Thermoforming Systems

Thermoforming is a plastics processing technique that heats and forms thermoplastic materials via vacuum and pressure. A true pioneer, ILLIG has developed many “firsts” in this industry including the first automatic machinery to work from pre-printed roll stock; the first high-speed automatic pressure forming machine for forming and punching in the same station; and the first calculation program to automate basic settings of vacuum forming machines. In 2001, ILLIG was instrumental in the development of the plastic coffee capsule, variations of which include K-cups and Dolce Gusto pods. In 2019, ILLIG launched the 4th generation of RDM thermoformers with the large-format RDM76Kb.

A key attribute of thermoforming is the ability to use materials to form parts with 100% barrier protection, usually in a structure like PP/EVOH/PP. Adding decoration to barrier films creates new avenues for part designers and product marketers, especially in mass-customization environments like supermarkets or specialty food stores. In-mold labeling for thermoforming (IML-T) offers considerable weight reduction opportunities versus similar injection molding labeled parts. Because the label is integrated into the forming process, IML-T reduces capex and floorspace, while providing a wider range of graphic options associated with label printing. And because the material is not pre-printed, there is no gas emission from print colors during heating, and the skeletal sheet can be easily granulated for re-use without contamination. ILLIG has championed IML-T and now counts over a dozen systems in operation world-wide.