Illig FS: Ultra Clean / Aseptic Form Fill Seal Thermoforming

FormstationFood production from small runs to high production output, the FS series machines offer the reliability and flexibility to grow meet your demand. Cycle speeds of up to 22 cycles/min can be achieved in combination with cam-controlled table movements in the forming and sealing station.

The FS series machines are designed to package a wide range of food products like water, puddings, fruit spreads, nut spreads, yogurts, condensed milk, etc. Aseptic and non-Aseptic versions available.

DSC_0009Each machine is customized to the customer’s requirements using Illig’s modular construction platform. Tool-less quick release format parts and a thoughtful change over process allow the operator to accurately convert format sizes to keep production moving. Large Lexan safety doors allow the operators and maintenance full access to the machines systems. Format specific parts allow for the most consistent package quality and to minimize material waste during production and setup.

Benefits of FS

Thermoforming

Auslaufs. FS 31The unrolled material reaches the heating station. During multiple cycles the contact heating plates gradually warm up the material to the optimum forming temperature. The format specific milled heaters, only heat the film areas which will be formed. Unheated regions minimize material shrinkage in longitudinal and cross direction. Upon machine stop the heating station automatically opens, to prevent excess heat buildup. Cups are formed with positive pressure air, forming is supported by pneumatically driven pre-stretching plugs.

  • Format-specific milled contact heaters
  • Forming with pre-stretching plugs and positive pressure air
  • Automatic waste-free start-up
  • Multiple-gripper transport system
  • Operating speed is adjustable from 10 – 22 cycles
  • Print mark registration for processing pre-printed lid materials
  • Punching methods yields minimum waste

In-Mold Labeling

KODOSILLIG IML system (in-mold labeling system) works by inserting pre-cut labels from magazines directly into the forming tool. All label variations are possible, from 2-sided labels through to 5-sided full decoration. Much more attractive labeling can be produced with this system. There are almost no limits with respect to container shapes. Perpendicular side walls, as required for band-rolled cups, are no longer required. Pre-cut, printed labels are inserted in magazines. The magazines are designed for operation of several hours. A special retaining system allows reliable, individual label supply. When labels have been transferred into the forming tool (designed as tiling tool) the cup is formed into the cavity – as conventionally done in thermoforming, i.e. forming and labeling are performed in one step.

Standard filling module

DSC_0009All different fillers can be offered from simple membrane fillers for mineral water through to servo controlled high-performance fillers set up for S.I.P. (sterilization in place) or C.I.P. (clean in place).Funnels with several sections, with or without stirring devices, as well as double-wall funnels with heating are available. Sterile air overflow in filling funnel, different hose systems or quick-change filling heads for different products are available. Subject to customer requirement the filler is mounted directly on the filling range or to its side.

Aseptic Filling modules

The complete system is constructed according to dairy standards and made of non-rusting materials such as stainless steel, aluminum, and plastic.

The system is delivered with all electrical and electro-pneumatic functions installed, including wiring to the drive motors and switching elements, and also includes the wiring between the main switching station and the control panel on the system. The complete module is operated independently for themselves, from the basic machine we need only signals to specify the status of the plant. The operation of the unit is via operator panel placed on the aseptic module.

We deliver the sterile module on a separate frame for initiating the sterile air production, the filter- and valve combination for maintenance of the tunnel and filler for cleaning, sterilizing and sterile air admission flow. The module is positioned directly next to the machine on the platform. The exact configuration details must be coordinated.

Sealing station with lid material feed

The parameters required for sealing, such as pressures and temperatures, are individually adjusted with respect to materials used. Precision-processing of printed lid material is ensured due to the print mark registration unit. Slight thickness variations of the material are automatically offset during sealing. This way cups are always precision-sealed. Upon machine stop the sealing electrode automatically lifts, thus overheating of material and product is prevented.

The ILLIG multiple gripper transport system provides for maximum safety during material transport through the machine. Very narrow lateral material edges of only approx. 6 mm, depending on the material processed, making sure the machine’s format area can be optimally used without any additional material waste.

Automatic positioning of sealing and punching station

Narrow edges can be achieved on steep packs thanks to the automatic positioning of these units as well as very safe operation. The formed cups are detected by light barriers across the feed direction and in case of mismatch the position of the sealing and/or punching station is automatically corrected (optional extra). This way even sealing and punching edges are achieved even after a machine stop. Malfunction due to material shrinkage and pack mismatch is avoided.

Punching station

The packs are punched out of the web. High punching forces can be applied due to the four-pillar guiding element. Indexing tolerances are offset by the automatic positioning of the punch press (optional extra). This way punching mismatch is prevented. The skeletal is reduced by a cross cutter and discharged from the back of the machine by a chute.

Technical Data
Forming Area Max 309-358mm
Feed Length Min 150mm – Max 450
Depth of Draw Max 100mm
Material Width Min 180mm – Max 480mm
Material Thickness Min 0.2mm – Max 0.8mm
Forming Method Positive Pressure Forming
Cycle Speed Max 30/min