Extrusion International 3-2026

16 Extrusion International 3/2026 INDUSTRY NEWS New Packing Solutions for Thermoforming Systems ILLIG packaging solutions i sexpand- ing ist end-of-line automation protfo- lio with two new box lling units. The new systems enable fully automated cartoning of products directly down- stream of the thermoforming process. With the new BFU 300 and the high- performance variant BFU 500, the company now offers fully integrated box lling units (BFU) based entirely on ist own drive, software and control technology, replacing third-party sys- tems. The aim is to provide customers with more exible, high-performance and seamlessly integrated packaging solutions from a single source. The per- formance of the thermoforming sys- tems remains unaffected by the new packers – a key advantage compared to standard market solutions. Both packers are positioned in a stationary setup, eliminatin 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 cur- rently 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 thermo- forming through to cartoning,” says Christoph Gusenleitner, CEO of ILLIG. Our customers bene t from higher performance, greater exibility in packing patterns and a uni ed opera - tion and service environment.” Two versions for different requirements The new end-of-line solution is avail- able in two versions. The BFU 300 is de- signed for standardized applications with round, standard parts and con- ventional stacking con gurations. Car - ton layers are transferred directly from the cross conveyor into the packer and placed into the carton via a lifting sys- tem. Thanks to its reduced mechanical complexity and limited number of for- mat and changeover parts, this variant is particularly suitable for customers seeking a robust, cost-ef cient solu - tion 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 con gura - tions, including unstable part stacks, as well as complex part geometries. The system includes two servo-driven pushers that can be used exibly. For high-performance requirements, a double-push mechanism is applied. For stack-critical parts, a counterhold- er ensures continuous support of the part stacks on both sides throughout the packing process. Tight packing schemes can be achieved through in- terleaving individual stacks or by form- ing A or B layers. Both systems support the process- ing of complete carton layers, which accelerates the packing process and increases process stability. Depending on the con guration 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 inte- grated into the ILLIG system environ- ment. Drive technology, software, user interface, commissioning and service are all provided by the Ger- man technology company. Both the thermoforming system and the pack- er are operated via the digital “ILLIG EasyTouch” control panel, enabling convenient control of all functions across the entire line – a clear advan- tage compared to third-party systems. In addition, the systems can be easily connected to further automation so- lutions, 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 solu- tions, ILLIG is further strengthening its position as a provider of integrated packaging systems. Customers ben- e t from clearly de ned interfaces, consistent operating logic and a single point of contact throughout the en- tire lifecycle of the system. „The market is increasingly demand- ing end-to-end, scalable process chains instead of standalone machines,“ adds Gusenleitner. „With our newbox pack- ers, we deliver this continuity at the end oft he line and enable our custom- ers to achieve higher line ef ciency.“ ILLIG packaging solutions GmbH www.illig.com ILLIG Box Filling Unit (BFU) (Source: ILLIG)