New system for the production of natural fiber packaging

For the first time, ILLIG is offering packaging development, process expertise and modular production systems for sustainable and economical packaging made of dry natural fibers from a single source
High product variety: from yoghurt cups to fruit and meat trays, a wide range of design and shape variants are possible for food and non-food packaging
Presentation of machine concept and packaging samples with high drawing depth at Fachpack 2024 trade show in Nuremberg: Hall 1, Booth 258

Fiber-based packaging with a high drawing ratio - such as round cups and trays - can be produced economically and sustainably using ILLIG's patent-pending process. — Fiber-based packaging with a high drawing ratio – such as round cups and trays – can be produced economically and sustainably using ILLIG’s patent-pending process. © ILLIG

ILLIG packaging solutions GmbH is presenting sustainable packaging solutions made of dry natural fibers (dry fiber) for the first time at Fachpack 2024. The German technology company is expanding its product portfolio of thermoforming and packaging systems to include a new product segment and will be presenting a modular production system for manufacturing dry fiber packaging for the first time at the trade fair in Nuremberg. Customers will be able to see the innovative and modular production system with a higher output than other natural fiber processes (scalable from 20 to 120 million packages per year) for themselves at the Heilbronn site from the fourth quarter of 2024.

ILLIG consistently focuses on dry fiber as the base material. This semi-finished product is a nonwoven material made of natural fibers. In contrast to wet-formed fiber, it can be produced and processed with significantly lower energy and without the use of water.

Jürgen Lochner, CSO/CTO of ILLIG: ‘Dry fiber is a game-changing technology in the packaging industry. The fiber material can be used flexibly in the production of sustainable FMCG packaging. In addition to the production of food packaging with barrier properties, packaging solutions made of dry fiber can also be used in a variety of non-food applications. The raw material based on natural fibers is cost-efficient and also sustainable in terms of production and recycling. By choosing dry fiber, we are responding to current and future demands for sustainable packaging systems from consumers, markets and country-specific regulations.’

With a new machine technology into a sustainable future

The new ILLIG Dry fiber Molding Machine (DFM) is based on a modular construction kit, as customers already know from ILLIG systems. The system was developed for the production of fiber packaging (including trays, lids and cups) with barrier properties. The barrier can be applied using various methods in the manufacturing process: For example, inline lamination or upstream coating is possible in order to produce the necessary barrier properties depending on the application. It is also possible to use dry fiber in the non-food sector, where it offers more diverse design options for packaging shapes than solid cardboard solutions.

The unique feature of the ILLIG machine concept (patent pending) is the high drawing ratio compared to solutions already on the market. With the new dry fiber process developed by ILLIG, more varied and, most importantly, deeper shapes can be produced. ILLIG has been working very closely with manufacturers of machines for the production of nonwoven materials based on the airlaid process right from the start in order to optimize the manufacturing process. The process was also developed in close cooperation with technical institutes and experts in the field of fibers.

Better cost efficiency and more sustainability with dry fiber

In addition to the wide range of possible applications in the production of packaging, ILLIG’s patent-pending new development focuses on high energy efficiency and a low CO₂ footprint during production. Dry fiber packaging is produced without the use of process water and the necessary infrastructure. Compared to other manufacturing processes such as wet fiber/pulp, packaging solutions made from dry fiber can be produced more sustainably and economically.

Frédéric Engel, Product Manager Dry Fiber: “From numerous discussions with customers, we identified the market’s need for a technology to produce fiber packaging with a high output rate. The requirements for a wide variety of shapes and specific properties for food and non-food applications were the focus of our development right from the start. With the new ILLIG Dry Fiber Systems, we now offer an alternative to existing solutions that offers significant advantages in terms of production costs, output and drawing ratio.”

The technology company based in Heilbronn (Germany), which operates under the new company name ILLIG packaging solutions GmbH since August 1, is convinced of the advantages of the new game-changing technology: In packaging production, dry fiber brings noticeable advantages in terms of production costs, speed (cycle time) and has significantly better consumption values.

Presentation of dry fiber packaging solutions at Fachpack 2024

At the Fachpack trade fair in Nuremberg from September 24 – 26, ILLIG will be presenting dry fiber packaging solutions in various shapes for the first time. Visitors can find out more about the modular machine concept of ILLIG Dry fiber Systems in personal discussions. The lamination of fiber packaging on the XLU laminating and labelling system will be demonstrated in hourly production runs at the ILLIG booth in Hall 1, 258. In addition, ILLIG will be presenting its entire machine and service portfolio in the field of packaging, from blister packaging systems for cardboard applications to high-performance thermoforming systems.

About ILLIG

ILLIG is a leading global supplier of thermoforming and packaging systems for the production of sustainable and recyclable plastic and cardboard packaging. The company’s services include the development, design, assembly and commissioning of complex production lines and tools, as well as brand-specific retrofit solutions. Packaging development is at the heart of the business: the company works with customers to develop resource-efficient and sustainable solutions and supports packaging converters in design and production. For more than 75 years, customers have valued the technology company as a reliable and globally active partner. ILLIG stands for innovative technology, top quality and comprehensive global service.