Smart Innovations for Sustainable Impact

From automated thermoforming technology to the new Dry Fiber Systems: ILLIG showcases technological developments for future-oriented, sustainable packaging.

Heilbronn, 11.08.2025 - In line with the motto Peak Performance – Sustainable Impact, ILLIG will present future-ready packaging solutions at this year’s Fachpack, taking place from September 23 to 25 in Nuremberg. These solutions consistently combine innovation and sustainability. As a system provider for thermoforming and packaging technology, ILLIG will highlight new technological developments, including the resource-efficient Dry Fiber technology, which recently received the German Packaging Award, and demonstrate how sustainable packaging concepts can be implemented efficiently and economically.

Following its restart as ILLIG packaging solutions GmbH, the technology company has further sharpened its focus on sustainable packaging solutions. In addition to developing and manufacturing complex thermoforming lines, the company is increasingly committed to developing sustainable packaging innovations in close collaboration with customers. ILLIG offers even greater freedom of choice – from plastics to cellulose. Whether driven by specific requirements, market conditions, or regulatory demands, the company provides the right tailor-made technology for every challenge. This allows customers to select the optimal material and system perfectly suited to their needs and packaging formats.

The ILLIG team welcomes visitors for in-depth discussions on packaging processes, machinery technologies, and innovations at Hall 1, Booth 258.

Innovative packaging solutions for FMCG and Food

At Fachpack 2025, ILLIG will showcase a broad portfolio of packaging technologies tailored to the needs of the food and FMCG industries. The offer ranges from sustainable blister pack systems to mono-material thermoformed packaging suitable for recycling, as well as new solutions for product infeed and end-of-line processes. ILLIG follows a holistic approach with its 360° packaging development, covering everything from the initial idea and packaging design to full-scale production. This process is supported by ILLIG’s longstanding expertise in toolmaking and the assembly of complex production lines.

The solution provider places a strong focus on automation across all systems to maximize efficiency, process reliability, and product quality throughout the entire production line. At the trade show, the company is presenting comprehensive system solutions for packaging and thermoforming lines – ranging from flexible feeding systems and precise inspection systems to highly automated end-of-line solutions.

New End-of-Line Packers for Thermoforming Systems

A key innovation is the launch of stationary end-of-line carton packers, designed to seamlessly integrate into the RDM thermoforming systems. These units feature dedicated drive technology, tailored software, and the proven ILLIG user interface, ensuring smooth operation within existing process environments. The "Basic Packer" and "Performance Packer" models offer scalable solutions for the complex requirements of modern packaging lines, allowing flexible adaptation to various formats and output levels. Further integration with other thermoforming systems of the ILLIG portfolio is planned. Both commissioning and service are centrally coordinated.

Dry Fiber: Fiber-based packaging with a market-leading drawing depth

A special highlight at the ILLIG booth is the enhanced Dry Fiber technology. With ILLIG Dry Fiber Systems, formed parts made from cellulose fiber material can be produced in large volumes. Since March, a pilot system has been operating successfully at the company’s Technology Center – trial runs with selected customers and development partners have yielded excellent results.

The fiber molding technology enables the production of fiber-based packaging with a drawing depth of up to 120 mm, premium tactile quality, and integrated barrier properties for food applications. Dry Fiber packaging is ideal for demanding applications in the food and FMCG sectors. Compared to conventional solutions, the Dry Fiber process reduces the use of fossil resources, saves water, and lowers energy consumption compared to wet-molded pulp applications. The system can be used to form cups, trays, and lids for both food and non-food products. Barrier properties, for example for sensitive contents, are integrated through inline lamination or functional coatings. The process also impresses with short cycle times and high cost-efficiency in industrial production.

The result: sustainable packaging that offers strong product protection, functional performance, and high-quality brand presentation – while also reducing production costs.

“Guided by our trade show motto ‘Peak Performance – Sustainable Impact’, we are demonstrating how innovative packaging can go hand in hand with real sustainability,” explains Christoph Gusenleitner, ILLIG CEO. “Our mission is to help customers worldwide implement packaging concepts that are not only sustainable, but also reliable and high-performing – with product protection at the core. Our Dry Fiber technology is a great example of this. But we also offer smart solutions for plastic packaging, focusing on material reduction and recyclability. Our decades of know-how and close collaboration with customers remain firmly embedded in our company DNA. Trade shows like Fachpack are the ideal platform for this exchange.”

ILLIG’s Dry Fiber Systems received the German Packaging Award 2025 in the category “Packaging Machinery”. The award ceremony will take place on September 23, 2025, at Fachpack in Nuremberg.

Images

01 – ILLIG Dry Fiber Systems (pilot machine)
02 – Packaging made from natural dry fibers