Emotions, motives and function make the decision. Thermoformed bottles for Functional Food

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1 Bottleformer BF 70

2 Emotions, motives and function make the decision Thermoformed bottles for Functional Food New packaging design, quality and high utility value make improved offers! Emotions, motives and functions decide and often control behavior of the customer. The key to success is mainly the contact to the user at PoS. Product design plays an important part all over the world. Billions of products are examined day by day everywhere in the world and that is when the consumer stands in front of shelves and displays. To offer trademarked commodities of superior quality and high utility value the manufacturer needs a package, which supports these product properties. for example for containers for marmalade, spreads, pudding and fruit yoghurts. Different volumes can be realized depending on design. So-called Functional Food and to this sector also belong yoghurt, vegetable and Wellness drinks, will increase continuously in the next years they already had a market share of 19 % in the total yoghurt market. The share of such bottles (especially in the sector between ml) will grow continuously. Basically these bottles had to be bought from a specialized manufacturer. Therefore we consequently integrated the market situation in the development of our thermoforming machines and developed the bottle forming machine, the bottle former BF 70. The advantages of thermoformed products like reduced container weight, high stiffness of formed part and constant quality remain fully unchanged. First the development concentrated on the forming procedure. Bottles with such significant undercuts can only be produced with movable tool parts. In addition a forming procedure had to be found, which enables an absolutely uniform wall thickness distribution Thermoforming offers cost effective production of bottles for yoghurt, juice, vegetables and isotonic drinks. A great benefit for design and functionality offers the possibility to work with undercuts like

3 Thermoformed bottles, Functional Food Economic Thermoforming, Forming and punching procedures BF 70 Comparison process sequences, thermoformed bottles and blown bottles Advantages of this machine series: despite reduced initial area and high depth of draw. At first sight no difference would be noticed between the conventional bottles and the thermoformed ones. However, by considering the weight, it can be recognized immediately that despite stability of the bottle in line with real market conditions the bottle often has only half of the weight! In the food industry and there especially in dairies these machines can directly be linked with existing filling and sealing lines. first tool system for forming and punching with steel rule dies, world-wide optimization and possibility of storing production parameters for high repetition accuracy, as well as reliable operation and without failures movable lower tool parts for demolding of bottles with significant undercuts definition of bottles with sterile pressure air The BF 70 is completely made of stainless steel and therefore also suitable for direct linkage with existing filling and sealing machines in dairies optimal forming temperature on account of the material being heated up by contact heater plates step by step high output rate at reduced maintenance high efficiency on account of reduced energy consumption optimal availability from the start, fast and reliable commissioning 2 3

4 The BF 70 for economic thermoforming The thermoforming procedure is a method by which, as usual, the product is deep drawn out of a flat material. However, due to the bottle design it is necessary to have movable tool parts to enable demolding of the bottles. With the use of specific tools in combination with a servo plug assist and control of the forming air it was possible to deep draw bottles at a stability in line with market conditions even out of a material only 1.4 mm thick (top load)! This applies for both the vertical load and the stability of the side walls. The movability of the individual tool parts and the feed area of the material require the bottles arranged in rows. Generally this is realized in two rows across operating direction of the machine. Due to the space of the tool opening required, the available format area can be used up to 20-up, depending on the shape of the bottle. A big benefit as far as the design of containers is concerned offers the possibility to work with undercuts. Nearly any shape can be realized to offer the consumer the optimal packing in line with real market conditions. TOP LOAD The stability of the bottle is a decisive feature for further procedures like filling, sealing and transport. Of course, it is not only bottles, which can be thermoformed with this procedure. Top load = 90 N (Deformation 2 mm)

5 Thermoformed bottles, Functional Food Economic Thermoforming, Forming and punching procedures BF 70 Comparison process sequences, thermoformed bottles and blown bottles The punching procedure The punching station is equipped with an automatic positioning device. The laser control examines the position of the cups and adjusts the station accordingly. In this case mismatch is avoided which is caused by material shrinkage. Therefore the bottle rims are always absolutely even round and can be sealed. The quality of the sealing rims is decisive for the exact sealing. The secure lock between round plate and bottle guarantees longer durability. The skeletal is cut uncontaminated, without rests in operating direction and removed or immediately reduced and recycled. The refunds reduce the material costs accordingly. Time benefits possible on account of automatic tool clamping, quick change of forming tools 4 5

6 Low bottle weight and shorter process chain Blowing and injection molding machines very often require higher investments at lower output rates. The Bottle former BF 70 makes bottles with considerably lower weight. A bottle made by blow molding has an average weight up to 8.5 gram. A thermoformed bottle stays far below this weight, the average weight is 4.5 gram. This results in a very cheap unit price and this at equivalent Top loads (test weight for bottle stability from the top and from the side) as well as at a very good even distribution of wall thickness. For thermoforming conventional PS up to a thickness of 2.0 mm can be used. Almost any bottle design can be made within the scope of the technical parameters of the bottle former. Direct linkage with fill and seal machines has the highest efficiency and a high saving potential. On account of the bottle production in the field, the costs for material acquisition, storage and handling are reduced for the user. Another benefit of the bottles deep drawn is the outside rim. It can be supported during the sealing process and thus takes care for an even sealing area. The bottle is closed safely and surely. Illustration above: reduced weight Thermoformed bottles have only an average weight of 60 % of the weight of a conventional container. ORDER Bottleformer BF 70 Illustration left: short sequences order material supply material store material produce and fill deliver

7 Thermoformed bottles, Functional Food Economic Thermoforming, Forming and punching procedures BF 70 Comparison process sequences, thermoformed bottles and blown bottles Process visualization Corrective actions can be taken for parameters relevant to forming Operator guidance and diagnostics Digitized function sequences allow practical operation philosophy The newly developed user interface is an innovation, which allows specific operator guidance through the individual process phases. All data required for the production process are entered by the operating panel and displayed in the comparison of setpoint value actual value. The effects of the measurements taken are exactly displayed on the operating surface. Important advantages of this visualization are the specific presentation of the necessary information and the auxiliary functions according to the principles of the professional industrial design. By means of diagnostic aid and / or monitoring of limit values help and support for the adjustment of machine and production process is guaranteed as well as for monitoring and quality assurance. Benefits by Panel PC Data save internal, Network, USB- Stick newly developed machine control with Soft PLC based on Windows operating system screen operating panel with high-contrast, brighter Touch -TFT Display for simplified operation and improved reading Bus connections Quick-change for forming and punching tools repeatable, safe process sequencing lead to optimal and constant product quality all setting data for the data set can be stored at any place (network, USB) diagnostic aid visual display of forming sequence Interfaces, USB, Ethernet Remote diagnostic, ILLIG Net-Service Process-optimized machine printer connection, s etting data and production report can be printed out improved operator guidance for installation and removal 6 7

8 ILLIG Maschinenbau GmbH & Co. KG Robert-Bosch-Strasse Heilbronn/Germany Telephone: +49(0)7131/ Telefax: +49(0)7131/ Internet: for Thermoforming and Packaging Technology Sheet processing machines Automatic roll-fed thermoformers for forming/punching tools Automatic roll-fed thermoformers, separate forming and punching Skin and blister packaging machines Form, fill and seal lines Produced Tooling e - subject to change