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KHS journal
1° 2008
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Coopers Brewery, Australia:
Quality as a passion
Labeling Champions
Coca-Cola is it –
also in China
The Market Leader
Jinro brings soju, Korea’s national
drink, to the whole world
Under the Sign of the Toad
Subject: Adhesive-pressure Labels
Plastic / Refillables / Glass
Removal Strategy
/
english
editorial
TRADITION MEETS INNOVATION:
IN 2008, KHS WILL BE 140 YEARS YOUNG
Valentin Reisgen,
Chief Executive Officer of KHS AG
Dear Readers,
When a company is still going from strength to strength 140 years after it was established it is not just an anniversary – it is quite a
special occasion, because successful involvement in the world market – now and in future – by a company with such a long history is
no doubt exceptional: The KHS Group will be 140 years young this year.
I deliberately use the word ‘young’, because in all this time the company never had an opportunity to become old. The reasons are
threefold. From an early stage, KHS was characterized by pronounced curiosity for new things and a willingness to engage in new developments. Right from the start KHS focused only on customer orientation: What customers need, how can they
fulfill their promises in the market, how can our services offer them a competitive advantage, and how can we
influence the future in collaboration with our customers? After all, for 140 years the quality of our products and
services has had top priority at KHS.
And this is how it began. In 1868 the company set up in Dortmund by two visionaries, Carl Kappert and Louis
Holstein, was the first to supply breweries with bottling equipment for bottled beer, which had just been introduced. The quality and technology horizon of the company expanded rapidly, supported by wine merchant Theo
Seitz, who was based in Bad Kreuznach.
Seitz was concerned about the fact that even his best wines showed hazing, although this was perfectly normal
at that time. In this quest for high-quality workmanship, the innovator was determined to find a solution and developed a revolutionary filter that allowed crystal clear juice of the grape to be bottled. His innovation was enthusiastically received in China as early
as 1904 as a harbinger of globalization.
The success of the KHS Group, which continued to grow through acquisition of further highly specialized companies, is a tribute to the
work of these pioneers. Today, KHS is a leading global supplier of filling and packaging technology for the beverage, food, and nonfood sectors with more than 1,300 patents that ultimately offer exclusive, customized complete solutions based on the unique and profound know-how of its nearly 5,000 employees, some of whom have been working for the company for generations. KHS and its business associates are passionate about delivering top quality, maximum efficiency, and integrated solutions.
All this forms the basis for long-standing business relationships that often last for decades, some of which are described on the following pages from different perspectives. It underpins the exceptional reputation our company group has been enjoying since day one.
KHS is wherever the customer is. It is this combination of know-how, determination and skill that now (after an eventful past) forms
the foundation for the future success of the company.
We thank you for placing your trust in us and promise you that ten years from now – on the occasion of our 150th anniversary – KHS
will be just as young and agile, for the benefit of our customers.
Yours truly,
» For 140 years, the quality of our products and
services has had top priority at KHS.
«
contents ° 1°2008
04
Tradition meets Innovation 140 Years of KHS
people+markets
08
11
news
Customers, Know-how, and Contacts
10
dossier
16
The New KHS Shrink Tunnel Concept
Ecologically Super
dialog+opinion
20
Interview with Lars Wallentin
“Packaging as the main tool of the marketing mix”
20
task+solution
24
Coca-Cola is it – also in China
The Market Leader
28
China: Union Brewery Group explores new avenues
PET for Beijing
30
The unbelievable success story of the Chongqing Brewery Group
The Miracle of Yangtze
32
South Korea’s largest brewery group continues to rely on growth
Hite: Open for Something New
36
Jinro brings soju, Korea’s national drink, to the whole world
Under the Sign of the Toad
40
Coopers Brewery, Australia: Quality as a passion
Labeling Champions
44
The Lao Brewery is writing a very special story
A Complete Success
48
Herbsthäuser Brewery uses high-tech cleaning technology from KHS
Brewers with Heart and Soul
50
To global success with Christmas Market mulled wine
The Original
32
36
44
technology+innovation
52
Innovation: Vacuum CIP for tank farms
One System. 7 Advantages.
54
Custom-fit palletizer for entry and medium capacity range
Compact Power
57
Subject: Adhesive-pressure Labels / Plastic / Refillable / Glass
Removal Strategy
60
Chlorine dioxide disinfectant
The Cleaner Upper
56
guest at KHS
63
Welcome to Seoul!
63
02*03
EMPLOYEES Right Shipping the first sheet filter to China in
1904 was a milestone for the employees. Center Colleagues
in the office. Left Even 100 years ago, KHS relied heavily on
the quality assurance specialists in the laboratory.
FOUNDERS Top The revolutionary wine filtration system
developed by wine merchant Theo Seitz from Bad Kreuznach
triggered a success story. Right Visionaries Carl Kappert and
Louis Holstein from Dortmund were the first to supply breweries with automated beer bottling equipment. KHS emerged
from the Gründerjahre boom period of these pioneers.
Tradition meets Innovation ° 140 Years of KHS
KHS
140 YEARS
04*05
What is more appropriate and at the same time more forward-looking in an
anniversary year than acknowledging one’s history? We look back – with pride
and a bit of nostalgia – at the timeline of KHS, a company with a great tradition.
TECHNOLOGY Right Since day one, KHS has
been active in the food sector with perfect
milk filling equipment. Top Practice- and
customer-oriented exhibition booths have
been attracting thousands of visitors worldwide ever since. Left Filtration on its way
into the modern age … Bottom left … and the
early days of bottle inspection technology.
LOCATIONS Top The steadily growing production facility in Bad Kreuznach … Bottom …
and the prospering headquarters in Dortmund – both are still recognizable today.
Tradition meets Innovation ° 140 Years of KHS
GLOBAL TIMES Top KHS’ production facility in India, which
was established in 2007, supports networked markets and
rising quality standards in Asia. Left The virtually floating
globe symbolizes the present and future of KHS as a global
partner for its customers – with more than 100 production,
distribution, and service locations worldwide.
fi
INFOBOX
TRANSPARENCY Catalogs for customers: Even in the old days, KHS provided transparent
and comprehensible information for market participants and the public. Today, the
Internet provides an additional medium: A new KHS company video illustrates the development, positioning, and visions of the KHS Group. It is available for download from
www.khs.com (Publications / Image film). Welcome to KHS!
06*07
Left At the inauguration of the Technology Center: Dr. Ing. Johann Grabenweger, Chief Operations Officer, Bernd Oestermann, Manager of the
Dortmund plant, and Frank Schlageter, Service Engineer. Right Practical training on 1000 square meters: View of one of the five training rooms.
NEW KHS TECHNOLOGY CENTER IN DORTMUND
KNOW-HOW FOR THE BEST
In December 2007, the KHS Group opened
its second Technology Center specially aimed
at the needs of customers at the company’s
headquarters in Dortmund. This competence center focuses on washing, pasteurizing, and conveyor equipment as well as
labeling and inspection technology. In the
already existing Technology Center at KHS’
Bad Kreuznach site, the main emphasis is
on the fields of rinsing, filling, and capping
technology for bottles and cans, filtration,
beverage blending technology, high gravity brewing systems, and flash pasteurizing
and deaeration systems.
On an area of approximately 1000
square meters, the new facility complements
the range of existing training centers with
practical training on machines and the cut-
ting-edge communications systems. Taking
part in the strictly practice-oriented programs (www.khs.com) are customers from
the beverage, food and non-food sectors
around the world who wish to
* provide warm-up training for their staff
relating to complex solutions on KHS
machines for future installation
* avail themselves of individual advanced
courses for their specialists, or
* make use of the overview seminars given
by KHS experts.
All under the motto: Maximum information and specific skills ensure the best
possible machine and system efficiency with
the highest quality processing for every company. KHS keeps the size of the groups par-
ticularly small in order to provide the maximum benefit for each trainee. However,
the courses are not only aimed at technicians but also at responsible marketing staff
(for sales-related labeling equipment, for
example).
KHS technology centers also act as
a proving ground for carrying out series of
tests on customers’ new product ranges or
systems, to explore the interaction of various factors for instance, or conveying behavior, possible conveying performance, or
material stressing, for example. In addition to training courses at both specialized technology centers, KHS also provides
customer-oriented training opportunities
at all production locations in Germany,
Brazil, U.S.A., Mexico, India, and China.
people+markets ° news
08*09
KHS IN-HOUSE: MATERNUS GEMMEL TURNS 65 /
BURKHARD BECKER BOARD MEMBER SINCE JANUARY 1ST
NEWS FROM THE EXECUTIVE BOARD
KHS executive board member Maternus Gemmel turned 65 on November 25, 2007. The Supervisory Board and the Executive Board
thanked Maternus Gemmel for the extraordinary, exemplary personal commitment to his company. Gemmel joined the group as a
trainee 47 years ago and later took on management tasks before
becoming a member of the executive board, a position he held in
equal esteem by staff and customers alike. Maternus Gemmel will
continue to be a trusted contact for KHS customers until the end
of 2008 and will ensure a smooth handover of his previous area of
responsibility.
Also offering his congratulations at the birthday celebrations was
Burkhard Becker (photo left), a new member of the KHS board since
January 1, 2008, who is in charge of the areas of finance, accounting, financial controlling, IT, and human resources (personnel director). Becker was recently in charge of similar financial areas as a
director of ThyssenKrupp VDM GmbH.
Maternus Gemmel, KHS CSO (right), thanks Burkhard Becker, new KHS
Finance / Human Resources Director.
KHS PRESENTED MAJOR AWARD IN POLAND
EUROPEAN BEER STAR AWARD 2007
GERMANY IN THE LEAD
The profession has conferred the European Beer Star Award in gold,
silver, and bronze in 40 different beer categories for the fourth
time at Brau Beviale 2007. More than half of the prizewinners come
from Germany. The visitors to the exhibition also voted for their
favorite beers from all the gold medal winners. The victors received
the public award. The coveted Consumers’ Favorite gold award went
to the Erlangen-based Kitzmann Brewery’s Weissbierbock. The
Brauerei Nachod a.s. from the Czech Republic achieved silver with
its Primator Premium Dark beer. The Private Weissbierbrauerei G.
Schneider was awarded bronze for its Aventinus white bock beer.
“THE BEST PRODUCT FOR THE
BREWING INDUSTRY”
KHS was awarded the coveted Polish industry prize ‘The
best product for the brewing industry 2007’ for its
100,000-cph Innofill DVD 184 volumetric can filler. The
award was presented at the annual conference of the
brewing industry with more than 380 participants –
including all the main breweries in the country – in
the fall of last year. KHS representative Jarek Gajda
briefed those attending by giving a talk on hygienic
beer canning with the Innofill DVD filler.
The first system of its kind in Poland is running at the
old-established Royal Tyskie Brewery, a production facility of SABMiller’s subsidiary Kompania Piwowarska. It
is contributing to increasing the capacity from currently
5.5 million to 11 million hectoliters.
NATIONAL FOODS GOES TO KIRIN
JAPAN MEETS AUSTRALIA
Kirin Holdings, Japan’s largest brewery concern, is taking over the Australian food company National Foods,
a subsidiary of the Filipino food company San Miguel.
National Foods is Australia’s biggest producer of milk,
yoghurt, and juice products and has a workforce of
around 3500 employees.
TREND RESEARCH
BEVERAGES ARE LIFESTYLE
Trend researcher
Matthias Horx: “Beverages
are lifestyle – not thirst
quenchers.”
In the latest issue of his Future Newsletter, the
German trend researcher, Matthias Horx, presents new marketing methods for the beverage
business. The core statement: “Beverages are
lifestyle – not thirst quenchers.”
Health and enjoyment, luxury and sustainability – all are no longer contradictions when it
comes to beverages. Someone who enjoys a
smoothie from Innocent Drinks, for example, is
not demonstrating that he is too lazy to peel a
piece of fruit, but that he has zeitgeist, humor
and a healthy style. Among other things, Horx
says it is important ‘to pick up customers on the
way’. Consumers’ expectations of takeout beverages have changed. In the future, enjoyment
and mobility will be one and the same. A close
eye should be kept upon the target group of
women in particular. ‘Women want refined quality products.’ Nuvo, a sparkling wine with refined
vodka, is an example of how things may develop.
The refined mixed drink is sold in a small perfume-like bottle bearing a typical cosmetic-style
inscription: L’Esprit de Paris – For Her.
SALZGITTER AG ACQUIRES SIG BEVERAGES
KHS GROUP PORTFOLIO COMPLETED
Salzgitter AG, with around 86 percent the majority shareholder in
the KHS parent company Klöckner-Werke AG, has acquired SIG Beverages (sales approx. € 150 million) from the Swiss SIG Group.
Included in this purchase are, in particular, SIG Corpoplast GmbH
& Co. KG, a PET pioneer in Germany, and the aseptic specialist SIG
Asbofill GmbH. With this acquisition, Salzgitter AG is strengthening its new ‘Technology’ business sector, as was already indicated
when the company took over the majority interest in Klöckner in
2007.
For Klöckner-Werke AG, and in particular its 100-percent subsidiary
KHS AG, this means a significant improvement in the product range,
as from now on KHS will be able to close the existing gap in the
PET blow-molding technology segment.
In this area, KHS has previously obtained the appropriate equipment from specialist companies. Valentin Reisgen, CEO of KHS
AG: “I consider our product range essentially complete in this regard,
particularly as a result of the Corpoplast blow molding machines.”
KHS Executive Managers: Guests from KHS India prior to a worldwide
management meeting.
TEN-YEAR-OLD KHS PLANT IN INDIA
ANNIVERSARY IN BOOM COUNTRY
KHS’ plant in India celebrated its ten-year existence in November
2007. KHS recognized globalization and the boom potential of
the continent in good time, and has been operating its own local
production facility there since the mid-1990s. This was not without success. In February last year, the new manufacturing facility
with an area of around 110,000 square meters was inaugurated in
Ahmedabad. Like all KHS plants around the world, the production
facility in India works according to two maxims: First, Consistent
quality management and second, everything revolves around the
customer. Although guests and employees of KHS India and their
associates celebrated the big day with a small piece of tradition,
it was mainly with the aspiration of continuing to be active in the
market as a reliable partner to its customers.
people+markets ° news
10*11
KHS AROUND THE WORLD
CUSTOMERS, KNOW-HOW, AND CONTACTS
KHS has been represented in world markets by its engineering and the proficiency of its employees
for 140 years. The company stands for absolute customer-orientation, problem-solving competence
of its high-tech experts, and the know-how of a consulting staff that contributes expertise on
economic issues. The KHS team demonstrates this worldwide day after day.
KRAFT FOODS, AVON, NY
KHS SYNONYMOUS WITH SPEED AND RELIABILITY
KHS USA has supplied two Innopack F2000 horizontal cartoners to Kraft Foods,
Avon, New York, for the packaging of trays with ready-to-serve meals. Each
machine processes 240 trays per minute. The company is also being provided
with a stand-alone backing card conveyor, which inserts up to 240 product
information cards per minute, as well as another backing card conveyor mounted
on the machine that feeds 160 backing cards per minute.
Background: KHS is carrying out
improvements to help increase productivity in an effort to assist Kraft
in coping with the increasing output. Kraft Foods is now achieving an outstanding overall equipment effectiveness (OEE) of more than 85 percent. The cartoner – the fastest – uses
infeed worms in order to achieve gentle, reliable product transfer. The standalone backing card conveyor also works with infeed worms for product transfer and reliable placement of backing cards. Kraft employees suggested using
a stand-alone backing card conveyor on the second line in order avoid downtime and increase productivity.
VIETTI FOODS, U.S.A.
SPEED: UP BY 150 PERCENT
Vietti Foods, U.S.A., has taken delivery from KHS of an Innopack Kisters TP50
tray packer, an Innopack T-100 tray turner and an Innopack 601-T tray wrapper,
as well as the system integration for processing chili and fish products
in cans. The machines, built by KHS USA in Sarasota, Florida, replace the
company’s more than 30-year-old equipment. KHS has provided service and
support – including intensive training of the Vietti staff. The result is a 150
percent increase in line speed (now 50 cartons per minute instead of 19 to
21) and considerably reduced changeover time while requiring fewer personnel and offering a higher standard of safety.
LINK SNACKS, INC., ALPENA, SOUTH DAKOTA
POUCHES? ONLY FROM KHS.
Ten Innopouch RPM and two Innopouch IM have been
supplied to Link Snacks, Inc., (LSI) in Alpena, South
Dakota. KHS is the sole supplier of pouching machines
to LSI. The company uses the machines to form different pouch sizes, the larger pouches being resealable by
means of press-to-close seals. LSI packages snacks in
different flavors, shapes, and sizes – from beef jerky
and turkey jerky to beef nuggets and sausage bits. Capacity: nearly 50,000 pph – an impressive 50,000 pounds
of product in 60 minutes. LSI chose to work with KHS
because of the outstanding reputation of its Innopack
products. The solutions have improved the profitability of LSI by maximizing production speed. The company has doubled its market share in a very short time.
In the meantime, KHS has received several orders
for Innopouch IM machines for LSI’s plant in Minog,
Wisconsin.
ASAHI BREWERY / KIRIN BREWERY /
SAPPORO CHIBA / SAPPORO NASU
LATEST KEG TECHNOLOGY
FOR JAPAN
KHS keg technology has always been in demand in Japanese breweries. Several leading breweries in the Land of the Rising Sun
have now confirmed their confidence in KHS and placed orders with
the company for the latest newly developed lines.
Market leader Asahi Brewery is taking delivery of a new
Innokeg Till CONTIKEG line. The main components are an Innokeg
Till CONTIKEG HR 32/32 main washer (1,155 kegs per hour) and
the new type 20/20 racker (1,100 5-, 10-, or 19-liter kegs, or 880
30-liter kegs per hour). In this Innokeg Till CONTIKEG design, the
cleaning and filling heads, product piping and the direct drive of
the starwheels with aseptic motors have been redesigned. The line
automatically separates all sizes of keg. The washer-racker is
equipped with automatic CIP caps.
Kirin Brewery, also one of the leading breweries in Japan,
has ordered the latest version of the Innokeg Till CONTIKEG (26th
Innokeg Till CONTIKEG machine to be installed at Kirin). The output of the main washer is 1,310 kegs per hour, while the filler
processes 1,250 7-, 19-, and 20-liter kegs per hour. The system,
with the same new features as the Asahi line, can be expanded to
1,400 kegs per hour.
Sapporo Chiba has also ordered this KHS high-tech process
for its new 10- and 20-liter Innokeg Till CONTIKEG line. The most
important figures: The newly developed Innokeg Till CONTIKEG AK
7-2 external washer, the first AK in this design to be delivered to
Japan, processes 1,600 kegs per hour, the Innokeg Till CONTIKEG
VR 20/18 pre-washer 1,570 kegs, the Innokeg Till CONTIKEG HR
32/32 main washer 1,530 kegs, and the Innokeg Till CONTIKEG F
24/24 processes 1,460 kegs per hour.
Finally, Sapporo Nasu will soon be putting a KHS Innokeg
Till TRANSOMAT 5/1 Mono into operation for 10- and 20-liter kegs.
SAIGON HANOI BEER, VIETNAM
COMPLETE FILLING LINE
KHS is supplying the Saigon Hanoi Beer Joint Stock Company
(Sahabeco) in Hanoi, Vietnam with a complete filling line for 18,000
cans of beer per hour (330 milliliter) with can depalletizer, rope
can conveyor and can rinser for fresh water, Innofill DVD volumetric can filler with Ferrum seamer, fill level and lid monitoring,
Innopas PI SC can pasteurizer, can coder, Innopack CA carton
unfolder, Innopack SP can palletizer with vacuum gripper for aluminum cans, Innopack CV carton sealer and Innopal palletizer
with matching pallet conveyors. The brewery outputs one million
hectoliters per year.
PEPSI-COLA / SMLC, LEBANON
48,000-CPH CAN FILLER
Following a target-oriented decision process, the licensed Lebanese
bottler of Pepsi-Cola, Société Moderne Libanaise pour le Commerce (SMLC), Beirut, has placed an order with KHS for a 48,000cph Innofill DVD 76 volumetric can filler (330 milliliters) for its
Pepsi-Cola CSD product range (including Pepsi-Cola and 7up). The
line processes soft drinks at 18° Celsius as well and non-carbonated juice drinks at 85° Celsius. In addition to the filler, this
project includes a blocked Ferrum seamer, a KHS Paramix Innopro
CMX, and a KHS Innopro HF juice heater. The filler is capable of
filling slim-cans (250 and 150 ml) as well as the classical 330-ml
soft drink cans.
INBEV GERMANY /
BRAUEREI BECK & CO., BREMEN
PERFECT PACKER
KHS is supplying an Innopack PPZ crater to Brauerei Beck & Co. in
Bremen for packing six-packs in pin-partition crates with a capacity of 325 cycles per hour. The high capacity is achieved with a
four-lane six-pack feed conveyor and robot technology, which additionally enables the six-packs to be positioned reliably and accurately. The robot axes are freely programmable.
people+markets ° news
12*13
PFUNGSTÄDTER BRAUEREI / HILDEBRAND, PFUNGSTADT
COMPACT KEG
The Pfungstädter Brauerei (Hildebrand GmbH & Co. KG) on the outskirts of Frankfurt is taking delivery of a complete, extremely
compact KHS Innokeg Till TRANSOMAT 5/1 Duo with a capacity of
180 kegs per hour (50-, 30-, and 10-liter kegs). The main components include a KHS Innokeg Till AK 1 exterior washer, a KHS Innokeg
Till TRANSOMAT 5-1 with DFC filling technology and KHS Innopal
articulated robot palletizing equipment. The main highlights of
the innovative solutions are as follows: One robot undertakes the
complete keg handling and therefore reduces investment costs.
The patented KHS DFC filling technology ensures maximum filling
performance and highest filling accuracy. In this case, KHS, as the
supplier of the previous system, also received an order to supply
the palletizing equipment in Pfungstadt. The successful private
brewery outputs approximately 350,000 hectoliters of its wide variety of products per year.
REFRESCOS BANDEIRANTES, BRAZIL
EVERYTHING FOR SOFT DRINKS
Refrescos Bandeirantes S.A., Coca-Cola producer in Trindade / Goiás
in central Brazil, is combining high-tech with the latest design and
has ordered a complete soft drink line for the GO Miscellaneous
plant (output: 24,000 2.0-liter bottles per hour) including air
conveyors, bottle, crate and pallet conveyors, Innoclean FR-EM
rinser, Innofill DRV-VF filler with 128 filling valves, Innopack Kisters
SP 060 shrink packer, Innopal PB palletizer, Innopro CMX 52 Paramix
system, and Innopal MPH pallet magazine. The company has also
ordered an Innofill DVD 50 filler (volume filling / tubular ring bowl)
and an Innopro CMX 15 for the canning line.
GRUPO ARCA, MEXICO
EMPHASIS ON QUALITY
Grupo Arca, with its headquarters in Monterrey, is the second
largest Coca-Cola group in Mexico and one of the fastest-growing businesses in the country. The management is therefore concentrating on continuously optimizing the quality of its plants
located mainly in the northeast. General improvements for different stages of the process equipment are currently being carried out at ten factories, in particular new blenders, in-line carbonation, and the CIP system. In detail, the group has placed
orders with KHS Inc. USA for seven new Promix blending systems for up to 75,000 gallons per hour (gph) and four in-line
carbonation systems for up to 15,000 gph. Grupo Arca will also
be taking delivery of four cleaning-in-place systems (CIP) for
optimum sanitizing of the filler.
DISTELL, SOUTH AFRICA
KHS CHOSEN AGAIN
Distell Limited in Stellenbosch, South Africa has once again chosen its proven partner KHS for its investment in a new filler and
CIP system for the Wadeville / Johannesburg plant. The investment involves an Innofill MFUP mechanical vacuum filler for 15,000
0.75-liter bottles per hour. Distell uses the system to process all
spirits such as vodka and whisky and Amarula, a cream liqueur made
from the marula fruit. The particularly flavor-preserving filling
process opens the return gas tubes only during the filling process.
The line is equipped with adjustable format parts because of the
large variety of bottles to be processed.
CASTEL, WEST AFRICA
MULTIREGIONAL
For the fifth time this year and in three countries at the same
time, the renowned West African Castel Group has chosen quality
from KHS. Two identical Innofill DMG fillers are destined for delivery to Port Gentil, Gabun and Cotonou, Benin (an Innofill DMG
99/15 KK for 30,000 0.65- and 37,000 0.33-liter bottles per hour
in each case). The Bafoussam plant in Cameroon has ordered an
Innoclean DMT bottle washing machine for 36,000 0.65- and 42,000
0.33-liter bottles per hour.
KELTEREI MÜLLER, BUTZBACH
MULTIFUNCTIONAL
A complete Innofill DNRF bottling and capping machine, which
optionally bottles non-carbonated products without pressure and
carbonated products under pressure, is destined for the Wetterau
district of Hesse, or more accurately to Kelterei Müller in ButzbachOstheim. The system is equipped with an 8-station roll-on capper
and an 8-station crowner. Nominal capacity: up to 10,000 bottles
per hour (contents 1.0 liter). Special feature: The line is equipped
with multifunction format parts (scissor system) that noticeably
shorten the time required to set up for production.
HEIL- UND MINERALQUELLEN GERMETE, WARBURG
KHS FOR THE FIFTH TIME
DE-VAU-GE GESUNDKOSTWERK, LÜNEBURG
BOOMING NATURAL FOOD MARKET
DE-VAU-GE Gesundkostwerk GmbH, a traditional and leading manufacturer of top-quality health products, intends to approach the
growing natural food market even more flexibly. The main plant
in Lüneburg has decided in favor of an Innoket ROLAND 16/4 VD
rotary labeling machine for the first time. With this machine, the
company will in the future also be able to label contour containers and dress them with front and back labels. The labeling machine
is equipped with VarioDrive servo-motor-driven lower chucks and
can process both neck ring and tamper-evident labels, and can be
retrofitted at a later stage with adhesive-pressure labeling stations
and an optical container alignment system with camera. DE-VAU-GE
is once again placing its trust in proven labeling equipment from
KHS: Several linear labeling machines are already in operation in
Lüneburg, and four KHS rotary machines are in operation in honey
lines at the Hünfeld plant.
NIEDERRHEIN GOLD / TERSTEEGEN, MOERS-KAPELLEN
INNOVATIVE FILTER
In close cooperation with Niederrhein-Gold Tersteegen GmbH & Co.
KG in Moers-Kapellen, KHS has developed new precoat filtration
technology using a test filter. Niederrhein-Gold is taking delivery
of an Innopro filtration system with GETRA ECO candle filters;
CORVUS trap filters; diatomaceous earth sedimentation tank, and
a CIP system including turbidity and Brix measurement.
Heil- und Mineralquellen Germete GmbH in Warburg / Germete, a
customer of many years, is now taking delivery of its fifth system
from KHS. The line this time is a 20,000-bph non-refillable PET line
for various bottle types equipped with a volumetric filler (servo
screw capper) as well as a KHS Kisters packaging area and KHS
Innopal palletizing equipment. It is the third non-refillable PET
line to be installed in the last seven years. As a reliable supplier
to the trade, the company is among the top 30 bottlers of nonalcoholic beverages and water in Germany, and accordingly places
great importance on innovative technology and high quality – in
line with the demanding requirements.
COMPANHIA DE BEBIDAS IPIRANGA, BRAZIL
ALL-ROUNDER FOR PET, GLASS,
AND ALUMINUM
Coca-Cola producer Companhia de Bebidas Ipiranga
S.A. in Ribeirão Preto, São Paulo in southeastern
Brazil distributes the more than 100 Coca-Cola products it produces to over 300 towns. The company,
which previously obtained all lines from KHS, has
now ordered an all-rounder for processing PET, glass,
and aluminum containers. Capacity: 11,000 2.0liter bottles per hour. Components: Air conveyor,
bottle, crate and pallet conveyors, Innoclean DTM
bottle washing machine, electronically controlled
Innofill DRS-VF filling system, Innopack Kisters SP
060 shrink packer, Innopal PB palletizer, Innopro
CMX 25, Innopal RS3 depalletizer and palletizer
for crates, Innopal PB palletizing system, Innopack
PPZ crater and decrater, and Innopal MPH pallet
magazine.
people+markets ° news
BRANDENBURGER URSTROMQUELLE, BARUTH
CERVECERIA POLAR, VENEZUELA
LEADING-EDGE BOTTLING
EQUIPMENT
FULLY HIGH-TECH
To reduce as far as possible or even completely eliminate
the use of preservatives without having to invest in costintensive aseptic or UCF technology and at the same time
reduce operating and maintenance costs as well as ensure
that new lightweight bottles and weight-reduced caps can
be processed – this was the demanding task set for KHS
by Brandenburger Urstromquelle GmbH & Co. KG in Baruth.
The solution: A 120-station Innofill DRV PET filler and a
servo screw capper contained in a patented KHS clean
room. The filler is designed for 45,360 0.5-liter bottles
per hour. The company bottles carbonated and non-carbonated mineral waters as well as soft drinks and spritzers for all major discounters on the German market. The
line replaces an existing KHS filler. The customer was
compelled by the new generation of KHS PET fillers without lift units, the hygienic design of the machine with the
KHS servo screw capper, and the special KHS clean room
concept.
HANOI BEER ALCOHOL BEVERAGE, VIETNAM
TURNKEY TIMES TWO
The Vietnamese beer market continues to grow. KHS will
soon be supplying two turnkey lines to HABECO, Hanoi
Beer Alcohol Beverage Joint Stock Company – an additional 30,000-cph canning line and a 20,000-bph non-refillable glass bottle line. Once again, it is the finest KHS
equipment soon to be installed in this expanding company – from the volumetric filling of 330-milliliter cans
to robot-controlled palletizing. The main modules in the
non-refillable glass bottle line for 450- and 330-milliliter bottles are the Innofill DPG filling system for the lowoxygen bottling of beer, and the new stainless steel KHS
Innoclean SEC bottle washing machine equipped with servo
technology.
The innovative SEC technology for the medium capacity
range (see page 48) can already be found in the modern
bottling lines that KHS has supplied to Ha Noi Hai Phong
and Saigon Baclieú (KHS journal 2/07). All customers
were impressed with the advantages of the SEC machine
including its compact design, the latest drive technology,
maximum energy efficiency with minimum consumption
of fresh water and new-style Drive-Jet sprays, and the use
of the KHS patented energy-saving bottle carrier.
14*15
KHS is delivering a complete high-tech and high-performance bottling line for malt beer in PET bottles (15,428 1.5-liter bottles per
hour) to Cervecería Polar in Los Cortijos Caracas, Venezuela. The main
line components include an air conveyor, bottle, crate and pallet conveyor, Innoclean ZR PET rinser, Innopro CIP system, Innofill DRV filler, Innopack Kisters SP 060 V shrink packer, Innopal RS3 palletizer
with layer centering, Innopal MPH pallet magazine, and Innopro KZE
flash pasteurizer. Cervecería Polar C. A. produces beer and malt beverages in four factories (Caracas, San Joaquin, Maracaibo, and Barcelona). The annual production is 23 million hectoliters.
FLENSBURGER BRAUEREI
FLENS FROM THE PETKEG® BY KHS
Flensburger Brauerei is the first company to use the PETKeg® system presented by KHS at Brau Beviale 2007 for
its good Flens, and is thus pointing the
way to a new dimension in keg filling
and marketing. KHS will be delivering
the automatic KHS Innokeg Till PF
racker in March 2008 (60 containers
per hour). As in all KHS keg systems,
the patented and proven DFC filling
process guarantees the best filling
results and quality. The PETKeg® is a
convenient 20-liter non-refillable packaging that can be connected to existing
tapping systems. It offers a real alternative to the stainless steel keg currently used worldwide. KHS developed
the plastic fittings and the PET preforms
are supplied by KHS’ affiliate REXAM.
REFRIGE, PORTUGAL
FILLER FOR COCA-COLA
Refrige S.A. in Palmela, Portugal, since 1977 the country’s
only bottler of Coca-Cola, has once again opted for KHS
technology. The company has ordered an Innofill DVD volumetric can filler with a capacity of 48,000 cans per hour.
Included in the scope of delivery is an Innopal ASH depalletizer, Innopack Kisters TSP 60 tray shrink packer, conveyors and an Innopro CMX Paramix system.
2
10 HIGHLIGHTS
ECO SHRINK TUNNEL
Reduced energy costs
Less CO2
Optimum technology
Best product handling
Thinnest film processing
Rapid readiness for use
Trouble-free changeover
Familiar handling
No additional energy costs
Not dependent on electricity
dossier °
16*17
Ecologically
SUPER
The new KHS shrink tunnel concept: Cut energy costs by 50 percent and decrease the environmental burden as well
Shrink tunnel packaging continues to gain ground worldwide.
Shrinking with traditional electrically driven shrink tunnels, however, results in
high energy costs. Now there’s an alternative worth trying: the eco-gas
shrink tunnel with all its advantages over classical electrical models.
Check what will fit your company best.
From New York to Rio and Tokyo, from
Spitzbergen to Cape Town: The shooting
star of the beverage, food, and non-food
industries in packaging, thanks to its many
advantages, is shrink film. The shrinking
of products has always been done reliably
in the classical shrink tunnel with electrical heat. But in some regions in the world,
this entails comparatively high costs, and
can also create problems if the electrical
power supply is unreliable.
KHS engineers don’t rest until they
find a solution to situations of this kind.
There had to be an alternative so that every
customer can deal with any problems that
might occur. So, voilà, here is the latest
KHS development in the shrink packer sector: a shrink tunnel model heated with gas.
This so-called eco-shrink tunnel has a whole
series of valuable advantages, which can
be added to the already existing plus points
of the classical KHS shrink tunnel. The
following overview should show why.
ADVANTAGE NO. 1: SAVE MORE THAN
50 PERCENT IN ENERGY COSTS
The new eco-shrink tunnel concept works
with gas instead of electricity. That allows
energy cost savings of more than 50 percent. Naturally, this percentage is a rough
rule of thumb, since energy costs vary from
country to country. The savings potential
is greater the higher the cost of electricity
versus the cost of gas at a given location.
The added costs generally amortize quickly
– especially for increasing energy prices.
An exact calculation of the amortization
period considering all the individual conditions, such as energy prices, power, and
average operating period of the shrink
packer, can gladly be provided by KHS
experts for any interested company.
ADVANTAGE NO. 2: UP TO
60 PERCENT LESS CO2
Something ever more important for companies in the context of ongoing economicecologic management, which customers,
business associates, and employees are
watching more and more closely: The CO2
emissions are reduced by up to 60 percent. The background for this environmental relief: Gas is converted directly into heat.
For electrical heaters, the generation of
electricity – due to multiple conversions
of the energy – there is always a significantly higher rate of CO2 emissions.
ADVANTAGE NO. 3: TECHNICAL
OPTIMIZATION
*
*
*
*
No air intake or outlet ducts – the
patented porous combustion technology means no chimney is necessary.
Only a gas connection is needed for
operation.
No classical combustion chamber. The
gas heater works with patented porous
combustion technology so there is no
open flame.
Compact machine design. The high
power density of the porous burner provides 3,000 kW/m2.
No soot. Porous combustion is so complete that is yields only hot gas and
radiant heat.
ADVANTAGE NO. 4: EVEN BETTER
PRODUCT HANDLING
The porous burner unit allows more exact
temperature settings than ever before, thus
more uniform temperature distribution on
2
the product. The result: visibly gentle product handling.
ADVANTAGE NO. 5: THINNEST FILM
MATERIAL USABLE
Due to cost pressure, companies want to
work with the thinnest materials possible
for their film multipacks. Gas heaters let
you use extremely thin films for the best in
product safety. The general rule, the thinner the film material used, the more important precise temperature distribution and
regulation in the shrink tunnel becomes
(see also Focus on Film).
ADVANTAGE NO. 6: FASTER READINESS
Heating with a gas burner is nearly twice
as fast as with electric heat. Besides the
remarkable energy savings, that means
increased line availability.
ADVANTAGE NO. 7: PROBLEM-FREE
CHANGEOVER
Companies already using KHS shrink packaging technology with electric heat who
want to profit from the extensive advantages of gas heat can easily switch to the
KHS SERVICE: FOCUS ON FILM
Shrink packing is especially good when the temperature is exactly suited to both the packaging and the quality of the film. That’s why KHS offers its customers around the world
individual consulting on film material:
* Film specifications are worked out for each task definition.
* Maximum reliability in production operation is provided even before delivery with KHS
testing of how the desired packaging formations, film quality, and hot air jet techniques
work together.
* KHS experts check which individual film multipacks are the most attractive and how products can be handled as gently as possible.
* Sophisticated KHS technology simulates and ensures millimeter-precision positioning of
the film material.
new eco-shrink tunnel. For newer shrink
packers, the conversion can even be completed in about a day, although for older
models it may take a little longer.
ADVANTAGE NO. 8: OPERATION
AS USUAL
For shrink packer operators, the switch to
gas operation doesn’t mean a thing. The
configuration of the machine is done in the
same way, and even the remaining handling
of the shrink tunnel is still the same.
ADVANTAGE NO. 9: NO ADDITIONAL
ENERGY INVESTMENT
In many cases, the energy savings aren’t
even the deciding point. Especially when
a new electrically driven shrink tunnel would
require greater additional investment.
Example: the plant’s existing power supply
wouldn’t be sufficient to run a shrink tunnel. Then the power company might charge
for higher connection power or additional
power lines required. With the use of the
eco-shrink tunnel, that’s no longer a problem. Or, the power company assigns power
quotas. When the quota is reached – at
least for a while – the power goes off. The
dossier ° The new KHS shrink tunnel concept
18*19
KHS eco-shrink tunnel:
Proven technology with a
new gas concept.
new eco-shrink tunnel takes the load off
the quota, allowing longer working hours.
ADVANTAGE NO. 10: NO DEPENDENCY
ON ELECTRICITY
In many countries around the world, continuous, reliable power supply can’t be taken
for granted. The less a company uses the
better. With gas, the company can manage
its affairs a lot more stably in case of doubt.
And the company can also install its own
gas tanks to remain independent from the
public supply grid.
WHETHER ELECTRICITY OR GAS,
CLASSICAL ADVANTAGES REMAIN
Variable hot-air jets in the shrink tunnel
housing can be set up precisely for any individual format, for either gas or electric.
Whether a single lane or two or even three
lanes are used, and regardless of whether
packages are small, large, tall, or short, the
jets always bring the hot air right to the
place it’s needed for optimum shrinking
results.
If the company switches between
single and multiple lanes within the shrink
packer, the hot air jets no longer needed
can be parked and cut off from the hot air
supply. And that in turn means that hot air
only emerges where it should – for perfect
shrinking results. Undesired air turbulence
is eliminated.
All these positive aspects apply for
the low-capacity range of KHS shrink packers (from 30 packages per minute) or for
the high-performance range (up to 400
packages per minute). And of course, both
KHS shrink tunnel models can be installed
and removed modularly. Whether a cleaning system, additional cooling fans, or the
latest in camera technology – all are feasible. Because with KHS – from New York
to Rio and Tokyo, from Spitzbergen to Cape
Town, we provide maximum benefit for customers in the beverage, food, and non-food
industries.
Dirk Langanki, Manager, Electrical
Engineering & Design, Packaging Technology
Competence Center, KHS AG
Werner Oster, Manager, Product Support,
Packaging Technology Competence Center, KHS AG
Thomas Lelie, Packaging Technology
Competence Center, KHS AG
fi
INFOBOX
• WEBSITE www.khs.com
• CONTACT
Dirk Langanki, Manager, Electrical
Engineering & Design,Packaging Technology
Competence Center, KHS AG, Kleve
Tel: +49 (2821) 503-440
E-mail: [email protected]
Werner Oster, Manager, Product Support,
Packaging Technology Competence Center,
KHS AG, Kleve
Tel: +49 (2821) 503-152
E-mail: [email protected]
Thomas Lelie, Packaging Technology
Competence Center, KHS AG, Kleve
Tel: +49 (2821) 503-171
E-mail: [email protected]
“Packaging as the main tool
of the marketing mix”
Interview with Lars Wallentin
Lars Wallentin knows what he wants. This has always been the
case, says the man whose life is creativity. Wallentin: “At the age
of 15 I knew that I wanted to be a designer. I made a start right
away by throwing away all my record album covers and creating
my own.” At the age of 15, Lars Wallentin thus already had an
idea about his professional career – an idea that turned out to be
even more perfect in reality than he fancied. After comprehensive training at the Graphic Design College in Stockholm, Wallentin started his career as a typesetter, bookbinder, and offset
printer. Working his way up from the bottom benefited him enormously during his 40-year career at Nestlé. Wallentin rose through
the ranks to become manager of the packaging design section.
During his time at Nestlé, Wallentin was involved in around 80,000
packaging projects. Wallentin was literally a born teacher – his
father was in fact a teacher, his grandfather a priest. He became
a sought-after speaker for packaging design while he was at Nestlé
and continues to give presentations around the world to this very
day. There aren’t many cities Wallentin hasn’t visited and no culture he is not familiar with. Wallentin: “Exchange of information
is essential. I like passing on my know-how and in the process
gaining further knowledge that I pass on again. This is the only
way for know-how to turn into packaging design without being
static.” KHS journal talked to Lars Wallentin, the man who was
not only one of the packaging design pioneers, but who is also
shaping the future of packaging design with each of his presentations.
KHS JOURNAL: Mr. Wallentin, hardly anyone has as much experience with packaging design as you have. Do you feel that packaging design has continuously improved over recent years and
decades?
LARS WALLENTIN: Unfortunately not. There can be no doubt
that packaging materials have become better. However, in terms
of packing design and functionality there has been a decline in
my view. One of the reasons is no doubt that costs are the key
factor today. Professional designers often have too little scope
for expressing themselves, and their creativity is stifled. In addition, large companies tend to have a large personnel turnover.
Product managers keep changing and have different ideas. However, product design requires continuity – ideas have to be developed over time. A further reason for a certain regression is the
lack of genuine professionals in the packaging sector. A professional designer should have extensive know-how in the areas of
design and also communication.
°
You mentioned that product design requires continuity, and
that ideas have to be developed over time. Do you mean idea
defined by products?
dialog+opinion °
20*21
Lars Wallentin has been working as a packaging designer for Nestlé for 40 years and continues to be a sought-after speaker worldwide. In
addition to his mother tongue, the native Swede is fluent in English, French, and German. In his adopted country of Switzerland, Wallentin
lives in Vevey with direct view of Lake Geneva. His home offers an exceptionally beautiful panorama that further promotes the strong
creativity of the packaging design expert. Wallentin is holding two beverage containers that he regards as perfectly designed: a Disco
Edition of the Absolut Vodka bottle and a special Christmas Edition of Evian.
good marketing means having a good idea for a prede*finedYes,product
and supporting this idea continuously. The more
support an idea receives, the stronger the brand will develop. Packaging design and all other activities the brand involves must go
hand in hand. Packaging, advertising, and sales promotion can
– and is the key point – only form a harmonious orchestra if a
perfectly thought-out idea is apparent.
you give us an example of a perfectly thought-out idea?
° Could
I say one word and you’ll immediately know what I mean:
*Absolut. Absolut Vodka is the forth-largest premium liquor brand
worldwide and available in 126 countries. Wherever you go in the
world, just say Absolut and everyone knows you mean Absolut Vodka.
The word Absolute indicates premium quality. An additional idea
is ‘vodka as medicine’. For this reason, the shape of the Absolut
Vodka bottle is reminiscent of a Swedish pharmacy bottle.
Once an idea has been found, what role do packaging and
packaging design play as part of the overall marketing mix?
Packaging is the key medium – period. The reason is easy to
explain: The packaging is what consumers hold in their hands at
the point of sale. The packaging is therefore the only truly tangible item for consumers. In addition, the packaging continues
to communicate with consumers at home. Many advertising agencies fail to give packaging the place it deserves. In my opinion,
this is a fatal mistake and leads to watering down of the brand.
°
*
The right thing to do would be to focus on packaging design with
marketing campaigns.
Let’s talk specifically about packaging design. What main
guidelines should be followed in your view?
When it comes to packaging, the basic task is to combine information and emotion. I would like to start by talking about the
design of the back of packaging. In my view, the back is very important because it established contact with consumers through information. Unfortunately, too few companies give the design of the
back the attention it deserves. This may result in illegible writing
or providing information that is simply irrelevant for consumers.
°
*
What criteria should a perfectly designed back take into
account?
It is crucial to establish what information consumers want to
know about a particular product. Take instant soup, for example:
The key information is no doubt how to prepare it. Another example is pretzel snacks: Consumers want to know if they are salty or
sweet. Wine is another: In this case, the focus is on which region
the wine originates from, the soil characteristics, and special taste
°
*
“Unfortunately too few companies give
the design of the
back of packaging the attention it deserves.”
“A good packaging designer develops a packaging concept
appeal to as many senses as possible.”
that
characteristics. What I want to illustrate with these examples is
that consumers don’t want to see a hodgepodge of information
on the back of packaging. The task is to provide specific information and to establish a hierarchy among the information. Copyrighting is journalistic work. The wording should be short, concise, and succinct. The key is to avoid superfluous words. Typography is another important factor for the back of the packaging.
What font should one choose? What font sizes are suitable for
the different types of information? Should one use different font
colors and features such as underlining, italics etc? There is a wide
range of design options for making the back interesting for consumers.
What about space allocation? Many product packs offer little
space on the back.
This is an argument one hears quite frequently. The task is
obviously easier if the rear surface is large. Nevertheless, the key
is to implement information hierarchies consistently and to convey short, succinct information rather than maximum area.
°
*
you have a few examples for perfect backs?
° Do
The back of the Kellogg’s pack is an excellent example. The key
*
is targeted information that invokes emotions: by underlining, coloring words differently, and much more. The design scheme of the
Swedish Arla dairy is very interesting. A certain part of the text on
the back of Arla milk cartons changes on an almost daily basis. This
imparts this packaging almost the character of a daily newspaper –
a successful means of maintain interest. The Pringles design is also
noteworthy. The back of each pack mainly contains statutory information about the content in 16 different languages. Well done.
°
Doesn’t the Pringles design conflict with your earlier statements? Isn’t it difficult to read such tightly printed information?
my view, the Pringles design is brilliant. The criteria are
*quiteIndifferent
than for yogurt, for example. For a yogurt I would
like to know what vitamins it contains, what the fat content is etc.,
while all this is irrelevant for Pringles. I venture to say very few
consumers buy and eat Pringles for dietary reasons. All that matters with Pringles is the taste. A key issue of the Pringles pack is
therefore cost-effectiveness, so that it can be sold throughout
Europe. After all, economy ultimately is ecology. The Pringles
example shows that there are no standard recipes for designing
the back of packaging, since all measures always have to be based
on an individual product idea.
mentioned varying texts used by the Arla dairy. Does con°stantYouchange
not lead to watering down of the information and
therefore the brand?
Not at all. Good packaging design is characterized by changes
to ensure that a brand keeps attracting attention and gives consumers something to talk about. Obviously, these changes shouldn’t affect the main features of the brand. Look at Coca-Cola as an
example of innovative brand design. There we have the Christmas bottle edition with shrink film or the refillable Coca-Cola
aluminum bottle. The key here is that all bottle shapes are based
on the original Coca-Cola bottle. Another example of successful
packaging options is Toblerone. Every few months logos are
modified or special campaigns launched. For example, in Switzerland Toblerone with its typical triangular design was recently offered
for sale in post offices, packed in cartons shaped as a post office
bus. With this and similar campaigns Toblerone achieves a clear
unique position, for which consumers are prepared to pay more.
Or look at Marmite sandwich spread, almost a cult object in the
U.K. Together with Guinness, Marmite developed a special St.
Patrick’s Day edition. Within quarter of an hour, all 300,000 jars
were sold out. These examples illustrate that new ideas are crucial for brands that want to remain popular. Easter, Christmas,
*
dialog+opinion ° Interview with Lars Wallentin
Mother’s Day, Halloween – there are many good reasons for special editions. Unfortunately, not many brands use this opportunity.
We talked about the design of the back of packaging and
seamlessly moved on to special editions. No doubt, there is a
lot of essential know-how relating to the front of the pack,
logo, packaging type, and color.
Of course. A good packaging designer develops a packaging
concept that stimulates as many senses as possible. The most
important parameter for packaging design is the color, followed
by shape, text, and sense of touch. Overall, the purpose of the
design is to address customers at an emotional level. Let’s briefly
talk about color schemes for packaging: This can be product-oriented or totally different.
Take Milka, for example: The color purple purposefully aims to
achieve a unique position in the chocolate sector. Over time, this
color has been charged with a range of emotions through numerous targeted communication measures. The campaign was so successful that in Germany many children believe all cows are purple.
By the way, Milo chocolate-malt drink, which is very popular in
Asia, is based on a similar concept. In this case, the ‘color recipe
for success’ is rich green. When it comes to shape, I already mentioned the Absolut bottle and the Coca-Cola bottle. These are two
examples for successful shapes. The text on the front of a pack of
course refers primarily to the brand logo. Here too, the Coca-Cola
logo and the Absolut logo are successful examples for strong emotional charging over time.
°
*
Coca-Cola and Absolut are brand products where logo, color,
and shape have remained similar for decades. When should
producers stick to so much continuity of a brand product?
Some brands, including the two already mentioned, have iconic
status. A further example from the beverage sector is San Pellegrino mineral water. It would be a mistake to change this kind of
iconic brand. There are other brands that offer scope for further
improvement until icon status is gained.
°
*
22*23
does one know when a brand has gained icon status?
° How
I’d like to return the beginning of this interview. All I can say
*is that a professional designer can tell if this level is reached and
companies should be prepared to spend money on a professional
designer, because it pays off in every respect.
As a sought-after speaker, you feel at home around the world.
Do different continents have different rules for packaging
design?
The rules for successful packaging design are the same everywhere. What varies is the importance attached to packaging. In
Europe, for example, virtually no one is willing to pay for packaging. In Japan, the situation is completely different. In the Japanese culture, packaging has its own soul. The result is that substantially more expensive packaging is common in the Japanese
market.
°
*
Last but not least, what about the future of packaging designs
from your perspective?
I would urge all producers of brand-name products to become
even more creative when it comes to packaging. Overall, I feel
companies are still not bold enough. After all, nothing ventured,
nothing gained. Another aspect that could become more popular
in future for packaging design is sound. Why not communicate
through and accompany the opening of a beer bottle with a fresh
fizz, for example? And why not utilize the sense of smell? In the
perfume sector, this is already normal procedure. Incidentally, a
few years ago Switzerland issued a chocolate-scented stamp. So
why not apply orange-scented soft drink labels that would give off
an aroma when rubbed? Packaging design still offers plenty of
scope for new ideas. However, when it comes to text design for
the back of packaging, I would urge producers of brand-name products to act according to the famous statement by Coco Chanel:
“Always reduce, never add.”
°
*
°
Mr. Wallentin, thank you very much for this interview.
Coca-Cola is it – also in China
The Market Leader
Coca-Cola adds a new chapter to its traditional history in China where the
brand first entered the market 80 years ago. KHS system technology is
playing an important role, with currently 40 systems installed. Dateline
today, at the Chongqing and Kunming plants.
In the meantime, Coca-Cola sells 4.5 billion liters of carbonated soft drinks yearly
in China. Each of the roughly 1.3 billion
Chinese drinks an average of only 3.5 liters
of carbonated Coca-Cola products. That
makes it impressively obvious that CocaCola’s growth story in China is far from over.
Even so, the company already has a 55 percent market share in this gigantic country.
As far back as 80 years ago, CocaCola opened its first bottling plant in Shanghai – and later, enjoyed great sales suc-
cesses: In 1948, the metropolis was the first
city outside the United States where the
sales volume of Coca-Cola exceeded the
magical boundary of a million unit cases,
equaling about 5.6 million liters. In 1981,
Coca-Cola restarted licensed production for
China – this time, in the capital of Beijing.
And today, 35 production facilities distributed throughout country fill the CocaCola range of brands.
Coca-Cola has always relied on perfect systems: “We rely largely on KHS technology in China’s Coca-Cola bottling plants.
In all, there are 40 KHS filling and packaging systems in operation at the moment.
We’re playing it safe. Because KHS filling
technology is a significant aspect of our
quality concept,” says Martin Jansen, CEO
of Coca-Cola China Industries Limited. For
instance, recently a KHS PET system went
into operation in the Coca-Cola plant, which
opened in Chongqing in 2005, and soon
another KHS PET installation will be following at the Coca-Cola plant in Kunming.
Within the company’s carbonated
product portfolio, of course, Coca-Cola is
in first place, but Fanta and Sprite also do
their part to support this success story. This
segment holds about 75 percent of CocaCola’s total sales in China. However, it’s
not just the bubbly soft drinks that enjoy
great popularity among both old and young;
non-carbonated beverages are also in
demand. For example, Coca-Cola was successful in introducing a non-carbonated
Minute Maid brand fruit drink to China.
Today, Minute Maid is in second place in the
sales statistics in this area. Minute Maid in
China contributes a good 12 percent to CocaCola’s overall success. The fruit beverage
Qoo, developed especially for children, is
also exceedingly successful. And then there
are the typical and globally accepted CocaCola brand products, like Nestea and
task+solution °
Bonaqua, along with additional excellently
positioned local water brands.
15 PERCENT ANNUAL GROWTH
“We’re very proud of the success of our brands
in China. But what we think is especially
important isn’t just the momentary market
share, but what we expect in ten years,” says
Martin Jansen looking towards the future.
After all, experts are predicting an annual
growth rate of 15 percent in the Chinese market for non-alcoholic beverages. In that
case, the market volume will have tripled
within ten years. The reason: Along with
growing incomes, consumer habits in China
are changing. People for whom a Coke is a
luxury today may be consuming it on a daily
basis ten years from now, as Europeans are
already doing. Martin Jansen says, “An enormous consumer potential.”
But the development in the country and the cities in China varies consider-
2
24*25
THUMBNAIL PORTRAIT: COCA-COLA CHINA
1927 First bottling plant in Shanghai
1948 Sales record: first time in a large city outside the U.S. to sell more than
1 million unit cases (5.6 million liters)
1981 Reintroduction to the Chinese market
2007 Production at 35 locations in China, with the entire Coca-Cola soft drink
spectrum, with 40 KHS filling and packaging installations
ably. In big cities like Beijing and Shanghai, soft drink consumption is already more
than 23 liters per capita. Jansen says, “To
talk about a uniform Chinese market would
really not do justice to this country’s variety.” About the global significance of the
market, the CEO says, “If we weren’t present here, in 20 years we would certainly
no longer be the global leader in carbonated soft drinks.”
1.25 BILLION DOLLARS INVESTED
No wonder the company has invested about
1.25 billion dollars in China to date and
employs about 30,000 people. Further
investments are also planned.
Because soft drinks are primarily
sold in PET bottles in China, investment is
particularly flowing into innovative, highperformance PET installations. For CocaCola in China – across all brands – the share
Left Air conveyor: Conveys the labeled PET bottles directly towards the
rinser-filler-capper block. Left center Mechanically controlled, singlechannel Innoclean FR-EM rinser: Sprays the bottles out with water.
2
OVERVIEW: THE NEW KHS TECHNOLOGY FOR COCA-COLA CHINA
FEATURE
CHONGQING PLANT
KUNMING PLANT
SPECIAL FEATURE
Output
18,000 0.6-liter bottles
40,000 0.6-liter bottles
Optimum output tuned to the
requirements for each installation
Filling
Ambient temperature
Ambient temperature
Filling range
Complete product line
0.6, 1.25, 2.0, 2.5-liter PET bottles
Complete product line
0.6, 1.25, 2.0, 2.5-liter PET bottles
Universally applicable, also prepared for future bottle sizes;
future-proof investment
Rinser
Single-channel Innoclean FR-EM
cold and warm water rinser
Single-channel Innoclean FR-EM
cold and warm water rinser
Outstanding hygiene values;
flexible use of water
Filler
Innofill DRV
Newly developed Innofill DRV, with
only two pneumatically actuated
membrane cylinders, pressurized
with gas from the ring bowl; use of
CIP plates for CIP sanitizing
In Kunming, low-wear due to the
lack of separate lifting elements
Capper
Innofill SV screw capper
Innofill SV-ACF
Highest standard of hygiene
Fill level and cap checking
Visual, according to the
line output
Innocheck PROMECON 4000
Kunming: automatic cap checking
Blender
Innopro Paramix CMX blender
Innopro Paramix CMX blender
Continuous production process
guaranteed by deaerating,
dosing, and mixing of water and
syrup
Packer
Innopack Kisters PSP pad shrink
packer
Innopack Kisters SP shrink packer
Custom solution for the special
requirements in Kunming and
Chongqing
Palletizer
Manual, according to the line output
High-performance Innopal PB palletizer and inline robot group
Kunming: particularly low-friction
palletizing handles packs gently;
low space requirements; reproducibility
RINSER-FILLERCAPPER BLOCK
task+solution ° Coca-Cola is it – also in China
26*27
Right center Freshly shrunk: 6-pack – the usual format for larger size PET bottle at Coca-Cola.
Right Martin Jansen, CEO of Coca-Cola China Industries Limited: “KHS filling technology is a significant aspect of our quality concept.”
of PET packaging is about 80 percent. No
wonder that PET technology is the key factor at the two Coca-Cola plants in Chongqing
and Kunming.
FULL FLEXIBILITY WITH KHS SYSTEM
TECHNOLOGY
It was important for both systems to be
able to process the entire spectrum of carbonated soft drinks from Coca-Cola, and
also all the different bottle sizes – from the
0.6-liter to the 2.5-liter bottle. The KHS
plant in Chongqing fulfills this task at an
output of 18,000 0.6-liter PET bottles per
hour; in Kunming the capacity will be 40,000
0.6-liter PET bottles/hour. Both plants,
by the way, fill at room temperature. While
in Chongqing the tried and true KHS Innofill
DRV filling system is in operation, Kunming
will be using its latest version for the first
time in China. Company boss Jansen says,
“With our innovative partner KHS, we like
to profit from new developments.” A special feature in this case is the newly designed
volumetric computer-controlled singlechamber Innofill DRV filling system that
uses only two pneumatically actuated membrane cylinders for the entire filling process,
including bottle lift, as well as pressing and
sealing the bottle mouth against the filling valve. The pressurized filling method
uses gas from the ring bowl to pressurize
the PET bottles.
The actual highlight of the system:
A membrane piston transfers the force
resulting from the pressurization pressure
directly onto the neck ring holder, which
is sufficient to lift the bottle and seal the
mouth against the filling valve. This eliminates the need for separate lifting elements. The pressing force is regulated fully
automatically according to the pressurization pressure.
While the filling process is identical in both filler versions, and the controlled
pressure relief process at the end of the filling phase allows filling of highly carbonated beverages with little foaming in the
bottle neck, the new filler variant offers yet
another highlight: CIP sanitizing. So-called
CIP plates seal the filling valves by simply
inserting them into a slot in the bottle
holder underneath the filling valve. And
what’s true of the bottle pressing is also
true for CIP sanitizing. The pressure of
the rinsing media automatically triggers
sealing of filling valve, adapted perfectly
to the internal pressure.
The rinser-filler-capper block is not
equipped with a front table and is thus particularly hygienic in design. Instead of
the usual product bowl with a rectangular
cross-section, the new Innofill DRV has a
tubular ring bowl with no corners or edges.
Using servo technology to drive the machine
reduces the number of mechanical drive elements significantly.
inhabitants. The fact that there is still enormous potential for growth here is shown by
a glance at the yearly per capita consumption of Coca-Cola products. In Chongqing,
it is merely 1.4 liters, significantly lower
than the country’s average. CEO Jansen
says, “As in many regions of China, we here
in Chongqing are just at the beginning of
a success story.” The experts consider the
overall market – and no wonder – as
extremely rich in opportunity. “Not just for
Coca-Cola, but actually for every internationally active company, China is a great
opportunity – provided, the companies are
ready to meet the high expectations of the
Chinese population. In my opinion, China
is the land of a thousand opportunities.
Coca-Cola has set its sights on making the
most of these thousand opportunities in
the truest sense of the word to a greatest
possible extent. With KHS as a partner we
can trust.”
Werner Gessner, Director,
Business Area China, KHS AG
Franz-Alfons Sassenroth, Sales Support Manager,
Business Area China, KHS AG
fi
INFOBOX
• WEBSITE www.coca-cola.com.cn
• CONTACT
HIGH PRAISE FROM THE TECHNICAL
MANAGER
Huaiyu Ren, Technical Manager of the CocaCola plant in Chongqing, says in praise, “Our
new line is now operating in three shifts
at an even higher system efficiency than
that promised by KHS.” That means the
company is ready for continued growth in
Coca-Cola consumption in Chongqing, the
world’s largest city with about 32 million
Werner Gessner, Director,
Business Area China, KHS AG
Tel: + 86 1 350013-0123
E-mail: [email protected]
Franz-Alfons Sassenroth,
Sales Support Manager,
Business Area China, KHS AG
Tel: + 49 (671) 852-2322
E-mail: [email protected]
China: Union Brewery Group explores new avenues
PET for Beijing
The Union Brewery Group sold their first beer in 1994, and today is among the
top 25 brewery groups in China – and they want to make it into the top 10.
How a relatively new company can use topnotch innovation to get to the top.
The future belongs to the daring. The Chinese Union Brewery Group has just started
the very first beer-in-PET installation in the
country. Zhang Feng, Managing Director of
the Beijing-based group, says, “We are
counting on great success with beer in PET.”
As early as 1999, the company put a line
into production in Shijiazhuang for the bottling of draft beer.
Zhang says, “Even then, we were pioneers
in China. Our KHS line triggered a real draft
beer boom. As one of the innovators of
the time, we’re still profiting today from
that decision.”
Before making the recent decision
for beer in PET, the management studied
the markets outside China very specifically.
Zhang reports, “In markets like Korea or
Russia, there’s been an increasing turn for
some time towards beer in PET on the part
of the consumer. Why shouldn’t the same
trend develop in the Chinese market?” After
all, the advantages of PET bottles are obvious: simplicity, convenience, and the option
of designing a variety of bottle shapes.
But innovation requires innovative
partners. That’s the reason, says Zhang,
task+solution °
28*29
Left Innofill DVF pressurized filling system: Fills PET bottles pneumatically and computer-controlled with long filling tubes, extremely gently. Right Innofill SV: caps PET
bottles with screw caps, before they leave the rinserfiller-capper block.
2
THUMBNAIL PORTRAIT: UNION BREWERY GROUP
In 1994, the Union Investment Company (manufacturer of spirits) opened a brewery in
Shijiazhuang, the capital of Hebei Province. Turnover: an outstanding 400,000 hectoliters.
1999: 1 million hectoliters. 2003: second brewery in Taiyuan, the capital of neighboring
Shanxi Province. 2006: sales growth in Shijiazhuang: 50 percent, market share around
33 percent in Taiyuan. 2007: third brewery at the gates of Beijing.
to choose KHS as a turnkey supplier. Not
least, because of the outstanding experience gained with the KHS draft beer line:
“It runs and runs and runs. We are extremely
satisfied.” The new PET installation will initially bottle the lager brand G & Her in 0.43and 1.8-liter bottles. Later, other PET bottle shapes and sizes could follow. The next
step planned: 0.7- and 1.0-liter bottles.
The line outputs 20,000 0.43-liter
or 9,000 1.8-liter bottles per hour. The particular advantages of the installation:
* The computer-controlled, pneumatic
Innofill DVF pressurized filling system,
with a long filling tube, works extremely
gently.
* Volumetric filling using magnetic inductive flow measurement ensures precise
filling volumes without overfilling and
thus saves product.
* The extremely low oxygen pickup (only
0.02 milligrams per liter) of the bottomup filling process retains the outstanding beer quality.
* The low CO2 consumption of only 600
grams per hectoliter specifically cuts
costs.
The
filling program can be called up at
*
the push of a button.
*
*
*
The X-ray fill level check yields a measurement precision that is independent
of the bottle diameter and bottle size,
and can also be used flexibly for nontransparent and metal containers.
The product heater avoids condensation
during labeling and packing.
The bottles can optionally be packed in
shrink or pad-shrink packaging.
Managing Director Zhang Feng sums
it up, “With KHS plant engineering, we are
on the safe side in every respect, and we
are above all able to supply our customers
top-quality beer bottled in PET.” Note: quality is a company philosophy at the Union
Brewery Group. That starts right at the brewing stage. Zhang says, “We let our beer
mature in peace, and orient ourselves
towards the high-quality German brewing
process.”
keting works. The slogan: Beer from the
region for the region.
This strategy works just as well for
the latest plant recently constructed near
Beijing. The goal is the market in and around
the city. Particularly in the capital, Zhang
sees great opportunities for beer in PET:
“Certainly the new package will allow us to
enter Beijing, which would have been impossible with traditional glass bottles.” Growth
is the plan, with a current yearly per capita
beer consumption in Beijing of about 50
liters. Experts expect increases in sales of
about 10 percent a year. With a population of 18 million, that’s a lot of extra beer.
And Union is looking at their next
bold innovation: home service. Distribution centers throughout Beijing will deliver
beer on call. The minimum order: one case.
“If the customers accept this idea as anticipated,” foresees Zhang, “we’ll start in Shijiazhuang and Taiyuan, too, then throughout the country.” The best chance to make
the top 10 among China’s brewery groups.
Because the future belongs to the daring.
Werner Gessner, Director,
Business Area China, KHS AG
fi
INFOBOX
BOLD BRANDING STRATEGY
• WEBSITE www.unionbrew.com
In the premium range, the company markets lager beers: G & Her (Hebei Province
and in Beijing) and Union (Shanxi Province).
The market share of G & Her in Hebei is 70
percent. Union in Shanxi: 30 percent. That
shows that the concept of regional mar-
• CONTACT
Werner Gessner, Director, Business
Area China, KHS AG
Tel: + 86 1 3500 13-0123
E-mail: [email protected]
The unbelievable success story of the Chongqing Brewery Group
The Miracle of Yangtze
The Chongqing Brewery Group relies on consistent regional growth. Fifty years ago,
the company started with 30,000 hectoliters of output, but soon it will be
1000 times that. And right from the start, KHS filling technology was there.
2
THUMBNAIL PORTRAIT:
CHONGQING
* Founded 1958, output 30,000 hl
* 2007: 22 million hl; 2010 planned: 30
million hectoliters
* Chongqing Province: Main brand Shan-
cheng (sales of 10 million hl/yr), regional
brand Chongqing (2.5 million hl/yr)
* Jiangsu Province: Regional brand
Tianmuhu (2.5 million hl/yr)
* Zhejiang Province: Regional brand
Da Liang Shan (1.5 million hl/yr)
* Sales 2006: 3.5 billion renminbi yuan
(about 350 million euros)
Until now, America has always been the land
of unlimited opportunity. Until now.
Because now China is taking that title from
the Americans. In the China, there are
superlatives that even the United States
can’t offer: for instance, Chongqing – taken
at its administrative borders, it’s the largest
city in the world. Nearly 32 million people
live in an area of about 82,000 square kilometers, almost the size of Austria. In comparison: All of California (424,000 square
kilometers) has about 35 million inhabitants.
Downtown Chongqing alone is home
to 4 million people. And right in the middle of this megacity, since 1958, is the
Chongqing Brewery, today China’s 4th
largest brewery group. Fifty years ago,
Chongqing started as one of ten breweries
the Chinese state founded in that year. While
the other nine breweries no longer exist,
Chongqing belongs to the top operations
in the country. That’s thanks to the company’s “many small and larger steps which
logically fit together,” as Yang Zhuo, Vice
General Manager of the Chongqing Brewery
Group, puts it.
The actual growth story at the end
of the eighties started with the granting
of brewing licenses for Chongqing brand
beers to five breweries within the administrative region. Later, the brewery took over
task+solution °
30*31
Left Shancheng: At around 10 million hectoliters, the most successful beer brand of the Chongqing Brewery Group.
Right The Innofill DMG-SVF single-chamber, pressurized filling system: Operates without filling tubes but with return
gas tubes and double pre-evacuation.
euros. The company has big plans for the
future: By 2010, they want to have hit the
30-million hectoliter mark.
… AND A CONSISTENT BRAND
STRATEGY …
An important pillar of the growth strategy
is the company’s brand policy. Insignificant local brands in the individual provinces
are being replaced step by step by the
group’s main brand, Shangcheng (meaning, roughly, ‘mountain’). Aside from that,
management wants to establish additional
brands in some provinces in order to take
regional details better into consideration.
those licensees, and integrated them into
the brewery group. During the nineties, the
brewery expanded by purchasing four more
breweries in the neighboring province of
Sichuan, as well as a brewery in Guizhou
Province. With that acquisition, the
Chongqing Brewery Group finally became
a decisive player in the southwest of China.
… WITH LAGER BEER AS THE BIG
SELLER …
The individual brands are characterized by
an extremely broad variety of styles. The
Shangcheng brand alone offers about 40
different beer styles, from Lager to Pils
and wheat beer, to non-alcoholic beer.
THE FOCUS ON YANGTZE …
… ALONG WITH RELIABLE
PARTNER KHS …
In 2000, the company management decided
to grow regionally along the Yangtze River.
Yang Zhuo sees it this way: “Beer brands are
strongest where they are produced.” This
means that the location of the breweries
defined the sales region.
So the brewery purchased numerous production facilities in the provinces of
Hunan, Jiangsu, Zhejiang, Anhui, and
Guangxi – today, a total of 29 plants, primarily breweries but also a few smaller soft
drink plants, belong to the company portfolio.
Last year, the Chongqing Brewery
group sold about 22 million hectoliters of
beer. Aside from the classical beer business, the segment of soft drinks has also
developed well. It accounts for about
300,000 hectoliters of sales. The group’s
sales in 2006 totaled about 3.5 billion renminbi yuan, equalling about 350 million
The growth curve of the company has been
accompanied by its partner KHS since 1985.
That’s the year the company first invested
in a complete line for the filling of 20,000
refillable glass bottles per hour. That line,
by the way, is still in operation – to the complete satisfaction of Vice General Manager
Yang. “We are extremely satisfied with KHS
solutions, and that’s why we keep relying
on KHS in our expansions as a trusted supplier.” Just as in 2007, most recently for
the central brewery in Chongqing, the enterprise invested in new KHS filling technology. The top requirement: quality and flexibility – today, the plant’s classical beer bottling is handled by a KHS Innofill DMG-SVF,
with an Innofill DRS-ZDS in operation in the
draft beer line.
During the investment cycles at
Chongqing – 1985, 1996, 2002, 2006, and
2007 – KHS accompanied growth with cus-
tom-fit solutions. Yang summarizes,
“Besides the fact that we can offer our consumers the best quality when we use KHS
filling technology, we also value the reliability of the technology, and of course, the
perfect service that KHS has provided us
over the decades. Incidentally, our people
like working in the areas with KHS filling
systems best. They’re easy to operate and
they need virtually no operator intervention.”
… DEVELOPING INTO ONE OF THE
LARGEST BREWERIES IN THE WORLD
So the Chongqing Brewery Group has long
since started down the road towards worldclass. Yang says, “Only as a world-class brewery group will our company continue to be
successful over the next few decades.” The
last 50 years show how the climb of a little
brewery to big player status can work. With
perfect products, a perfect strategy, and
perfect technology, this incredible success
story continues unstoppably, even in its
anniversary year of 2008.
Werner Gessner, Director,
Business Area China, KHS AG
Alexander Modrok, Sales Manager,
Business Area China, KHS AG
fi
INFOBOX
• WEBSITE www.khs.com
• CONTACT
Werner Gessner, Director, Business
Area China, KHS AG
Tel: + 86 1 3500 13-0123
E-mail: [email protected]
Alexander Modrok, Sales Manager,
Business Area China, KHS AG
Tel: + 86 106 410 6706
E-mail: [email protected]
South Korea’s largest brewery group continues to rely on growth
Hite: Open for Something New
The Hite Brewery Group is not only open-minded, but is always ready to
accept innovative ideas. The company has export hits in more than 30 countries – and KHS has been its trusted partner for nearly 30 years.
task+solution °
South Korea’s first brewery came into being
75 years ago in 1933 in the form of the
Chosun Brewery. The Chosun Brewery
started exporting some 30 years later. The
good-tasting South Korean quality beers
quickly became popular abroad, and have
remained so to the present day. What was
started by Chosun as the first brewery in
South Korea about 30 years ago, the newly
formed Hite brewing concern is now continuing – in the meantime, with export hits
in 30 countries. KHS has been supporting
the company throughout this time as a reliable technology partner. The latest project is the investment in modern bottle washing and filling equipment and sophisticated
robot technology. Dr. Bong Soo Son, Managing Director of the Hite Brewery in
Hongchun: “When it comes to quality, we
are on the safe side with KHS equipment.”
When the two companies started
working together, the present-day Hite did
not yet exist. About 15 years ago, the
Chosun Brewery introduced a new beer brand
– Hite – to the South Korean market. This
beer was brewed with pure spring water from
Left Maximum willingness to innovate with
the can filler. The most recent investment
has been in the Innofill DVD computer-controlled KHS volumetric filling concept.
Bottom Open to the world: Reception area at
Hite headquarters.
a depth of 150 meters. The brewing process
does not use pasteurization. From the very
beginning, the beer was an overwhelming
success. One billion bottles had already
been sold by the middle of 1995, and three
billion in 1997. The celebration by the
Chosun Brewery of its 65th birthday in 1998
was the occasion for Chosun to change its
name to Hite. Incidentally, the company
spells – and understands – Hite thus: H for
Humanity, I for Innovation, T for Trust and
E for Excellence of Product.
Today, Hite brews at three locations,
in the provincial capital Jeonju, 230 kilometers south of Seoul, in the seaport town
of Masan and in Hongchun, in Kangwondo Province, with a total capacity of around
11 million hectoliters per year. Currently,
the output is about 10 million liters – a
utilization of more than 90 percent. About
70 percent of this is accounted for by the
premium brand Hite.
The Hite organization not only uses
the highly popular refillable glass bottle (53
percent share) but also kegs, cans, and PET
bottles.
Particularly in the case of beer in
PET, Hite sees itself – as so often in the company’s history – as the forerunner for the
entire industry in Korea. As long ago as
2003, the company was the first brewery
in South Korea to introduce PET in 1.0- and
1.6-liter sizes. Within four years, PET already
accounts for fifteen percent of the total
sales. In the meantime, Hite has two PET
filling and packaging lines along with nine
refillable glass and three each can and keg
lines within the Brewery group.
NUMBER ONE PRIORITY: TOP QUALITY
For the customer, the best is only just good
enough – this motto applies without restriction at Hite from the brewing recipe via
the raw materials and production systems
to the marketing of the bottle.
Take production as an example. In
all lines, Hite relies on KHS filling equip-
32*33
ment, on KHS bottle washing technology
for its refillable bottle lines. Dr. Son: “We
have had nothing but positive experience
with KHS equipment over the decades.” And,
“our consumers deserve the best technical
solutions.” Such as the most recent investment in KHS filling technology.
Along with the KHS Innofill DMG
mechanical filling systems for refillable
glass bottles that have already been
installed, Hite has now invested once more,
this time in an electronically controlled
filling system.
FILLING SYSTEM 1: INNOFILL DRS-ZMS
FOR REFILLABLE GLASS IS …
In 2000, Hite already invested for the first
time in the computer-controlled, pneumatic
2
THUMBNAIL PORTRAIT: HITE
1933 Founded as Chosun Brewery
1993 Introduction of the new Hite beer brand
1998 Renamed to Hite Co., Ltd. after the beer of
the same name
1999 Market share more than 50 percent for the
first time
Three production facilities
* Jeonju, Jeollabuk-do Province, 3 million hl/year
* Masan, Gyeongsangnam-do Province, 3 million
hl/year
* Hongchon, Kangwon-do Province, 5 million
hl/year
Main brands
* Premium brand Hite, 70 percent of total sales
* Prime, Stout, Exfeel, Exfeel-S, and Max beers,
jointly with a share of 30 percent.
Max and Exfeel-S are the newest members of
the family. Max is brewed in accordance with
German purity laws, target group young men;
low-calorie and low-alcohol Exfeel-S, target
group: women
pressure filling system, the Innofill DRSZMS. Dr. Son says in retrospect, “That was
a step in the right direction, so when it came
to the new investment in filling equipment
for our glass refillable line in Hongchon, we
also chose this solution.”
… economic …
The Innofill DRS-ZMS uses only small
amounts of CO2 during the extremely lowoxygen-pickup filling process. It also features a filling level probe, which accurately
determines the filling level. Triple pre-evacuation and double purging with CO2 is followed by the pressurizing and filling process.
The CO2 consumption is an excellent 230
grams per hectoliter of beer; the O2 pickup
is a very good 0.02 mg/l.
FILLING SYSTEM 2: INNOFILL DVD FOR
CANS …
Hite also relies on innovation when it comes
to can filling. Hite is one of the first companies in the world to invest in the KHS
Innofill DVD computer-controlled volume
filling concept.
2
… saves product …
The magnetic-inductive flow measurement
ensures maximum filling accuracy. Tolerances with cans, which have been supplied
by different manufacturers, are no longer
important. If a particular filling quantity
is programmed, then exactly this quantity
will be found in the can.
… and can be changed over hygienically
The Innofill DVD can be changed over at the
push of a button without further intervention in the machine. For example, if it is
required to change from the 355 to the 500milliliter can, the operator only has to issue
a single command via the monitor and the
rest is carried out automatically by the
machine – uncomplicated, safe, and microbiologically perfect.
FILLING SYSTEM 3: INNOFILL DVF FOR
PET BOTTLES …
Hite was the innovation leader when it introduced beer in PET bottles to the Korean market. Dr. Son says, “The Innofill DVF is the
optimum filling solution for beer in PET.”
BRAND BUILDING: OPEN UP! HITE
Hite is Number One in South Korea – and it is to stay that way.
The Group has therefore invested strongly in marketing. The
Brewery intends to establish itself in the consciousness of the
customers as being close to the people and at the same time upto-date.
The slogan “Open up! Hite” is the core statement of the new campaign – Hite as an open-minded company. Hite is involved in
sponsoring sports events, supports charitable causes, and astonishes customers with a fantastic visitors’ tour of its own breweries. In Kangwon, there is a dedicated visitors’ tour with tasteful presentations relating to the subject of beer and an instructive as well as entertaining presentation of the Hite brewing
process. Visitors like it: Around 200,000 beer enthusiasts come
each year – almost 0.5 percent of the population of South Korea.
… is gentle on the product and can be
changed over quickly
This computer-controlled volumetric pressurized filling system allows the use of the
bottom-up filling process with long filling
tubes, and results in a particularly gentle
filling process with at the same time low
oxygen pickup in the product. The filler is
designed so that it only needs a minimum
amount of time for changeover. “This leaves
nothing to be desired,” says Dr. Son.
BOTTLE WASHER: DOUBLE-END
SYSTEM AT ITS FINEST …
The use of double-end cleaning equipment is
advantageous in the warm regions of the
Far East, as this keeps contaminated and clean
bottles physically separate. An important
hygiene aspect, as germs finds the ideal conditions for breeding in the unwashed returned
bottles when the ambient temperatures are
high. The double-end washing equipment
allows several caustic baths to be arranged
one after the other for the perfect hygienic
cleaning process. At Hite, this traditionally
means three caustic baths with three label
removal systems. Hite is therefore able to
objectively control the step-by-step reduction of impurities by means of different caustic concentrations and temperatures.
… with only two caustic baths
The new KHS development of a special infeed
section of the double-end bottle washer
task+solution ° South Korea’s largest brewery group continues to rely on growth
34*35
Left In spite of great satisfaction with mechanical KHS filling systems, electronically controlled KHS Innofill DRS-ZMS filling systems are now being installed
in order to be up-to-date and benefit from technological progress. Center Space saving: Freshly filled beer bottles are transported on different conveyor
levels. Right KHS double-end washing machines only: This is the Hite philosophy for washing equipment in refillable glass systems.
enabled Hite to use only two caustic baths
with corresponding label removal systems
when it came to the most recent investment
in KHS bottle washing equipment. The reason: A special pre-washing system already
ensures an intensive cleaning effect. Two
rotating tubes spray the bottle internally at
high pressure to remove the remaining liquid. Coarse impurities are discharged with
outstanding efficiency, which significantly
increases the service life of the subsequent
caustic baths. As part of the new infeed
section concept, the bottles are heated by
means of an external spray at the same time
as the pre-wash. Wastewater from the washing machine spray zones after the caustic
baths is used for this and provides further
cooling as a positive side effect.
PALLETIZER: ARTICULATED ROBOTS
IN HONGCHUN …
When replacing the palletizing equipment,
Hite Brewery opted for modern articulated
robot technology for both locations,
Hongchun and Masan.
The robots currently depalletize and
palletize 20-bottle plastic crates containing 640- and 500-milliliter glass bottles and
also 30-bottle plastic crates containing 330milliliter glass bottles. In Hongchun, Hite
opted for another innovative solution from
KHS, the Innopal PBL column palletizing
robot, equipped with a low-level pack feeder.
An inline robot grouping system is located
upstream of the palletizer.
… AND IN MASAN
In Masan, in addition to the depalletizing
system for a refillable glass bottling line,
the company has also replaced the palletizing systems for three refillable glass bottling lines. This has given rise to a veritable palletizing center in the palletizing area
at the Masan site. Two articulated robots
– positioned directly opposite one another
– handle the crates in one glass line. In
total, 3 groups of 2 articulated robots each
(for 3 glass lines) operate in the palletizing center; another articulated robot is
located in the center of the lines, and controls the detailed pallet handling. “With a
total of 14 new articulated robots for the
depalletizing and palletizing processes at
our Hongchun and Masan sites, KHS has
delivered yet another masterpiece for the
Hite Brewery Group,” says Dr. Son delightedly. He is certain: “Let the future come.
We are well equipped for all forthcoming
eventualities even today, not least thanks
to KHS equipment.” With regard to Hite
exports, this could mean that the export
quota of total sales could pass the 15 percent mark in the near future. In this regard,
Hite is also thinking about building its own
brewery outside South Korea. Dr. Son says,
“We are currently considering several future
options – with an ear to the market.” This
customer orientation in the past has made
Hite what the company is today: Number
One in South Korea.
Oliver Schneider, Sales Manager,
Business Area Far East / Australia, KHS AG
H. W. Kim, President KHS South Korea
fi
INFOBOX
• WEBSITE www.hite.com
• CONTACT
Oliver Schneider, Sales Manager, Business Area
Far East / Australia, KHS AG, Bad Kreuznach
Tel: +49 (671) 852-2623
E-mail: [email protected]
H. W. Kim, President KHS South Korea, Seoul
Tel: +82 2 518 59068
E-mail: [email protected]
Jinro brings soju, Korea’s national
drink, to the whole world
Under the Sign of the Toad
Jinro has always been Number One in South Korea on the soju market.
The company logo with the toad, which in the country is a symbol of true
luck, is also increasingly becoming an internationally known brand label.
KHS has supported the company’s expansion for many years with individual technical solutions.
2
THUMBNAIL PORTRAIT: JINRO
* Founded 1924
* South Korea’s largest producer of soju
* Market share 53 percent
* Export share 6 percent, main market Japan
* Product range: soju, liqueur, fruit wine
* Sales mainstay: soju
* Bottling facilities in Cheongwon, Icheon, and Masan
While in earlier times, almost every household distilled soju, today the drink is usually produced industrially. Jinro started large-scale production as long
ago as 1924. Today, the company is the undisputed
market leader in South Korea with a market share of
about 53 percent; since 2005, it has been a member
of the Hite Group, which has a market share of around
50 percent for alcoholic beverages. In both cases,
the secret of success is best quality at reasonable
prices.
* Member of the Hite Group since 2005
THE SECRET OF OUTSTANDING QUALITY …
A South Korean would take three things with him to a
desert island for survival rations: rice, kimchi, and soju.
While kimchi is mostly fermented Chinese cabbage, soju
is a spirit, which is almost always made from rice in
combination with wheat, barley, or sweet potatoes.
Korea has been drinking soju since the 14th century –
and soju is still the national drink today, more popular than beer or wine.
The high quality of Jinro soju is substantiated by many
awards. Even back in 1980, Jinro style soju won six gold
medals at the International Wine & Spirits Contest. In
the same year, gold medals were added in eight categories at the Monde Selection in Paris. Young Jin Lee,
Vice President of Jinro Ltd., is particularly proud of
two prizes from the year 2006, the ‘Grand Prix for Hit
Products’ and the ‘Grand Prix for Marketing’. For both
prizes reflect the consumer’s high satisfaction with Jinro
soju.
task+solution °
“We are building national as well as international success on the high customer satisfaction – and thus the
circle closes,” says Lee.
Jinro produces at three locations in South Korea:
in the cities of Icheon, Cheongwon, and Masan. The
company mainly sells soju in 360-milliliter refillable
glass bottles; its share of total sales is around 85 percent. The remaining 15 percent is bottled in 500milliliter refillable glass bottles and numerous PET
bottles from the 0.2- to the 4.0-liter size. While Jinro
mainly uses the small bottle for promotional purposes,
the 1.8-, 2.7- and 4.0-liter PET bottles are intended
for the South Koreans’ domestic consumption.
… AND AN OBJECTIVE PARTNERSHIP
As far as the production and system equipment is concerned, KHS and Jinro have been collaborating since
the early 1990s. Take filling equipment, for example.
Jinro needs extremely flexible technology for the widely
differing sizes of bottle. KHS has specially developed
a filling system, which is unique in the world: the Innofill
NMH isobarometric filling system, which effortlessly
fills 4.0-liter as well as 2.7- and 1.8- or 0.2-liter PET
bottles. This is because the system can be quickly
changed over mechanically to the different bottle sizes
using a specially developed gear solution. Young Jin
Lee: “We see KHS as a company, which not only provides outstanding technical solutions, but also responds
extremely flexibly – as is shown particularly well by
the example of the PET filling system.”
ULTRA-MODERN KHS FILTRATION SOLUTIONS
As already mentioned, soju is distilled. The distillate
has to be filtered several times – a production step,
which significantly influences the soju quality, and each
stage of which Jinro guards as a trade secret. However,
the fact that Jinro currently uses five Innopro COSMOS
horizontal mesh filter systems is no secret. While three
KHS horizontal mesh filters are working in Icheon and
two in Cheongwon, Icheon also has an Innopro GETRA
ECO candle filter system for filtering a higher proof soju
variety.
But however that may be, the KHS team matches
the optimum design of filters in cooperation with the
customer to suit the beverage to be filtered and the
required batch size. The most important thing when
filtering soju is the separation of hazy substances, con-
2
SOJU – A NATIONAL BEVERAGE
Soju is the most popular alcoholic beverage in South Korea. The
basic ingredient of soju is rice, usually combined with other additives such as barley, wheat, or sweet potatoes. The alcohol content is about 25 percent. The clear liqueur has been distilled in
Korea for more than 700 years. The average per capita consumption of soju in South Korea is currently 30 liters per year.
tamination, and foreign flavorings and, to a small measure, the separation of microorganisms, yeast, and proteins.
FULLY AUTOMATIC PROCESS WITH
INNOPRO COSMOS
Before the actual filtration, soju is mixed with activated
charcoal. After a short dwell time, this pre-filtrate is
passed to the Innopro COSMOS. The filtration process
is carried out using round sieves precoated with diatomaceous earth, which serve as filter elements. If there is
an interruption, the filtration process can be resumed
later without extensive cleaning or setting up being
necessary. This is because the filter aids always remain
on the round sieves when the system stops.
Efficient operation. All KHS Innopro COSMOS
filtration systems provide a filtration service life of at
least five days at a capacity of 650 hectoliters per hour.
36*37
Top Innofill UMF bottles soju in refillable glass bottles.
Bottom Innopack PPZ packer: Part of the new KHS dry area concept for the Jinro
production facility in Cheongwon.
The resulting reduction in the time required for precoating the filter aid (diatomaceous earth) and the saving on filter aid were the main reasons in favor of KHS
from Jinro’s point of view.
High stability. The Innopro COSMOS also offers
considerable stability. The filter bowl consists of a vertical cylindrical pressure vessel, inside which the round
sieves, which serve as filter elements, are stacked on
top of one another on a rotatable central hollow shaft.
A top and bottom pressing cruciform in conjunction
with external tie rods ensure that the filter packet is
stable.
Full control. Intelligent measurement and control equipment combines continuous monitoring with
a high degree of integrity as far as the results of the
filtration are concerned: turbidity, pressure characteristics, flow, microbiology – the system records all important values without exception.
INNOPRO GETRA ECO CANDLE FILTER
The Innopro GETRA ECO closed candle filter system
features
* low diatomaceous earth consumption,
* low water consumption,
* continuous data processing,
* reduced preparation times,
* extended filter service life, and
* reduced maintenance.
2
GREAT BRAND VARIETY
Jinro has a large number of different brands to offer the soju enthusiast in South Korea:
* Chamisul (alcohol content 20.1 percent),
* Chamisul Fresh (alcohol content 19.5 percent),
* Gold Soju (alcohol content 25 percent).
A particular specialty is Chun-Kook, which is made from chrysanthemums and 14 other herbs, with 14 percent alcohol content.
For South Korea wine connoisseurs, Mae Hwa Su plum wine (alcohol content 14 percent) is a household name. The Jinro Soju
brand (alcohol content 24 percent) is intended for export.
The system at a glance. The special design
of the filter candles in the Innopro GETRA ECO considerably reduces the diatomaceous earth consumption
compared with conventional candle filter solutions. The
special design results in a diatomaceous earth absorption capability of nine kilograms per square meter of
filter area. This significantly extends the filter cycles
and at the same time reduces the work involved, as
larger batches can be filtered before the filter has to
be cleaned and prepared for the next filtration. The
optimum candle diameter is 34 millimeters and the pitch
83 millimeters – this ensures the maximum utilization
of the vessel volume and promotes long filter service
life.
The candle head is fitted with a bayonet cap,
which saves time when fitting, removing, and above
all maintaining the filter elements. Based on proven
filtration mechanisms, the Innopro GETRA ECO candle
task+solution ° Jinro brings Soju, Korea’s national drink, to the whole world
filter generation improves operational reliability and
economy compared with conventional candle filter systems due to reduced overall diatomaceous earth consumption, lower water consumption, extended filter
service life, reduced cleaning and set-up times, and
considerably reduced maintenance effort. Lee praises,
“We are more than just satisfied with KHS filtration systems. We rely on KHS system technology at all times.
The solutions are robust and they work and work and
work.”
PLUS: INVESTMENT IN KHS DRY
AREA TECHNOLOGY
For the Cheongwon site, KHS has developed a special
solution for the dry area, which ensures an output of
up to 84,000 refillable glass bottles per hour to be
achieved. The key stations are as follows.
Depalletizing. Depalletizing is handled by an
Innopal PKT featuring an integral centering device.
On every single decrating operation, this special solution centers the layer of crates under the crates to be
lifted and prevents individual crates from getting caught,
and thus guarantees high system efficiency.
Decrater. Bottles are removed from the crates
by the continuously operation Innopack PPZ packer.
The special solution here is that the packer uses special mechanical packing bells. They work without wear,
as, due to their design, the sealing rings, which are still
on the returned bottles, cannot cause damage. This
reduces costs and considerably increases system efficiency. It is almost superfluous to mention that the
decrater is also modular in design.
Crate washer. The crate washer at Jinro also
has something special. It is designed with two lanes
and feeds the existing line and the new line simultaneously.
Crate magazine. The integral crate magazine is organized by the Innopal RS 3 robot palletizer.
It is equipped with additional centering and hold-down
devices. When the crates are loaded into the magazine, increased pressure is applied to the crates already
stored in the magazine. The newly introduced layer of
crates therefore engages securely with the existing layer.
On removal, the packing head lifts the top layer of crates
and at the same time holds the crates beneath it in
place. This prevents crates, which are stuck inside one
another, from being placed on the crate conveyor. An
Jinro strategy: Eight Innopro COSMOS horizontal mesh filters
and one Innopro GETRA ECO candle filter. The most important thing
when filtering soju is the separation of cloudy substances,
contamination, and foreign flavorings.
Innopack PPZ is also used as a crater in the line. Young
Jin Lee: “The example of our new dry area once again
shows that KHS has implemented our requirements
exactly. We are dealing with a supplier here whose solution expertise goes far beyond standard applications.”
All under the sign of the toad.
Rainer Hilgert, Director Business Area
Far East / Australia, KHS AG
Oliver Schneider, Sales Manager,
Business Area Far East / Australia, KHS AG
fi
INFOBOX
• WEBSITE www.jinro.com
• CONTACT
Rainer Hilgert, Director
Business Area Far East / Australia, KHS AG
Tel: +65 656 09313
E-mail: [email protected]
Oliver Schneider, Sales Manager, Business Area
Far East / Australia, KHS AG, Bad Kreuznach
Tel: +49 (671) 852-2623
E-mail: [email protected]
38*39
Coopers Brewery, Australia: Quality as a passion
Labeling Champions
Coopers, a traditional brewery and family enterprise for five generations, has always had a reputation for premium beers and top quality in Australia. The brewery recently installed an innovative Innoket SE 2090 labeler from KHS that offers a capacity of up to 72,000 bottles per hour
within a minimum amount of space. It is the fastest modular cold glue machine in the world.
More than 150 years ago, Ann Cooper, the wife of
Thomas Cooper, fell ill at their home near Adelaide in
Australia. It was nothing serious, but to invigorate
his wife Thomas brewed a special ale based on a traditional family recipe. Ann made a quick recovery and
enthused about the tasty brew her husband had produced, a feeling shared by friends and neighbors. This
was the hour of birth of the Coopers Brewery in the
colony of South Australia, which was only 26 years old
at the time.
The news of Thomas Cooper’s ale spread like
wildfire. He had already started supplying customers
with Sparkling Ale and Extra Stout with his own horse
and cart. “We have entered the brewery trade,” wrote
Thomas Cooper to his brother John in 1862. This was
the year when the Coopers Brewery was officially
task+solution °
founded. To the present day, the company has remained
a family brewery, which is unique down under. It is
the third largest brewery on the continent with a market share of around 12% in the high-growth premium
beer market.
Dr. Tim Cooper manages the operation in the
fifth generation, with active support from other family members. The descendants of entrepreneur Thomas
Cooper are keen to brew beer of the highest quality.
Cooper said, “Times have changed and the brewery has
grown, but the quality of our beers remains the same.”
Marketing director Glenn Cooper adds: “Maintaining
Coopers quality remains our passion.”
40*41
Birell under license from Carlsberg. The company
also offers no less than 19 historically evolved home
brew beer kits for hobby brewers, available in supermarket chains and special home brew shops or via
the Internet. Coopers is the main supplier of home
brew beer kits worldwide and exports them to 14 countries in Europe, North America, and Asia.
In addition, the management staked out a further lucrative business area: Coopers is the main Australian malt extract exporter, offering seven different varieties. The company supplies around 5,000 tons
per year to the beverage and food trade in Australia,
the U.S.A., Canada, Japan, China, Malaysia, Indonesia, Hong Kong, Thailand, and South Korea.
WIDE PORTFOLIO AND PLENTY OF INNOVATION
However, the range of beers offered by the brewery
has increased significantly. In addition to Sparkling
Ale and Best Extra Stout, Coopers produces Original
Pale Ale, Mild Ale, Premium Lager, Premium Light, Dark
Ale, and Extra Strong Vintage Ale, plus alcohol-free
AUSTRALIA IS ALE COUNTRY
The sales structure of Coopers brand products illustrates that Australia is ale country: Pale Ale has a
66% share while Sparkling Ale has an 18% share (the
two also hold the highest share of exports). The remain-
World innovation Innoket SE
2090: With a reference circle
of just under 2.40 meters, the
labeler sets a new labeling
record of up to 72,000 bottles
per hour.
2
THUMBNAIL PORTRAIT: COOPERS BREWERY
Founded: 1862
Characteristics: Australia’s only family brewery (now in its fifth generation) and the third largest brewery on the continent (12% share of the market for premium beer)
Main products: Pale Ale, Sparkling Ale, Best Extra Stout
Types of packaging: glass bottles (75%), kegs (22%), aluminum cans (3%)
Exports: U.S.A., Europe, Asia
Headquarters: Regency Park, Adelaide
Employees: 116
Sales 2007: AUS $141 million (€84 million)
ing 16% is shared by Best Extra Stout, Premium Lager,
Premium Light, Birell, Dark Ale, and Extra Strong Vintage Ale. Main export markets: U.S.A. and Europe, with
an upward trend. In its home market of southern Australia, Coopers brewery is traditionally particularly
strong with a 21% percent share of the bottled beer
market and 27% for keg beer. In order to be able to
grow in the rest of the country, five years ago the company established a specialist distribution operation
under the name of Premium Beverages that operates
outside the core area. Coopers Brewery has an 80%
share in this venture, the rest is held by American
beverage distributors, which simplifies import of Budweiser. Of all Coopers beer, 75% is sold in glass bottles, 22% in kegs, the remaining 3% in aluminum cans.
SALES REACH 141 MILLION AUSTRALIAN DOLLARS
Coopers beers are popular: Over the last five years
total sales increased by AUS$ 39 million (€23 million)
to AUS$ 141 million (€84 million). In 2007 alone,
sales increased by almost AUS$ 18 million (€11 million). The company has a staff of 116 employees.
This success can largely be attributed to Tim
Cooper’s decision to invest in a new brewery. About
ten years ago, the company director realized that the
original brewery did not offer sufficient room for future
growth. Cooper therefore acquired a plot of land at
Regency Park, Adelaide, and gave himself three years
for detailed planning and construction of a new brewery. At the same time, initial discussions with KHS
took place. Today the new brewery, which opened in
2001, features several KHS lines:
* A two-lane Innokeg Till TRANSOMAT 5/1 keg line
* An Innopack Kisters WP wrap-around packer
* An Innofill DRS ZMS filler for low-oxygen beer filling, and
* An Innopas P pasteurizer.
Dr. Cooper sums it up, “We are extremely satisfied with our KHS equipment. For this reason, and
because KHS once again offered exactly the right solution, with our latest investment in labeling technology we also opted for a line from our trusted partner.”
WORLD INNOVATION INNOKET SE 2090 …
The modular Innoket SE 2090 labeling machine from
KHS is a world innovation that was specially designed
for Coopers. With a reference circle of just under
2.40 meters, the high-precision labeler is able to
task+solution ° Coopers Brewery sets Australian records with KHS labeler
Left center A gem of a plant: The new brewery at Regency Park, Adelaide. Right Dr. Tim Cooper, CEO of Coopers
Brewery (left): “We are extremely satisfied with our KHS equipment. Not least because KHS offered a solution that
exactly meets all our requirements.” With him is Kurt Hofmann, Managing Director, KHS Pacific.
process up to 72,000 bottles per hour. This is a world
record for cold glue labelers. Tim Cooper: “Some
people didn’t believe such a high performance would
be possible, but KHS set them straight. Our machine
passed the acceptance test with flying colors – both
in terms of the quality of the labeled products and in
terms of performance.” The basic machine configuration is deliberately simple: It is based on a table construction with a central labeling carousel.
The Innoket SE is used for labeling all the brewery’s glass beer bottles. The company currently mainly
uses the 375-milliliter version. Three styles of ale
are bottled exclusively in 750-milliliter glass bottles.
The machine is currently equipped with three cold glue
labeling stations for body and shoulder labeling for
the Australian market plus an additional back label for
exports. Coopers use wet-glue equipment that applies
glue to paper labels. A servo motor drives the station.
An external double cam race controls the sequences
of motion. Glue segments remove the labels gently
from the label hopper and guide them with an optimum peeling angle to the gripper cylinder, which finally
applies the label to the bottle.
… and exceptional efficiency …
Three Innoket ALM automatic label magazines – one
label magazine per cold glue labeling station – ensure
high user-friendliness and maximum machine efficiency. Each magazine features an active label store
and five spare units that are used sequentially. The
operator only has to refill labels when all the labeling materials have been processed. Each ALM magazine holds up to 50,000 labels.
… and the perfect adhesive
Labels and glue must harmonize with the technical
solution. With the KHS Innocoll label adhesive, KHS
offers a perfectly matching glue. All materials and the
interaction between glass bottle, adhesive, and label
were tested in KHS’ in-house laboratory. Naturally, a
test run under production conditions was also carried out. Dr. Tim Cooper said, “It all has more than
paid off. After delivery and connection the machine
has been operating like clockwork ever since.” Even
after 150 years, quality is still a key parameter for
Coopers Brewery.
Michael Zwilling, Manager,
Labeling Technology Product Support, KHS AG
… with maximum flexibility …
Kurt Hofmann, Managing Director,
The Innoket SE is always ready to process a widest
range of bottle sizes and shapes. The machine could
easily be converted to adhesive-pressure labels by
replacing (any) labeling stations at the central labeling carousel. Whether cold glue, adhesive-pressure,
hotmelt, or roll-fed labeling stations – they are all
doable. A further option is docking of a camera
module.
… with long service life …
The tried and tested KHS cold glue labeling stations
are characterized by long service life. The first overhaul is due after 20,000 hours of operation at the earliest. Key features: Rotation of the gluing segments
prevents vibrations, overload, and wear. Direct drive
without additional gear stages. Conical coupling without play. Multiple labyrinth seal. External circulating oil lubrication. Integrated hot water spray. Tim
Cooper is impressed: “In addition to top performance,
flexibility, quality, and user-friendliness, a further key
feature of our Innoket SE is its robustness and associated long service life.”
KHS Pacific, Melbourne
fi
INFOBOX
• WEBSITE www.coopers.com
• CONTACT
Michael Zwilling, Manager, Labeling Technology
Product Support, KHS AG, Dortmund
Tel: +49 (231) 569-1578
E-mail: [email protected]
Kurt Hofmann, Managing Director,
KHS Pacific, Melbourne
Tel: +61 (3) 933 51211
E-mail: [email protected]
42*43
The Lao Brewery is writing a
very special story
A COMPLETE SUCCESS
With two plants, one brewery supplies an entire country with beer – a dream?
No – until recently, it was reality in the little Southeast Asian country of Laos.
task+solution °
44*45
Left Innopal PK depalletizer: Handles the removal of returned crates brought by the pallet into the plant. Right After decrating, the crates go
straight to the Innoclean KW crate washer, refillable glass bottles to the Innoclean DMT double-end bottle washer.
The Democratic Peoples’ Republic of Laos
is a little inland country in Southeast Asia,
with about six million inhabitants. Not
everybody can find it on the map, but on
the world map of beer brewers, this country is a fixed value: Here – and this was
really unique in the entire world – the Lao
Brewery supplies the entire country with
2
LAOS AT A GLANCE
Form of government: Democratic people’s
republic
Location: the only inland country in Southeast Asia, bordering on China, Vietnam,
Cambodia, Thailand, and Myanmar
Inhabitants: six million
Capital: Vientiane, 600,000 inhabitants.
Second largest city: Pakse, 90,000 inhabitants
Per capita income: 475 euros per year
Per capita beer consumption: 20 liters
per year
Per capita soft drink consumption:
10 liters per year
beer, from just two breweries. Their market share was an unbeatable 99 percent.
The reason this is no longer the case has to
do with the market launch of the Asia Pacific
Brewery. More about that later. The Lao
Brewery calls the capital, Vientiane, home.
The 600,000 inhabitants there alone
account for 50 percent of the nation’s beer
sales. The per capita consumption is about
20 liters per year. Not much? Maybe so,
but even that’s an all-time high. Considering that the yearly per capita income in
Laos is just 475 euros 20 liters is a lot of
beer, also knowing that a 640-milliliter bottle of Beerlao beer costs the equivalent of
0.60 euros.
VERY SPECIAL SUCCESS STORY
If we look at the development of the Lao
Brewery, then even its history is a very special success story. In its founding year of
1973, the brewery sold just 30,000 hectoliters of beer. Today, sales are at a proud
1.3 million hectoliters. And the company
has ambitious growth goals. Kissana
Vongsay, Managing Director of the Lao Brewery Co, Ltd., expects sales to increase by
10 to 15 percent every year in the future.
That’s why at the end of 2007 the Lao Brewery ordered a fourth turnkey system from
KHS for the newly completed brewery (capacity 500,000 hectoliters) in Pakse, the second largest city in Laos. The city is close
to the border with Cambodia, Vietnam, and
Thailand. And the company wants to
increase its exports to those countries in
the future. Today, exports already go to the
United States, Japan, Australia, New
Zealand, France, Great Britain, and Russia.
The fact that the quality is there was recently
proved by the Lao Brewery, when the Beerlao brand was awarded two gold medals
for Lager and a silver medal for dark lager
at the ‘Monde Selection International Institute for Quality Selections’. The classical
lager beer, with a 98 percent share of the
brewery’s sales, is their absolute top seller,
but it is complemented by sales of dark lager
and light beer, as well as Carlsberg Beer,
bottled under license.
Ninety percent of beer is sold in 640milliliter refillable glass bottles; eight percent is distributed in 330-milliliter bottles. The remaining two percent is canned.
Unquestioned leadership of the market also
has one great advantage for bottling: The
2
LAOS AT A GLANCE
* Brand: Beerlao
* Production in Vientiane (1.5 million hecto-
*
*
*
*
*
liter capacity) and Pakse (500,000 hectoliter
capacity)
1973: Founding as a joint venture of the
Laotian state and the French investor BGI,
with sales of 30,000 hectoliters.
1975: BGI’s share taken over by the state
1993: Entry of the companies Loxley and
Italian Thai
2002: Entry of the Carlsberg Group (today
holds a 50 percent share)
2007: Beer sales 1.3 million hectoliters
Extraordinarily suitable for low-oxygen beer bottling: Innofill DMG SVF single-chamber, pressurized filling system with double pre-evacuation.
Lao Brewery hardly needs to worry at all
about sorting out bottles from other companies. So far, they’ve hardly found a single foreign bottle among their returned empties.
INVESTMENT IN TWO KHS TURNKEY
SYSTEMS
KHS technology comes into play during the
processing of the returned empties at Lao
Brewery: “Quality wherever possible, that’s
our motto. We therefore rely exclusively
on KHS turnkey lines in our brewery. That
already gives us a significant standard of
quality from palletizing to depalletizing,”
says Kissana Vongsay.
The Lao Brewery invested in KHS
technology for the first time in 1993, then
in 2002 and 2007 orders followed for two
identically built systems with an output
capacity of 24,000 640-milliliter bottles per
hour. Even though the company is currently
filling only one type of bottle at the Vientiane plant, there would be no great effort
involved in converting the installation to
new formats. Only a few new format parts
would be required. At the present time, the
system is operated entirely without the need
for changeover – this ensures maximum effi-
ciency. The following steps illustrate how
the line operates.
well-suited for this very low-oxygen beer
filling.”
Step 1: Decrating
Step 4: Pasteurizing
An Innopal PK depalletizer depalletizes the
crates returned to the plant, layer by layer.
The layer clamping head holds each individual crate layer securely, and transfers it. An
Innopack PPZ designed based on the KHS dry
area modular concept decrates the 640-milliliter glass bottles out of the 12-bottle crates.
Pasteurization is done by the Innopas PII
SC modular double-deck pasteurizer with
integrated PU control. Because there’s no
superheating or high sprinkling temperatures, the beer is particularly gently handled. A heat exchange, continuously operating between the heating and cooling
zones, ensures minimal water and power
usage.
Active spraying on each deck of the
Innopas PII SC ensures uniform pasteurization. Several pumps and separate water
trays in a heating or cooling zone allow
the additional gradation of temperature.
Step 2: Washing
After unpacking, the crates head for the
Innoclean KW crate washer, while the refillable glass bottles go to the Innoclean DMT
double-end bottle washer. The combination of a series of various caustic baths allows
different lengths of treatment times. Heat
insulation and heat recovery facilities optimize the amount of energy and fresh water
used by the system. Special drains allow
the environmentally friendly disposal of broken glass, labels, and contaminants.
Step 3: Filling
An Innofill DMG SVF fills the freshly cleaned
glass bottles. Vongsay says, “This filling
system isn’t just rugged, it’s outstandingly
Step 5: Labeling
The Innoket KL 2040 cold glue labeling
machine applies front, back, and neck ring
labels to the bottles. High availability, simple operation, and minimal maintenance
costs with perfect labeling quality characterize these machines. The hygienic values measure up, too, because many parts
of this station are made of stainless steel.
The machine has two labeling stations. While
task+solution ° The Lao Brewery is writing a very special story
46*47
Left Innoket KL 2040: Ensures perfect label appearance of Beerlao brands at the point of sale.
Right Crates readied on pallets: Innopal PK.
one station handles front and neck labels,
the other applies the back labels.
With the Innoket KL 2040, the Lao
Brewery relies on mechanically controlled
cam rotation. A precisely defined bottle
rotation ensures exact labeling and the perfect label alignment. That makes Beerlao
visually attractive, too.
Step 6: Crating
An Innopack PPZ packer places the finished
bottles in clean crates that are finally palletized by an Innopal PK. Kissana Vongsay
says, “We’re just as happy with our new KHS
line as we were with the two older ones.
As usual, KHS hasn’t just provided us with
a great technical solution, but also best possible service. We also like KHS’ close proximity to the market and the comprehensive expertise they have in Laos, the Southeast Asian markets, and the global market.”
TWICE AS GOOD: TWO IDENTICAL
TURNKEY SYSTEMS
That was one of the reasons the Lao Brewery also ordered a turnkey system for the
Pakse plants, which was identical to the one
in Vientiane. Another important reason for
the investment is the fact that this year the
Asia Pacific Brewery is going to try its luck
in Laos as a competitor, with its own brewery and Tiger Beer brand of beer.
Managing Director Kissana Vongsay
remains rather unperturbed: “The citizens
of Laos see Beerlao as their own brand, and
they see this beer from a thoroughly patriotic point of view.” And for good reason:
The Lao Brewery isn’t just a successful company, but also one that’s been strongly
involved in the country for more than 30
years. Educational assistance, sports sponsoring, and cultural support – the brewery
is always involved. So Vongsay is counting
on future profit from further growth of the
domestic beer market, and only anticipates
the loss of a few percentage points of the
market share to the competition Asia Pacific.
curement, too, management wants to
explore new avenues. For a planned fruit
drink, Vongsay can easily imagine buying
the ingredients needed from local farms at
fair prices and thereby support the local
economy. And so the cycle closes: The Lao
Brewery lives from Laos, and Laos lives from
the Lao Brewery.
Rainer Hilgert, Director, Business Area
Far East / Australia, KHS AG
Peter Haas, Sales, Business Area
Far East / Australia, KHS AG
fi
INFOBOX
• WEBSITE www.beer-lao.com
• CONTACT
BIG PLANS IN A SMALL COUNTRY
To be able to grow strongly in the future as
well, management is planning to expand
the variety of products. Lao Brewery is
already selling Tiger Head brand drinking
water – and very successfully. Last year
alone, the company sold 20 million liters.
In the future, more soft drinks could be
added to the product line, along with new
alcoholic beverages. In raw material pro-
Rainer Hilgert, Director, Business Area
Far East / Australia, KHS AG,
Bad Kreuznach
Tel: +49 (671) 852-2462
E-mail: [email protected]
Peter Haas, Sales, Business Area Far
East / Australia, KHS AG, Bad Kreuznach
Tel: +49 (671) 852-2319
E-mail: [email protected]
Herbsthäuser Brewery uses high-tech cleaning technology from KHS
Brewers with Heart and Soul
The Innoclean SEC bottle washer from KHS was specially designed for mediumsized breweries. As the first user of this new high-tech machine, Herbsthäuser
Brewery plays a pioneering role while utilizing no less than ten special benefits.
From the region for the region. That’s how it is at Herbsthäuser
Brewery based in Herbsthausen, Baden-Württemberg, Germany,
and has been for generations. “And so consistently,” smiles Klaus
Wunderlich, who has been managing the brewery since 1975 in
the fourth generation, “that reporters have referred to us as
‘radically regional’.” Wunderlich: “I was pleased about this. Because
the Latin stem of radical essentially means ‘getting to the root’.”
This also includes investment decisions. His son Christian, who
joined the management team last year, said, “We personally had
a close look at the bottle washer options offered by the market
for SMEs.” Klaus Wunderlich added, “In the end it was clear
that only one machine fully met our requirements – the KHS
Innoclean SEC, which was specially developed for medium-sized
companies.”
But first, back to Herbsthäuser’s motto. “Our purity law
begins in the region,” says Klaus Wunderlich. All our grain comes
from farmers operating according to strict guidelines for integrated
and controlled farming. In addition, the brewers leave their beer
to mature for a long period of at least 40 days. ‘Brewers with Heart
and Soul’ is the name of an association of ten owner-managed
breweries in Baden-Württemberg with different sales areas. The
philosophy is to brew better beer based on ten specific principles
with ‘refillable’ close to the top of the list.
In addition to classic 0.5-liter NRW bottles, for the last four
years Herbsthäuser Brewery has been offering 0.33-liter longneck
bottles with ring pull closures in order to satisfy the taste of the
younger generation (with double-digit growth rates). “No way
one-way,” says Klaus Wunderlich, “because in a clearly defined distribution area refillable offers environmental benefits that should
not be underestimated.” This is where KHS comes in. Klaus Wunderlich: “Our new KHS bottle washer offers top performance when
it comes to energy and water consumption. This makes not only
sense ecologically, but also offers economic benefits.”
INNOCLEAN SEC: TEN ADVANTAGES FOR MEDIUM-SIZED
COMPANIES
1. Compact design saves space. Herbsthäuser’s single-end
machine with a capacity of 12,000 to 15,900 bottles per hour
is very compact and can be fully integrated in existing line
equipment. One machine side has no fittings so that the
machine can be positioned close to a wall.
2. Triple-i-Drive technology …
… makes manual pushover to the bottle outfeed when changing bottle types unnecessary. The principle: As the last row
of the current bottle type moves out of the bottle washer, the
removal process is triggered automatically if bottle pushover
is activated. In this case, the swinging motion goes beyond
the normal path of motion thus pushing the row of bottles onto
the conveyor belt.
… offers rapid changeover through the option of decoupling
the infeed from the drive. The result: While the machine continues cleaning any remaining bottles, changeover work can
commence on the drive without having to stop the machine.
3. Energy-saving bottle carrier saves 10 to 15% of heat
and 15 to 20% of water.
4. The heat exchanger for the heating the caustic requires
5% less energy. The principle: Designed as a plate cooler it
increases the efficiency of steam utilization.
5. Final draining and pre-soaking before pre-spraying
removes any beverage residue and foreign objects before
caustic treatment.
6. Innovation drive jet spray ensures ideal hygiene. The prin-
ciple: Conventional full-jet spraying meets Triple-i-Drive. Once
task+solution °
2
48*49
THUMBNAIL PORTRAIT: HERBSTHÄUSER BREWERY
* Family-owned for five generations
Left Designed for medium-sized companies: Innoclean SEC
* Beer output: nearly 55,000 hl/year
bottle washer: High-performance cleaning equipment with
* Non-alcoholic beverage output: 7,000 hl/year
ecological and economic benefits. Right Klaus Wunderlich
* Product range: Edel-Pils, Gold-Märzen, lager, bock and wheat
(left) and his son Christian Wunderlich (center), owners of
beer, Christmas beer, soda pop, cola mix, table water
* The philosophy: Regional quality for the region.
Herbsthäuser Brewery, and brewmaster Markus Lutz agree:
“The investment in the Innoclean SEC was the right decision
in every respect.”
the spray jet reaches the bottle mouth, the bottle to be cleaned
moves forward very slowly until the spray jet impacts the end
of the bottle mouth. The machine speedily moves to the next
spray station in order to accurately catch up with the preceding slow motion during a predefined cycle.
7. Fresh water consumption is particularly low. Herbsthäuser
Brewery only requires 160 milliliters of fresh water per 0.5liter bottle, saving approximately 4 million liters of water per
year. The principle: Full-jet spraying for pre-spraying and spraying after caustic cleaning (four spray zones). The crucial factor: Final water spraying stops during the period in which no
bottles are present for spraying. And, the system features cascading water circulation.
8. Caustic carryover reaches top value. With 8 milliliters
per 0.5-liter bottle caustic carryover at Herbsthäuser Brewery
is even less than the values encountered in other high-performance lines.
9. Excellent label discharge rate. The principle: Specific
flow control in caustic bath combined with submerged caustic flushing. Herbsthäuser was able to reduce chemical consumption by around 30 percent.
10. Full stainless steel design for longevity.
Klaus Wunderlich is impressed by these advantages: “Perfectly clean bottles are a prerequisite for top-quality beer and bev-
erages. With the Innoclean SEC we are on the safe side while at
the same time saving energy, water, and cleaning agent. What
more could one want?” Brewmaster Markus Lutz reports that
friendly companies are very interested in the new line: “Once a
year the brewmasters of our association get together. In 2007,
the highly efficient, new Innoclean SEC at Herbsthäuser was clearly
the main subject.” Hardly surprising, among brewers with heart
and soul.
Bernd Molitor, Manager, Cleaning Technology Competence Center, KHS AG
Jan-Karl Nielebock, Product Management, Cleaning Technology, KHS AG
fi
INFOBOX
• WEBSITE www.herbsthaeuser.de
• CONTACT
Bernd Molitor, Manager, Cleaning Technology
Competence Center, KHS AG, Dortmund
Tel: +49 (231) 569-1573
E-mail: [email protected]
Jan-Karl Nielebock, Product Management, Cleaning
Technology, KHS AG, Dortmund
Tel: +49 (231) 569-1340
E-mail: [email protected]
Gerstacker Winery: To global success with
Christmas Market mulled wine
The Original
The Franconian Gerstacker Winery wants to be in the Top Ten of
the German wine sector. The prospects for this are excellent.
All the more so, as a new production facility with a highperformance KHS filler block significantly expands the capacity.
It is synonymous with a German Christmas
throughout the world: the Nuremberg Christmas Market mulled wine. Every year, some
200 dealers in the historic old city offer their
deliberately traditional wares and sweetmeats. The visitors’ culinary focus is on
three delicacies in particular: Nuremberg
Bratwurst, Nuremberg Lebkuchen, and
Nuremberg Christmas Market mulled wine.
This special and unique mulled wine has long
been a real hit that is not just confined to
Nuremberg. In the meantime, the Gerstacker
winery’s ‘star product’ has become available throughout Germany as well as in
numerous other European countries and
even overseas. With growing success.
Owner Hans-Friedrich Gerstacker
explains it thus: “We offer only the very best
quality for all the products in our range.
That goes down well with the consumer.”
The product range includes a wide variety
of winter, spring, summer, and autumn beverages. “We are a specialist in seasonal beverages, just like the consumer wants,” comments daughter Stefanie Gerstacker, who in
the third generation decisively manages the
company.
The objective is to elevate the company from its current 15th position to one
of the 10 largest wineries in Germany. HansFriedrich Gerstacker is confident: “The next
generation is up and coming, and I believe
that there will be more extensive growth”.
The family success story begins with
its founding in 1945 – and with spirits.
The former distillery was initially active in
the Franconian homeland. Wine was then
added in the 50s and 60s. The Gerstacker
Winery was already represented at the
Nuremberg Christmas Market at this time.
In the early 70s, the winery began to offer
a mulled wine by the glass, made especially for the Christmas market, which was
an outstanding success. Hans-Friedrich Gerstacker: “More and more customers also
wanted to enjoy our Christmas Market mulled
wine at home.” The rest is quickly told:
The company was virtually overwhelmed
by the demand.
Today, the specialty, made in accordance with the family recipe, is the main
premium mulled wine in Germany. At any
rate, sales are about 10 million liters per
year. The family guards the recipe with care.
What Hans-Friedrich Gerstacker does reveal
however is that only high-quality red wines,
mixed with elaborate combinations of spices
for more than 24 hours, are used. Of the
2
THUMBNAIL PORTRAIT: GERSTACKER
* Founded: 1945
* Special feature: Specialist in seasonal
beverages
* Main product: Original Christmas Market
mulled wine
* Portfolio: 50 products
* Total sales: 50 million liters/year
20 different spices, aniseed, cardamom, nutmeg, cloves, allspice, and cinnamon are the
most well known.
50 MILLION LITERS WITH 50 PRODUCTS
Further styles of mulled wine – such as bilberry, cherry and Albrecht Dürer mulled wine
– have been added to the range as time
has gone by. In the summer months, Gerstacker offers classic fruit punches, fruit
wines, wine spritzers, cocktails, and exotic
coolers. “In future,” says Stefanie Gerstacker, “we are planning to tackle the classic wine segment even more aggressively.
task+solution °
50*51
Top KHS rinser-filler-capper block: Worm blocking conveys the bottles to the individual stations. Center Hans-Friedrich Gerstacker
and daughter Stefanie today lead the company as the second and third generation and place their trust in the advantages of a family
business. Bottom Highlight of the Gerstacker Winery: Original Nuremberg Christmas Market mulled wine.
The company presently has more than 50
different products with annual total sales
of around 50 million liters.
“As a family company, we are immediately ready to do business,” says HansFriedrich Gerstacker. “That is a clear competitive advantage.” The speed with which
the management’s plans are implemented
is shown by the construction of a new production facility. In the previous plant
directly in Nuremberg, there was no possibility of any further expansion. The search
for a suitable piece of land for the new building began in the middle of 2006. The right
location was found in October. Building
work began at the end of October. The company moved into the completed plant in
June 2007. Production finally restarted
in early August. In the meantime, the
branch plant established in the Thüringen
town of Crossen in 1995, bridged the gap
in production by increasing their bottling
activities. “We always put ideas into practice quickly,” agree Hans-Friedrich Gerstacker and daughter Stefanie. “This is part
of the company philosophy and at the same
time one of our recipes for success.”
THE BEST IS ONLY JUST GOOD ENOUGH
The decision was also quickly made to install
another bottling line in the new production
facility. Hans-Friedrich Gerstacker: “Here
we went by the familiar saying ‘The best is
only just good enough for us’ and ordered
the new rinser-filler-capper block from KHS.”
One of the reasons was that the company
is very satisfied with existing KHS equipment. As long ago as 1993, Gerstacker
invested in a KHS bottling system, which
according to Hans-Friedrich Gerstacker “runs
and runs and runs and,“ Gerstacker emphasizes, “is able to provide the individual treatment for every single beverage in our product range.”
The Gerstacker Winery presently uses
different varieties of 1.0-liter and 0.75-liter
glass bottles. But this does not always have
to be the case. Other bottle sizes and shapes
or even PET are also conceivable. The output of the new KHS rinser-filler-capper block
is up to 15,000 bottles per hour. It is
installed in a straight line. This means that
the rinser, filler, and capper are interconnected by worm blocking. Advantage 1:
All components of the block are easily accessible. Advantage 2: The possibility of overseeing both block concepts simultaneously,
which can be done by only one operator.
The first bottle station within the
new block concept is the Innoclean FRZM
rinser equipped with 60 rinsing stations, a
mechanically controlled two-channel rinsing system that processes the bottles with
two rinsing media. Rinsing programs for all
products are stored in the system memory.
When changing product or bottles, the
changeover is carried out from the monitor at the push of a button.
As a computer-controlled, pneumatic
long-tube pressure filling system, the
Innofill DRF is a real all-rounder and works
on the principle of bottom-up filling. It is
therefore equally suitable for filling at high
temperatures and for cold filling. The
Innofill DRF also adjusts itself perfectly to
suit other requirements, such as varying CO2
content, for example.
The bottom-up filling process is a particularly gentle filling process with associated low oxygen levels in the product. In the
case of cooler products with fruit pulp content, it prevents clumping in the bottle neck.
Two-stage snifting makes the system particularly suitable for the foam-free
filling of sensitive beverages. There is also
the option of diverting the return gas
through a separate channel instead of feeding back the return gas to the ring bowl in
the traditional manner. The filling valve
settings for the individual filling phases,
the initiation of cleaning processes when
changing product and the correction of filling levels are carried out centrally at the
push of a button.
The Innofill SV screw capper processes classic 28-mm aluminum roll-on caps. A second capper for ‘long caps’ has already been
ordered and will be installed shortly. A special feature is that the capping systems
can be engaged and disengaged as required.
In this way, only one capper is in operation at a time, while the others are idle. The
advantage is that there is less wear and
the operating costs are lower, as filled bottles do not pass through any of the inactive capping systems.
The block has a motorized height
adjustment facility to ensure rapid
changeover. The quick changeover of guide
starwheels makes for higher line availability, less wear and the need for spare parts,
and therefore cuts costs.
For this purpose, a dummy is placed
in the filler and in the respective capper
guide starwheel. The starwheels then only
have to be adjusted and locked in place.
Incidentally, the entire system works with
servo drive technology. Stefanie Gerstacker
is convinced that “KHS equipment prepares
us well for future success.” Good – among
other things – for Christmas Market mulled
wine.
Walter Senft, Manager, Wine, Champagne,
Juice and Spirit System Sales, KHS AG
fi
INFOBOX
• WEBSITE www.gerstacker-weinkellerei.de
• CONTACT
Walter Senft, Manager, Wine, Champagne,
Juice and Spirit System Sales, KHS AG,
Bad Kreuznach
Tel: +49 (671) 852-2380
E-mail: [email protected]
In conventional CIP sanitizing
systems for tank farms, pumps are
used for returning the cleaning
agents.The new CIP vacuum system
from KHS does away with such
pumps. It is suitable for the entire
beverage industry and offers several
tangible benefits.
Innovation: Vacuum CIP for tank farms
7
The current situation: During conventional
CIP sanitizing of beverage tanks with media
temperatures of up to 50°C, a supply pump
mounted on the CIP frame delivers cleaning media and fresh / batch water to the
tanks and pipes to be cleaned. Permanently installed or portable pumps in the
tank farm are then used for returning the
media. Maintaining especially pumps of
this kind, however, can be very demanding. For reliable operation they not only
require good supply conditions, they also
have to be protected against running dry.
Now available: KHS recently developed a vacuum CIP system that eliminates
the need for return pumps for cleaning
media. This means: The media are returned
by means of a vacuum system that offers
a number of advantages:
* No intermixing of cleaning media
* Smaller container volumes
*
*
*
*
*
*
*
One System.
Advantages.
Less space required
Lower energy consumption
Less time required for cleaning
Cost-effective operation
Fewer components
Low-noise operation
Full flexibility
The principle of vacuum cleaning is
quickly illustrated: A circulation pump
mounted on the CIP frame and a jet device
generate a vacuum that pulls back the liquids from the product tanks and the piping into the CIP tanks during each cleaning step. The respective cleaning medium
serves as motive fluid.
WHAT IMPROVEMENTS DOES THE KHS
INNOVATION OFFER?
Advantage no. 1: Loss-free media
changeover, cost-effective operation
Unlike systems using return pumps, the CIP
vacuum system returns the cleaning
medium from the storage tanks and from
the piping without leaving residue in the
tanks or piping. The same applies to the
CIP feed pipe, which is purged with compressed air after each media changeover.
The result: clear separation of media for
lower consumption of caustic, acid, and
fresh water. Rinsing amounts are reduced
significantly compared with conventional
systems, and the system does not have to
be filled with water.
Advantage no. 2: Small tank
capacities, less space required
The CIP vacuum system requires very little
space, because the associated storage tanks
can be much smaller due to reduced amount
of water and cleaning media: Depending
on the application, tank volumes can be
technology+innovation °
reduced by up to 50% versus conventional
CIP solutions.
2
OPERATING PRINCIPLE OF A KHS VACUUM CIP SYSTEM
Water
Caustic concentrate
Heating water
Advantage no. 3: Less energy,
lower energy costs
CIP return
Energy costs are also reduced, because the
system does not use return pumps and uses
less energy for heating and cooling.
CIP return
CIP
CIP feed
CIP return
Rinsing
filter
A further key advantage of the new vacuum CIP system is its high operating speed,
which enables a significantly higher number of cleaning cycles in any given period.
The CIP tanks have a lower volume and
the system returns almost completely segregated media, leading to reduced overhead for recharging of cleaning concentrates and for heating of water and cleaning media. The result: The vacuum CIP
system is available more quickly for new
sanitizing tasks.
conventional sanitizing tasks of complete
systems at higher temperatures as required.
All flexible CIP application options are available in a single system.
Advantage no. 5: Fewer components,
reduced complexity
FURTHER KEY PARAMETERS
FOR USERS
The system is less complex since there is
no need for several permanently installed
return pumps. All can be replaced by a single circulation pump in the CIP area. The
new system also offers advantages compared with a portable pump solution,
because it requires no frequent and timeconsuming relocation and connection of
portable pumps within the tank farm and
it eliminates the necessity of installing pipe
sections in the tank farm along with the
related interfaces. All devices required for
perfect CIP sanitizing are concentrated
on the CIP frame.
Individual monitoring
The high level of pump noise frequently
produced by conventional systems is irritating to operating crews working near the
product tanks. The vacuum solution
resolves this problem.
Advantage no. 7: All options,
full flexibility
The new vacuum CIP system combines tank
cleaning at temperatures of up to 50°C with
CIP feed
CIP feed
Advantage no. 4: Greater speed,
shorter sanitizing times
Advantage no. 6: No cavitation,
low-noise operation
52*53
CIP feed
Storage
tanks
Product
CIP feed
Cooler /
heater
Filter
Product / CIP
Heating water
Cooling water
System operating, visualization, and monitoring are handled at a central KHS touch
panel. All operating data such as the vacuum pressure, flow, conductivity, and temperature can be called up, saved, and displayed as required at the push of a button. This ensures trouble-free cleaning and
documentation.
Product / CIP
Drain
tank farms for wine and fruit juice with
media temperatures up to 50°C and pipe/
system sanitizing at higher temperatures.
All system solutions are tailored and
adapted to the required parameters and
operating conditions.
Alfons Abels-Rümping, Product Management,
Process Technology, KHS AG
Matthias Ringholt, Process Engineering Design,
Process Technology Competence Center, KHS AG
Michael Breil, Process Engineering Design,
Process Technology Competence Center, KHS AG
fi
INFOBOX
Individual design
• WEBSITE www.khs.com
Before embarking on design work for a specific system, KHS will undertake a joint site
visit with the client in order to ascertain
all key system parameters such as dimensioning, pipe lengths and routes, size of
the product tanks, type of spray balls used,
and distance between CIP system and product tanks to be sanitized. System design
– be it a CIP vacuum system or an integrated solution – only commences once
this task has been completed.
• CONTACT
Individual solution
With the development of this system, KHS
covers all sanitizing tasks in different sectors of the beverage industry, including
Filler
Alfons Abels-Rümping, Product Management,
Process Technology, KHS AG, Bad Kreuznach
Tel: +49(671) 852-2211
E-mail: [email protected]
Matthias Ringholt, Process Engineering Design,
Process Technology Competence Center,
KHS AG, Bad Kreuznach
Tel: +49(671) 852-2739
E-mail: [email protected]
Michael Breil, Process Engineering Design,
Process Technology Competence Center, KHS AG,
Bad Kreuznach
Tel: +49(671) 852-2280
E-mail: [email protected]
Custom-fit palletizer for entry and medium capacity range
Compact Power
The requirements for palletizing are varied. In the Innopal LH, KHS has developed
the perfect basic solution for the entry and medium capacity range, which still
keeps all the options open for the food, non-food, and beverage sectors.
Individual and custom solutions are a mark
of successful products, and always the result
of specific development work. So during
the design of the new KHS Innopal LH palletizer, later purchasers played a significant role even in the preliminary stages:
KHS started by interviewing a target group
in the food, non-food, and beverage industries before development of this innovative palletizing system. Result of the poll:
The optimum palletizer must
* be rolled out for the entry and medium
capacity range,
* be focused on carton packaging,
* have a compact palletizing concept easy
to integrate into existing lines, and
* come equipped with a reasonable
price / performance ratio.
All these requirements went into
the development of the Innopal LH. The
result is a system, which optimally satisfied those many requirements at a high
rate of package feed, providing palletizing
solutions for cartons – the preferred packaging form at stores and discounters.
TOP RESULTS IN THE ENTRY TO
MEDIUM CAPACITY RANGE
The Innopal LH palletizes up to 1,500 packs
or up to 150 layers per hour and processes
any standard cartons from wrap-around and
tray packaging to multipacks. The perform-
ance range includes packs with length /
width / height dimensions from 200 x 200
x 100 millimeters up to a maximum of 400
x 400 x 400 millimeters. The block height
of the pallets forms can be up to 1800 millimeters – at a maximum block weight of
1500 kilograms.
SIMPLE SYSTEM SUPPLY
The elevated pack feed keeps passages open
for forklifts and the operating crew. That
significantly simplifies and accelerates the
material supply of the palletizer and other
parts of the line.
BASIC VERSION
The core of the compact palletizer concept is the basic version of the Innopal LH.
It can be used to form column layer patterns. In the standard version, the operating crew handles filling with empty pallets and the removal of loaded ones. A
variety of extension options makes the
Innopal LH a true ‘all-rounder’. And the
customer has access to the extensive, reliable palletizer line from KHS. Special KHS
software helps, too.
SOFTWARE FOR SELECTING THE
RIGHT OPTIONS
The first option of the Innopal LH isn’t even
in the system, but in a computer. Using a
specially developed program, even in the
planning phase you can precisely test and
determine which requirements the palletizer will need to satisfy later in production.
For instance, the program provides
information about the throughput at which
the specified packs and pack information
can be processed. All conceivable system
options can be tested on the display screen
to see if they meet the requirements of the
respective customer.
But how does the system work in
practice? Even before the cartons enter
the Innopal LH, packages are stacked and
lined up without gaps in between. Then
conveyors with differential speeds space
the packages individually according to prespecified distances in order to count them
using a light barrier signal. Then the packages pass over a roller conveyor into the
Innopal LH.
Option 1: Interlocking layer former
Besides the formation of classic column
layer patterns as a standard solution, the
new palletizer system also allows the formation of interlocking layers. A pack turning system can be integrated into the
upstream conveying system. But whether
column or interlocking layer formation, the
pack feed stops after the desired number
of packs has been fed by a roller conveyer
to the Innopal LH. A row pusher brings the
technology+innovation °
incoming packs to the pushover plate. This
process is repeated until the entire pallet
layer is formed. Only then does the row
pusher move together with the pushover
plate, carrying the freshly formed carton
layer, towards the pallet lifter. The advantage: The row pusher handles the function of a layer pusher, managing layer formation and palletizing in one step.
2
PRECISION LANDING IN THE FIELD
INDUSTRY REQUIREMENT
Palletizer for the entry
to medium capacity range
1,500 packs per hour
150 layers per hour
All types of carton:
- Trays
- Multipacks
- Wrap-arounds
Option 2: Automatic pallet magazine
The integrated pallet lift is supplied with
individual pallets using a lifting cart. This
can also optionally be done fully automatically by a pallet magazine. Here, the
pallet lift raises each pallet until it reaches
a certain position a few millimeters below
the pushover plate, which is filled with a
layer cartons. Output of the layers formed
is done by pulling the pushover plate back
out, then the row pushers and pushover
plate return to their starting position. The
pallets are lowered together with the load
exactly one pack height. This process
repeated until the pallet is fully loaded and
removed from the system, either by lift cart
or fully automatically. The new KHS palletizing system loads not only full-size pal-
INNOPAL LH
High ease of use
Easy access
Package counting by light barrier
Palletizing capability
Palletizes full, quarter, and halfpallets with column layer patterns
or interlocking layer patterns
Low wear
Belt drive
Vulkolan rollers
Quiet, gentle materials handling
High flexibility
Powerful basic version
Numerous expansion options
Compact machine design
Low space requirements at
3 m / 3.40 m height
Service
Planning: Software simulation;
operation: maintenance through
Remote Diagnostic Service (ReDiS)
possible
54*55
Custom-fit palletizer for entry and medium capacity range
Top Modern, maintenance-free cog belts: Service as drive element for the pushover plate
and the row pusher. Bottom After the packs enter the machine, they are moved from the feed
conveyor onto the docked pushover plate.
lets; it can also palletize half and quarter
pallets.
Option 3: Inserted liner handling
and load securing
Slip-sheet inserters and an inserted liner
magazine can also be integrated into the
palletizing system for full system flexibility since the number of inserted liners can
vary. Once pallet formation is finished, a
pallet wrapper can secure the loaded pallet for transport.
with maximum positioning precision. In
the drive concept, KHS relies on maintenance-free belt drives – cog belts handle
the motions of both the pushover plate and
the row pusher, while flat belts are take
care of the lifting motion of the pallet
lift. Instead of classical metallic rollers,
lubrication-free Vulkolan rollers are used
as guiding elements. Besides the reduced
maintenance overhead, the entire drive
unit is very low-wear and low-noise. The
customer profits from high availability and
the machine’s long service life. Regular
maintenance tasks are reduced to an oil
change in the drive motors and replacement of belts.
… COUPLED WITH COMPACT DESIGN …
LOW MAINTENANCE,
LONG SERVICE LIFE …
Servo motors drive the Innopal LH, enabling
short cycle times, and high output coupled
fi
INFOBOX
• WEBSITE www.khs.com
Even in the basic version, the Innopal LH
is characterized by its low space requirements. It gets by with a height of only
three meters. The model with a pallet segment and associated automatic pallet supply and removal needs only 3.40 meters.
That means that for older plants, costly
construction, or renovation are unnecessary.
• CONTACT
Hans-Werner Holzer, Product Management for
Packaging and Palletizing Systems, KHS AG
Tel: +49 (6247) 97-3351
E-mail: [email protected]
… AND INTEGRATED
CONTROL CABINET
The control cabinet is attached directly to
the machine, allowing fast commissioning.
Of course, KHS delivers the palletizer with
preconfigured parameters. On site, the
only thing needed is fine adjustment. In
addition, the modern control systems can
connect to Remote Diagnostic Service
(ReDiS) and new software configuration
can be done online through the KHS ReDiS
Service Center.
KHS PROGRAM EXTENSION FOR
PACKAGING EQUIPMENT
The extensive KHS packaging equipment
program is the ideal extension to palletizing solutions. For instance, Innopack CA
carton folders, single-column Innopack SP
packers, or the Innopack PPZ portal packer
and Innopack CV carton sealers integrate
into the system design very easily, and KHS
tray, wrap-around, or multipackers can be
installed upstream.
CONCLUSION
In all, a carefully designed concept that
extends the range of innovative KHS solutions in the entry and medium capacity
range for the food, non-food, and beverage industries. It is characterized by high
availability, very simple use, low maintenance overhead, compact construction,
market-tuned design, and fast startup. And
the outstanding price / performance ratio
speaks for itself.
Hans-Werner Holzer, Product Management for
Packaging and Palletizing Systems, KHS AG
technology+innovation °
56*57
Subject: Adhesive-pressure Labels /
Plastic / Refillable / Glass
Removal Strategy
Along with perfect application, individual processing
in the bottle washer is the decisive factor when it
comes to adhesive-pressure labels on refillable glass
bottles. An exclusive study from the KHS laboratory shows
the way to optimum label removal.
Adhesive-pressure labels and the no-label look are important trends in the brewing and beverage industry. When
refillable bottles are returned, the decisive factor is how
the adhesive-pressure labels react in the bottle washer.
Depending on the label manufacturer, this in turn
depends on the design of the labels and their quality
– whether they are made from one type of plastic such
as PET or from different plastic materials.
Even before adhesive-pressure labels captured
the market, together with leading label manufacturers,
KHS had extensively researched the behavior of plastic label materials during and after washing. The laboratory investigations concentrated mainly on three
areas:
1. What general knowledge is available relating to the
behavior of adhesive-pressure labels in the bottle
washer?
2. What must be taken into account regarding the features of the machine?
3. How should the process at the customer’s premises be structured?
1. GENERAL: HOW ADHESIVE-PRESSURE
LABELS BEHAVE
Removal time. Plastic adhesive-pressure labels can
be removed more quickly than classic paper labels. In
removal tests, the temperatures, caustic concentration
levels, additive manufacturers, and additive concentration levels were varied. The following phenomenon was
observed: During the removal process, the sides of the
adhesive-pressure labels curled up causing them to peel
away from the bottle.
Removal effect. While paper labels are removed
by dissolving the glue, with self-adhesive labels this occurs
mainly due to the thermal effect – the caustic concentration level thus plays only a minor role. The adhesive
remains on the removed plastic label. Different shapes
are produced, which are reminiscent of cigars, weaving
shuttles, and even drinking straws, for example – substantially dependent on the type of plastic label material
used. The diameters can be from four to ten millimeters.
Because the label curls up, more space is required between
the bottle and the wall of the bottle pocket.
Subject: Adhesive-pressure Labels / Plastic / Refillable / Glass
Removal of adhesive-pressure labels: Different shapes with diameters from four to ten millimeters are formed.
After removal. How do labels behave after they have
been removed? A series of tests with extended processing times has shown that the plastic and the ink separate from the label. And, while paper labels always
float in the caustic and can be easily transported by the
flow of liquid, removed adhesive-pressure labels behave
indifferently; some float and others sink. In practice,
this raises the question what should a suitable label
discharge system be like? Recently label manufacturers have increasingly been designing labels so that they
permanently sink to the bottom and yet can be easily
discharged by controlled flows.
2. MACHINE: WHAT FEATURES?
As standard, KHS bottle washers have helpful features
for processing adhesive-pressure labels.
Gate valves. Gate valves are always provided.
There is no jamming of plastic labels in butterfly valves
or possible clogging of the piping.
Drivers. Drivers on the label conveyor belts
ensure that paper labels – even different types of
adhesive-pressure label – are discharged without
any problems.
Pumps. Filter elements are installed ahead of all pumps
in bottle washers. These filters guarantee long pump
life and also prevent plastic labels from disintegrating
in the pump impeller.
Conversion kits. KHS provides a large number of conversion kits depending on the equipment level
of the machine and the design of the bottles and adhesive-pressure labels.
3. CUSTOMER: PROCEDURE STRUCTURE
Laboratory test. If the customer wants to wash refillable glass bottles labeled with adhesive-pressure labels
using conventional KHS machines, KHS needs samples
of the bottles and the labels to be processed for the
initial exclusive laboratory tests. The experts first
check and document the individual behavior of the
label during the removal process. How long does it
take to remove the label, at what temperature and with
what degree of alkalinity? Do ink and glue remain on
the label even after extended soaking? Does the label
float or sink? What does the label look like exactly
after it has been removed? What is the effect of various storage conditions on the empties? Is addi-
technology+innovation °
tional space in the bottle pocket necessary for optimum discharge?
Practical test. A practical test is carried out
once this knowledge has been obtained. Thorough
cleaning of the bottle washing machine is an essential
requirement for accurate results.
The team then requires a defined number of the
normal bottle mix labeled with paper and adhesivepressure labels. This is the only way to obtain meaningful results under real-life conditions.
Inspection. When the test bottles have passed
through the machine, the caustic is drained and the
bottle washer subsequently inspected in minute detail.
The objective is to optimize the discharge behavior.
Measures. After taking stock, individual measures must be defined in order to achieve optimum
removal and discharge of the labels in operation as well
as perfect cleaning. If, for example, a large number of
adhesive-pressure labels remain within the bottle pockets, in the case of a single-end bottle washing machine
it is conceivable to incorporate an additional flushing
stage in the pre-caustic. If the single-end machine has
previously run without pre-caustic, a pre-caustic bath
with integral flushing unit can be retrofitted. This
entails a slight increase in the length of the machine.
If required, additional flushing units can also be integrated into double-end washing equipment – in this
case however within defined caustic baths. If sufficient
flushing units are available, but the flushing process
does not operate at the required pressure and / or
with the necessary amount of water, a larger quantity
of water for the flushing units or larger nozzles are
required. The spatial removal behavior can be influenced by varying the temperature. Additional automatic label discharge stations can be incorporated within
the recooling zones if necessary.
New investments. Up to now, the discussion
has revolved around existing KHS bottle washing equipment. In the case of new machines intended to wash
refillable glass bottles with adhesive-pressure labels,
it is recommended that some important criteria be taken
into account from the very beginning. Take the bottle
pockets as an example. Allowance should be made for
a greater space requirement – whether single-end or
double-end bottle washing equipment. This makes it
considerably easier to discharge the adhesive-pressure labels from the bottle pocket and makes it unnecessary to possibly install additional flushing units and
nozzle systems later. An important factor for single-
58*59
The label removal process is obstructed if there is not
enough space between the label and the bottle pocket.
end washing machines is to include the pre-caustic in
the machine concept.
CONCLUSION
Whether new or existing bottle washers, double-end
or single-end, the washing concepts for adhesive-pressure labels must be exactly right for every customer.
Because adhesive-pressure labels simply behave too differently.
Bernd Molitor, Competence Center Manager,
Cleaning Technology, KHS AG
Jan-Karl Nielebock, Product Management,
Cleaning Technology, KHS AG
fi
INFOBOX
• WEBSITE www.khs.com
• CONTACT
Bernd Molitor, Competence Center Manager,
Cleaning Technology, KHS AG, Dortmund
Tel: +49 (231) 569-1573
E-mail: [email protected]
Jan-Karl Nielebock, Product Management,
Cleaning Technology, KHS AG, Dortmund
Tel: +49 (231) 569-1340
E-mail: [email protected]
Technical terms in practice: Chlorine dioxide disinfectant
The Cleaner Upper
In the food industry – and particularly in beverage production –
cost-efficient and effective sterilization of water plays an important role in meeting stringent hygiene requirements as economically as possible. Practical requirement: The sterilization process
must not have a negative impact on product quality. The solution: Chlorine dioxide.
Chlorine in the form of chlorine gas or sodium / calcium hypochloride is the most commonly used disinfectant for water treatment worldwide. There can be
no doubt that the processes implemented are proven
and economical, and there is no shortage of the required
products. However, the use of chlorine has certain disadvantages that can be avoided with chlorine dioxide.
The raw material for the production of chlorine
dioxide is sodium chlorite (NaClO2 – not to be confused with sodium chloride (NaCl), which is common
salt). Two processes have become established for the
production of chlorine dioxide:
* The first process is the so-called chlorite acid process,
in which either hydrochloric acid (HCl) or sulfuric
acid (H2SO4) is added to sodium chlorite.
* The other process is known as the chlorite chlorine
process, whereby sodium chlorite is oxidized through
chlorine gas.
The chlorite acid process tends to be used for
the quantities commonly encountered in the beverage
industry:
technology+innovation °
THE FORMULA:
5 NaClO2 + 4 HCl <–> 4 ClO2 + 5 NaCl + 2 H2O
or
10 NaClO2 + 5 H2SO4 <–>
5 Na2SO4 + 8 ClO2 + 2 HCl + 4 H2O
CHARACTERISTICS:
Chlorine dioxide is an orange-yellow gas. The melting
point is -59°C, the boiling point is 9.7°C. The MAC value
(maximum allowable concentration) is 0.1 ppm. In concentrations exceeding 5 ppm, it has a noticeable odor
similar to chlorine or ozone.
It is easily soluble in water (50 g/l). Chlorine
dioxide is basically an unstable compound. The desired
stability essentially depends on the following factors:
* Level of concentration (the higher, the faster the
breakdown)
* Temperature (the higher, the faster the breakdown)
* Storage conditions (the more contact with air, the
faster the breakdown), and
* Application conditions (the presence of organic or
inorganic matter has a draining effect).
The disinfectant effect is based on the breakdown of chlorine dioxide, leading to the formation of
radical oxygen that has an oxidizing effect on organic
components.
ClO2- + 5e- <–> Cl- + 2 O.2(The notation O.2- indicates a radical)
In contrast to chlorine, chlorine dioxide does
not react with water ingredients, which could lead to
unpleasant or toxic substances.
LIMIT VALUES:
The current limits for chlorine dioxide according to
the list of treatment substances and disinfection procedures provided in Section 11 of the German Drinking
Water Ordinance (Part C) are:
1. Maximum permissible dosage: 0.4 mg/l
2. Maximum permissible concentration after water
treatment: 0.2 mg/l, and
3. Maximum permissible chlorite quantity after water
treatment: 0.2 mg/l.
NEGATIVE IMPACT OF WATER INGREDIENTS
The application of chlorine dioxide requires iron and /
or manganese, sulfides, nitrite and any organic matter to be removed from the water, because these substances interfere with the process.
DOSING IN PRACTICE
Drinking and product water
The above-mentioned maximum values are usually not
applicable for drinking water purification. The quantities normally used with suitably benign water and
adequate dwell times are 0.1 to 0.2 mg/l. For product water, the same dosage rates apply as for drinking water purification, because product water is either
the same as drinking water or obtained from it. Should
a particular application require higher chlorine dioxide concentrations due to reduced dwell times, for
example, the chlorine dioxide can be removed from
the water with activated charcoal filters or ultraviolet light. At 0.1 to 0.2 mg/l no impairment of the product taste is to be expected.
COOLING CIRCUITS
In cooling circuits, chlorine dioxide prevents formation of heat transfer inhibiting deposits (biofilms) at
a constant concentration of 0.2 mg/l or daily batch
dosing at 1 mg/l. Any corrosion and scale inhibitors
must be resistant to chlorine dioxide.
Equipment disinfection, CIP, rinsing
and washing water
Since chlorine dioxide is used in very low concentrations and contains no other auxiliary substances apart
from sodium chlorite and hydrochloric acid, it can easily be flushed out and rinsed off. This is reflected in
lower water consumption.
The highest concentrations are required for
treating product tanks that are left for some time after
cleaning (for example on weekends). In this case,
concentrations of up to 4 ppm can be used. For static
disinfection, a concentration of 3 ppm is generally used.
60*61
Technical terms in practice
A further application option is self-cleaning and disinfection of bottle and can conveyors. Chlorine dioxide is added to the belt lubricant in proportion to the
quantity, generally around 4 ppm (caution if the conveyor comes to a standstill, in which case concentration build-up can lead to corrosion).
The high effectiveness – particularly for
biofilms, which are dissolved by chlorine dioxide –
results in significantly reduced cleaning effort
(although this does not mean that manual cleaning
is redundant). This leads to improved hygiene of the
conveyors and floors, and in turn results in reduced
germ counts in the room air.
OTHER APPLICATIONS
*
*
Chlorine dioxide production system from ProMinent ProMaqua GmbH.
*
In pasteurizers to combat algae and slime-forming microorganisms.
For cold filler flushing.
For headspace disinfection of bottle washers.
ANALYTICS
Concentrations of 0.5 to 3 ppm are possible if chlorine dioxide is used in a CIP system. If chlorine dioxide is used at the fresh water stage of the CIP system,
the limit values specified in the Drinking Water Ordinance must be observed.
In bottle washers, chlorine dioxide can be used
both for cold spray-off and in the cold or warm water
zone.
Chlorine dioxide is also increasingly used in
rinsers, where it can be applied in two ways:
* simple spraying out of bottles as the last or only
rinsing step, or
* in a multi-channel rinser as a disinfection stage.
In this case, the concentration depends on the
treatment time the individual rinser types.
fi
INFOBOX
• WEBSITE www.khs.com
• CONTACT
Karl-Ludwig Schenk, Beverage Engineering,
KHS AG, Bad Kreuznach
Tel: +49 (671) 852-2488
E-mail: [email protected]
During system operation, the chlorine dioxide concentration is usually monitored with redundant measuring systems. Commonly used procedures include
redox, chlorine dioxide, and pH measurement. By monitoring the oxidation potential, the active substance
content (chlorine dioxide) and the pH value, machine
operators are able to respond rapidly to any system
problems.
COSTS
Chlorine dioxide is a very cost-effective disinfectant,
although investment costs are significantly higher
than for conventional disinfectants. The costs for a
dosing unit using monobromoacetic acid or peracetic
acid are only around 1,000 euros, for example, while
a corresponding chlorine dioxide system including
measuring, control and dosing equipment for 2 or 3
consumers can cost up to 25,000 euros, depending on
the configuration. The costs associated with connecting additional consumers such as a CIP system, for
example, are around 5,000 to 6,000 euros per consumer.
However, experience shows that the investment is likely to pay for itself within two years through
savings in chemicals and lower water consumption.
Karl-Ludwig Schenk, Beverage Engineering, KHS AG
guest at KHS °
62*63
Welcome to
Seoul
Seoul by night: World Class City for entertainment
How can I explain Seoul to you? Some say that it is the most
American city after New York; others think South Korea’s capital is
the most modern face of Asia with a long history of honored traditions. Seoul probably has elements of both. It is clear that the
city has experienced unbelievable growth over the last decades and
that it took an enormous leap into a new era.
In the mid 70ies, the city was still home to three to four
million people. Today, there are about 11 million inhabitants just
within the city itself, the greater Seoul area accounts for well beyond
20 million persons. After Tokyo and Mexico City, Seoul has the
largest metropolitan population in the world.
But scales and density do not suffice to size up the city,
even though we Southkoreans are known for having a weakness
for all kinds of rankings. No, the heart of Seoul, site of the historic Royal residence, is also comprised of more than 600 years of
rich capital culture and history. Often you will find palaces, temples, and historical buildings nestled in between skyscrapers giving the city its unique flair and even small side streets bear signs
of the city’s immense history.
Nevertheless, a visitor is certainly not expected to start
experiencing the capital by exploring its past, but on the third or
forth day, a trip to Changdeokgung, the Palace of Illustrious Virtue,
may prove to be a welcome respite from the hustle and bustle of
the mega city. It was the residence for the Royal family until
1989, and in addition to beautiful parks and palaces, it also features the mysterious Biwon Garden. Even though not every Seoul
traveler has heard about it, it is well worth a visit and has been
officially registered in UNESCO’s World Cultural Heritage list since
1997. Or you can see a traditional dance and music performance
at the National Theater of Korea (every Wednesday at 7:00 pm).
Additionally and maybe most prominently, Seoul is the premier world class city for relentless progress, business, culture, education (home of 36 universities alone) as well as entertainment,
culinary treats – and of course shopping. Don’t forget to make time
for Myeong-dong, the foremost shopping Mecca that is a must for
all who want to wander through a colorful array of small streets
and culinary delights.
with an endless number of stores. And don’t miss Namdaemun Market, which has a more distinct Korean appearance starting even
with its patrons. Also, treat yourself with a couple of hours or a
full day in Insadong, the former district of royal officials and aristocrats. It is worth it. The winding small streets and roads are
filled with dozens of art galleries and antique stores. An opulent
meal in one of the restaurants close to Sudo Pharmacy is a memorable experience.
Oh, yes, Korean cuisine. You will love it. Of course, it is
flavorful and spicy like almost everywhere in Asia, but it is also very
nutritious and low in calories. Most importantly, main dishes include
a large variety of vegetables and typical spices. If you only once
try kimchi (specially prepared cabbage), bibimpab (different kinds
of vegetables mixed with rice), galbi (grilled ribs) or haemultang
(seafood stew), you may become a fan for life. The traditional
Korean wines and liquors are world-famous, especially soju, our
national beverage. But I'm probably not telling you anything
new. Welcome to Seoul!
Sincerely, H. W. Kim, president, KHS South Korea
Tradition in the midst of state-of-the-art: Royal guard in front of
Gyeongbokgung Palace, Seoul, South Korea.
KHS AG
Juchostrasse 20
D-44143 Dortmund, Germany
Tel
+49 (231) 569-0
Fax
+49 (231) 569-1541
Planiger Strasse 139-147
D-55543 Bad Kreuznach, Germany
Tel
+49 (671) 852-0
Fax
+49 (671) 852-2411
Enzingerstrasse 139
D-67551 Worms, Germany
Tel
+49 (6247) 97-0
Fax
+49 (6247) 97-3215
Ruwoldtweg 14
D-22309 Hamburg, Germany
Tel
+49 (40) 63703-37100
Fax
+49 (40) 63703-37150
Boschstrasse 1-3
D-47533 Kleve, Germany
Tel
+49 (2821) 503-0
Fax
+49 (2821) 26110
Am Kirchfeld 3
D-34454 Bad Arolsen, Germany
Tel
+49 (5691) 8909-0
Fax
+49 (5691) 8909-15
Kapellenstrasse 47-49
D-65830 Kriftel, Germany
Tel
+49 (6192) 491-0
Fax
+49 (6192) 491-144
Industriegebiet Scheid 16
D-56651 Niederzissen, Germany
Tel
+49 (2636) 9746-0
Fax
+49 (2636) 9746-45
E-mail: [email protected]
Masthead
KHS UK LTD.
Unit 6 Monkspath Business Park,
Highlands Road
Shirley Solihull, Great Britain
West Midlands B 90 4NY
Tel
+44 (121) 713-6900
Fax
+44 (121) 713-6935
E-mail: [email protected]
KHS USA, INC.
880 Bahcall Court
Waukesha, WI 53186, U.S.A.
Tel
+1 (262) 797-7200
Fax
+1 (262) 797-0025
E-mail: [email protected]
5501 N. Washington Blvd.
Sarasota, FL 34243, U.S.A.
Tel
+1 (941) 359-4000
Fax
+1 (941) 359-4043
E-mail: [email protected]
KHS PACIFIC PTY. LTD.
P.O. Box 378
1-3 Freight Road
Tullamarine, Vic. 3043, Australia
Tel
+61 (393) 35-1211
Fax
+61 (393) 35-1331
E-mail: [email protected]
KHS ASIA PTE. LTD.
25 International Business Park
# 3-15/19 German Centre
Singapore 609916
Tel
+65 6560-9313
Fax
+65 6560-9910
E-mail: [email protected]
KHS MACHINERY PVT. LTD.
15, Madhuban, Nr. Madalpur Underbridge
Ellisbridge, Ahmedabad - 380 006, India
Tel
+91 (79) 2644-0331
Fax
+91 (79) 2644-5146
E-mail: [email protected]
KHS worldwide: You will find further addresses and contacts at
www.khs.com
PUBLISHER
KHS AG, Dortmund
EDITORS
Friederike Arndt, Maternus Gemmel, Manfred Rückstein,
jj-media, Cologne
GRAPHIC
Konzeption+Design, Trawny / Quass von Deyen, Cologne
Layout: Yvonne Voss
CONTRIBUTIONS
Alfons Abels-Rümping, Michael Breil, Werner Gessner,
Peter Haas, Rainer Hilgert, Kurt Hofmann, Hans Werner
Holzer, H. W. Kim, Dirk Langanki, Thomas Lelie, Alexander
Modrok, Bernd Molitor, Jan-Karl Nielebock, Werner Oster,
Matthias Ringholt, Franz-Alfons Sassenroth, Karl-Ludwig
Schenk, Oliver Schneider, Walter Senft, Michael Zwilling
TRANSLATION
Fachübersetzungen CP MacKusick
PHOTOS/ILLUSTRATIONS
Friederike Arndt, Asahi Brewery, Brauerei Beck & Co,
Brauereigruppe Hite, Coopers Brauerei, K+S Fotostudio
Koechlin, Burkhardt Hellwig, Hans Gronauer, Kraft Foods,
Frank Reinhold, Link Snacks, ProMinent ProMaqua GmbH,
shutterstock.de (Ioannis Ioannou, lonly vectors, CraigT,
In-Finity, Grzegorz Slemp, NatUlrich, Jonathan Heger,
hipopotamus, WizData, Gina Smith, Neil Wigmore), vision
photos, Klaus Vyhnalek
KHS journal offers young students and graduates of the
University of Applied Sciences in Dortmund and Münster
the opportunity to put their photography talents into
practice.
This information is non-binding. Only the technical specifications of our quotes are determinative with regard to
design and scope of delivery.
Subject to design modifications.
30 1992-01-987/2 0308 GW
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