Packaging
THIRD GENERATION ILLIG TECHNOLOGY BOOSTS PRODUCTIVITY AND CUTS WASTE AT ANSON PACKAGING
Thursday 30. July 2009 - The latest third generation RDM 70K thermoforming system, developed and manufactured by Illig, Europe's leading supplier of thermoforming and packaging technology, is being used by Anson Packaging as part of an innovative production line for 101 and slim-pot food containers.
In particular, the Illig system has helped Anson make significant improvements in cycle speeds, while reducing both scrap material and total material usage by enabling pots to be formed from recycled PET (rPET) with thinner walls without affecting overall strength or rigidity.
The new RDM 70K was installed by Anson at its UK headquarters near Ely as part of a large contract, to supply food producer Bakkavor with a major share of their 101 and slim pot requirements. The contract also stipulated that the pots should be produced using rPET, and that the weight of each pot should be up to 20% lower than similar food containers previously used by Bakkavor, which would make a significant contribution to their packaging weight reduction targets, and additionally help them meet the goals of the Courtauld Commitment drawn up between WRAP and major UK grocery organisations.
As a major supplier of containers to the European food industry Anson already made extensive use of Illig pressure and vacuum forming machines and the two companies therefore worked closely together to meet the specific requirements of the Bakkavor contract by using the latest third generation technology. Andrew Osborne-Smith, Managing Director of Anson, explains, “We have had considerable experience with Illig machines over the years and felt that the company was best placed to help us create an effective method of providing the production output required, while at the same time reducing the weight of containers”.
The RDM 70K is part of a new generation of Illig thermoforming machines that make extensive use of the latest computer, electronic and electro-mechanical technology to achieve exceptionally high cycle rates and levels of precision and repeatability.
In particular, the RDM 70K incorporates advanced management systems that provide infinitely variable control of the speed and positioning of transport, tooling, heating, cooling and cutting functions at each process stage, allowing Anson to achieve high speeds.
Features such as multiple valve units control the flow of forming air, while air reducing systems combined with carefully regulated water cooling mechanisms, with up to four individually controlled cooling circuits in each mould tool, ensure accurate and consistent cooling temperatures; combined, these features help to reduce compressed air and energy consumption by around 50%. Similarly, the directly cooled and independently controlled downholder helps to deliver exact distribution of the material during the forming process.
Andrew Osborne-Smith points out that the standard features of the RDM 70K, “Already went a long way in helping us meet our objectives. In addition, however, Illigs design engineers helped us create dedicated tooling that in conjunction with the new downholder overcame one of the problems with earlier forming systems, where the pressure of the downholder would have a rapid cooling effect on rim of each container as it formed. As a result, containers often had a thin bead of material around the rim, which made them difficult to stack.
The new system has enabled us to eliminate this bead, so we can now stack more containers in each box for transit. Just as importantly, the system gives us precise levels of control over the forming process, with variations in the thickness of formed material now being reduced to just a few microns; this has allowed us to reduce the wall thickness of each container without any reduction in top-load strength.”
For Ansons production team the new RDM 70K thermoforming system is simple to set up and operate, with fast start-up in just three machine cycles, quick tool changeover in less than one hour, and full diagnostics via a centralised touch screen controller. The system is also linked directly to an Illig granulator, so skeletal waste can be reduced in volume prior to being re-processed and extruded on-site by Anson.
Andrew Osborne-Smith concludes, “Installation of the latest Illig system is part of a long term, multi-million pound programme of investment in new technology. This programme is designed to improve and further our commitment to sustainability, whilst continuing to increase our levels of productivity and performance. Working closely with customers and key suppliers such as Illig is critical to this process, and weve found that Illig in particular with its UK engineering and technical support services has become a valuable partner in our ongoing success”.