Thermoforming and Tooling Systems
Since 1946, ILLIG has been at the vanguard of thermoforming technology. Our founder, Adolf Illig, literally wrote the book and built a company that became a global leader. With over 20,000 systems in operation around the world, ILLIG’s network serves a wide variety of industries and applications.
A commitment to quality has resulted in numerous breakthrough innovations including tilt-molding machines, integrated decoration technology (IML-T), intelligent software controls, and many more.
ILLIG thermoforming systems are categorized as follows:
- UA Series: sheet processing machines
- RV Series: vacuum forming machines
- RD Series: pressure-assist forming machines
- RDM Series: high-pressure, tilt-mold, trim-in-place machines
- RDK/P Series: high-pressure, steel-rule die machines
- STAL Series: high-speed horizontal trim presses
- Ancillary machines include pre-heaters, rim rollers, and granulators
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Illig’s packaging machinery is renowned for quality and longevity. With semi-automated, fully-automated, and customized systems, we have a solution for companies of all sizes. Our blister sealing machines are primarily used in CPG retail while our FFS machines are used in the most demanding dairy and food applications where the highest standards of hygiene are required. New demands for paper blisters and dust-free package designs have driven the development of the new HSU35b.
Illig packaging machines are categorized as follows:
- HSU 35b: 6- or 8-station rotary hot sealer for plastic or cardboard blisters, with options for automation
- HSA 50d: fully-automated inline forming & sealing system
- BSA 37: fully-automated inline blister sealing machines
- FS 37 & FS 48: high-speed automatic form, fill, seal systems for dairy and food markets
- FSL 48: high-speed, servo-driven, stainless steel aseptic machine with IML capabilities
Read about ILLIG’s new partnership with Boucherie Global for production and distribution of a new generation of packaging machines: Boucherie partnership
Designed for Recycling
NEW: Brilliant cardboard decoration with IML-T® Cardboard
ILLIG is leading the way once again by unveiling its innovative IML-T® Cardboard, a plastic-cardboard combination packaging, designed with recycling in mind. ILLIG engineers preserved what was good, fine-tuned the existing technology and added new improvements. This innovative application can be produced on ILLIG IML-T® machines. The advantage of the newly designed packaging, developed specifically for the new circular-economy market demands, is the reduction of plastic and simplified sorting for easy recycling.
The IML-T® Cardboard application can be produced on existing ILLIG thermoforming systems with an IML unit. That means packaging specialists that already own an ILLIG IML-T® machine line can produce the new packaging without having to first invest in a new machine. All that is needed is a tool set with the required packaging design. The IML unit, which is connected to the thermoforming machine, extracts the cardboard labels with the pre-printed decoration from the magazine and places them into the forming tool’s cavities before the forming process begins. The end product is a cup or tray with a fully new design concept.
IML-T® technology lets you use a different pre-printed label for each cavity, and changing production is quick and easy. Combined with the high productivity typical of ILLIG thermoforming systems, users are ensured production of resource-efficient and sustainable packaging.
Designed for recycling and sustainability
The leading specialist for thermoforming systems has once again been able to develop a solution to meet the latest market demand for a circular-economy solution in the shortest of time with its IML-T® Cardboard. Within the context of their Pactivity®, 360° custom-made packaging development, the experts at ILLIG from the packaging lab, R&D and tool and machine engineering departments were able to put their heads together to come up with this resource-efficient application and bring it to market. The key concept driving the development of this innovation was an ecodesign and a package that could easily be recycled. With this development, ILLIG stays true to its identity as an innovation leader in thermoforming.
Good for the environment, the contents and the consumer
The advantage of the IML-T® Cardboard packaging is its very thin-walled plastic interior (less material consumption) with an outer layer of cardboard, which increases the stability of the packaging and thus guarantees a high top-load strength. The pack can be sealed and the carton brilliantly decorated with marketing messages printed completely on one or both sides. Once the packaging has served its original purpose, the plastic can be easily separated from the cardboard by either the consumer or the collection center and the materials recycled. It eliminates the greatest hurdles to the circular economy by simplifying the sorting process for easy recycling. This in turn also promotes a positive brand image of the packaged product. In particular regional brands can improve their brand image with this sustainability concept.
The application is an absolute novelty, which will impact the market for decorated thermoformed packaging, especially in the premium products segment. IML-T® Cardboard is ideal for applications such as meat trays (MAP), vegetable trays, ice cream containers and frozen TV dinners, as well as packaging for delicatessen, dairy products, margarine, cream cheese, spreads, jams, jellies, cereals, pet food and non-food products. And even more applications making use of this new packaging solution can be expected in the future to spruce up the product at the PoS — to the benefit of the environment, the package contents and the consumer.
Flexible solution for an impressive design
Not only a feast for the eyes – but a good reason to buy! Because the visual appearance of a product has a huge impact on consumers when deciding to purchase a product. The more attractive the packaging design, the greater the chance the product is perceived positively by the consumer and therefore selected.
With the decoration technology of the In-Mold Labeling in Thermoforming, abbreviated to IML-T® , ILLIG offers a flexible solution for the realization of considerably more attractive decorations for cups and containers in different shapes and sizes.
With the ILLIG IML-T® system pre-printed, pre-punched labels or cardboard are inserted directly into the forming tool. Then the cup is formed into the cavity. Forming and decorating are thus effected in only one work step! Result: top appearance and quality from a single source.
Decisive advantages for you
- Protective layer.
- Design for Recycling.
- Reduction of plastic, as the stability is provided by the cardboard.
- Easy separation of cardboard and plastics.
- The decoration impresses with its excellent quality and high shine, which is achieved in the offset or gravure printing.
- The container base can be decorated. It is important the EAN code at the base is prominent.
- The label improves the side wall stability so that the output material thickness can be reduced.
- Efficient realization of particularly demanding decorations, e.g. real-like photo decorations.
- IML-T® makes possible the use of smaller font and thus more information on less packaging space.
- Simple change of the container décor during running production.
- Unique possibilities for cup design through optical singling-out of available relief.
- Shorter processing time compared to time-consuming post-printing.
- Cost benefit as opposed to other manufacturing processes as there is considerably higher output.
More Options in Label Design
Label materials or cardboard can be combined with cup materials without effort, e.g. PP labels on PP, PS labels on PS, paper labels on PS or APET. ILLIG IML-T® System Technology – for impressive appearance of your premium products on the shelves.
Photo-realistic IML-T® Decoration
It is important to present high-quality products appropriately in terms of optical effects. In this way consumers can recognize right away the content‘s special quality. The more concise and appetizing the decor, the greater the incentive to buy at the PoS. ILLIG IML-T® technology helps to achieve the brilliance required.
New perspectives for excellent packaging
Dairy products in attractive packs: brilliant decoration by thermoforming and multi-lane filling. The FSL 48 form, fill and seal line allows hygienic filling and packaging especially of dairy products, and also brilliant IML-T® decoration of thermoformed cups of different shapes.
From Packaging Ideas to your Tool and Production System
ILLIG has decades of experience designing and developing packaging solutions and helping packaging manufacturers. Each project is treated independently, as no two packages are ever exactly the same. Development begins with the customer’s initial idea and ends with an outstanding final product.
Packaging for fresh fruits and produce is a good example of how multifaceted a packaging container can be. It must ensure visibility of it contents while also protecting them. It must be suitable for transport throughout the entire logistics process. Our team of packaging experts develops different variants for ventilation (hole vents or closure knobs with spacing for clamshell trays) and package closure (hinged lids, separate lids, or no lids). Product, material choice, volumes, and decoration – with IML-T® – all have to be analyzed to determine the design possibilities. This is what we do.
Once the initial criteria have been successfully determined, an extensive testing phase begins with the production of samples. This is followed by product testing, and finally ends with the customer’s approval. By de-risking the project for our customers, only then can work begin on the production system.
360° Custom-made Packaging Development in Thermoforming
Application (formed part / requirements)
Support from experienced packaging consultants. Together, the properties (application profile) are defined, which serve as the foundation for creating a quotation for the packaging development.
Idea (briefing of the possibilities)
Analysis (all relevant options are explored)
Know-How (packaging developed with supply chain review)
Test phase (sample creation / sample tool)
Production system (final configuration of line)
Examples of ILLIG Packaging Development
ILLIG North America maintains a full inventory of spare parts for rapid delivery. Our Indianapolis facility is centrally located and close to a major FedEx hub. Our technical service team includes 3-US based technicians as well as full back-up from Germany for remote / VPN connections.
Parts maintained for the following machine groups:
- UA 100 / 150 / 200 / 225
- RDM 54 / 70 / 73 / 75 (all generations)
- RDK 54 / 80 / 90
- RDKP 72
- RV 74
- HSA 50
- BSA 37
If we don’t have it in stock, we can drop ship directly from Germany via FedEx, UPS, or DHL. Need us to keep certain parts on-hand for you? Get in touch and let us know.