I do have both and I can happily compare my EMR and my ILBE main pack.
I believe all Kifaru tactical packs (such as my EMR) are made from 1000 denier nylon. By comparison, the ILBE is made of lighter weight 720 denier nylon. The ILBE is also MARPAT, a pattern Kifaru tactical packs aren't available in (to my knowledge). They both have aluminum stays (though Kifaru allows you to replace aluminum stays with ultralight composite stays which I've done in my EMR) and I believe both packs stays are 24" in length. The EMR is one of Kifaru's largest packs and is therefore a much taller pack which can affect your center of gravity while carrying it.
Both packs have an interior divider for separating the internal compartment, however the ILBE main pack is top and side-loaded only, which affects the order you pack large things in. Conversely, the EMR can be packed from the top, bottom and sides. There are more internal pockets inside the EMR for storage and the lid itself (mine has the XTL lid) has MOLLE on the top and the bottom (the part facing the inside of the pack) where one can mount additional pockets for storage.
The EMR is designed to accept a hydration bladder inside the bag if you choose, the ILBE pack is not, but with 4 radio antenna ports you could rig up a hangar for an internal bladder and have a place to route the tube rather easily. However, the intended setup with the ILBE main pack is to use the ILBE issue hydration bladder and weave it into the MOLLE on the ILBE. This makes it easier to fill, doesn't take up any space inside your pack and in the case of leakage it won't get the contents of your pack wet.
The hip belt on the EMR is taller and more pliable than the hip belt on the ILBE, allowing it to conform to your body a little better. The hip belt on the ILBE is thicker and stiffer. The padding on the portion of the EMR that is against your back is much thicker and makes for a more comfortable experience under load. The shoulder straps on the EMR aren't as thick as those on the ILBE, but the material feels more dense and more pliable than that used in the ILBE, again allowing the shoulder straps to conform to your body. While the padding in the shoulder straps on the ILBE main pack is thicker, it's less dense and seems to deform more easily (and ultimately not provide as much cushioning).
The ILBE main pack comes with something roughly equivalent to what Kifaru sells separately as
the "Grab-it". Kifaru intends you to use it to hold onto something you want to be easily accessible on your pack. Presumably the same is true for the ILBE main pack but it also has an additional function here. On the ILBE main pack, it's used to attack the ILBE assault (i.e. 3-day) pack. The EMR, like all Kifaru tactical packs, has a myriad of attachment points for all kinds of additional things. This is in
addition to the rows of PALS on both packs for mounting MOLLE gear.
Weight is one reason I'm getting rid of the ILBE. I believe the ILBE weighs about 8lbs 13 ounces. With the ultralight stays installed, my EMR is about the exact same weight but with an additional 3000 cubic inches of space and a frame capable of hauling.
There are some really cool features found on the ILBE main pack that aren't found on the EMR. Such as the side sleeves and side pockets which allow you to carry everything from two Nalgene 1L bottles two two rifles (or shotguns). Also the zipper pulls on the ILBE are huge and there's no way anyone would have trouble opening the pack. The ILBE main pack also has side handles with the same handles from the zipper pulls on either side of the pack. The ILBE main pack also includes elastic loops to police all the straps. If you want to police the straps on a Kifaru pack, you either must buy a bunch of
ITW web dominators,use tape or supply your own elastic. Many people describe Kifaru packs as having spaghetti monster straps.
Both packs are relatively bombproof, but it's not exactly a fair comparison when comparing a pack from a company that still makes their packs one at a time in Colorado to packs that were manufactured by the thousands. I spent about $200 on my ILBE pack whereas I'm sure I've spent about $600 on my EMR in its current configuration.
-Jeff
ETA: I realized after writing all of the above that the EMR has 26" stays, not 24" stays.
Jeriah wrote:Jeff Nathan (jnathan) has a Kifaru EMR, I believe, and an ILBE that he is selling in Bartertown right now. You could ask him.