Using different tools in one flexible thermoforming system

Thermoforming is a process that requires various tool systems. Unfortunately, if the latter originate from different manufacturers, they often cannot be used together in one system. Illig took on the challenge and came up with a successful solution.

The new flexible RedLine RDF 85 thermoforming system now enables the application of off-system tool systems. In this K-MAG interview, Frédéric Engel talks about the possibilities the innovative system opens up for manufacturing companies.

Mr. Engel, what prompted you to develop this system?

Frédéric Engel: During our conversations with our customers across the globe, we learned that they want to invest in our ILIIG technology, which is the most reliable and most productive on the market. However, the customers already had existing tools from other manufacturers that matched the respective systems. For our customers, a switch to ILLIG systems would have meant replacing their existing tools. We have overcome this investment hurdle by developing the flexible RedLine RDF 85 thermoforming system with its variable mold interface. In doing so, we addressed the request of our customers and now offer an entry-level machine that delivers the highest quality and features clients have come to expect from ILLIG. Our success since the market launch of the RDF 85 shows we are on the right track.

How important is it for manufacturing companies to integrate several tools into the system?

Engel: There are obvious advantages. Thanks to the creativity of our developers and the use of modern motion control, our new machine allows the use of different types of tools from a process technology perspective. With the RDF 85 thermoforming system, manufacturers get the desired high quality of ILLIG technology but can continue to use their existing tools from third-party providers. This generally requires no adaptation and, thus no additional investments. The system is so flexible, customers with mold and tool making capabilities can even design their own tools and set them up in the RDF 85 system. This gives our customers maximum flexibility and efficiency when it comes to production order processing.

What are the benefits of the innovative system for processors?

Engel: The RDF 85 system has other benefits apart from the variable mold interface. When we developed it, we also used the opportunity to design a fully flexible system from film infeed to molded part outfeed. The processing companies also benefit from variable heating system length to best suit the respective material they want to process and the film thickness. Our customers can also choose between different end-of-line stacking systems.

Are there any drawbacks to this, such as more frequent maintenance?

Engel: No, we are not aware of any drawbacks in this setting. Quality, ergonomics, and availability meet our high ILLIG standards. This includes the use of the well-known double toggle lever mechanism for the forming and punching station, for example.

Which sectors primarily use the system?

Engel: The RDF 85 system is ideal for producing plastic packaging, such as cups, shells, containers, and technical components, such as transport trays. The pre-blowing mechanism for the manufacturing of high-quality technical parts is an interface that complements the RDF 85 system. It enables our customers to expand into new markets. Incidentally, the system has a maximum forming area of 800 mm x 600 mm, which is equivalent to a Euro half pallet, making it possible to produce transport trays or other technical parts by maximizing space on pallets.

How does your thermoforming system take steps towards the future and strengthen sustainability in the plastics industry?

Engel: ILLIG has always developed technical solutions to meet future needs and requirements. It means we adapt our machines and tools to meet current and future market developments with high performance, flexibility, quality, and sustainability as our top priorities. The same applies to our new RedLine RDF 85 thermoforming system. This machine can process numerous plastics and their recyclates. The HTS series ceramic radiators used for film heating are energy efficient. The entire system is equipped with energy recovery systems. The mold surface area offers maximum utilization. The machine delivers high process reliability, ensuring fast first time yield at input. The new as well as our other thermoforming systems are designed to help reduce the carbon footprint of the plastic manufacturing industry.