Machine builder ILLIG makes the ever-changing food packaging industry more flexible and forward-looking with the openness of the Bosch Rexroth Automation Toolkit ctrlX AUTOMATION technology.
Debut at Interpack 2023: The modular ILLIG SLU complete series future-proofs food packaging and increases its efficiency with the ctrlX AUTOMATION automation system platform from Bosch Rexroth.
Pictured is the type of PLU used for laminating pulp trays. (Image source: ILLIG Maschinenbau GmbH)
Packaging is of great importance for climate protection. The food industry is achieving this through a combination of cardboard with plastic, as well as laminated trays made of cardboard or pulp where each part can be separated and recycled.
However, from the machine manufacturer's point of view, it is not economical to develop and maintain individual machine series for each packaging type, whereas it is much more cost-effective to use a modular system concept, such as the XLU series from ILLIG Maschinenbau GmbH & Co. KG. The company, an internationally influential company, has completed the development of the SLU series with the support of the Bosch Rexroth forward-looking automation toolkit ctrlX AUTOMATION.
Modular packaging machine
Headquartered in Heilbronn, the company is one of the world's leading suppliers of thermoforming and packaging systems as well as machine tool systems for cardboard, paper and plastics. With the unveiling of the XLU product range at interpack 2023 in Düsseldorf, the family-owned company with a deep tradition has created a future-proof machine series that significantly expands the application prospects of laminated pulp and paperboard. For maximum freedom in the choice or combination of packaging materials, the modular XLU series is available in three different versions: the CLU version straightens and laminates cardboard trays, the PLU version is designed for lamination of pulp containers, and the TLU version provides cardboard wrapping (tray labeling) for plastic pallets.
Digitalization and investment protection
In addition to flexibility, the future viability of the series was a key requirement for the customer. Markus Peter, Head of Electrical Development at ILLIG Maschinenbau, explains: "The packaging machine is a long-term investment that needs to be operated for 20 years or more. To ensure that the new machine concept could keep up with the changes brought about by digitalization, ILLIG opted for ctrlX AUTOMATION, an open automation solution from Bosch Rexroth, its long-standing technology partner. Markus Peter emphasises: "In terms of software and hardware, our machines need to be ready for future applications and retrofits. In this regard, Bosch Rexroth can provide everything we need. ”
Based on an open automation platform
With ctrlX AUTOMATION, ILLIG has opted for a new generation of control and drive technology that is flexible and open in order to match its machine concept. Markus Peter: "The modular design allows the development of a platform for future-proof machines. Open hardware and software modules ensure excellent process quality and enable us to obtain data that contributes to the continuous improvement of productivity and energy efficiency. ”
The space required for the control cabinet is reduced
To automate the modular machine series, ILLIG uses not only the ctrlX CORE control platform, but also the ctrlX I/O module and the compact servo drive ctrlX DRIVE as well as the precision servo motor MS2N for all process-relevant axes, such as handling, film unwinding or feeding via a rotary table. The combination of scalable drive technology and highly integrated two-axis devices, converters, inverters and I/O enables the control cabinet to be significantly reduced. The XLU series, for example, is about 40% smaller than conventional designs.
Forward-looking connectivity
When it comes to internal and external connections, ctrlX AUTOMATION also offers mechanical engineers great design freedom. ILLIG has chosen the industry-standard EtherCAT for bus communication at the machine level, enabling the seamless integration of customer-specific components from different manufacturers. Markus Peter explains: "Bosch Rexroth has become a well-established automation partner. "In addition to the openness of the technology, its industry expertise and excellent application support also contribute to the expansion of the partnership. According to the head of electrical development, "Bosch Rexroth has provided us with strong support in the basic engineering of the new machine series. Assistance in the planning and design of drives, I/O and other modules also helped us to complete the task on schedule under a very tight schedule. ”
Sustainability of automation
With the new scalable automation toolkit, ILLIG is able to develop small and complex applications in a cost-effective manner. Flexible programming is a key element of this. Markus Peter explains: "We can use the most appropriate language for our needs, including the latest IT languages such as Java, JSON or Python. With the current shortage of professionals, finding a job as a programmer will become a little easier. Our professionals can quickly adapt to the new world of automation and can make a large amount of existing code perpetuated. With ctrlX AUTOMATION, we can continue to support technologies that are more than 20 years old without any problems. This means that automation is sustainable. ”
Faster time to market
ctrlX AUTOMATION was developed to draw on Bosch Rexroth's decades of experience in motion applications. This is also evident in a web-based development environment that meets the needs of low-code. The control system ctrlX CORE can be virtually simulated on a PC, which helps to speed up the programming of the system. Markus Peter: "The code generated with the virtual axes can be quickly ready and ready for use in advance. All we had to do was convert the machine to a state where the shaft was used, which saved even more time. ”
Long-term service through remote maintenance
In addition to control, programming, safety and applications, the comprehensiveness of ctrlX AUTOMATION includes a future-proof service concept as well as software updates, a support hotline and a long-term global supply of spare parts. International suppliers such as ILLIG can provide protection for customer investments for 25 years or more. Digital tools such as the ctrlX Digital Service Assistant, Service Indicator, and ctrlX Device Portal enable rapid remote diagnostics, troubleshooting, and the rollout of new applications and software capabilities.
Tobias Gerhard, Head of Business Development at Bosch Rexroth Consumer Goods, explains: "In terms of demand-based development work, Rexroth customers can find a wide variety of applications from third-party suppliers in Rexroth and from its partner ctrlX World. These applications are available through the ctrlX Store (ctrlX Store) and are used for a variety of industrial automation tasks. We also offer apps and libraries for creating personal applications, further increasing usability freedom. ”
Future-proof cost structure
According to Jürgen Lochner, CTO of ILLIG, the decision to adopt ctrlX AUTOMATION and the resulting reduction in total costs will help to increase the company's competitiveness on an international level. "Even in this era of rapid development, we can create the best cost structure for our customers with the unique combination of openness and security of this technology. We have strengthened our international competitive position with our modular machine concept and at the same time offered attractive retrofits. ”
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