process optimization. Automatic optimization of the

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possible number of cycles not subject to operator’s skills. All opti
mization parameters are automatically adapted. Highest produc 2nd Generation
tion performance, absolutely reliable. Servo driven machine

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3. Compensation of ambient influences during process. Automatic
adaption of the heater setting values with changed ambient influences
(Initial temperature of material roll, ambient temperature and 3 rd Generation
temperature of machine stand). Process optimized machine

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4. Faster mold change. Guided and safe mold change thanks to
different technical levels. For faster perfect mold change which is
IC - The next Level
not subject to operator’s skills. ILLIG Intelligent Control Concept

5. Self-adaptive start-up (sas-up®). Start-up operation with reduced

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cycle speed (Forming time, table speed and valve switching like in production). Especially with new molds or after mold changes

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with reduced material consumption until optimum product quality is achieved.

Machines equipped with the „ILLIG Intelligent Control Concept” 6. ILLIG NetService. ILLIG Heilbronn Service Department gets remote access to machine. Fast error diagnosis, minimum machine
are marked with the addition „IC”. standstill times, service call on site not required.
The IC concept raises thermoforming to a new, higher level.
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4-5

This is Reproducibility Availability Productivity

how you Market requirements Conversion times Increased performance
benefit Quality control
Maintenance Energy efficiency
from
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ILLIG IC Process control Guided processes Process skills

Consequence
Operator has to deal with increasing complexity
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Technology Drive technology / Sensor system / Computer performance / Visualization technology

Realization ILLIG Intelligent Control Concept

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PROFIT
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 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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RV-Thermoforming systems –
automatic roll-fed machines, s eparate forming and punching

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Perfect vacuum forming
with small batch sizes.
Tailored forming programs and
fast format changes. Unique

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mold system and system of RV 74d with hole punch press
standard parts for building
forming and punching tools as

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well as stacking devices.

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RV 53d with hole punch press RV 74d

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RV 53 RV 53d
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Economical and efficient, also for small batch sizes The RV 53d und RV 74d generation -
Forming parts can be produced economically and efficiently, even in small
an innovative concept for vacuum forming supported by compressed air for higher
batch sizes, using the RV vacuum forming technology in combination with performance and improved part quality
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+ 3bar
molds of simple design. In positive forming the automatic pre-blowing me- The RV-d series features a higher automation level and facilitated operation as well
thod allows a uniform wall thickness in high parts by pre-stretching the as convenient, rapid mold changes. Wall thickness is improved in high parts when
material. produced in the positive forming method combined with automatic pre-blowing and
P (t) pre-stretching of the material. Forming is performed by vacuum, supported by 3 bar
compressed air. P (t)
The total forming pressure is available within a very short time since forming air distan-
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ces were reduced. This equipment is suitable for the production of formings of superior
quality and definition with higher output at the same time.
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-1bar -1bar

Using the RV technology,

uniform wall thickness is achieved by pre-blowing. In the RV 53d and RV 74d series parts are formed by
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Part forming is carried out by vacuum. vacuum, supported by 3 bar compressed air.
 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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RV 53 Thermoformer
the standard for small batch si zes

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Digitalized sequencing allows practical operation.

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RV 53 for economical batch sizes
RV machines feature simple tool technology for forming, punching and stacking of thermoformed
parts. Using this technology vacuum forming can also be applied for the production of small batch

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sizes. The forming station is equipped with 4 independently working tool carriers. Forming tables
and clamping frames are moved pneumatically. Subject to mold design and forming program, stro-
kes of table and upper frame can be set.

Parameters for pre-blowing, suction and demolding can be digitally set on the central operating

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panel. These setting data can be saved and filed to ensure further repeatability. Up to 22 cycles can
be achieved by using molds with direct or indirect cooling.

After forming the parts are punched in the punching station and transported to the stacking sta-
tion suspended in the skeletal.

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Proven machine program and simple mold technology

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Mold change
The quick change system includes automatic setting of the material transport to mold width as well as quick clamping of forming and
Samples of mold designs punching tools. Material index length, material transport acceleration, material transport speed, upper clamping frame stroke, pre-
suitable for vacuum forming on RV machines. blowing, suction, table stroke, table speed and demolding air can be digitally set during machine operation. All mold and format parts
can be changed from the operating side of the machine. Operation by touch screen.
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Stacking station RV 53
Formed parts are stacked in upward direction into format-dependent stacking cages. The parts, suspended in the skeletal, are clam-
ped in the stacking station and separated from the break-out plug. A further movement takes the formed parts into the stacking
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cage. Product stacks are formed using a counting device; subsequently they are moved to a discharge sheet by a pushing-out device.

The setting parameters of the stacking movements are entered on the operating panel. The stacking station can be moved in ope-
rating direction in order to ensure precise stacking. Parts produced in small series are removed manually, automatic stacking is not
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required.
 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems
RV 53d Thermoformer
flexible and intelligent
Economical thermoforming of
different batch sizes. Higher
forming speed due to short
forming air distances.
Formed parts attributed to
pressure forming so far can be
manufactured on these machi-
nes in a cost-effective way.
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Molds RV Technology ILLIG Systems
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Thermoforming with the RV-d series fea-
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tures improved performance, availability,
flexibility and low format part costs. The
core element of the innovative technology
is a cost reduction of formed parts, also for
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smaller batch sizes.
Some of the major benefits of RV 53d are:
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Economical production of packaging artic-
les made of all materials suitable for ther-
moforming, simple operation, high output,
fast mold change, and computer-aided ba-
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sic setting.
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Versatility and high productivity
Innovative forming programs and optimized positioning of all elements involved in the forming process allow production of sophisti-
cated part contours. Combined with tailored standard parts, inexpensive format sets are available which allow economical application
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of vacuum forming for small batch sizes as well. Based on newly developed standard parts customers benefit from for economical
vacuum forming, also for small batch sizes. Short cycle times and a high automation level for forming, punching and stacking com-
bined with a tried and tested quick-change mold technology ensure the demanded availability with high productivity at the same
time.
Materials such as PS, PVC, PET and PP can be processed on RV machines. Materials at a range of 180 my up to 1.5 mm can be pro-
cessed on RV 53d machines, as well as optionally up to 2 mm. The basic RV 53d machine is equipped with heating, forming and pun-
ching station. The machine can be upgraded by adding a stacking device as well as a hole punch press.
Thanks to heating and material transport features PP can be processed without problem. Roll pre-heaters are available as additional
modular elements for pre-heating. Shortest filling times for the individual cavities thus allow shortest cycle times with optimum
part definition. Forming air and vacuum are available for upper and lower table with optional switching. Thanks to the pre-blowing
device with pneumatic material pre-stretching a more uniform wall thickness is achieved in sophisticated parts manufactured by the
positive forming. By using cooled molds up to 45 working cycles can be achieved with the RV 53d, subject to equipment level. PP is
processed at 3 bar, with spreading and reinforced cooling performance.
 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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RV 74d Thermoformer
larger version intelligent and e fficient

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Thermoforming line for higher output. The

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RV 74d, featuring a larger forming area, pro-
vides the same benefits for forming and
punching as the RV 53d.
Heating and forming station are basic ele-

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ments of the line. An individual thermo-
forming system can be tailored by adding
modular elements, such as hole punch press,

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steel rule punch press and stacking device.

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Optimum thermoforming conditions by pilot heating technology Individual thermoforming system for your requirements
Upper and lower heater come as standard. The individual rows of heater Longer service lives of steel rule dies thanks to higher flexural strength of the steel rule punch press. The steel rule punch press
elements can be pilot-controlled. Heater element rows which are not re- is equipped with movable upper and lower table. Higher cycle speeds are achieved by employing a servo drive. Based on this new
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quired are automatically switched off, subject to index length and material
width. The upper heater is equipped with longitudinal row control; the lower
heater is equipped with cross row control. Optionally, a row of small heater
elements is available on the mold side. Benefit: Cold influence is compen-
sated.
A heating profile is calculated by the computer-aided basic setting in relati-
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drive technology, the punching tables can be moved by indexing or in various stages of creep speed. This is especially beneficial for
adjustment of the steel rule dies. The play-free height adjustment of the upper bridge reduces the cutting shock and improves the
service lives of the steel rule dies. The steel rule cutter can be moved in longitudinal and cross direction to achieve a uniform punching
contour. The position is recalled by the computer-aided basic setting program.
Servo-driven material transport for precision positioning during high transport speeds
Width and index length setting of the material transport is carried out by the basic setting program. The servo positioning drive redu-

on to the center row of heater elements. All thermoforming possibilities can

ces index length tolerances to ± 0.2 mm. The spreading device moves apart the material transport in the area of the forming station,
be optimally utilized with this type of heater equipment.
the material is stretched and thus webbing is prevented during the forming process. This is especially beneficial for PP processing.
Material spreading in the RV 74d is carried out by servo motor. Spreading parameters are entered on the operating panel. Materials
up to 2.5 mm can be processed.
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Example RV 74d: Hole punch press

The upper heater is equipped with longitudinal row control;
the lower heater is equipped with cross row control. A hole punch press is available for the punching of bottoms and lids. Automatic positioning of the movable hole punch press by
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Pilots computer-aided basic setting.

 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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Cost-effective and
versatile system solutions

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Last but not least the part quality depends on the characteris-

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tics and the reliability of the individual production steps. ILLIG
offers a broad and mature range of stacking system solutions,
adjusted to the corresponding requirements.

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Improved setting and operating convenience in RV 74d due to servo drives which are emplo-
yed for the stacking movements. Distances of break-out plug and push-out device can be
set very easily by using the teach-in method. The strokes set by the operator are converted
by the machine control into setting values. These values can be stored. They reduce set-up

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times and result in higher efficiency.
In the stacking variant for RV 74d where stacking is performed in downward direction, the RV 74d stacking station
with upward stacking
break-out plugs push the formed part out of the web onto a stacking conveyor which de-
scends cycle by cycle.

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Stacking variants for all automation levels
Efficiency is based on the quality of the product stacks, cost-effective format parts, reliabili- Descending distances can be programmed in different ways, thus causing formed parts to nest firmly or only slightly. When the set
ty as well as ergonomic end packaging. The concept of the stacking systems also meets the number is reached, the stacks of counted parts are transferred to the discharge conveyor and discharged from the machine.
requirement for fast and simple change of format parts.
The different stacking variants, among other things, also influence the forming process. This means better stacking, for example of

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Additionally, the position of the stacking station is calculated by the basic setting program hinged packs, thus 30 cycles/min are possible.

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with respect to the index length.
The position can be changed and stored during operation. Consequently, no setting work is
required for repeat orders and a fast and reliable start-up is ensured.
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RV 74d stacking station

with downward stacking
(optionally RV 53d)
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 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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Mold making manual – ILLIG – a perfect match
Our system solutions allow simple and quick

for your individual success sys tem

integration in the most diverse production lines.

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Even interlinkage in highly complex plants,
linked from material manufacture through to
completely decorated cups, is a standard task

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for us which we manage successfully on a daily
basis.

Requirements on formed parts in terms of quality and efficiency will continue to grow
in the future as well. Our automatic roll-fed machines are an essential factor for long-

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term competitive production. The mold is the second, equally important component.
ILLIG: provides trend-setting support also for this topic, so potentials of the RDKP
machines can be utilized to the full extent – the ILLIG mold making manual.

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Integrated development and perfect synchronization of both elements result in a
production system of utmost flexibility, productivity and reliability.

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ILLIG brand mold innovations: Often copied – still unequaled Exclusively available from ILLIG: Clever details with highest customer value
ILLIG possess comprehensive experience in realizing revolutionary machine Customers can build their own molds in a cost-effective way by using the clearly arran-
technology - best requirement for the development of corresponding molds. ged and user-friendly „Mold making manual“. An investment which will pay for itself
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When we launch new machine concepts, we also offer suitable forming and fast and last but not least in the thermoforming of food packs.
punching tools. Tested on the original machines, tailor-made for your individual
requirements, developed and manufactured by ILLIG.

Benefits
II Optimum processing quality: Thanks to unique technical details.
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II Efficient and reliable operation: Thanks to minimum standstill

times, low maintenance effort and long service lives.
II Future-proof: Thanks to unique performance data.
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 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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Future-oriented system techn ology –
noticeably short mold change times

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Automatic roll-fed machine, separate forming and punching RV 53 Applications Applications Automatic roll-fed machine, separate forming and punching RV 53d

Forming area mm max. 500 x 365

Mold width between
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Forming area mm max. 500 x 350

mm max. 524
material transport
Mold width between
mm max. 516
material transport RV 53 RV 53d RV 53 RV 53d Mold length in feed direction mm max. 390

Mold length in feed direction mm max. 366 Hinged pack with euro hole ✔ ✔ Tray for vegetables ✔ ✔ Mold height on upper table mm max. 130
Deli cup - ✔ Hinged pack for croissants - ✔
Mold height on upper table mm max. 130 Plant tray - ✔ Hinged pack for felt pens ✔ ✔ Mold height on lower table mm max. 75
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Mold height on lower table mm max. 50 Carrier pallet for work pieces ✔ ✔ Hinged pack for felt pens ✔ ✔ Material width with mm max. 550
Tray for chocolate marshmallows ✔ ✔ Tray for sweets ✔ ✔
Material width with mm max. 550 Blister ✔ ✔ Hinged pack for salad ✔ ✔ Index length mm max. 395

Index length mm max. 380 Insert for chocolate candies ✔ ✔ Tray for pharmaceutical products ✔ ✔ Part height above material level mm max. 100
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Hinged pack for bakery products - ✔ Tray for electronic components ✔ ✔

Part height above material level mm max. 100 Hinged pack for fruit salads ✔ ✔ Corner protection - ✔ Part height below material level mm max. 40

Part height below material level mm max. 30 Round tray with flat bottom ✔ ✔ Hinged pack for cake ✔ ✔ Forming pressure bar max. 3
Hinged packs with punched holes for fresh fruit - ✔
Cycle speed with process optimization 1/min. max. 22 Cycle speed with process optimization 1/min. max. 45
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 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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Future-oriented system techn ology –
impressive XL format

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Automatic roll-fed machine, separate forming and punching RV 74d Applications

Forming area mm max. 704 x 530

Mold width between
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mm max. 724
material transport
Mold length in feed direction mm max. 554 RV 74d RV 74d
Mold height on upper table mm max. 150 Hinged pack with euro hole ✔ Tray for vegetables ✔
Deli cup ✔ Hinged pack for croissants ✔
Mold height on lower table mm max. 80 Plant tray ✔ Hinged pack for felt pens ✔
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Material width with mm max. 754 Carrier pallet for work pieces ✔ Hinged pack for felt pens ✔
Tray for chocolate marshmallows ✔ Tray for sweets ✔
Index length mm max. 556 Blister ✔ Hinged pack for salad ✔
Part height above material level mm max. 120 Insert for chocolate candies ✔ Tray for pharmaceutical products ✔
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Hinged pack for bakery products ✔ Tray for electronic components ✔

Part height below material level mm max. 40 Hinged pack for fruit salads ✔ Corner protection ✔
Forming pressure bar max. 3 Round tray with flat bottom ✔ Hinged pack for cake ✔
Hinged packs with punched holes for fresh fruit ✔
Cycle speed with process optimization 1/min. max. 40
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 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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ILLIG – a complete spectrum to meet your requirements

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Thanks to innovative power, high quality standards and a complete orientation to our Excellent performance – you can rely on us

customers‘ needs and requirements, ILLIG has become the market and technology
leader in the sector of thermoforming and packaging technology.
We drive progress significantly further onward and today we offer you the most
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The ILLIG range of services comprises development, design, ma- Our products and
nufacture, assembly and commissioning of complex production
lines and individual components. We are an owner-operated our skills
company with about 750 employees, own subsidiaries and re-
presentative offices in over 80 countries and present in all mar- Thermoforming Systems
kets. We are your competent and reliable partner. The name

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II Sheet processing machines
stands for superior technology of excellent quality and a com-
II Automatic roll-fed machines for
extensive range of state-of-the-art machines and the appropriate molds. At ILLIG prehensive, global service.
forming/punching operation
you really do receive everything from one source. Innovative whole solutions for the Whatever you want – you‘ll find it at ILLIG
II Automatic roll-fed machines,
separate forming and punching
most diverse industries and applications, exactly adjusted to your individual tasks.

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ILLIG offers you not only machines for the most diver-
se applications, but also corresponding accessories and Packaging Systems
molds. This way you can utilize the substantial potenti-
Everything you need – for sustainable and successful production and a permanent II Skin and blister packaging machines
als of our lines to the full extent and the high availability and
II Form, fill and seal lines
productivity are ensured over the long term. Synergies that
competitive edge.

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pay off – definitely.
Molds
Our range of products is completed by a comprehensive range of
molds. Specifically coordinated with our machines, designed and
manufactured in the ILLIG mold shop.

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 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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ILLIG – evolution of thermofor ming

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ILLIG stands for pioneering inventions and innovations. ILLIG has been setting technological milestones for decades

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We actively invest in the research and development
of new technology and work together with lea-
ding research institutes. 1946 1956 1960 1963 1964 1968

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On May 27 Adolf Type UA 100: Introduction of First high-speed New RDM series First packaging
Illig founds a Construction of the R 650: World’s first pneumatic forming machines introdu- machine line that
Using the latest hardware and software maintenance and first ILLIG vacuum roll-fed automatic and punching ced. Founding of integrates forming,
repair workshop in forming machine. vacuum forming machine. Beginning ILLIG tool and mold filling and sealing.
tools our highly specialized engineers the garage of his machine for produ- of market-proven shop complements First piston dosing

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RDM series. product range for machine for pasty
are developing forward-looking so- parents’ home. cing lids from pre-
printed material. the production of ingredients.
lutions. Solutions that offer decisive cups and lids.

advantages to our customers, such as

higher quality products produced in

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less time and at reduced costs - inno-
vations that make our customers even
more successful.
1983 1984 1989 1993 1994 1995

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Development of RDM 50K – first First software First In-Mold Fully aseptic form, Development of in-
pre-heaters with larger automatic program to Labeling production fill and seal lines novative molds for
heated aluminum thermoforming automate basic line for applying with a capacity of forming and pun-
rollers for conti- machine with tilt settings of vacuum PP labels to PP 700,000 yogurt ching technology
nuous PP heating. technology. It sets forming machines. margarine tubs. cups per day. that set new stan-
the new standard dards in precision,
for hygiene temperature control
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24 - 25 conditions in the and service life.
packaging industry.
Today:
Customers all over the world manufacture
sophisticated and high-precision parts and
packages for brand products.
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2004 2005 2006 2008 2013 Today

RDM 78K, ILLIG’s Premiere of Conversion of ILLIG Presentation of ILLIG designers ILLIG’s IML-T deco-
first 3rd generation In-Mold-Labeling high-performance BF 70 – first bottle achieve quantum ration technology
machine line in for form, fill and thermoformers former worldwide leap in thermofor- prevails among
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operation. seal lines. to 3rd generation of its kind ready for ming with IC machi- customers.
technology. serial production. nes (ILLIG Intelligent In-Mold-Labeling
Control Concept). lines conquer
the market.
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Looking back:
The first ILLIG UA 100 vacuum forming
machine was built based upon the know-
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how of the repair shop and dryer production.

 Welcome to ILLIG ILLIG Intelligent Control Concept IC RV Thermoforming systems Molds RV Technology ILLIG Systems

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The success system –
for your successful production

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ILLIG IC-RV line technology - probably the most comprehensive program of state-of-

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the-art lines in the sector of automatic roll-fed machines for separate forming and
punching.
In this product group you obtain everything from one source: Innovative whole solu-
tions for most diverse industries and applications, directly suitable for your individual

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requirements.

Simplified operation => ILLIG IC for higher availability

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Better cleanliness => Perfect for food sector
Mechanical improvement => Higher availability of processes
Contact details

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IC-RV: Everything you need for long-term successful production and a permanent ILLIG Maschinenbau GmbH & Co. KG
competitive advantage. Worldwide. Robert-Bosch-Str. 10
74081 Heilbronn

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Germany

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Phone: 0049 7131 505 0
Fax: 0049 7131 505 303
E-Mail: info@illig.de
Web: www.illig.de
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 ILLIG systems for thermoforming
and packaging technology

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II Sheet processing machines
II Automatic roll-fed thermoformers for
forming/punching tools
II Automatic roll-fed thermoformers,

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separate forming and punching
II Skin and blister packaging machines

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II Form, fill and seal lines
II Mold shop

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3122.02.2017 - en - Subject to change

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SYSTEMS
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ILLIG Maschinenbau GmbH & Co. KG

Robert-Bosch-Strasse 10 Tel. +49 7131 505-0 E-Mail: info@illig.de
74081 Heilbronn I Germany Fax +49 7131 505-303 Internet: www.illig.de