New Box Filling Units (BFU) increase flexibility, performance and integration capabilities

Heilbronn, April 1, 2026 – ILLIG packaging solutions GmbH is expanding its end-of-line automation portfolio with two new box filling units. The new systems enable fully automated cartoning of products directly downstream of the thermoforming process.

With the new BFU 300 and the high-performance variant BFU 500, the company now offers fully integrated box filling units (BFU) based entirely on its own drive, software and control technology, replacing third-party systems.

The aim is to provide customers with more flexible, high-performance and seamlessly integrated packaging solutions from a single source. The performance of the thermoforming systems remains unaffected by the new packers – a key advantage compared to standard market solutions. Both packers are positioned in a stationary setup, eliminating the need for machine movement during tool changes. Initially, the new box packers will be available for RDM/RDML systems, with solutions for RDK systems currently in development.

“With the new box packers, we are closing an important gap in the end-of-line segment and enabling a consistent process logic from thermoforming through to cartoning,” says Christoph Gusenleitner, CEO of ILLIG. “Our customers benefit from higher performance, greater flexibility in packing patterns and a unified operation and service environment.”

Two versions for different requirements
The new end-of-line solution is available in two versions. The BFU 300 is designed for standardized applications with round, standard parts and conventional stacking configurations. Carton layers are transferred directly from the cross conveyor into the packer and placed into the carton via a lifting system. Thanks to its reduced mechanical complexity and limited number of format and changeover parts, this variant is particularly suitable for customers seeking a robust, cost-efficient solution with solid performance.

For more demanding applications with high cycle rates, tight packing schemes or non-round parts, the BFU 500 offers an optimal solution. This packer is equipped with servo-driven pitch adjustment and a servo-driven gripper, enabling reliable processing of a wide range of stacking configurations, including unstable part stacks, as well as complex part geometries. The system includes two servo-driven pushers that can be used flexibly. For high-performance requirements, a double-push mechanism is applied. For stack-critical parts, a counterholder ensures continuous support of the part stacks on both sides throughout the packing process. Tight packing schemes can be achieved through interleaving individual stacks or by forming A or B layers.

Both systems support the processing of complete carton layers, which accelerates the packing process and increases process stability. Depending on the configuration and application, up to nine carton layers per minute can be achieved.

100 percent ILLIG – from control to service
The new box packers are fully integrated into the ILLIG system environment. Drive technology, software, user interface, commissioning and service are all provided by the German technology company. Both the thermoforming system and the packer are operated via the digital “ILLIG EasyTouch” control panel, enabling convenient control of all functions across the entire line – a clear advantage compared to third-party systems. In addition, the systems can be easily connected to further automation solutions, such as loading and unloading systems, automated guided vehicles or warehouse logistics.

An RDM system with integrated BFU will be available for demonstration at the ILLIG Technology Center (ITC) from July 2026. Quotations for RDM systems are available immediately.

End-to-end solutions as a competitive advantage
With the new box packing solutions, ILLIG is further strengthening its position as a provider of integrated packaging systems. Customers benefit from clearly defined interfaces, consistent operating logic and a single point of contact throughout the entire lifecycle of the system.

“The market is increasingly demanding end-to-end, scalable process chains instead of standalone machines,” adds Gusenleitner. “With our new box packers, we deliver this continuity at the end of the line and enable our customers to achieve higher line efficiency.”

ILLIG will showcase the solutions at interpack 2026, which takes place from May 7 to 13 in Düsseldorf, Germany. Visitors are invited to experience the packer solutions at the company’s booth (Hall 6, Booth 6A60) and explore a wide range of additional innovations. ILLIG is happy to arrange individual meetings or interviews in advance – please feel free to get in touch to schedule an appointment.