Modular automation with less plastic

Packaging plays an important role in climate protection. Political regulations such as the European Plastic Act aim to limit the use of plastics. The food industry is pursuing this goal with cardboard-plastic combinations and laminated trays made from cardboard or pulp whose individual parts can be separated for recycling. From the point of view of machine manufacturers, however, it is uneconomical to develop and maintain a separate range of machines for each packaging type. Modular system concepts such as the XLU range from ILLIG Maschinenbau GmbH & Co. KG are much more economical. The company with an international presence developed it with the help of Bosch Rexroth’s futuristic automation toolkit ctrlX AUTOMATION.

Modular packaging machines

The company based in Heilbronn is a world-leading provider of thermoforming and packaging systems as well as tool systems for cardboard, paper and plastic. With the XLU product family presented at interpack 2023, the tradition-steeped family business has created a future-oriented machine range that significantly expands the application possibilities for laminating pulp and cardboard. To allow maximum freedom when selecting or combining packaging materials, the modular XLU range is available in three different versions: While the CLU model straightens and laminates cardboard trays, the PLU model is designed to laminate containers made of pulp. And the TLU version gives plastic trays a cardboard wrap (tray labeling).

Digitalization with investment protection

In addition to flexibility, a key customer requirement was the future viability of the range. “Packaging machines are long-term investments that need to work for twenty years or more,” explained Markus Peter, head of electrical development at ILLIG Maschinenbau. To ensure that the new machine concepts can keep up with the changes resulting from digitalization, ILLIG opted for ctrlX AUTOMATION, the open automation solution from its long-standing technology partner Bosch Rexroth. “In terms of their software and hardware, our machines need to be ready for future applications and modifications,” stressed Markus Peter. “Bosch Rexroth offered us everything we need for this.”

Open automation platform as a basis

With ctrlX AUTOMATION, ILLIG opted for a new generation of control and drive technology with maximum flexibility and openness to match the machine concept. “The modular approach is a good platform for developing future-proof machines,” said Markus Peter. “The open hardware and software modules ensure high process quality and allow us to obtain data which can be used to continuously improve productivity and energy efficiency.”

Less space required in the control cabinet

In order to automate the modular machine range, ILLIG uses not only the control platform ctrlX CORE but also ctrlX I/O modules and the compact servo drives ctrlX DRIVE with precision servo motors MS2N for all process-relevant axes such as handling, film unwinding or product feeding via a rotating table. Thanks to the combination of scalable drive technology and highly integrated double axis devices, converters, inverters and I/Os, the control cabinet is much smaller. In the case of the XLU range, it is around 40 percent smaller compared to the conventional design.

Futuristic connectivity

ctrlX AUTOMATION offers mechanical engineers great design freedom when it comes to internal and external connectivity too. For bus communication on a machine level, ILLIG chose the industry standard EtherCAT, as a result of which customer-specific components from different manufacturers can be seamlessly integrated. “Bosch Rexroth was already an established automation partner,” said Markus Peter. In addition to the technological openness, the company’s industry expertise and its excellent application support also spoke in favor of expanding the partnership. “Bosch Rexroth supported us intensively and on an equal footing with the basic engineering for the new machine range,” said the head of electrical development. “The support when planning and designing drives, I/Os and other modules really helped us to keep to the tight schedule.”

Sustainability in automation

With the new, scalable automation toolkit, ILLIG is able to produce not only small but also complex applications in an economical manner. Flexible programming is a key factor here. “Depending on the situation, we can use the most suitable language, including the latest IT languages such as Java, JSON or Python,” explained Markus Peter. “Given the current shortage of specialist staff, this makes it easier to find programmers. Our specialists quickly got used to the new automation world and could carry over a great deal of existing code. With ctrlX AUTOMATION, we can continue to support technology that is more than 20 years old without any problems. This means sustainability in automation.”

Reduced time to market

Bosch Rexroth's decades of experience in motion applications went into developing ctrlX AUTOMATION. This is also reflected in web-based development environments which meet low code requirements. The control system ctrlX CORE can be simulated virtually on a PC, which helps to speed up the programming of the system. “The code produced with virtual axes was ready quickly and could be put into use in advance,” said Markus Peter. “All we had to do was to convert the machine to work with the real axes, which saved even more time.”

Long-term service with remote maintenance

In addition to the various disciplines such as control, programming, security and apps, the integrated approach of ctrlX AUTOMATION also includes a future-oriented service concept with software updates, a 24/7 support hotline and a global spare parts supply with long-term availability. International providers such as ILLIG can protect their customers’ investments for 25 years or more. Digital tools such as the ctrlX Digital Service Assistant, the Service Indicator and the ctrlX Device Portal allow quick remote diagnostics, troubleshooting and the rollout of new apps and software features.

“For needs-based development work, Rexroth customers will find a wide range of apps from Rexroth and third-party providers in the partner world ctrlX World. They are available on the ctrlX Store and are suitable for a wide range of industrial automation tasks,” explained Tobias Gerhard, responsible for Business Development in the Consumer Goods division at Bosch Rexroth. “We also provide applications and libraries for the creation of individual apps, thus further increasing the freedoms available.”

Future-proof cost structure

CTO Jürgen Lochner believes that the decision in favor of ctrlX AUTOMATION and the resulting reduction in the total cost of ownership helps to boost the company’s competitiveness on an international level. “With this unique combination of technological openness and procurement security, we were able to create an optimum cost structure for our customers, even in these fast-moving times. As a result, we have strengthened our international competitive position with modular machine concepts and can offer attractive retrofits at the same time.”

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