Illig, the system provider for thermoforming, presents Pactivity, a 360° customised, active packaging development. The combination of the terms „packaging“ and „activity“ describes conceptual and practical solutions in thermoforming and their technical implementation.
For many decades, the Heilbronn-based family business has been involved in the Packaging development and thus supports customers in the successful market launch of innovative and sophisticated packaging materials. Packaging is always designed for the respective product, for example the thermoformed, tightly sealable „take-away box“ or cups decorated with IML-T with or without barrier properties.
From the packaging idea to the production system
It always starts with the customer's initial idea and the joint description of the attributes (application profile) by experienced packaging consultants as the basis for preparing a quotation for packaging development. At the end of the process, the result is an outstanding packaging product that fulfils all requirements. There are numerous development steps in between and answers to technical questions must be found. The product, packaging material, volume and feasibility must be analysed and design options, tool design and the line concept must be determined. Because in the field of thermoforming Various procedures available for the production of packaging.
Which thermoforming process is used is primarily determined by the properties that the packaging should have. The Shapethat Material and the Required throughput decisive roles. Once the first points in the packaging development process have been successfully worked out, a detailed Test phase, which begins with sample production and ends with the customer's approval after various necessary product tests. ILLIG has the relevant expertise in mould and machine construction and now knows all the technical requirements. The line is configured together with the experienced engineers according to the packaging solution developed and the realisation of the production system can begin.
Thermoformed, liquid-tight tray with lid for the first time
A current Pactivity example is the development of a thermoformed, stackable and liquid-tight „Take-away bowl“ for the Asian market. There, hot soups and food are filled in restaurants and at mobile sales stands and taken away by customers. A cost-effective and safe transport solution for this purpose did not exist until now. The tray with lid is produced from transparent PP on an IC-RDK 80 automatic pressure moulding machine with a 12-cavity mould. The packaging specialists at ILLIG designed and implemented all stages of packaging development, from the initial idea to the selection of the packaging material and the production of the mould. This also included Own application tests in terms of tightness and stackability (top load).
Individual labelling with IML-T
Interesting approaches for packaging development are offered by the In-mould labelling in thermoforming (IML-T) from ILLIG. The Pactivity projects that have been realised with customers are as varied as the possibilities. The specially designed IML unit takes the blanks (labels) printed with the motif from a magazine and inserts them into the cavities of the mould in the forming station of the thermoformer. During the subsequent moulding of the film, the label is permanently bonded to the moulded part wall with precise contours. With the IML-T, almost all cup shapes can be flexibly decorated with photo-quality labels on all sides of the cup right up to the edge of the moulded part.
A particular advantage of IML-T technology is the Large decor areaDepending on the geometry and properties, the label can contribute to increasing the rigidity of the packaging. This allows the thickness of the packaging film used to be reduced while still maintaining the required top load of the pack. In addition to this significantly lower material consumption, there is also an efficient energy requirement during processing.
IML thermoforming offers economic advantages above all because Multi-cavity moulds can be used. Another advantage of the IML-T technology developed by ILLIG is that each cavity of the mould can be fitted with an individually printed label and that product changes can be carried out quickly and easily. All common materials, from PS and PP to paper, can be processed as labels. Sustainable, unmixed recyclable packaging can be realised to match the cup material.
Cup with barrier property and IML-T decoration
Unrivalled in terms of quality, production efficiency and cost-effectiveness, IML-T decorated packaging with integrated barrier layer. This barrier packaging is used in particular for oxygen and UV-sensitive products to extend their shelf life. The seamless barrier reliably protects the contents. Together with a well-known packaging manufacturer, ILLIG realised a barrier cup for 250 gram contents from the customer's initial idea right through to the production line. The thermoforming line with IML-T unit used by the packaging manufacturer produces millions of differently labelled cups with barrier properties every year.
Variable packaging for dairy products
ILLIG IML-T technology is also used in moulding, filling and clamping systems (FFS lines). especially in the dairy industry integrated. Here too, the machine manufacturer has already realised pactivity projects with several customers at home and abroad on the FSL 48 designed by ILLIG. The great variability of the system allows simultaneous filling and packaging of product families. Product changeovers can be carried out quickly and easily. All common film materials suitable for FFS lines can be processed on the FSL 48, such as PS, PP, multilayer material, APET and even films made from the biopolymer PLA.
