07.224 KHS Journal 01_07 e

KHS journal
1° 2007
English
ACF method of dry sterilization
with condensation
The All-Rounder
Spa relies on innovative
packaging technology
The Water of Kings
KHS “One 4 Two”
keg system
Fit for Fittings
Jägermeister – ready to spring
into the Top 10 worldwide
Leader of the Herd
INDIA
The New KHS Plant
• Position as global player in
Asia further expanded
• Market leader in filling and
packing technology
• Opening ceremonies with
chief minister
editorial
A NEW ERA FOR KHS
Valentin Reisgen
Chief Executive Officer KHS AG
Dear Readers,
Salzgitter AG, Salzgitter, will become the new majority shareholder of Klöckner-Werke AG, Duisburg, Germany, with the acquisition of
more that 80% of all outstanding shares. In doing so, KHS, as one of the world’s leading suppliers of bottling and packaging technology, will also receive a new corporate controlling company above Klöckner-Werke AG. Am I being too presumptuous to therefore speak
of the dawning of a new age for the entire KHS Group? I would answer with “no” for two reasons.
First, KHS has established and reinforced its know-how and its unsurpassed level of confidence among its international customer base
over nearly 140 years with premium quality products and services. That is a very long time span of unwavering challenges and consistent levels of performance. Salzgitter AG is, in its own right, also a company that is rich in tradition that has also, just like KHS, always
placed the customer at the focal point of everything the company does. On the other hand, KHS has faced turbulent, insecure, and
rapidly changing times, and this not only in the most recent history. That is why the entire staff and their representatives, the Supervisory Board and the Executive Board of KHS welcome the entrance of the very successful Salzgitter AG into the areas of steel and technology, areas with an annual turnover of far more than € 8 billion, a step that represents not only a successful but quasi decisive break
into a stable and sustainable promising future.
The course has now been laid down as far as can be. The plan for change that was initiated in late 2005, 2010plus, which is being totally
supported and endorsed by the new majority shareholders, is now beginning to bear fruit. Fiscal year 2006, the results from which are
now currently available, was very successful for KHS.
Please allow me to emphasize just a few key figures: Sales increased by 6%, from € 713 million to € 752 million and EBITDA improved
by more than 20% to € 33 million (EBIT: approximately € 20 million; an increase of 40% in comparison to the previous reporting period).
Orders received were at € 880 million, 20% above the previous year and, in their sum, at a record level. In the process, the pricing levels continued to stabilize during the strong second half of the year, following a disappointing first half-year.
Against the background of
* a current fiscal year that is very successful,
* operative improvements that are currently in place,
* an attractive order backlog – thanks to our customers – that both motivates and obligates to carry on, and
* the future companionship of a parent organization that is economically thriving,
a new era for the entire KHS Group is now awakening. As we move ahead, we will continue to do whatever it takes and go wherever
needed, as we have in the past, to continue to be a reliable partner for you. And on behalf of all of us here at KHS, that’s a promise!
Sincerely,
Valentin Reisgen
» Thanks to the future companionship of a parent organization that
is economically thriving, KHS is on its way into a promising future.
«
contents ° 1°2007
people+markets
04
11
news
Customers, Know-how, and Contacts
04
KHS 2010 plus
14
Interview with Dr. Johann Grabenweger, Chief Operations Officer KHS
Focus on Production Offensive
dossier
16
ACF with Condensation
The All-rounder
16
dialog+opinion
20
Interview with Andreas Steinle, Director of Zukunftsinstitut
What Does the Future Have in Store?
20
task+solution
24
The Oettinger Group pursues ambitious growth targets
The Market Loyalists
28
The Spadel Group relies on innovative packaging technology
The Water of Kings
31
Okertaler Mineralbrunnen: A company reestablishes itself
Agenda 100.000.000
34
Jägermeister – ready to spring into the Top 10 worldwide
Leader of the Herd
38
Wine specialist Caves Garnier relies on KHS systems expertise
Entrepreneurial Power
40
RhönSprudel invests in the latest
KHS ultra-clean system technology
Stuff of Life
24
40
technology+innovation
44
A new, advantageous complete
concept for PET bottles
Lean Design
46
‘One 4 Two’: New KHS system for changing fittings
Fit for Fittings
48
Perfect ACF inspection technology
Playing It Safe
50
New: Camera system guarantees quality in shrink process
Light in the Tunnel
52
Technical terms in practice
Microorganisms: Noble Knights
44
Guest at KHS
55
Welcome to Stuttgart
52
55
02*03
Ready for the customer: New KHS production facility in India
BASTION
IN ASIA
Top left The new administration
building. Right The new manufacturing
shops. Bottom In India the elephant
has always been revered as a symbol
of strength, wisdom, and luck.
people+markets ° news
The new KHS plant in India started production a few weeks ago. A milestone for
the whole KHS group and its customers in the Asiatic region. Against the background
of prospering markets and noticeably increasing quality expectations of the
market, with this plant KHS is extending its position as a long-term global player
in the Far East: A bastion in Asia.
2
3 X INDIA: BOOM FOR BEVERAGES AND PACKAGING
* 45% of the population is aged between 15 and 35
* Average forecast growth in the sales of packaging machines per year
2005 to 2010: 11.1%
* Expected growth rates per year
•
•
•
•
•
Water 20%
Juices 15%
Beer 15%
Spirits 15%
Soft drinks 12%
04*05
A well-known Indian proverb says: “Fear has never yet
achieved a major objective.” In this spirit of courageous, innovative, forward-thinking ambition, the
opening ceremony of the new KHS plant took place in
the Indian city of Ahmedabad on 26 February 2007.
With this plant, the company is able to considerably
expand its operations as planned in the second largest
political economy in the world. This against the backdrop of enormous growth potential in the region and
increasing demand in other Asiatic markets. Along
with imports from the global group of companies, KHS
will now supply its Far East customers both from India
and also from the KHS company GLM2 in Chinese Shantou, Guangdong Province.
A quantitative highlight: The new manufacturing
plant in Ahmedabad covers an area of 110,000 square meters
(equivalent to almost 20 soccer fields) and has a built-on
area of 25,000 square meters. With the plant, KHS is considerably increasing its production capacity in India.
Left The varied arrays of Indian
dolls are displayed in Calcutta’s
National Museum. Center Many
of India’s well-maintained temples are UNESCO world cultural
heritage sites. Right Young
people dominate the street
scene. The Indian population is
increasing annually by 17 million
people.
With regard to quality: Like all KHS factories worldwide, the new Indian production facility is consistently
focused on the KHS quality strategy. For only in this
way can the group give its international customers the
assurance that every single KHS product – whichever
factory it might come from – represents true value and
satisfies the highest quality standards. In short: All
KHS machines are ultimately planned and manufactured “from the same mold”. In addition to the plant
in India, KHS also has eight German production facilities, as well as plants in Brazil (São Paulo), U.S.A.
(Waukesha, Sarasota), Mexico (Zinacantepec), and
China (Shantou). In addition to this, customers can
call upon more than 60 sales and service bases on all
continents.
As a global player, KHS currently realizes approximately 15 percent of total sales in Asia and Australia
(30% Central Europe, 15% Eastern Europe, 24% North
America, 6% Latin America, 10% Africa and the Mid-
people+markets ° news
06*07
Left Press conference: (From left to right) Yatindra R. Sharma, Executive Director KHS India, Valentin Reisgen, Chief Executive Officer of
KHS AG, Mahendra N. Patel, Managing Director Center (from left to
right) At the opening ceremony: Valentin Reisgen, Roland Flach,
Chairman of the KHS AG Supervisory Board, Shri Narendra Modi,
Chief Minister of Gujarat, Mahendra N. Patel. Right Valentin Reisgen
thanks the international guests for coming. Bottom Grand Mogul
Shah Jahan built the Taj Mahal in memory of his wife who died in
1631.
dle East). In India, KHS is the undisputed market leader
in the filling and packaging technology sector. As long
ago as 2005, the company received the Indian Manufacturing Excellence Award presented by the renowned
consultancy firm, Frost & Sullivan.
In his opening speech, Valentin Reisgen, Chief
Executive Officer of KHS AG emphasized: “With the
opening of our new production facility in India, we are
once again documenting that the KHS slogan ‘Your
markets are our home’ is a living reality for KHS staff.
KHS offers customers global expertise, and at the same
time acts as a reliable partner who is always on hand
and always takes account of the local situation.” This
philosophy is reflected in another wise Indian proverb:
“The smile that you radiate will come back to you”.
2
DID YOU KNOW …
… that the population of India has risen from 250 million in
1920 to more than 1 billion today?
… that India has 21 recognized national languages?
… that chess originated in India?
… that our decimal system was developed in India?
… that India is the world’s largest consumer of gold?
… that the first university in the world was in India?
… that India has the most post offices on earth?
… that India is the largest democracy in the world?
WORLD INNOVATION INNOFILL DNRV
KHS RECEIVES INNOVATION PRIZE IN GOLD
AT INTERVITIS INTERFRUCTA
The German Winegrower's Association has awarded the new KHS Innofill DNRV
filling system its Innovation Prize in Gold in the 'Filling, Sealing & Packing Technology' category at this year's INTERVITIS INTERFRUCTA, which took place from
22 to 26 April 2007 in Stuttgart. And this is what this top award is all about:
It satisfies the requirements of the beverage industry of enabling non-carbonated and carbonated beverages and plastic bottles with different mouth diameters to be processed by one and the same filling system, with changeover ideally completed automatically.
The new Innofill DNRV filling system meets these requirements fully by enabling
users to run the following programs:
* Non-carbonated or carbonated beverages in bottles with size 28 bottle mouths
* Non-carbonated beverages in bottles with size 38 bottle mouths
* Insertion of rinsing caps for cleaning/sterilization
In aseptic filling systems, fully automatic changeover to different beverages and
containers represents a productivity advantage. This also avoids manual intervention into sterile systems.
KHS was represented at the trade fair with many other innovations: A selection:
2
INDIA
FIRST DRINKTEC CONGRESS
Messe München is organizing a drinktec Congress in
India for the first time – a cooperation with the trade
association VDMA and the technical journal PET
Planet. KHS is one of the main sponsors. The Congress will take place on 29 and 30 November 2007
in the Grand Hyatt Hotel in Mumbai. Find out more
at www.dpet.com.
RUM IN PET
The Indian Rampur Distillery of Radco KHA, Rampur,
now sells 375 milliliters of Radico-Contessa brand
white rum in a glass-like PET bottle. The bottle has
a printed aluminum screw cap with tear-off tamperevident strip
Rinser-filler-capper block. Maximum flexibility + outstanding filling results +
consistently high hygiene standards + latest drive technology + environmentally friendly concept.
Innoclean FR-ZM two-channel rinser. Sixty stations + mechanical + fully variable rinsing times + variable rinse media and methods + push-button rinse programs + trouble-free changeover + water recycling program.
Innofill DRF filling system. Seventy stations + processes wine and all beverages under pressurized conditions + variable filling temperatures + differing
CO2 content + long-tube filling system with bottom-up, gentle filling process
+ minimum oxygen pickup + push-button filling phases + variable return gas
control + product heat retention facility + automated conductivity and Brix
measurement + burst bottle function + motorized height adjustment + adjustable
format parts + different capper variants (also in series) + sloping front table
concept for optimum hygiene + servo drive technology + highest system efficiency.
The system exhibited was already ordered by Gerstacker Winery in Nuremberg,
one of Bavaria’s largest wine bottling businesses.
people+markets ° news
08*09
EUROPEAN BEER STAR AWARD
ELITE HOPS
At the Brau Beviale in Nuremberg, a prestigious international jury of experts singled
out the stars among the top international
beers from the 440 beers submitted – with
the European Beer Star Award 2006. The
assessment was carried out in 35 different
beer categories from German wheat beer to
English Best Bitter. The Association of Private Breweries and the Association of Small
and Independent Breweries in Europe organized the competition.
Beer lovers were also asked for their opinion. Visitors to the world’s most important
trade fair for the beverage industry also
chose their favorite beers from the range
of European Beer Star gold medal winners,
the Consumers’ Favorites. This coveted public award was received by:
* Consumers’ Favorite in Gold: Kitzmann
Brauerei white beer
* Consumers’ Favorite in Silver: HirschBrauerei Honer “Dunkle Hefe Weisse”
Consumers’ Favorite in Bronze: Samuel
Adams Black Lager from the Boston Beer
Co.
Breweries from all over the world, including the U.S.A., Russia, Tanzania, Mongolia,
and Japan, as well as almost all countries
in Central and Eastern Europe entered their
beer specialties for the European Beer Star
Awards 2006. A new participant record.
All details at
www.european-beer-star.de
*
RUSSIA
FROM VODKA – TO BEER COUNTRY
Beer consumption in Russia in 2006 climbed by almost 10 percent
to 99.9 million hectoliters. The Ministry of Economic Affairs expects
that by the end of the decade Russia will have overtaken Germany
to become the fourth largest beer-brewing nation after China, the
U.S.A., and Brazil. Beer consumption in Russia has almost doubled
since the year 2000. More and more Russians are also giving up
high-proof vodka and turning to beer for health reasons.
ANHEUSER-BUSCH
MARKETS BUDWEISER BUDVAR
Who would have thought it: Anheuser-Busch, the U.S. brewing giant,
is now selling the beer of the Czech brewery Budweiser Budvar in
the States. Six hundred North American wholesalers distribute the
brew from Budweis under the name Czechvar.
VOSS NORWAY
STYLISH WATER
The Norwegian mineral water, Voss, now comes to the consumer in
a glass container that is more reminiscent of a perfume bottle than
a classical mineral water bottle. Bottle sizes: 375 and 800 milliliters. The noble glass container was created by Neil Kraft, former
Creative Director at Calvin Klein. Up to now, a large part of the production has gone to the U.S.A.; Europe, Asia, and the Middle East
are also on the agenda.
AUSTRALIA
GLASS ON THE
WINE BOTTLE
Wine bottle and glass in one –
this is what the Hardy Wine Company, Australia, is offering. The
company is marketing a 187-ml
plastic wine bottle, which strictly
speaking is capped with a plastic wine glass. When you open
the bottle, you are holding the
glass directly in your hand. The
creation is intended mainly for
sporting and other outdoor
events.
KHS BOTTLING LINE
FOR HEINEKEN RUSSIA
CARGO
It is not every day that an 85-ton bottling line flies halfway around the world.
On 23 January this year the time had come. From Frankfurt-Hahn Airport,
located near KHS’ plant in Bad Kreuznach, a beer bottling line for PET bottles
destined for the Heineken Brewery JSC Amur Pivo took off for Khabarovsk. The
filler alone weighed 20 tons. The Antonov 124 swallowed an exact total of 17
individual crates delivered from different KHS locations. The KHS installation
crew was already at the destination site, and, shortly after the landing of the
heavyweight, began installing the equipment, which processes 24,000 1.5 and
2.0-liter bottles per hour. Just five weeks later, JSC Amur Pivo was bottling
the first beer with this line.
PRESS WORKSHOP SESSION
KHS AND BOSCH REXROTH
STRONG PARTNERS
Representatives of the technical press were invited to
the Global Rexroth Technology Summit, which was presented jointly with KHS. Totally in keeping with the
“joining forces” philosophy of Bosch Rexroth and KHS,
Dr. Achim Wapniewski, Director of Global Marketing,
KHS AG, explained to the participants the consistently
customer-oriented link between KHS technology and
Bosch Rexroth components. For only the use of modern drive technology and high-quality compressed air
systems enables KHS systems and machines to work
perfectly. With Bosch Rexroth – one of the world’s leading providers of drive, control, and motion solutions –
KHS is intentionally placing its trust in a supplier that
meets the high KHS standards and also supports the
stringent quality philosophy. Bosch Rexroth is therefore jointly responsible for everything working perfectly, particularly in the filling, labeling and packing
processes. According to Dr. Wapniewski, the motto is
to provide the customer with added value in every
respect with common technology and comprehensive
know-how.
TRENDS
WATER IN THE LEAD
According to studies by the market research institute, Canadean, the world’s
population consumed around 137 billion liters of bottled water in 2006 – twice
as much as in 1998. On average, each person drank 21 liters last year. Consumption continues to vary considerably between individual regions. For
example, West Europeans consumed 113 liters of bottled water in 2006, while
Africans consumed just 4 liters. And Canadean gives the water industry reason to hope for more: The per capita consumption is expected to be around
25 liters in 2009; that would be a total of 167 billion liters of bottled water.
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 almost 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.
DERHIM INDUSTRIAL, YEMEN
THE ALL-ROUNDER
KHS is delivering a non-refillable bottling line for glass and PET bottles with an output of 52,000 bottles per hour to Derhim Industrial
in Hodeidah, Yemen on the Red Sea, one of the hottest places on
earth. The line is intended
* for 200 and 250 milliliter glass bottles for hot-filling fruit juices
and carbonated beverages,
* for 300, 330, 350, 500 and 750 milliliter PET bottles for carbonated beverages and still water or optionally 19,500 1.5-liter PET
bottles for carbonated beverages.
The line is a complete KHS bottling system from the depalletizer for
new glass bottles via the rinser, filler, mixer, and carbonator to the
wrap-around labeler and tray packer. The heart of the line is an
Innofill DNRF filler, a computer-controlled long-tube filler, which
processes carbonated beverages and also provides pressureless hot
filling or filling of sterile water.
Derhim has been a customer of KHS since 1981 and, since then, has
ordered several canning and non-refillable, refillable bottle lines
from KHS as a result of positive experience with the cutting-edge
technology and the reliability of the lines supplied. The management is particularly impressed by the output of the first DNRF filler
for the hot filling of fruit juice drinks. With hard work and skill, the
Derhim family has made its company the fruit juice market leader
in the Yemen. Not to be underestimated: A staff of reliable and
experienced employees who know how to use modern plant equipment.
FLUIDI
NEW CUSTOMER IN KOSOVO
As the first KHS installation in the company, Fluidi in Kosovo is taking delivery of a complete canning line with a capacity of 10,000 cans
per hour for 0.33 and 0.25-liter soft drinks for its plant in Gjilan.
COCA-COLA FORTUNE, SOUTH AFRICA
GOOD PERFORMANCE MAKES AN IMPRESSION
Coca Cola Fortune is taking delivery of a 30,000-capacity non-refillable PET line for its Polokwane site in South Africa. The line processes
empty bottles (500 and 2000 milliliters) with four different shapes
labeled by a KHS Innoket RF roll-fed labeling machine, and is prepared for two additional sizes of bottle. In 2005, the company took
delivery of a similar line from KHS for Port Elizabeth, the success
of which was a crucial factor in the purchase of the new KHS system. All machines have semi-automatic or fully automatic format
parts – with the objective of shortening format change times.
CIA. MARANHENSE (COCA-COLA), BRAZIL
PRODUCTION SYSTEM EXPANDED
Cia. Maranhense, Coca-Cola bottler in Brazil, has
commissioned KHS to adapt the glass and PET
bottle production lines at its São Luis plant
(in the state of Maranhão) to carbonated beverage bottling:
* for glass, this includes an Innopack GT
crating/decrating system, an Innoline bottle and pack conveyor, a VF 60 filling system,
and an Innopro Z module,
* planned for the PET bottling line are an Innopal ASH palletizer,
Innoline pallet, bottle, and hanger conveyors, and a KHS Kisters
Innopack packing system.
KHS also undertook the expansion of the cooling and compressed
air plant for an Innopro system. With excellent development,
the Brazil Division is the third largest arm of the Coca-Cola Company in the world. Cia. Maranhense is an authorized bottler,
which fulfils all of Coca-Cola’s international quality standards,
and produces, bottles and distributes all Coca-Cola products in
Brazil.
ASIA PACIFIC BREWERIES-PEARL + HEINEKEN / SABMILLER INDIA / SOUTH ASIA
BREWERIES + CARLSBERG / UNITED BREWERIES
KHS INDIA: SUCCESS IN A BOOM MARKET
The Indian beer market is growing at an attractive 15- to 20-percent rate annually. Although the breweries are still relying primarily on refillable glass at present, the canned beer segment is
gaining ground – slowly but surely. One reason is the explosive
growth of the retail trade in this gigantic country. Only a few
large brewing companies have dominated the industry until now.
But, since last year, there have been new developments in the
Indian beer market. International global players like Heineken
and Carlsberg are setting up their businesses – generally as joint
ventures together with domestic brewing companies. And often
enough, KHS India – represented by domestic production facilities – is the trusted partner.
Asia Pacific Breweries-Pearl + Heineken:
Complete packaging system
A joint venture of Asia Pacific breweries (APB), the
investment branch of Heineken in India, and the
Pearl Group (PepsiCo’s franchise bottling company in India) in Hyderabad, Andhra Pradesh,
is receiving from KHS India a complete packaging system for refillable glass designed for
an output of 21,000 bottles an hour. The
first project of a new brewery to be set up
by the partners includes the planning of
production facilities for several
Heineken/APB brands in India. The whole
packaging system, except for the inspection equipment, is being manufactured
by the new KHS India plant. The system is expected to go into production before the end of 2007.
SABMiller India:
Fifth packaging system plus can shrink packer
SABMiller India, our first Indian customer, already ordered an extensive packaging system back in 2002. Since then, there have been
three additional orders. And now, the company has ordered a fifth
KHS line for Skol Breweries (SICA) in Pondicherry. Capacity: 21,000
refillable glass bottles per hour. SABMiller India thus relies on the
technology of a trustworthy partner to a degree unlike any other
manufacturer. Evidence of this fact is also provided by the installation of an Innopack Kisters PRIMUS shrink packer for cans – an
SP 35 model capable of processing at 35 cycles per minute – at SABMiller India in Aurangabad, Maharashtra, in the fourth quarter of
last year. This machine, like the shrink packer for United Breweries,
is one of the first can shrink packers for printed film in the Indian
brewing industry. And KHS’ performance must have been very convincing considering that in early 2007, SABMiller India already
ordered the next machine of this type.
South Asia Breweries + Carlsberg:
First Indian refillable glass system for Carlsberg Beer
The joint venture of South Asia Breweries and Carlsberg Breweries
in India has just entrusted KHS India with the manufacture and
installation of a complete packaging system in Alwar, Rajasthan to
process refillable glass bottles at 21,000 bph. The brewery, which
is yet to be built, will be the first production plant for Carlsberg
Beer on the subcontinent. Although the main brewery equipment
will come from Europe, the complete packaging system will be manufactured in the KHS India plant.
United Breweries:
First can shrink packer for printed film in India
During the last quarter of 2006, KHS India successfully installed a
Kisters Innopack PRIMUS shrink packer to wrap cans in printed film
– an SP 35 model operating at 35 cycles per minute – at United
Breweries for Bombay Breweries in Tajola, Maharashtra. Like SABMiller, United Breweries is a pioneer in high-quality, attractive can
packaging in the form of printed shrink film.
In addition to the above, KHS India has installed a large
number of bottle washing machines, fillers and dry-area packaging equipment, including a palletizer (the first palletizer from KHS
in India for such an application), for various existing United Breweries production facilities in India.
United Breweries Ltd (a joint venture with Scottish & Newcastle, United Kingdom), the leading company in the Indian beer
market with a market share of over 40%, has likewise chosen KHS
as its trusted partner.
people+markets ° news
12*13
PRIMO SCHINCARIOL, BRAZIL
TWO NEW SYSTEMS: BOOMING BEER SALES
HEINEKEN ESPAÑA
THE KEG IS THE KEY
Heineken España will soon be taking delivery of a turnkey
keg washing and racking system including the dry area
and all the process engineering equipment. The fully
automatic, high-performance rotary machine of the latest generation at the Valencia site, designed for 800
and expandable to 1000 kegs per hour, is already the
third power line for the company in Spain after Cruzcampo und Heineken Madrid. Other KHS keg systems
in the medium output range are also installed at Heineken
Arano and Heineken Jaen. The keg is a strategically
important type of container in Spain with a market share
of over 30 percent.
The new technologies from KHS have once again shown themselves as deciding sales factors: The Brazilian beverage company Primo Schincariol has just
ordered two bottling lines for beer with a capacity of 62,000 bottles per hour
each, for locations in the states of Pernambuco and Ceará. Each line is equipped
with an Innopal RS3 depalletizer / palletizer, inspection facilities for pallets,
labels, full bottles, and full and empty packs, an Innopack PPZ crater / decrater,
bottle and pack washing system, pack and bottle conveyors, pasteurizer, an
Innoket KL 2040 labeler, CIP sanitizing system, and Innofill DRS-ZMS filling
system.
The filling system – equipped with a biological front table – boasts a modern,
electromechanical filling design, in which an electrode integrated into the
filling valve controls the fill volume. The Innopas C pasteurizer is equipped
with the ECOBUS system enabling Primo Schincariol to save even more water
and energy. Schincariol primarily bottles mineral water, beer, and soft drinks.
The group has a respectable market share of 12.2%, is a 100% Brazilian company with more than 6,000 employees, and has the largest industrial campus
in South America.
LOZAR PELISTERKA
PET LINE FOR MACEDONIA
The mineral water bottler, Lozar Pelisterka A.D. Skopje in Macedonia, purchased a
KHS line as long as 20 years ago. Because this system has long since proved its
worth, Lozar Pelisterka has now ordered a second system for the Bitola site from
the trusted manufacturer. The new, modern PET system processes carbonated and
non-carbonated water at a rate of 12,000 1.5 and 0.5-liter bottles per hour.
PIVOVARNA LASKO
KHS KEG-TECH FOR SLOVENIA
A keg line and a Keg-Boy are destined for the Pivovarna
Lasko Brewery in the Slovenian town of Lasko. The KHS
Innokeg TRANSOMAT 5/1 keg system with a rated output of 320 kegs per hour is the first of its kind in the
company and also in Slovenia. The management decided
in favor of KHS due to the company’s advanced keg technology, the excellent relationship between quality and
price – and last but not least because of the outstanding DCF racking system.
Pivovarna Lasko, the group also includes the Fructal
fruit juice business and the Radenska mineral water
springs, also ordered an Innokeg Keg-Boy C2 – especially for washing and racking Cool Kegs. Important:
Transomats are also able to process Cool Kegs and, for
its part, the Keg-Boy is capable of handling large 30
and 50-liter kegs.
JSC KRINITSA, WHITE RUSSIA
PET SYSTEM FOR THE NUMBER ONE
The leading brewery in the Republic of White Russia, JSC KRINITSA in Minsk,
has ordered a complete PET bottling line from KHS for its much-vaunted beer.
The line has a capacity of 14,400 bottles per hour for 1.5-liter bottles and alternatively processes 12,500 2-liter bottles per hour. The company already took
delivery of a 12,000-capacity KHS line in 2004.
DUBAI REFRESHMENTS
90,000-CAPACITY CANNING LINE
The Pepsi-Cola bottler Dubai Refreshments in the United Arab Emirates recently
ordered a turnkey canning line with a capacity of 90,000 cans per hour. Production commences in June 2007. The line processes five different sizes of can
with the greatest flexibility. With this line, Dubai Refreshments is considerably expanding its capacity in the canning sector – and is once more reverting
to proven KHS technology.
KHS renewal concept 2010 plus
Focus on Production Offensive
Interview with Dr. Johann Grabenweger, Chief Operations Officer KHS AG
Begin with the end in mind. In mid-2005, KHS established a renewal program. The aim: Top quality
at all times for customers anywhere – worldwide. The approach: A continuous improvement process
throughout the entire group. KHS journal spoke with Dr. Johann Grabenweger, KHS Chief Operations
Officer, about the production offensive embedded in this strategy.
KHS JOURNAL: An offensive invariably
involves some kind of attack. Whom or what
does the KHS production offensive attack?
DR. JOHANN GRABENWEGER We are basically attacking ourselves, in order to make
progress on several fronts, ultimately for the
benefit of our customers. We simply must try
and implement the large number of ideas we
have more quickly. What is ultimately needed
is speed and reliability. We still have immense
potential in this area. Last year we integrated
all our German plants into our production
alliance. During 2007, we will integrate all
plants worldwide. To this end, we implemented a central order control department.
Identical systems such as SAP and CAD form
the basis for exchangeability and comparability of information. A production system
we are currently developing will make us faster,
better and more efficient, and our products
will offer the same Made by KHS quality, irrespective of where they are produced.
service provision chain (production, logistics,
service and purchasing), which are analyzed
and implemented step by step. Improved
organization of the working environment
(missing parts / setup times, workstation
design, etc.) should ultimately make life easier for KHS employees and lead and to higher
productivity, in order to achieve fine adjustment of the main production factors (quality, time, and costs).
How does the production offensive fit in
with the overall renewal concept of the
group?
Through a new culture of open interaction, we create trust and commitment, which
we can later experience on a daily basis in the
form of improved performance and quality
that can be measured specifically. Our goal
is continuous improvement. Our production
aims are consistent with our corporate objectives of performance, growth, culture, and
quality.
°
*
and what does it look like in practice?
° …Imagine
magic triangle. The challenge
*is to balance amaximum
quality with minimum
costs and optimum cycle times. This task is
made more complex by the fact that these
parameters interact with each other.
The magic triangle of
production management
TIME
(faster)
does this mean for your staff?
° What
It means that worldwide around 2,000
*KHS production specialists at 14 production
locations are dealing with more than 600
internal optimization projects along the entire
Avoiding waste
COSTS
(more efficient)
QUALITY
(better)
do you control all this in practice?
° How
Through regular routine meetings and
*telephone and video conferences, coupled
with continuous implementation controls.
Our strategy is based on coordinated communication and a common database, so that the
best ideas can become the standard that can
be used as reference for practical application
worldwide. The process of learning from each
other has a name: best practice. Today, we
are already seeing evidence of this in many
places in our plants. Put simply: My job is to
exchange all objectives and experiences in
dialog with my colleagues, to create resources,
to motivate everyone, to control, to avoid
risks for the company, and to learn from mistakes.
… and how is this implemented in the
company?
We are in the process of establishing a
perfect internal communication system, because
no doubt we have some catching up to do in
this respect due to numerous company acquisitions over recent years. This process involves
installing identical systems and optimizing
networks, so that everything operates based
on 100 percent identical data. In practice
and with respect to solutions for the customers this means: who does what and how,
and by when. Everything is precisely tuned,
like in an orchestra. Schedules and deadlines
are coordinated between the plants and shortages are detected in good time so that delivery dates for our customers can be met.
°
*
KHS 2010plus °
How are individual production locations
affected?
Our aim is to be able to produce each product at a minimum of two locations worldwide,
with one location acting as “lead plant” for
the whole group, taking responsibility for
developing the product further.
°
*
For example?
Our top specialists for ACF produce these
systems in Hamburg for reasons partly relating to our company history, although we can
build the same systems at Bad Kreuznach. For
fillers, on the other hand, the lead plant is
Bad Kreuznach, while the ascendants in this
case are the United States, Brazil, and India.
°
*
of sub-projects. We are investing in EDP equipment in order to speed up and automate
processes. Suppliers are classified and assessed,
and, where possible, general agreements are
bundled globally. We intend to negotiate new
contracts with all large suppliers and to enter
into strategic partnerships. To this end, our
procurement managers meet on a regular basis.
I personally attend meetings once a week and
we also set up a Purchasing Club Global Sourcing that meets on a monthly basis via video
conference.
High ambitions, with high demands on
employees.
Indeed. However, the KHS team has been
used to that since day one. Certainly, we integrate colleagues, we hold target discussions
with other plants, and we break this process
right down to each individual. We specifically
support qualification, including multiple qualification.
°
*
the advantage…
do you expect this system to have
° …… with
° When
that we can balance capacities and
been perfected?
*benefit from full flexibility in terms of plant
Never. Because a company
*with(laughing)
goals such as KHS never stops learning.
utilization. Any balancing should not only
take place among German plants, but internationally. Of course, we also take into account
business management aspects. Added to this:
The approach offers maximum international
know-how transfer within the group.
do you manage it all?
° How
By using the same data, we can follow all
*aspects of an order, including sale, design,
purchasing, assembly, and field installation.
sales there is purchasing…
° Before
… naturally. Our purchasing activities
*are also based on a global approach. In short:
all-embracing, consistently quality-oriented,
paying attention to the quality of the suppliers and ultimately also their conditions. To
this end, we have established a wide range
We have to create a climate that promotes continuous improvement and indeed demand it
from everyone. Simplicity does it. Each plant
has an A4 sheet stating its main objectives.
detailed is this process?
° How
We have just started improving all main
*processes
in order to control KHS better. The
objective is to measure performance where
services are rendered, where deadlines have
to be met, and, of course, where measurement
is indeed meaningful. I would also like to
reduce red tape. Everyone in the company
must know how to contribute to our success.
°
Can the outcomes of this complex offensive be measured in a meaningful way at
all?
14*15
We developed an indicator system
*thatYes.
makes the output measurable systematically. Parameters include cycle times, costs,
quality costs, adherence to delivery schedules for whole projects, added value, shortages, utilization, etc.
sounds very mathematical and …
° This
… is indeed a numerical parameter that
*we need in order to know whether or not we
are improving. Perhaps an even more significant goal may be to further enhance mutual
trust among colleagues and to integrate them
in the projects, which is something we are
already trying to achieve specifically in each
plant, even those abroad.
What is the current state of the production offensive – just over a year after it
started?
Together we have already achieved a lot.
The quality loop, including all stages from
development to final acceptance at the customer site and the accompanying service, has,
with all due modesty, largely been closed and
is being improved on a daily basis. We have
become more productive and already achieved
a 10% reduction in quality costs. We have
successfully introduced a number of products
around the world and transferred know-how.
Our current level of international staff exchanges
is unprecedented. In all plants, we have
improved the logistics processes and reduced
our costs through intensive negotiations with
our suppliers.
°
*
Dr. Grabenweger, to stand a chance of
success, all grand ideas have to have a
simple core. What is at the core of the
KHS production offensive?
Do it more simply, faster, and more flexibly. Think of the customer in whatever you
do. Don’t be afraid to refine yours ideas and
put them into practice. For me it will always
be the people who lead KHS to success.
°
*
Aseptic Cold Filling (ACF) is continuing its conquest of the non-alcoholic beverage industry. KHS is
one of the pioneers of this technology and has already installed more than 30 modern aseptic
installations worldwide. There are several good alternative systems. But which method is the most
suitable for which type of operation? The new KHS ACF process of dry sterilization with condensation comes with a whole series of pluses.
THE ALL-ROUNDER
ACF with Condensation
Aseptic Cold Filling (ACF) setzt seinen Siegeszug in der alkoholfreien Getränkebranche immer weiter
fort. KHS ist einer der Pioniere dieser Technologie und installierte weltweit bereits über 30 moderne
Aseptikanlagen. Dabei gibt es alternativ mehrere gute Systeme. Doch welche Methode ist für
welchen Betrieb am Besten geeignet? Das neue KHS-ACF-Verfahren der trockenen Sterilisation mit
Kondensation kommt gleich mit einem ganzen Paket an Pluspunkten.
dossier °
16*17
+++ safe +++ flexible +++ gentle to bottles +++ cost-cutting +++
It’s a good idea to take a look back occasionally – so you can assess the future better. KHS had already started real pioneering work in aseptic filling by the end of the
1980s. The focus at that time was on cold
filling and wet sterilization of glass bottles. Today, modern ACF (Aseptic Cold Filling) is directed more towards processing
sensitive beverages in non-refillable PET
bottles – handled with the process of dry
sterilization. For years, KHS was the only
provider of rotary machines in this area for
the beverage industry. And that means
they have particularly comprehensive knowhow in this field that is probably one-ofa-kind in the industry.
And that already brings us to the
future. Because today, the question of
questions for bottlers of non-alcoholic, sensitive beverages: Which ACF process – wet
or dry – is going to be the best suited for
my operation, even tomorrow? Practical
experience shows that both KHS processes
are absolutely safe. But while dry sterilization is attractive to some because no rinse
water is needed for bottles and caps, which
saves money, others swear by wet sterilization precisely due to the traditional bottle and cap rinsing process.
Whichever way you go, one thing is
certain. The wet rinsing process is recommended if you aren’t sure that the bottles
and caps are going to enter the ACF block
free of particles, fluids, and condensation.
That is usually the case when the blow molder
is not installed directly ahead of the block.
EVEN MORE PLUS POINTS:
CONDENSATION METHOD OF
DRY STERILIZATION
For dry sterilization, KHS specifically relies
on the so-called condensation process using
H2O2. This technology for bottle interior
sterilization is based on a three-stage process
worked out in painstaking detail to ensure
the highest possible degree of safety.
1. An H2O2 -water mixture diluted to a few
percent vaporizes in the sterilizer area of
the machine, using a heat exchanger directly
at the bottle mouth.
2. The resulting vapor is blown directly into
the bottles by means of sterile air.
3. The H2O2 can thus take effect directly on
the walls of the bottle, without breaking
down beforehand. Because the plastic bottle is at ambient temperature, the H2O2
vapor mixture condenses due to the temperature difference directly on the bottle
walls.
A visible moistening of all bottle
interiors means that the condensation
process is extremely easy to confirm visually. At the same time, it is certain that
the system moistens all parts of the bottle
2
equally. Even for undercut shapes, edges,
and angles, such as ribbed bottles often
have, for instance. This can also be verified using an infrared thermometer. The
H2O2 volume used is always precisely defined
and adapted to the bottle shape and size
to be processed.
Thus the KHS condensation process
provides a high degree of safety, allows
individual variations corresponding to the
requirements of the customer, and additionally handles containers extremely carefully (plastic bottles are never heated to
more than 65 degrees Celsius).
BRIEF DIGRESSION:
THE STERILIZATION PROCESS
*
Just the H2O2 -water mixture condensing
on the bottle walls results in a mean logarithmic germ-kill (MLK) of at least two.
WORLD INNOVATION: THE NECK RING ISOLATOR
On the basis of the KHS ACF process of dry sterilization with condensation successfully established on the market, KHS has developed the concept of the neck ring isolator. A world first.
The principle:
The neck ring isolator isolates plastic bottles from the neck ring up – both inside and out.
Class 100 clean room conditions are thus only needed above the neck ring.
Advantages (over and above the advantages of the condensation process itself):
* Clean room volume of only 10 percent with respect to the (already low) clean room space
requirements for dry sterilization. No exterior sterilization is required.
* Neck ring isolator allows the processing of nearly any bottle materials and shapes, such
as plastic bottles today, cardboard cartons tomorrow, and pouches the day after.
* Costs are significantly reduced even further:
1. No exterior sterilization
2. Low clean room volume means a smaller flow of sterile air and thus fewer HEPA filters needed.
2
CHECK: THE GAS PROCESS
On the ACF line market, there is also the so-called “gas process”. The process flow
is significantly different from the KHS condensation process. A comprehensive
overview follows.
STERILIZATION MEDIUM CHECKPOINT
In the gas process, hydrogen peroxide (H2O2) is brought into the vaporous state in the
evaporator, and is then heated to about 200 degrees Celsius. This generally favors the
fast decomposition of the H2O2. This already starts at temperatures of less than 100°
Celsius, greatly accelerating at increasing temperatures.
* The result: Even before its introduction into the bottle, a large part of the H2O2 present has already broken down. And there are also high power costs from heating the
air.
BOTTLE SHRINKING CHECKPOINT
H2O2 heated to about 200 degrees enters the bottle, which in turn has been preheated
to about 50 or 55 degrees Celsius. Especially for thin-walled PET bottles, this is a critical load stress limit.
* The result: A higher PET bottle weight seems to be necessary. An increased cost burden can therefore not be ruled out. Moreover, when using the gas process – and KHS
has tested this – due to the higher temperatures, you can count on correspondingly
increased bottle shrinkage for all plastic bottle materials.
CONTROL OPTION CHECKPOINT
In the gas process, due to the heating, there is no condensation effect on the walls of
the bottles (no visual effect).
* The result: It is neither detectable nor measurable whether the entire surface of the
bottle has been contacted by the H2O2 gas mixture.
*
*
STERILIZATION MEASUREMENT CHECKPOINT
It is absolutely possible – as is generally the case when introducing gas into plastic bottles – that turbulence of the H2O2 occurs within the bottle and the gas is not evenly distributed due to the resulting backpressure.
* The result: It cannot be guaranteed that a sufficient concentration of free radicals
is reached at all points on the interior bottle wall.
*
COMBINATION INTERIOR / EXTERIOR STERILIZATION CHECKPOINT
All in all, with the gas process there are a series of unreliable factors for interior bottle
sterilization – from the viewpoint of the competent KHS process engineer. Some users
of the gas sterilization process use KHS’ condensation process to ensure exterior sterilization. However, the exterior sterilization by condensation occurs even before interior sterilization with the gas process, which takes place on a separate carousel.
* The result: It is possible that during interior sterilization at higher line speeds, unsterile air may escape from the interior of the bottle and recontaminate the exterior of the
bottle.
*
*
*
CHEMICAL USE CHECKPOINT
In the gas process, there are few options for controlling the actual sterilization process.
* The result: It is necessary – and this is basically unavoidable – to include a high safety
factor in the dosage of H2O2. In the condensation process, is it possible to use a significantly smaller amount of chemicals due to the reproducible process that can be controlled in every phase.
Proved by numerous test procedures
with what is probably the germ most
resistant to H 2O 2: Bacillus subtilis.
The sterilization process itself starts as
soon as warm air is blown evenly into
the plastic bottle – within an activator
zone connected to the sterilizer.
The H2O2 broken down by the warm air
generates free radicals such as the OH
radical and atomic oxygen. Both products of this decomposition attack the
cells of microorganisms directly.
This means that the H2O2 condensed in
the bottle, after introduction of warm
air, ensures the reliable sterilization
effect directly at the location needed
(the point of kill).
For a perfect sterilization effect, either
one activator or even two activators
connected in series are required.
KHS makes its plans based on the plastic bottle sizes and shapes used, as well
as the products to be filled and the
installation’s output. This means that
the visible and measurable sterilization
process maintains radical formation
until the H2O2 is completely gone from
the wall of the bottle.
dossier ° ACF with Condensation
18*19
Dry sterilization of bottles and closures: KHS relies specifically on
the so-called condensation process using H2O2 – the best tested, with
all the plus points.
*
*
*
*
*
KHS guarantees kill rates of MLK 5 (based
on Bacillus subtilis) when using the
condensation process of dry sterilization. Numerous validations demonstrate this kill rate.
Exterior sterilization: In the tunnel zone
installed ahead of the activator, H2O2
is condensed onto the body of the bottle using nozzles (both visibly and by
direct measurement).
The warm air blown into the bottle interior in the activator causes a heat transfer from the bottle interior to the exterior, meaning that the formation of radicals on the exterior of the bottle is just
as reliable as within the plastic bottle.
A significant aspect for reliable sterilization: Exterior sterilization takes place
virtually simultaneously with interior
sterilization.
During the process of introduction of
warm air into the activator area, air is
displaced by the hydrogen peroxide out
of the interior of the bottle.
VALIDATION
The worth of a technology is shown by validation. With ACF, that means total micro-
biological control. The experts carry out
testing down to the last detail.
Step 1: The line. It starts with a precise
check of exterior sanitizing. The entire ACF
line is sprayed with a suspension of diatomaceous earth, precipitate chalk, or kaolin.
A white film remains once the suspension
has dried. Cleaning is next, followed by a
search for any remnants of haze, indicating those areas where thorough cleaning
was not possible. The knowledge gained
from this process is then used to make structural changes or to build in additional cleaning jets. The next step is to take smear
samples at critical points in the system
(mainly in the filler/capper area). Step for
step, the experts test each individual machine
component, performing each test several
times. This is a task requiring meticulous
attention to detail.
Step 2: The filling results. The culmination of the validation is the testing of filling results. Usually, the filling of 10,000
bottles at once under aseptic conditions.
These are stored at 28° C for a period of
three weeks in a closed room. The validation process is only considered successful
if the following examination indicates that
no more than one bottle is infected with
beverage-contaminating microorganisms.
fi
Besides the nine validated KHS systems
working with dry sterilization using the condensation process, there are another twelve
KHS systems soon to be validated. This
includes the ACF line at Gehl’s Dairy in the
United States, which is being validated
according to strict American FDA guidelines.
CONSISTENT ORIENTATION TOWARDS
THE CUSTOMER
KHS has had significant success with ACF
dry condensation. External experts also
agree: This procedure is the future of the
industry. And it’s also the basis for further
development activities (see box, The Neck
Ring Isolator). And that in turn speaks volumes about the innovative spirit and force
of the company and its ongoing, consistent orientation towards the needs of its
customers. Yesterday, today, and tomorrow.
Dr. Hartmut Evers, Manager of the
Beverage Engineering Department,
KHS AG, Bad Kreuznach
Manfred Michl, Manager of Technical Sales,
Process Engineering Competence Center,
KHS AG, Bad Kreuznach
Diana Wolf, Beverage Technology
Department, KHS AG, Bad Kreuznach
INFOBOX
• WEBSITE www.khs.com
• CONTACT
Dr. Hartmut Evers, Manager, Beverage Engineering Dept., KHS AG, Bad Kreuznach
Tel: +49 (671) 852-2252, E-mail: [email protected]
Manfred Michl, Manager of Technical Sales, Process Engineering Competence Center,
KHS AG, Bad Kreuznach, Tel: +49 (671) 852-2325, E-mail: [email protected]
Diana Wolf, Beverage Technology Department, KHS AG, Bad Kreuznach,
Tel: +49 (671) 852-2611, E-mail: [email protected]
What Does the Future
Have in Store?
Interview with Andreas Steinle, Director of Zukunftsinstitut
Future and fascination – two terms that have more in common than
just the first letter. Since time immemorial, the future has always
been associated with a degree of fascination – people want to
research, understand, and utilize the future. This is the mission of
the German “Zukunftsinstitut”, established in 1998 and located –
what else could be expected – directly at Zauberberg [Magic Mountain] in Kelkheim near Wiesbaden. Given the degree of future fascination and magic, Andreas Steinle’s definition of future sounds
comparatively simple. According to the Zukunftsinstitut Director,
“Future is what is in store for us.” And, “We see our purpose as
facilitators of the associated change.” KHS journal spoke with
Andreas Steinle.
KHS JOURNAL: Before you became director of Zukunftsinstitut
you were head of Trendbüro in Hamburg. What is the difference
between trend research and futurology?
ANDREAS STEINLE: Trend research deals with periods of up to
five years, while futurology examines developments over the next
five to thirty years.
futurology based on trend research?
° IsDefinitely.
same time, futurology also has a good deal to
*do with the pastAtandthewith
the present. Future is basically always also
encapsulated in the present and emerges at the periphery of society, because anything new is formed as a variation of the norm, be
it a new industry or a new behavior pattern, or whatever. Think of
the cell phone, for example. The first cell phones were as heavy as
suitcases and were only established in small segments of society.
Which areas of society that are currently at the periphery do
you regard as potentially becoming significant for the future?
Art is always a peripheral area of society that can tell us a lot
about the future. It tends to deal with topics that are in store for us
but don’t currently play a significant role in everyday life. Art is literally a playground for new ideas. Example: transgenic art. Artists
work with genetically modified organisms that fluoresce or luminesce
under certain light conditions. For example, a fluorescent jellyfish
gene was recently introduced into the genotype of a hare. Under UV
light, this hare now shows green luminescence. Of course, such an
experiment won’t lead us into a future of green hares. However, this
kind of art illustrates new options for intervening in our human existence.
Just like art, design, architecture, literature and the media offer
valuable sources that can help us find out more about conceivable
future social and therefore economic change.
°
*
You advise companies regarding the future. What do you regard
as the main aspects of future consulting?
We see our purpose as facilitators of the associated change. We
illustrate future organization options for companies. Jointly with
our customers, we fill the individual “scope for the future” with ideas
and strategies.
Our field of activity mainly covers two areas. On the one hand,
we provide general information about the change to be expected –
including the periphery illustrated above. We offer all-embracing
information that is usually not available to companies, who tend to
look at the world from within their own markets. On the other hand
– and this is probably the main aspect – we facilitate internal dis-
°
*
dialog+opinion °
20*21
Andreas Steinle has a degree in communications management and is
managing director of “Zukunftsinstitut” in Kelkheim near Wiesbaden,
Germany, and also director of the associated “Zukunftsakademie”. Before joining the Zukunftsinstitut, Steinle
was managing director of the Hamburg-based Trendbüro. Steinle has written numerous studies and books.
The title of his most recent study is “Service-Märkte – Die neuen Dienstleister” (service markets – the new
service providers). Steinle is well known as a speaker at numerous international conferences.
cussions about the future, thereby supporting the essential communicative function in the company.
Do companies who want to position themselves well for the
future have to engage in specific internal future communication?
Specific communication is a key aspect. If the exchange of information is inadequate, each member of staff will produce a different
idea of the future, and many people will work in many different directions. As a result, movement is difficult to realize. In order to prevent this, “facilitators for the future” should bring staff across departments together at a table so that issues can be discussed and a common vision of the future can be developed.
°
*
Should a vision for the future have been formed before this
exchange?
This could only be a roughly defined vision, because the future
itself is not static. We live in a very dynamic social and economic
environment. Changes happen so quickly today that any vision of
the future will have to be adapted to new conditions time and again.
This in turn illustrates the importance of anchoring a continuous,
future-related flow of information within the company.
°
*
Would it be beneficial to integrate “future cells” or “future sections” in companies?
This strongly depends on the structure of the respective company. No doubt, it would be useful to integrate a “future section” as
a kind of think tank. Information should be concentrated in this
think tank and emanate from it to all staff. This way, think tanks can
°
*
form a continuously glowing core of ideas. If responsibility for the
future is handed to a department that does not press for exchange
between staff, there is generally little one can achieve. Nevertheless, ideally companies shouldn’t need a separate future section,
because each individual member of staff deals with future. In this
case, all that is required is facilitation of future as mentioned above
– through an external consultant or dedicated in-house staff.
How can companies get each individual member of staff to
reflect on the future?
Many small steps are required. There is no switch that can simply be set to future. Future invariably has to do with communication. The more future is to be anchored within the company, the more
people from different areas have to be encouraged to engage in continuous exchange. Here are a few examples of routes towards continuous communication and therefore towards continuous future
communication. The Swiss hearing aid manufacturer Phonak offers
a large cafeteria that is also used as a large meeting room. The
employees not only meet for meals but also stay there for hours to
discuss projects and research initiatives or make valuable contacts.
Another example from Procter & Gamble, Germany: Employees are
encouraged to use the cross-departmental online platform to arrange
to meet for lunch in order to find out more about each other. These
two examples are basically quite simple. Nevertheless, they can
°
*
“The future is always also encapsulated in the present and
emerges at the periphery of society.”
communication. The more the future is to be
people from different areas have to be
“The future has to do with
anchored within the company, the more
encouraged to engage in exchange.”
change a lot, because they are based on the idea of exchanging information across departmental boundaries.
Are there any examples for successful internal future facilitation
and functioning future sections?
Of course. Google offers a good example for successful internal
future facilitation. The chief product manager is responsible for innovation and ideas management. Every day between 4 PM and 5.30 PM
all employees– regardless of hierarchy level – are invited to see her
in order to present their ideas. Together with a small group of tinkerers, the suggestions are then briefly examined for about five minutes. Important: Anyone presenting an idea receives rapid feedback.
Another example for a future section designed as a think tank:
Swarovski. Here we have the iLab concept, involving around 15 people. This ‘ideas laboratory’ is intended to act as a collection and distribution station for ideas within the company. Each individual idea
is forwarded to all staff and departments within the company who
may be interested. Here too, the emphasis is on rapid feedback.
°
*
All this shows that staff visions for the future are crucial for the
future viability of the respective company. How much importance will companies place on staff as human beings with all
their requirements in future?
A great deal of importance. Companies of all sizes increasingly
discover that they need committed employees in order to be successful and innovative, and that employees will make up the competitive
advantage of companies in future. BMW, for example, is already
demonstrating that success and “taking care of staff” go hand in
°
*
hand. BMW is cooperating with service providers offering childcare
and care for sick parents of staff members. The result: Staff can concentrate better. In addition, employee turnover is lower and for new
appointments, the company can choose between outstanding recruits.
From the future, viewed from an internal company angle, to an
all-embracing view of the future. Will globalization trends
intensify the further in the future?
Essentially, globalization is something that has been driving people and the economy for centuries. Globalization has been contributing to the development of the economy since day one. Globalization
is currently viewed with a degree of fear, particularly by Western Europeans. This is based on old ways of thinking and has nothing to do
with the future. In my opinion, globalization will offer companies
in Western and Eastern Europe (as well as globally) opportunities for
finding new customers, among other benefits. Based on Thomas
Friedman’s wonderful book The World is Flat, I would like to describe
the process of globalization as follows: Today we find ourselves on a
playing field where everyone has similar prerequisites, everyone plays
for the world championship, and everyone ultimately has an opportunity to win it. Aren’t these excellent prospects?
°
*
How can companies utilize opportunities offered by globalization in practice?
First of all, I would recommend talking to companies that are
already successful outside their respective countries. In most cases,
the previously held abstract fear blocking the view towards new opportunities will disappear. The general rule is that companies wishing
°
*
dialog+opinion ° What Does the Future Have in Store?
22*23
to generate future growth are well advised to look beyond the borders of their own country.
the market. They are aimed at those requiring examinations and
medication for minor ailments.
On the subject of brand power and retail power – what are the
future trends in your view?
Our industry was formed based on brand-name articles. Through
the increasing power of the retail sector, brand-name articles have
sometimes come under intense pressure from so-called no-name products.
This situation is now reversing again. Retailers have realized that
they have to offer brand products in order to remain attractive to
customers in the long term. In the future, innovation will continue
to be expected to come from brands.
°
°
*
do you see the consumer of the future?
° How
Consumers will become even more powerful, because offers are
*becoming increasingly transparent, and consumers are becoming
increasingly clever. Education standards are continuing to rise across
the globe, the Internet will become even more significant, and price
comparisons will become even easier. This results in a continuous
increase in pricing pressure, not least for brand products. Anyone
who isn’t the cheapest will have to answer the following simple question: What additional benefit can I offer customers so that they are
prepared to pay my price? For electronic products, this could be outstanding service, for example. The creation of product worlds offering consumers a sense of belonging will become increasingly important as a form of added value for brand products. Well-known companies have already started demonstrating this today. Dr. Oetker,
for example, just recently opened the Dr. Oetker World. I understand
that tours are sold out for months. Or Swarovski: Swarovski built a
museum showing crystal worlds that has become one of Austria’s
main attractions. Another and quite different example for added
value comes from the United States, where in supermarkets customers can not only buy food – integrated Minute Clinics also treat
minor conditions such as colds. These Minute Clinics advertise with
the slogan “you are sick, we are quick” and are directly integrated in
KHS is one of the main producers of filling and packaging technology for the beverage industry worldwide. In this context, a
final question: How should the beverage industry in particular
prepare for the future in your view?
For the beverage industry and the food industry health will become
an increasingly significant issue in the future. All people on all continents want to have a long and healthy live. This desire will continue to intensify in the future, and the goal will be to achieve excellent quality of life with optimum health in old age. Food groups such
as Unilever and Nestle are already leading the way today by defining themselves as health providers. I would advise the beverage
industry to focus more on the health aspect with new developments
and to aim for health drinks with verifiable effect. Another recommendation refers to the development and communication of product worlds. These product worlds don’t necessarily have to be located
on site, as in the Swarovski and Dr. Oetker examples. Fruit juice suppliers, for instance, could establish fruit juice worlds in the form of
juice bars located in city centers. Mineral water producers could set
up stylish mineral water bars in the main hotel chains. There is no
end to the possibilities. Last but not least, in this context I would
once again like to point out that the future is not a fate that we can’t
change. On the contrary, the future offers plenty of scope for utilization by individual companies for their own ends.
*
°
Mr. Steinle, thank you very much for this interview.
The
The Oettinger Group pursues ambitious growth targets
1
THE TASK To accompany the con-
sistent growth of the Oettinger
Group with expansion and new
equipment for their production
lines.
2
THE SOLUTION Over 40 years of
custom-built KHS plant equipment,
which is already equipped today for
tomorrow’s expansion steps.
Market Loyalists
From a small family brewery in Franken, the Oettinger Brauerei has
developed into the largest-selling brewery group in Germany – and
KHS line equipment has been there all along.
Less is more. That’s what Oettinger Brauerei’s
recipe for success boils down to. “We avoid
any extensive and expensive advertising,”
confides the Web page of the successful
Bavarian brewery, with a design rather
spartan in contrast to those of some of its
competitors. “We avoid costly packaging
such as glossy labels or printed crown corks,”
it continues. At Oettinger, not a single
cent is spent on advertising – they just
spend on the beer. Because after all, according to the company philosophy, it’s not the
packaging that matters, it’s the contents
that counts. And that tastes great, according to local beer fans: The Oettinger Group
is Germany’s biggest-selling brewery, with
more than 7 million hectoliters of production.
For many decades, the company has
been led by the Kollmar family of brewers
from Franconian Fürnheim. The fact that
Oettinger experts are conscious of both
cost and quality is explained by the company’s history: In 1956, the family took
over the small Fürstliches Brauhaus brewery in Oettingen, and for many years, entrepreneur Günther Kollmar ran nearly the
entire business, almost single-handedly.
“Selling beer, talking to banks, investing
in technical solutions – I was the sole contact for all these areas,” reminisces the
company boss. And that set the stage for
task+solution °
24*25
Left As far as the eye can see: Oettinger beer. Top Innoket KL 2000: Ensures perfect bottle appearance at Oettinger.
Bottom Innofill DMG filling system: Promoted to standard at Oettinger and the oldest system has been running extremely
reliably in 3 shifts for 17 years.
2
THUMBNAIL PORTRAIT: OETTINGER GROUP
* 1956 The Kollmar family takes over the Fürstliches Brauhaus
Oettingen.
* 1969 Start of exclusive delivery to large-scale retail industry
* 2006 With 7 million hl output, the largest-selling brewery
group in Germany.
Target production: 10 million hl. About 1 100 employees.
* Five breweries with the following production capacities: Oettingen (5.5 million hl beer/soft drinks) / Mönchengladbach (2.7
million hl) / Gotha (2.1 million hl) / Schwerin (0.6 million hl) /
Dessow (0.3 million hl)
* Product range: Sixteen styles of beer, including: Pils, Export,
and white beer (45% share of production) as well as specialty
beers: black beer, alt beer, malt beer in addition to soft drinks
and table water.
* Special features: in-house fleet of 200 trucks, delivery to
10,000 markets.
… WITH A STRONG BRAND CONCEPT
customer expectations and cost consciousness right to the present day.
SUCCESS IS BASED ON THREE
PILLARS …
Kollmar cites three main pillars for Oettinger’s success: First, the owner-managed
operation and the many years of ties with
suppliers and customers – Oettinger and
KHS, for instance, have been working
together since the early 1960s. Second, a
decision was made in 1969 to rely exclusively on the big companies in the grocery
industry.
To supply their trading partners
efficiently and cost-effectively, Oettinger
has built a network of five breweries over
the years: in Oettingen, Mönchengladbach,
Gotha, Schwerin, and Dessow.
In Oettingen, capacity has recently
been expanded again. “We’re aiming for
the 10-million-hectoliter mark. In no more
than two years, we expect to reach that
goal,” reveals owner Kollmar. He wants to
reach his sales goal by means of internationalization into the European grocery
trade. That’s because German grocery
chains are increasingly making their way
out into European and even into numerous non-European markets. And Oettinger
can – and will – grow along as partner of
the retail trade.
Even today, the company is selling its beer
in more than 30 countries. The main export
nations are Italy, Spain, Greece, France,
and Belgium, with about 60 percent of the
export trade. Market penetration in China,
Japan, and the United States immediately
pending, says Kollmar. Wherever in the
world Oettinger sells its beer – the customer are be able to rely on quality. Günter Kollmar says, “Oettinger may be at home
in the lower price range, but our beers are
quality beers and represent a powerful
brand policy directed towards our segment.” For instance, the group will not be
changing the brand name around the world.
And naturally, the group also isn’t
compromising with the typical tastes of
the Oettinger beer varieties. “With our 16
different styles of beer, we can satisfy the
tastes of both the Southern Germans and
the Northern Germans,” says Kollmar. The
selection ranges from classical Pilsner and
Export beers to specialties like yeast wheat
beer, black beer, alt beer, and malt beer.
Left The Oettinger principle: Best quality at an attractive price. Center Innoclean EE: Excellent bottle washing effectiveness and
high environmental friendliness save plenty of water and power. Right Günther Kollmar, owner of the Oettinger Brewing Group
(left): “Besides the best technical equipment and perfect consulting, we value our relationship of trust with KHS which has continued to grow over the years. On the right in the picture: Günter Unkrig, Director, Central European Business Area, KHS AG.
RETURNABLE GLASS DOMINATES –
FOR NOW
So far, returnable bottles in returnable
crates have dominated at Oettinger. Only
in the export markets is Oettinger also
available in cans. But this year, that will
be changing slightly. German beer fans
will be able to purchase Oettinger in oneway bottles. In the future, according to
market strategist Kollmar, cans for export
will comprise about 20 percent of sales, 10
percent will go into non-refillable glass
bottles for the domestic and export markets, and the other 70 percent will remain
in returnable glass bottles in returnable
crates.
The Oettinger Group currently has
eight KHS lines in operation, and besides
their selection of beers, they also fill soft
drinks and table water. Two of those lines
are can lines, while the other six exclusively fill refillable glass bottles.
INVESTING IN THE FUTURE …
With a comprehensive investment program,
Oettinger is setting its sights on more
growth. After line expansions made in the
past year, the company still wants to invest
strongly in 2007.
…AT THE OETTINGEN PLANT …
In March of this year, KHS delivered a new
filling line for the Oettinger production
facility, designed for an output of 55,000
bottles per hour. This filling line should
already be going into production by the
end of April 2007. In 2006, KHS not only
installed new conveying equipment, but
also an EE-type Innoclean bottle washer
with the newly developed “Oettinger head
section”. The special feature of this head
section: an additional integrated label
discharge. Labels that have already loosened during pre-soaking are discharged
out of the machine here. Another advantage of this machine that was a key item
in the decision in favor of this machine
and KHS is the low water and steam consumption.
…AT THE GOTHA PLANT …
For this brewery, KHS delivered a pin-partition system (a recrating system) equipped
with both an Innopack PPZ combined crater
and decrater as well as a combined palletizer/depalletizer. A highlight of this
line: The system enables Oettinger to provide the consumer with the greatest possible product convenience by crating sixpacks in pin-partition crates. Loose bottles are decrated out of the pin-partitioned
crates, processed into six-packs, and crated
back into pin-partition crates by the same
machine. The KHS Innopal RS3 column
robot is yet another KHS multiple-function
machine. The pin-partition creates with
loose bottles are depalletized, those with
the six-packs are palletized, and the pallets needed are placed in the magazine or
removed from the magazine by the column
robot. Thanks to the combination of multiple functions in the same machine, it is
possible to achieve high system throughput while taking up very little space.
This recrating system works independently of the existing KHS filling line
at the Gotha plant.
… AND AT THE MÖNCHENGLADBACH
PLANT.
At Oettinger’s plant in the Lower Rhine
region, KHS has installed an Innopas C pasteurizer in an existing line. Like all KHS
system components for the company, the
modularly designed pasteurizer is specifically adapted to Oettinger’s needs.
The highlight of the component:
environmental friendliness and cost-effectiveness. The Innopas is equipped, for
instance, with a three-tank buffer tank
system. These individual tanks separate
the water into hot, cold, and mixing temperature ranges and prevent thermodynamically disadvantageous mixing of indi-
vidual temperature phases. A stable waterheat balance is maintained by heat recovery facilities between the heating and cooling zones. The buffer tanks have a regulating effect during startup and shutdown,
suspended operation, and pasteurizer standstill. It is not necessary to supply additional heating or cooling energy or fresh
water over a defined time period.
Process engineering specially
matched to the buffer tank system ensures
quick reaction in conjunction with the KHS
PU control and thus economical pasteurizer operation under all operating conditions. The PU control furthermore allows
quick integration of product changes or
product innovation into the pasteurization
process.
JOINTLY DEVELOPED SOLUTIONS
Günter Kollmar sums it up: “For me, working together with KHS means more than
merely supplying technology. We get the
solutions we need to continue to expand
our market position and many additional
services as well.” For instance, when Oet-
task+solution ° The Oettinger Group pursues ambitious growth targets
tinger was planning the new south brewery at their headquarters in the 1990s, KHS
designed the supply and disposal paths
together with Oettinger during building
planning, so that the entire plant was perfectly prepared for the modular extension
of the plant equipment.
Despite comprehensive KHS services, of course, even at Oettinger the quality of the technical solutions determine
whether line systems will be purchased.
Kollmar sees it this way: “We promise our
customers the best of quality at a reasonable price. And KHS technology enables
us to keep that promise.”
PERFECT FILLING SYSTEMS
The mainstay of any line is – as far as product quality is concerned – the filling system. When it comes to KHS canning technology, Oettinger relies on the mechanical Innofill DMD filler, and for KHS glass
lines the mechanical Innofill DMG filler.
At Oettinger, the latter has become
the standard in glass filling technology.
“KHS filling technology gets an A+ from
me,” praises the company boss. So, too,
what is probably the oldest KHS filling system: For 17 years, the line has been in operation with an output of 56,000 0.5-liter
bottles per hour in three-shift operation
– more than 3 billion bottles, or 15 million
hectoliters, have been filled by this filler
over the course of its life to date. Even
today, the oxygen content of the beer and
the CO2 consumption are still “absolutely
tops,” as Kollmar says. And to that, add
the fact that this filler can be trusted with
bottling the most demanding of beers: “This
system fills wheat beer at the same speed
and just as perfectly as Pilsner or Export.”
The Innofill DMG determines the
fill level using a return gas tube. The bottles are pressurized with CO2 until a balanced pressure is created between the bowl
and the bottle. Then the liquid valve opens.
The liquid displaces the pressurization gas,
which is then returned to the ring bowl.
The filling phase ends once the rising fluid
level closes the return gas tube. The snift
valve depressurizes the bottles.
The advantages of this filling process:
gentle, low-oxygen pickup filling, simple
operation and service, and the high fill
level accuracy.
26*27
solid sales growth. And Oettinger will also
remain one of the few owner-managed
brewery groups. The company boss says,
“We aren’t on the menu of the big brewery groups. My son Dirk has already taken
over the helm. The company will stay in
the family.” And it is still on course for
growth and continues to take on new challenges. Someday, Kollmar is very sure,
there will be Oettinger everywhere in the
world – and of course, still under the Oettinger brand name.
Günter Unkrig, Vice President, Central European
Business Area, KHS AG, Dortmund
Mike Herrmann, Sales Manager Baden-Württemberg and Key Account Manager
Oettinger Brauerei-Gruppe, KHS AG, Ulm
ALL FROM ONE SOURCE
As another plus of the “KHS sole-source”
concept, Kollmar cites the high sense of
identification by his employees with “their
KHS systems”. The technical solutions are
familiar, and every employee knows exactly
what needs to be done during system operation. Then there’s the advantage of replacement parts stocking – with identical lines,
quick and efficient part management.
THE FUTURE STARTS TODAY
As the strongest German brewery group in
sales, Oettinger – Kollmar is absolutely certain – will continue to be one of the few
brewery groups that will continue to see
fi
INFOBOX
• WEBSITE www.oettinger-bier.de
• CONTACT
Günter Unkrig, Vice President, Central European
Business Area, KHS AG, Dortmund
Tel:
+49 (231) 569-1602
E-mail: [email protected]
Mike Herrmann, Sales Manager BadenWürttemberg and Key Account Manager
Oettinger Brauerei-Gruppe, KHS AG, Ulm
Tel:
+49 (231) 569-6606
E-mail: [email protected]
The Spadel Group relies on
innovative packaging technology
The Water of
Kings
The Belgian mineral springs in Spa continue their success
story – KHS technology is helping with perfect systems for well-packaged goods.
1
THE TASK Installation of innovative
packaging technology for a mineral spring,
in which a variety of different PET bottle
formats must be optimally packaged.
2
THE SOLUTION KHS provided the Spadel
Group with packaging solutions that packs
packages a wide variety of non-refillable PET
bottles in different shrink packs or classical
bottle crates
Wanderer, when you come to the Belgian
Spa, tell that you have drunk the water –
that’s one way of putting a well-known
poem. Because for centuries, the guests
of the health resort have praised the extraordinary quality of the mineral water there.
Among the regular visitors were and are
the European aristocracy and high-ranking personalities from around the world –
from Czar Peter to Queen Christina of Sweden, all sorts of British and French kings,
and the Shah of Persia. They all valued the
pleasing effect of the mineral water and
the health resorts in Spa. It’s no coincidence that the term spa became a household name and a synonym for feeling well
and taking care of health, beauty, and relaxation.
Just as popular as the baths is the
water of the same name from the mineral
springs, which today belongs to the Spadel
Group. High-quality mineral waters are a
specialty of the beverage company. Besides
Spa, the company’s mineral springs in Belgium include Spontin and Bru-Chevron. In
Wales, Spadel owns the Brecon springs, and
in France the Wattwiller mineral springs.
Spadel has succeeded in making
each of these outstanding mineral waters
into strong, internationally successful
brands. Spa, with sales of 465 million liters,
is the best selling of the Spadel springs.
The other mineral strings together account
for some 135 million liters in sales.
SPA: MARKET LEADER IN THE
BENELUX STATES
In the Benelux states, Spa is a market leader
among brand-name mineral waters. The
flagship of the brand family: Spa Reine,
exported into more than 20 countries; the
main consumers are France, the United
Kingdom, and Germany. Spa Reine accounts
for some 60 percent of Spa’s total sales.
Also in the company’s market portfolio are
the mineral water brands Spa Barisart and
task+solution °
2
TWO LINES – MANY BENEFITS
SPA SOFT DRINK LINE
SPA MINERAL WATER LINE
BENEFITS FOR THE CUSTOMER
Packaging technology
Type
Output
Use
Mode of operation
Formations
Options
Innopack Kisters PSP
Pad shrink packer
80 cycles/minute
Shrink
pad-shrink packs
Innopack Kisters TSP
Tray shrink packer
80 cycles/minute
Shrink packs and
tray shrink packs
One- or two-lanes
4- to 20-bottle formations
Drive
Option: Conversion to
shrink packs possible
Modular design allows reconfiguration
Use of additional components, like leaflet inserters,
partition inserters, and perforation stations
Servo motors
Line design
Clean design with smooth surfaces, without corners or recesses
Design
Expansion options
Shrink tunnel
Conveying of film packs
Temperature
Handle applicator
Type
Machine configuration
Crater
Type
Machine configuration
Speed compensation belt conveys film packs
into the shrink tunnel
Individually configurable for film quality and pack size
Innopack Kisters CSM
Use with shrink packs and pad shrink packs,
extension to tray shrink packs possible
Innopack PPZ
Latest generation of dual-axis machines
with PC-based control system
Control system connected to absolute displacement
measurement system
Fills 6- and 12-bottle crates
with one-way PET bottles
Use of multifunction head
High output
Special solution for each
product group
Flexible use, according to product
requirements
Flexible use; easy push-button
changeover
Offers options for future use of other
product variants
Full flexibility
Extension options available for later
production requirements
Low-noise/low-wear, optimum
synchronization of the servo drive via
computer-supported master control,
speed adaptable to other machine
components
Simple, fast cleaning, easy access,
reduced entry of dirt and dust particles
Gentle handling of loose film wrapper
Ensures quality by implementing
product-specific specifications
Increases carrying comfort
for the consumer
Easy access, simple operating,
low space requirements
No sensor components required
Fulfills the consumer demand
for one-way bottles packed in crates
Minimizes time required for
format changeover
28*29
The Spadel Group relies on innovative packaging technology
Left Formations created: Match up precisely with the pads in the pad shrink packer or the trays in the tray shrink packer.
Right Michel Diricq, Spa’s Technical Manager (center): “KHS solutions put us in a position to be able to meet the highest consumer expectations when it
comes to attractiveness.” In the picture on the right: Hennie van der Graaf, Manager of KHS Benelux B.V.; left: Herman Miseur, Sales, KHS Benelux B. V.
2
THUMBNAIL PORTRAIT: SPADEL GROUP
* Among the top 20 mineral springs worldwide
* Medium term goal: Top 10
* Market leader in mineral waters in the Benelux
states
* Sales of 247.3 million euros (2005)
* Spa turnover of 465 million liters
* Sales percentages: Spa Reine 60 percent,
Spa Barisart and Spa Marie-Henriette
25 percent, soft drinks Spa & Fruit and
Spa & Tea 15 percent each
* Solid brand policy
* Innovative technical concepts
fi
INFOBOX
• WEBSITE www.spawater.com
• CONTACT
Hennie van der Graaf, Manager of KHS Benelux
B.V., the Netherlands
Tel:
+31 (76) 572-3230
E-mail: [email protected]
Herman Miseur, Sales, KHS Benelux B. V., the
Netherlands
Tel:
+31 (76) 572-323
E-mail: [email protected]
Spa Marie-Henriette, with a sales share of
25 percent. The remaining 15 percent are
accounted for by the soft drink division.
Under the names Spa & Fruit and Spa & Tea,
the customer can select from more than 20
different flavors.
To be able to visually position each
individual water ideally for the customer,
Spadel relies on modern, elegant shapes
when choosing packaging types and kinds.
The concept pays off and is extremely successful on the market. For the Spa mineral
springs alone, the assortment of pack styles
includes PET and glass bottles, along with
cans and cartons.
According to director Michel Diricq,
Spa has been particularly successful in
establishing the non-refillable PET bottle,
which has recently attained a respectable
70 percent share of the packing mix. The
consumer has sizes available ranging from
the little 0.33 liter PET bottle up to the
voluminous 3-liter PET container. Particularly popular is the 1.5-liter family-size
bottle, with a share of about 50 percent of
total PET bottle sales. There is great growth
potential in the 0.75 and 0.5-liter PET nonrefillables, as well.
THE FOCUS IS ON ONE-WAY PET
Since the beginning of 2006, Spa has consistently relied on one-way PET packaging.
Among other reasons, this is because the
visual attractiveness of non-refillable PET
bottles does not suffer from the multiple
use of refillable PET bottles. Especially the
perfect visual impression is of decisive for
brand products. And that’s why Spa is now
investing in three packing machines and
two handle applicators – for a soft drink
line with an output of 30,000 PET bottles
per hour and for a mineral water line with
an output capacity of 36,000 PET bottles
per hour. Michel Diricq says, “With this
investment, we’re meeting the highest of
consumer expectations where attractiveness is concerned.” For details on the modules and advantages of the lines, see INFOBOX
Two Lines – Many Benefits on page 29.
Even during the planning of the
installation, the comprehensive consulting services of KHS were another plus:
Besides the latest in machine technology,
KHS provided the Spadel Group with the
complete packaging know-how of its experts.
For instance, the subsequent interplay of
packages, packaging materials, and shrink
tunnels were KHS factory tested in advance.
“As soon as KHS equipment is installed in
our plant, we can start production without
lengthy test phases. That’s how cooperation with KHS has worked for decades, and
that’s the way we like it,” explains Diricq.
Obviously, only the best is good enough for
King Customer.
Hennie van der Graaf,
Manager of KHS Benelux B. V., the Netherlands
Herman Miseur,
Sales, KHS Benelux B. V., the Netherlands
task+solution °
30*31
AGENDA
100,000,000
Okertaler Mineralbrunnen:
A company reestablishes itself
Okertaler Mineralbrunnen, part of the Weydringer group of companies since
2005, intends to increase output from 30 million to 100 million bottles
within the next two years. How will that be possible? One thing is for sure:
A KHS PET line will be part of the act.
1
THE TASK
A bottling line for
water and similar products, which
fulfils all the requirements for processing a complete range.
2
THE SOLUTION A KHS PET non-
refillable line, which fills everything:
• from sparkling or still mineral
water to wellness drinks and
orange soda pop,
• all sizes of PET bottle, and
• a wide range of PET bottle
shapes.
Manfred Weydringer began his entrepreneurial success story in 1976 with the acquisition of a specialized beverage wholesale
business and mineral water producer in the
North Rhine-Westphalian town of Holzminden. Today, the group of companies includes
two specialized beverage wholesalers (70
million euros turnover in 2006) and two
mineral water producers:
* the beverage wholesaler Weydringer &
Strohte in Holzminden,
* the beverage wholesaler WVG in Siersleben (Saxony-Anhalt),
* 160 company-owned beverage markets
* Bad Harzburger Mineralbrunnen, and
* since 2005 Okertaler Mineralbrunnen.
Says Jens Weydringer, Managing Partner
of Bad Harzburger Mineralbrunnen and
Okertaler Mineralbrunnen and son of the
company founder, “With mineral water
producers, specialized beverage wholesalers, and our own beverage markets, we
have several cornerstones that harmonize
perfectly. That’s the really important thing.
There is no more important and no less
important company sector in our group
run by my parents, my brother, and myself.
It is the big picture that counts.”
The following success story focuses
on the bottling businesses in which the big
sister, Bad Harzburger, takes a lead function for Okertaler throughout. Bad Harzburger
Mineralbrunnen
* is mainly oriented toward the wholesale trade with a sales quota of about
95 percent,
* supplies a wide range (also to its own
160 beverage markets),
* filled 100 million bottles in 2006 (1999:
35 million),
Okertaler Mineralbrunnen: A company reestablishes itself
Bottom The Innofill DRV-VF/N is a computer-controlled volumetric filling system, which uses only two pneumatically actuated membrane
cylinders for the entire filling process. Left A generously designed buffer system maintains the flow within the line. Right Also integrated into the
dry area concept: a special buffer table where the PET bottles are distributed by separating the stream of containers in a “zipper” process while
traveling past the tip of a fixed-position plow tip.
*
*
is one of the 40 largest mineral water
producers in Germany, and
has a range, 70 percent of which is made
up of mineral water of the Juliushaller
and Urquell brands, and 30 percent of
a wide variety of soft drinks (wellness
drinks such as grape-mango flavored
with grape-mango and ginseng, green
and herb tea; classic soda pops; flavored mineral waters; fruit juice drinks,
and even the aktiv & fit sports drink).
OKERTALER MINERALBRUNNEN
*
*
*
2
AT A GLANCE: THE NEW BOTTLING SYSTEM
This is how the innovative Innofill DRV-VF/N filling system operates with just two
pneumatically operated membrane cylinders:
* The PET bottle moves into the neck ring holder on the filling valve.
* A cam-controlled spring integrated in the filling valve pushes the bottle mouth
against the center of the rubber contact seal with only a slight amount of force.
* This contact force is sufficient for pressureless filling of non-carbonated beverages.
* When filling under pressure, pressurization is achieved by means of gas from the ring
bowl.
* The secret: The force created by the pressurization pressure is transmitted by a membrane plunger directly to the neck ring holder.
* This force alone lifts the bottle and seals the bottle mouth to the filling valve (no
additional lifting elements are necessary).
* The pressing force is regulated fully automatically according to the pressurization
pressure.
* Once the PET bottle is pressurized, the filling valve opens electropneumatically.
* The product passes over a swirler to the walls of the bottle.
* The filling speed is reduced in the bottle neck after the fast filling phase in the generally cylindrical area of the bottle.
* The filling valve is closed electropneumatically as soon as the pre-specified filling
volume is reached.
* The controlled pressure relief process at the end of filling makes it possible to also
bottle highly carbonated beverages without excessive foaming in the bottle neck.
mainly serves the food retail trade,
bottled about 30 million bottles at the
time of the takeover in 2005, and
plans 100 million filled units for 2007
– made possible by investing in a new
KHS non-refillable PET line.
The decision was clearly made in favor of
KHS. Jens Weydringer: “For one thing,
because we can look back on extremely positive experience with KHS equipment and,
for another, because with KHS we are placing our trust in a German manufacturer,
which maintains the high standard of service that we expect.” Dieter Bonitz, Managing Director of Bad Harzburger Mineralbrunnen and Okertaler Mineralbrunnen, sees the
future Okertaler range to be as equally diverse
as in Bad Harzburg. Bonitz: “Here, we are
just building up a complete range, which
will be absolutely in line with the requirements of our Okertaler target group.”
THE CAPABILITIES OF THE KHS PET LINE
Okertaler Mineralbrunnen intends to be
prepared for all eventualities with the new
KHS PET non-ref illable line with its
capacity of 25,000 bottles per hour. Be it
sparkling or still mineral water, whether
wellness drinks or classic orange soda pop
– everything must be possible. Added
this is highest flexibility with regard to
the PET bottles used (currently 1.5 and
0.5-liters).
task+solution °
A blow molder incorporated into the line produces the PET bottles, and a KHS Innoline
LTR air conveyor guides them gently to the
rinser-filler-capper block. Key features:
Neck handling / optimum hygienic conditions / radial fan that reduces flow losses
and energy consumption / specially shaped
louvers drastically reduce the amount of
air needed for conveying.
The mechanically controlled twochannel Innoclean FR-ZM rinser is designed
for two types of rinsing media. Key features: Disinfection phase with chlorine dioxide followed by rinsing with sterile water
(reliably removes contamination) / rinser
bypassed using transfer starwheel when
bottling less sensitive beverages (reduces
operating costs).
The rinser system is blocked with
the Innofill DRV-VF/N computer-controlled,
volumetric filler. Key features: 120 filling
stations/only two pneumatically operated
membrane cylinders for the complete filling process (see box on page 32)/aseptic
membrane and sealing technology/smooth
surfaces advantageous for CIP and exterior
sanitizing.
The bottles are capped by a stainless steel Innofill SV – also with a very high
standard of hygiene. The rinser-filler-capper block is designed without a front table
and has an open and particularly hygienic
construction. The complete system can
therefore not only be cleaned safely but
also very easily. The block also has freestanding glass safety paneling and a filter
cover equipped with HEPA filter units. The
drive within the block concept is implemented using servo technology.
The buffer has been generously
designed in order to maintain system flow
in the event of possible malfunctions on
individual machines. After filling level and
cap checking, the PET bottles are conveyed
via these buffer sections in the direction
of the labeler. There is also an integral
buffer table, which equally ensures the gen-
tle handling of the PET bottles and the optimum utilization of the production area.
When entering the buffer table, the PET
bottles are distributed by dividing the containers into two partial flows, which are
fed past a permanently mounted plow tip
without contact. The flow of containers is
automatically divided by a patented chain
guide. Several drives ensure an optimum
scaling down of the conveying speed and
a low-pressure transfer of the PET bottles
onto the buffer system outfeed according
to the principle of first-in first-out.
Jens Weydringer is proud of this
rinser-filler-capper block, which is not only
highly innovative, but at the same time
incorporates tremendous flexibility and
maximum future-proofing: “We see this
block concept as a technical highlight.”
The Innopack Kisters SP 50 B shrink
packer works with a capacity of 50
cycles/minute. Key features: Two-lane processing of the incoming pack formations (6packs with 1.5 or 0.5-liter bottles with transparent or printed film)/allows alternative
formations/rapid changeover.
There is space in the line for an
Innopack Kisters TP tray packer in order to
retain flexibility. This would combine the
shrink packs to form tray packs. The Innopal
PBN gives outstanding service when it comes
to palletizing. Key features: Designed in
accordance with the KHS modular dry area
concept/PC-based robot control/direct realtime communication links and computercontrolled sequences of motion.
32*33
Jens Weydringer and Dieter Bonitz are
thrilled with the innovative KHS system
technology. And even if 100 million fillings of PET non-refillable bottles should be
required in 2007, the KHS system will not
yet have reached its maximum capacity.
Bonitz: “We will then only be working two
shifts and will still have one shift in reserve.”
Jens Weydringer adds, “If the demand by
the retail trade for Okertaler mineral water
and soft drinks should increase further,
then there is still enough room in the plant
for new equipment.” The success story is
sure to continue.
Andreas Waldscheck, Sales Manager
North Germany, KHS AG, Dortmund
Matthias Stammer, Sales Germany,
KHS AG, Dortmund
fi
INFOBOX
• WEBSITE www.okertaler-mineralbrunnen.de
• CONTACT
Andreas Waldscheck, Sales Manager
North Germany, KHS AG, Dortmund
Tel:
+49 (231) 569-1734
E-mail: [email protected]
Matthias Stammer, Sales Germany,
KHS AG, Dortmund
Tel:
+49 (231) 569-1595
E-mail: [email protected]
e
orldwid
Top 10 w
e
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t
to
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ready to
–
r
te
is
e
Jägerm
Leader
of the
Herd
This success is unique: For many years, Jägermeister has been the most important
international German spirits brand; KHS is supplying innovative filling and
packaging equipment, which fulfills the highest quality expectations, for the latest
German location, the Linden plant.
1
THE TASK
Installation of an innovative, flexible bottling
line for the gentle and smooth filling of herbal liqueur.
2
THE SOLUTION One of the highest-capacity bottling
lines for contour spirits bottles in the world for 20,000
0.7-liter bottles per hour with many highlights. Detail
on the side: Painted in Jägermeister corporate colors.
Rudi and Ralph are real leaders of the herd and it is now hard to
imagine Jägermeister’s TV commercials without them. They keep
a watchful eye on things at the bar counter, and have made a major
contribution to the herbal liqueur being one of the most successful spirits in its home market. But Jägermeister is also in demand
in the rest of the world. The liqueur started on its worldwide conquest from Wolfenbüttel in Lower Saxony about 40 years ago.
Today, the brand is known and successful in more than 60 countries. The trademark characteristics – Hubertus stag’s head, concise text, and bottle shape – are the same all over the world.
The firm principle: Only if it says Jägermeister, will it be
Jägermeister – and the friends of the herbal liqueur appreciate
the fact. The turnover of privately owned Mast-Jägermeister AG
has risen continuously in recent years. In 2005, turnover was
around 266 million euros and sales in 0.7-liter units were an impressive 66.5 million bottles – a plus of 14 percent compared with the
previous year. So where does this success come from?
SUCCESS FACTOR: BRAND-ORIENTED CREATIVITY
Jägermeister’s marketing concept has made a decisive contribution to this success. The company develops advertising strategies
tailored to the requirements of the target groups for every individual sales market – often in close cooperation with local sales
partners. While in Germany, for example, the focus is on the animated stags in TV commercials and numerous promotions, interpersonal relationships play a major marketing role in Italian TV
commercials.
Another characteristic of Jägermeister is the unusual
events, which emphasize the special status of the brand. An example: Swimming events normally take place in the summer. But in
December 2005, Jägermeister launched an “open air swimming
party” in Berlin. Jägermeister fans cavorted in water temperatures of just 4° Celsius. Or, when last year the whole of the advertising world pounced on the soccer World Cup, Jägermeister had
already taken advantage of the enthusiasm for soccer two years
earlier – at the European Championships. “We were aware that a
lot of companies would take up the subject of soccer at the time
of the World Cup. We wanted to get in on the act somewhat earlier, as it is not Jägermeister’s style to stand in line,” reveals Dirk
Löding, Head of Production and Merchandise Management at MastJägermeister AG.
task+solution °
2
34*35
BRIEF PORTRAIT JÄGERMEISTER
Original recipe from 1934
Marketing in more than 60 countries
Share of exports 70 percent*
Largest export market U.S.A.
13th place among the world’s top 100 spirits
Turnover: 66.5 million 0.7-liter bottles *
Sales revenue 266 million euros*
(not including alcohol tax)
* Annual net profit 68.9 million euros*
* Equity ratio 70 percent*
*
*
*
*
*
*
*
*2005
Recessed chucks in the rotary ensure that labels are
exactly applied to the Jägermeister contour bottles.
SUCCESS FACTOR: CLEAR COMMUNICATION CONCEPT
Mast-Jägermeister’s communications strategy is based on six pillars: classical communication, event marketing, Jägermusic, promotional campaigns with Jägerettes/Jäger Dudes, sales marketing trade campaigns, and infotainment website www.jaegermeister.com.
With regard to the unusual concepts and the strategy on which
they are based, Dirk Löding says, “We either swim against the current in order to achieve specific independence, or we are simply
faster than the others.”
SUCCESS FACTOR: CONTINUITY WITHOUT COMPROMISE
Like the bottle, the recipe for the herbal liqueur is of course
unchanged. To ensure that the taste as specified in the original
1934 recipe always remains the same requires the very highest
attention to quality. The basic ingredients of the Jägermeister
production are comprised of 56 different herbs, roots, and fruits
from many different countries including spices such as cinnamon,
bitter orange peel, saffron, root ginger and many more tasty additives, which are all subject to stringent controls before the start
of production. They are then weighed, ground and mixed. This is
followed by a multi-stage maceration process and finally storage
of the base material. This aging process in oak casks alone takes
twelve months. Only then is Jägermeister produced, in the form
in which it is served ice-cold in the bars of this world, by adding
alcohol, sugar solution, caramel and softened water.
SUCCESS FACTOR: SOPHISTICATED SALES STRATEGY
The herbal liqueur satisfies the current requirements for taste.
This is confirmed by numerous awards and a worldwide increase
in sales and turnover:
*
*
Sales in 1999 around 30 million 0.7-liter bottles (export share
about 50 percent)
66.5 million 0.7-liter bottles were sold in 2005 – more than
double (export around 77 percent). In Germany alone, Jägermeister sold approximately 19 million 0.7-liter bottles in 2005,
and is therefore the spirits brand with the highest turnover in
this country, coming in fourth place in the sales rankings of
German spirits brands.
And, as is shown above, the “drink from Germany” is more in
demand abroad than ever before. The U.S.A. is main export market where the trend continues to increase. An impressive 45 percent of total Jägermeister sales went to the United States in 2005.
Here, with the equivalent of 31.1 million 0.7-liter bottles sold, a
two-digit growth rate of 21 percent was achieved. Further strong
export markets are Italy, Hungary, Canada, and Finland. Jägermeister is also successful and showing strong growth in Australia,
Japan, China, South Africa, and other countries. Jägermeister is
striving for a Top Ten placing in the Impact International Top 100
list of premium spirits worldwide: in 2003, the brand – as the best
German brand – was only at Number 19; in 2005, it improved from
the previous year’s Number 15 slot to 13th place.
SUCCESS FACTOR: STRONG PARTNERS
Around the world, all growth is governed by clear sales rules: First
the restaurants, then the retail trade. Jägermeister always cooperates from Germany with the strongest local distribution partners who also provide the input for country-specific marketing
campaigns. But the Jägermeister base ingredient continues to be
produced exclusively at the headquarters in Wolfenbüttel. The
licensees only add alcohol, liquid sugar, and water, and then bottle the finished Jägermeister. The company has three further locations in Germany in addition to the Wolfenbüttel site. Added to
this are four foreign licensees in Brazil, Denmark, Italy, and Austria.
SUCCESS FACTOR: INNOVATIVE SYSTEM TECHNOLOGY
The latest German bottling location is Linden, only a few kilometers from the company headquarters. Here, KHS has recently
installed a new bottling and packaging line. Dirk Löding summarizes the expectations of this line in one sentence: “With Jägermeister we are providing a premium spirit based on a concept,
which only allows high-quality technical solutions to be used for
bottling and packaging activities.”
The installed KHS line has an output of 20,000 bottles per
hour. It is therefore one of the highest capacity spirit bottling systems for contour bottles in the world. It is initially processing six
different sizes of Jägermeister bottle from the 0.35-liter to the
1-liter version. If other bottle sizes should be added later, the
appropriate format parts can be easily retrofitted; maximum flexibility is an important part of the system design. A not unimportant feature is that the system also makes a visual impression – it
is painted completely in rich Jägermeister orange and herbal liqueur
green. The highlights of the Jägermeister line are as follows.
HIGHLIGHT 1: INNOPAL ASN DEPALLETIZER –
GENTLE AND TIME-SAVING
Forklift trucks place the pallets of new glass bottles on the pallet
conveyor, thus making them directly available to the Innopal ASN
new-bottle depalletizer. It operates in accordance with the KHS
modular dry area concept and with an automatically adjustable
head section – when the bottles to be processed are changed, the
depalletizer is easily changed over at the push of a button, which
saves a considerable amount of time. A handling robot is included
and removes the inverted trays positioned between the individual layers of new bottles. These pass down a chute to a special
disposal position. At the same time, the handling robot stacks
the empty pallets on a pallet conveyor for automatic conveying to
the removal position.
HIGHLIGHT 2: CONVEYOR LOGISTICS –
LOW-NOISE AND HYGIENIC
After depalletizing, the bottles pass to the motor-controlled
removal of contour bottles, which takes place several rows at a
time. In the line, plastic chain mats convey the bottles gently and
quietly. These chains are distinguished by outstanding gliding
properties so that there is no need to use belt lubricants, and
moisture is prevented from sticking to the bottom of the bottle.
The bottles are turned in the lengthwise and brought together in
a row by means of pressureless bottle combiners with a downstream alignment station for possible mavericks.
They continue through the line hygienically and with low
noise, for the bottle conveyor is completely enclosed right up to
the infeed to the rinser-filler-capper-labeler block. The segments
of the bottle table cover can be moved underneath each other horizontally, thus allowing easy access to the individual elements.
HIGHLIGHT 3: INNOCLEAN FR-ZR TWO-CHANNEL RINSER –
HYGIENIC AND FLEXIBLE
The electronically controlled Innoclean FR-ZR two-channel rinser
is blocked directly with the filler and can be individually adjusted
by program selection. As required, the bottles can be blown out
with sterile air, rinsed with a water/alcohol mixture, or cleaned
using a combination of both methods.
HIGHLIGHT 4: SERVO EQUIPMENT –
EFFICIENT AND LOW-WEARING
Servo equipment drives the complete rinser-filler-capper-labeler
block. This reduces the use of mechanical drive elements to a minimum. All machines on the line can be adjusted at the push of a
button by means of a motor-driven height adjustment when bottle types are changed. Unwanted external disturbances are likewise quickly corrected: in these cases, a computer automatically
restores the synchronism of the block.
HIGHLIGHT 5: INNOFILL NRF-OFE FILLER –
GENTLE AND PRECISE
The computer-controlled 80-station Innofill NRF-OFE bottling
machine fills the bottles. It works on the filling level principle
with a long filling tube. On the one hand, this always ensures
task+solution ° Jägermeister – ready to spring into the Top Ten worldwide
36*37
Left After depalletizing: Motorized row-wise removal of contour bottles. Right Dirk Löding,
Head of Production and Merchandise Management at Mast Jägermeister AG: “We now have
system equipment that meets all our requirements.”
maximum line efficiency. It allows the system “to breathe”. The
80-meter long buffer section allows the rinser-filler-capper-labeler
block to continue producing at full capacity for about three minutes while the Innopack PPZ packer is changed over to a new box
format, for example.
HIGHLIGHT 8: INNOPACK CA –
FULLY AUTOMATIC
AND FLAWLESS
exact fill levels. On the other, because of the bottom-up filling,
this method works extremely gently, as it prevents loss of flavor
and alcohol and minimizes oxygen pickup in the product. Because
a sieve gas lock is also integrated within each filling tube, the system works without dripping and thus prevents loss of product.
Dirk Löding: “As far as we were concerned, from the very beginning we would only consider a bottling system that took all aspects
of product quality into account.”
HIGHLIGHT 6: INNOKET ROLAND 20/5 LABELER –
BLOCKED AND RELIABLE
After the filling process, bottles pass to the capper, which places
and rolls on the aluminum caps. The bottles are labeled with front
and back labels by the Innoket ROLAND 20/5 labeling machine
with two hot melt labeling stations. The double-worm feedscrew
provides optimum guidance for the bottles. Recessed chucks in
the rotary ensure that the bottles are exactly aligned with the correct labeling position. The bottle turrets can be easily replaced
when contour bottles are changed. The system can be retrofitted
with the appropriate bottle turrets for new bottle types at any
time. Traveling label applicators in the machine rotary provide
additional labeling reliability. The labeler’s automatic magazine
feed offers maximum operating convenience. “Our expectations
of the labeling are high. After all, it is the label that first communicates with the consumer at the point of sale,” says Dirk Löding.
HIGHLIGHT 7: INNOCHECK PROMECON 4000 –
PRECISE AND RELIABLE
The PROMECON 4000 ensures perfect quality control of the filling
level, cap, and label. In the Innocheck PROMECON 4000, a diode
lighting field in conjunction with a camera recording provides
information on the exact filling level by averaging different measuring points. A dynamic buffer after the bottle inspection ensures
Installed ahead of the packer are two Innopack CA carton unfolders, which unfold cardboard box blanks made from solid cardboard
(for the German market) and from corrugated cardboard (for export
markets), fold in the bottom flaps and glue them in place with hot
melt, as well as two partition inserters. Two Innopack CV carton
sealers apply the glue and thus ensure perfect sealing of the carton lids.
Exactly like the depalletizer, the Innopal PBN palletizer
operates fully automatically when it is necessary to change over
to new cartons without taking a great deal of time. Each layer is
automatically centered from all sides prior to discharge onto the
pallet. The result: Perfect layer formations, gentle-to-product
handling, and high overall stability of the pallet load. The Innopal
PBN palletizer with elevated infeed works with two carton feed
lanes and external pack-turners (without mechanical stops). For
export goods, the integral handling robot places so-called slip
sheets on the empty pallets. Production on the KHS line in the
Linden plant ends with pallet wrapping and transport of the pallets to the appropriate storage areas. Rudi and Ralph are now
hurrying back to their stomping grounds.
Walter Senft, Manager, Wine, Champagne,
Juice and Liquor System Sales, KHS AG, Bad Kreuznach
fi
INFOBOX
• WEBSITE www.jaegermeister.com
• CONTACT
Walter Senft, Manager, Wine, Champagne, Juice and
Liquor System Sales, KHS AG, Bad Kreuznach
Tel:
+49 (671) 852-2380
E-mail: [email protected]
Wine specialist Caves Garnier relies on KHS systems expertise
Entrepreneurial
POWER
As one of the leading suppliers of wine to the Swiss trade, Caves Garnier provides a
complete range of domestic and foreign quality wines. This quite definitely
requires perfect bottling and maximum flexibility. The company has now invested
in innovative KHS filling technology – a model for the wine industry.
1
THE TASK A bottling line for wine, which
can handle changing capacity ranges, wine
qualities, closure types, and bottle formats
as quickly as possible.
2
THE SOLUTION
A line specially designed
for the wine sector with the innovative
Innofill DNRT filling system, which fulfils all
customer requirements one hundred percent.
Switzerland is a small wine country, but a
fine one. For it offers a great deal of diversity. More than 50 different varieties of
grape – most of which are outstanding – are
grown by 33,000 producers. Caves Garnier,
specialist in the bottling of widely different
wines and therefore an important supplier
to the Swiss food retail trade, has been a
reliable partner to the Swiss producers and
the wine trade for almost 150 years.
Caves Garnier, located in Münchenbuchsee near Bern, is a 100 percent subsidiary of fenaco, a group of companies
belonging to the Swiss agricultural sector.
In addition to Swiss produce, foreign wines
from all four corners of the earth have great
importance.
For the company, quality and flexibility are the measure of all things. After
the company had successfully grown over
20 years with a KHS bottling line, which had
proved to be highly satisfactory, it was now
necessary to invest in a modern filling system. KHS was the first choice. Peter Fink,
Caves Garnier’s Plant Manager and Member
of the Executive Board: “We first gathered
extensive information. In the interests of
our customers, we wanted to be absolutely
sure that all wines were bottled in accordance with their requirements and that the
filler could be changed over quickly.”
Bottling trials were even carried out
in advance jointly with KHS in KHS’ plant.
Peter Fink: “After this, it was clear to me
that only one bottling system could satisfy
our high requirements: the KHS Innofill DNRT
filler – a worthy successor to our always reliable KHS bottling system.”
INNOFILL DNRT FILLER:
THE HIGHLIGHTS
1. High capacity range. The Innofill DNRT
is outstandingly suitable both for the medium
and the higher capacity range: from 10,000
up to 50,000 bottles per hour (20,000 bottles at Caves Garnier).
2. Suitable for all qualities of wine. The
system can be used equally for still wines as
well as for sparkling wines, champagne,
selection wines, quality-tested wines, quality wines, and table wines. Fink: “Our white
wines are known for their sparkling freshness. We would never allow ourselves to use
a bottling system where any effervescence
would be lost during the filling process.”
The computer-controlled singlechamber filling system carries out filling
under pressure as well as pressure-free filling and provides the option of pre-rinsing
with CO2 or nitrogen once or several times
before the filling process. Single or multiple pre-evacuation is also possible.
3. Electropneumatic opening and closing. Short tube filling system: The filling
valve opens electropneumatically at the
beginning of the filling process. A swirler
system spreads the product to the walls of
the bottle. The filling process is completed
when the level of the product being filled
rises beyond the tip of the filling tube.
The filling valve closes electropneumatically. The bottle is overfilled by a specific
amount.
4. Trinox process: accurate and essentially drip-free. The filling system has a
task+solution °
2
THUMBNAIL PORTRAIT:
CAVES GARNIER
* Founded in Switzerland in 1863
* 100-percent subsidiary of fenaco
* Important supplier of wine to the Swiss
retail trade
* Trusting in a new KHS bottling system after
20 years of excellent experience
also essentially drip-free. A most important
aspect from the point of view of hygiene.
Digression: Accurate fill levels are
particularly important in the wine industry
when the filled bottles are sealed with natural corks. Microbiological problems can
occur if they are even slightly overfilled.
5. Sealers for all eventualities. Among
Top The capper/corker systems can be
engaged and disengaged as required.
Bottom The Innofill DNRT filling system is
equally suitable for still wines and for
sparkling wines and champagne.
The Trinox process – a key highlight of the
filling system.
special Trinox channel. This can be supplied
with air or inert gas. An overview of the
technology:
* From the Trinox channel, a pressure is
built up in the bottle, which is 0.3 to 0.5
bars higher than the pressure of the ring
bowl, both in the case of balanced pressure and pressurized filling.
* Positive pressure in the bottle ensures
that excess product is forced gently back
into the ring bowl through the Trinox
tube in the center of the bottle and filling valve.
* This process ends exactly at the moment
that a minimum defined gap is produced
between the level of the product and the
end of the Trinox tube.
The result: Trinox technology produces
extremely accurate fill levels with standard
deviations of one millimeter and less. It is
other things, Caves Garnier uses the Innofill
NK natural cork corker and – in order to be
flexible – has also incorporated the Innofill
SV screw capper and the Innofill KK crown
corker as additional alternative sealing
machines within the filler-capper block.
A special feature of the capping/
corking systems is that they can be engaged
and disengaged just as required. Only one
closure system is therefore in action at any
one time, while the others are in the rest
position. A further plus point is the associated reduced wear on the capping/corking systems. In addition, an automatic closure feed system makes for user-friendly
operation.
The natural cork corker has an automatically adjustable cork compressor heater
– microbially extremely safe – and a vacuum
device, which evacuates the empty space in
the bottle neck before the cork is put into the
bottle. This prevents increased oxygen pickup
and increased pressure inside the bottle. Furthermore, the filling level is automatically
changed over by means of an automatic central adjustment of the return air tube, which
can also be carried out during operation.
Instead of changing the return gas tube, a
push of a button is now all that is necessary.
38*39
6. Adjustable format parts. Format parts,
which are adjustable in their own right, also
ensure increased system availability. A new
and significant KHS development. For when
a bottle change occurs, guide stars no longer
have to be changed as has previously been
the case, but instead they can be converted
to suit new conditions in a matter of seconds with very little effort. A dummy is
placed in the filler and in each of the capper guide stars affected. The stars are then
fixed and locked in place. And that’s all
there is to it. Changeover to a new bottle
diameter is complete. Managing Director
Fink praises,” The system provides us with
the future-proofing we need.”
7. Optimized filler front table. Another
new development, which represents optimum hygiene, is the filler front table. Made
entirely from stainless steel, it has a sloping tabletop.
The result: With innovative KHS filling equipment, Caves Garnier is equipped
for all future bottling tasks. For what the
trade needs, the trade gets. Managing Director Peter Fink has the last word: “With our
new KHS filler-capper block, we will be able
to grow with the trade in any way.”
Herbert Bartnick, Central European
Business Area, KHS AG, Dortmund
Thomas Rams, Manager KHS Sales Office
Switzerland, Wolfwil
fi
INFOBOX
• WEBSITE www.garnier-vins.ch
• CONTACT
Herbert Bartnick, Central European Business
Area, KHS AG, Dortmund
Tel:
+49 (231) 569-1589
E-mail: [email protected]
Thomas Rams, Manager KHS Sales Office
Switzerland, Wolfwil
Tel:
+41 (629) 262-313
E-mail: [email protected]
RhönSprudel invests in the latest KHS ultra-clean system technology
Stuff of Life
RhönSprudel – one of the German mineral springs richest in tradition –
is now relying for the third time on PET technology from KHS. This time with
the latest in ultra-clean filling technology. An ideal solution.
1
THE TASK
Installation of a line for the
hygienic filling of
• mineral water and
• carbonated spritzers.
2
THE SOLUTION
Design and installation of a complete line for
• PET bottles and
• filling in a UCF system.
There aren’t many companies in Germany
whose origins can be traced back for over
two centuries and who have been successful throughout the entire time. RhönSprudel
is without a doubt a member of that exclusive group of special firms: The mineral
springs, as one of Germany’s most traditional springs operations, can look back on
226 years of history, and today rank number twelve among the 320 German mineral
spring companies.
Since 1911, the company has been
owned by the Schindel family; in 1989, Egon
Schindel took over operations as the third
generation. Over the years, the company
has grown continuously to form today’s
RhönSprudel Group, which besides several
mineral springs also includes fruit juice
companies and breweries. Their own trading company and beverage market chain
round out their offering, right down to the
retail trade.
In the past year, the RhönSprudel
Group, with 800 employees, realized sales
totaling 200 million euros. In the future,
according to Egon Schindel, sales are expected
to rise by 5 percent annually. However, the
focus here is not sheer growth in volume –
instead, a strong brand should result in
RhönSprudel’s growth, characterized by
outstanding product quality and the highest in customer satisfaction.
BROAD SELECTION OF BEVERAGES
The RhönSprudel selection is broad; mineral
waters account for about 60 percent of sales,
while 40 percent go to soft drinks. In this
product segment, the spritzers are particularly successful, with about 50 percent of
sales. No wonder, since it was RhönSprudel,
which in 1994, was the first German mineral springs to bring these bubbly soft drinks
to their current popularity with the mineral
water apple juice spritzer Apple Plus.
Also included in the product range:
classical soda pops, Club Cola, and numerous health drinks such as ACE beverages
task+solution °
and near-water drinks like Apple Water and
Hollerblüte. An absolute first, available
since March of 2007, are organic soda pops
under the brand Bio-Rhöni and an organic
apple spritzer under the brand name Biosfere. Naturally, all the basic ingredients
are exclusively the products of organic agriculture.
And how do the beverages get to
the customer? RhönSprudel relies heavily
on PET when it comes to packaging. In the
meantime, the share of PET around 54 percent. Of that, 37 percent is bottled in refillable PET and 17 percent in one-way PET or
PET two-way, deposit bottles. In installation technology, the company has relied
for years on know-how from KHS – both
with classical glass lines and also with PET
lines for one-way, two-way deposit, and
refillable processing. In 2000 for the first
time, RhönSprudel invested in a KHS refill-
2
THUMBNAIL PORTRAIT: RHÖNSPRUDEL
RhönSprudel, Germany’s Number 12 mineral springs, looks back on 226
years of history.
*
*
*
*
*
*
*
*
1911 The Schindel family takes over the springs
1989 Egon Schindel is the third generation to manage the company
1990 Acquisition of the Bad Liebenwerda mineral springs
1992 Expansion of Bad Liebenwerda plant; joint venture with
Bauer Fruchtsaft
1994 Acquisition of Alsfelder Brewery and Vogelsberger mineral springs
1995 Integration of Adelbodner mineral and healing water springs
2002 Acquisition of Herborner Bärenbräu
2007 Start of “Biosfere”, its own family of organic soda pops
2006 figures from the RhönSprudel Group
Sales totaling 200 million euros, 800 employees, product mix
* 60 percent mineral water
* 40 percent soft drinks
of which 50 percent are spritzers
40*41
Left RhönSprudel products: perfectly filled under class 10.000 clean room conditions.
Center Space-saving integration: the Innoclean EE single-end bottle washer. Right Egon Schindel,
owner of RhönSprudel (left) and Thomas Storch, operations manager for RhönSprudel (right) agree:
“With innovative KHS ultra-clean filling technology, RhönSprudel is ideally prepared for the future.”
able PET bottling line, which is able to
process both one-way and two-way deposit
PET bottles. A pure KHS one-way / two-way
deposit PET line then followed in 2002.
THE PUREST IN SYSTEM TECHNOLOGY
Recently, RhönSprudel put their third KHS
PET line into operation: a refillable line for
0.75 and 1.0 liter PET bottles with an output of 30,000 bottles per hour, equipped
with
* KHS Superblock
* KHS bottle washer
* KHS process engineering
* the latest in KHS ultra-clean filling technology, for the cold filling of beverages
in extremely low-germ atmospheres
under class 10.000 clean room conditions.
2
EVERYONE LIKES SPRITZERS
A summer without a refreshing spritzer – today, it’s
no longer imaginable. But it was just twelve years ago
that the bubbly refreshment became popular – starting in 1994 when RhönSprudel introduced its first
apple spritzer. The Stiftung Warentest testing institute gave it its higahest praise: Apple Plus was a test
winner. Today, the company offers an assortment of
six different spritzers – all with 60 percent fruit juice
content by the way: Apple Plus, Ananas Plus, Cherry
Plus, Cassis Plus, Grape Plus, and Orange Plus.
An ideal solution, because still mineral
waters and spritzers are particularly sensitive in the filling process, requiring the
highest in hygienic measures. “Ultra-clean
filling makes it possible to run our entire
line of spritzers without any preservatives
at all, and simultaneously provides the highest possible safety when filling still mineral water. After validation and a subsequent production approval, KHS UCF (ultraclean filling) has always been able to meet
our requirements. There were no microbiological complaints,” explains RhönSprudel’s
Plant Manager Thomas Storch.
AND HOW DOES THE LINE WORK?
Superblock. After depalletizing and unpacking, the refillable PET bottles enter the new
line directly at the KHS Superblock. It handles the sorting, decapping, delabeling, and
foreign material inspection of the bottles.
Bottle washer. Flawless bottles then
enter the Innoclean EE single-end bottle
washing machine. The bottle feed is in the
lower area and the outfeed is in the upper
area of the front end. RhönSprudel decided
on the single-end machine due to its spacesaving design.
The Innoclean EE provides RhönSprudel with two advantages:
Advantage 1 – Triple-i-Drive: The integrated modern Triple-i-Drive reduces
changeover time for the processing of different PET bottle shapes and sizes to a minimum.
Advantage 2 – disinfection. The Innoclean
EE sprays the bottles with disinfectant
before they leave for the ultra-clean block.
That ensures a long soaking time for the disinfectant, until the bottles reach the rinser.
Two-channel Rinser. In the ultraclean block, the electronically controlled
Innoclean FR-ZR two-channel rinser works
with two rinse media. After rinsing with
disinfectant, the machine sprays the PET
bottles out with fresh water. A highlight:
A special catch container collects the rinse
water and conducts it directly to the bottle washing machine. That means that the
bottle washer can cover its fresh water needs
exclusively with the rinse water in ongoing production: that massively reduces the
consumption of fresh water and significantly improves the ecobalance.
Innofill DRV filling system. The
rinser is grouped with the volumetrically
computer-controlled single-chamber filling system Innofill DRV equipped with 120
filling stations. A highlight: The entire filling process – including bottle lift, pressing of the bottles, and sealing of the bottle mouth against the filling valve – operates with only two pneumatically actuated
membrane cylinders.
Innofill SV-ACF Capper. The
Innofill SV-ACF capper is characterized by
a tension belt-driven anti-twist lock developed by KHS especially for the aseptic
process. The constant capping force offers
the end consumer greater opening convenience.
In order to satisfy the highest of
hygienic requirements, the capping process
has been separated into the rotational
movement of the cap and the vertical move-
task+solution ° RhönSprudel invests in the latest KHS ultra-clean system technology
fi
42*43
INFOBOX
• WEBSITE www.rhoensprudel.de
• CONTACT
ment of the bottle. Each capping spindle,
operating independent of the machine
speed, is equipped with a servo drive tailored to the particular style of cap.
Changeovers are carried out at the push of
a button making mechanical adjustment
work unnecessary. Another plus point:
Because all elements of the capper have an
open structure, they can be cleaned perfectly.
Before the caps reach the capper,
they pass through H2O2 cap sterilization
with uniform surface application regardless of shape and material. The system then
removes the H2O2 medium leaving no residue
whatsoever behind so that there is no carryover of residue.
THE ULTRA-CLEAN CONCEPT
For ultra-clean, KHS relies on a closed clean
room concept. The rinser/filler/capper
block is enclosed in a glass isolator with a
ceiling equipped with filters that clean the
shop air. In the closed system, there is
always a slight amount of overpressure, and
thus a permanent air flow from the ceiling
to the floor. Special gaps in the paneling
allow the controlled escape of the air enter-
ing the isolator into the filling shop. The
inside areas of the filler and rinser carousels
located outside the isolator also conduct
the return air away.
In ultra-clean filling, operating personnel are subject to strict hygienic guidelines. When entering the glass isolator, clean
clothing, head covering, and hand and shoe
disinfection are mandatory. After opening
the glass isolator, all machine surfaces are
disinfected. During operation, production
stops briefly every four hours for automatic
surface disinfection of the entire machine
group as well as the interior surfaces of the
isolator. This reliably prevents all growth of
germs. General system sanitizing takes place
every 72 hours. This includes sanitizing the
exteriors of all machines, cleaning the internal walls of the glass isolator, and running
all CIP and SIP cycles.
SYSTEM SOLUTION FROM ONE SOURCE
In the ultra-clean solution, all components
are from a single source:
* Innopro KZE flash pasteurizer,
* Innopro CIP system, and
* Innopro PARAMIX CMX blending
system.
Andreas Waldscheck, Sales Manager,
North Germany, KHS AG, Dortmund
Tel:
+49 (231) 569-1734
E-mail: [email protected]
A complete solution with the latest in KHS
process technology, on which RhönSprudel
already relied with the KHS refillable PET
line installed at the Bad Liebenwerda mineral springs. The non-refillable PET line
manufactured in the year 2002 is also completely equipped with KHS process technology. Egon Schindel: “With this uniform
all-inclusive concept, RhönSprudel well prepared. Because it includes the possibility
of providing the market with many interesting innovations in the future as well.”
Top quality is just good enough, considering that “the customer is the measure of
all things”. And that’s the foundation of
success.
Andreas Waldscheck, Sales Manager,
North Germany, KHS AG, Dortmund
A new, advantageous
complete concept for PET bottles
Lean
Design
Lean design – an important keyword for the
KHS complete PET bottle concept developed
especially for the non-alcoholic beverage
industry. This complete concept, besides
its mainstay, the Innofill DRV, also includes
rinser and capper solutions adapted precisely to the requirements of non-alcoholic
beverage operations. Integration of a stretch
blow molding machine into the concept is
also possible. If desired, it can be directly
blocked with the Innofill DRV.
HYGIENIC DESIGN AT ITS FINEST …
During development, hygienic design was
the first principle. The KHS complete PET
bottle concept works with no filler front
table at all. The mechanical connection of
the individual elements uses braces. An
additional positive aspect when it comes to
hygienic design. The front-table-free design
ensures accessibility heretofore unimagined.
The outer surfaces of the filler are either
round or sloped. That makes it possible for
liquids to run off quickly, ensuring perfect
hygienic design.
A central element is the tubular ring
bowl. There are no corners or edges. That
significantly reduces weight. The lightweight
construction reduces the drive forces needed,
thus reducing power consumption and maintenance costs.
An innovative KHS filling system for soft drinks bundles the
enormous advantages of lean construction and hygienic
design. It’s unique on the market. And it also includes
ongoing cost advantages, as well as higher line efficiency.
… FOR CARBONATED BEVERAGES …
Outstanding: As a filling system for carbonated beverages, the Innofill DRV operates with only two pneumatic cylinders per
filling valve. These two pneumatic cylinders control the entire filling process –
including lifting the bottle and sealing the
bottle mouth against the filling valve. That’s
possible due to the transfer of the pressurization pressure over a bellows designed
according to aseptic criteria to the neck
ring holder. This means that the force of
the pressurization pressure forces the PET
bottle onto the filling valve thereby entirely
eliminating the bottle lifting elements
required by conventional filling systems.
The pressing force exerted on the PET bottle is regulated fully automatically depending on the filling pressure. It couldn’t be
more precise. At a high filling pressure,
the system forces the bottle onto the filling valve with the correspondingly high
force required. If the filling pressure is low,
a correspondingly lower pressing force is
sufficient. This in turn ensures gentle handling of the plastic bottle and minimizes
the stress on the sealing systems.
… UNIQUE ON THE MARKET
Because this filling principle gets by with
the lowest number of switched elements,
KHS holds a unique position in the market.
During the filling process, there is only minimal movement at the filling valve, due to
the self-regulating pressing force. The main
advantages:
* Reduced number of wearing parts
* Extremely low failure susceptibility of
the system
* High reliability and low maintenance
* Noticeable cost advantages (improved
cost of ownership relationship)
* Swirlers, a significant element of KHS
single-chamber filling systems for more
than a decade, offer high flexibility in
filling due to the elimination of any spray
technology+innovation °
44*45
Left Innofill DRV: The tubular ring bowl has no corners or edges.
Right Lean design: offers a lot of advantages.
elements projecting into the bottle (allowing a variety of bottle shapes and sizes
without changeover work)
* No excessive foam buildup and the possibility of filling even highly carbonated
beverages at temperatures of 20 degrees
Celsius and higher.
FOR NON-CARBONATED BEVERAGES
If non-carbonated beverages are also filled,
another pneumatic cylinder is added. Switching to the pressureless filling process is
possible with the push of a button.
Another variant of the Innofill DRV
also allows triple-chamber pressure filling
for carbonated beverages, naturally also
under ultra-clean conditions. In classical
triple-chamber pressurized filling, the pressurization is carried out exclusively with
sterile filtered inert gas. The displaced
gases – unlike single-chamber pressure filling – no longer return to circulation, but
leave the system.
FLEXIBILITY IS EVERYTHING
Aseptic membrane and sealing technology
within the filling valve is a given, just as
for all product and sterile gas carrying channels and paths.
From the 0.1-liter to the 5-liter PET
bottle, any bottle size and shape can be
processed. Filling capacity: up to 80,000
bottles per hour. Maximum filler diameter: about 6.5 meters, accommodating up
to 220 filling stations.
Changeover time is minimized.
Change of bottle shapes and sizes at the
push of a button. Even when the product
changes: no manual changeover work.
Another special feature: CIP cleaning. The sealing of the filling valves is handled by so-called CIP plates (inserted into
a groove in the bottle holder below the filling valve). Cleaning follows the same principle as for bottle pressing. The CIP plates
can optionally be extended fully automatically during one filler round. Retraction
– also during only one rotation of the filler
– is also fully automatic.
THE OTHER COMPONENTS
The drive connection between the rinser,
filler, and capper block is handled by modern servo technology.
Plastic gripper elements hold the
PET bottles above the neck ring and ensure
the highest degree of safety. The plastic
grippers will break if deformed bottles jam
inside the system. That protects valuable
machine components. The gripper elements
can be replaced quickly and inexpensively.
Within the shortest possible time, the system is ready to resume production; in comparison with traditional solutions, this is
very effective and cuts down the total cost
of ownership (TCO) calculation outstandingly.
The transfer of bottles from the air
transporter into the rinser is simple, extremely
safe, and requires no changeover work when
bottles are switched. This cuts costs.
The transfer of filled plastic bottles
to the capper is handled by a transfer disk
using neck handling. Screw capper: either
the classical Innofill SV or the Innofill SVACF designed according to aseptic criteria.
fi
INNOFILL SV-ACF: A MUST
FOR ULTRA-CLEAN
The Innofill SV-ACF is a must for ultra-clean
filling. Here, there is a closed glass isolator. A part of the ceiling of the ultra-clean
isolator is equipped with filter units. These
filter units filter the bottle shop air. There
is a continuous air flow – again due to the
slight overpressure within the glass enclosure – from the ceiling to the floor area.
This means that the area where open bottles are transported is continually supplied
with filtered air.
The result: the new KHS PET bottle
concept practices consistent lean design
and, in doing so, offers only advantages:
simple rinsing, simple filling and capping,
simple changeover, simple cleaning, simple
maintenance, simple compliance with hygienic
operation, simple drive systems, and simple operation. Simply simple – lean design.
Manfred Michl, Manager of Technical Sales,
Process Engineering Competence Center,
KHS AG, Bad Kreuznach
Ludwig Clüsserath, Construction/
Development Manager, Process Engineering
Competence Center, KHS AG, Bad Kreuznach
Lothar Wilhelm, Manager, Process Engineering
Competence Center, KHS AG, Bad Kreuznach
INFOBOX
• WEBSITE www.khs.com
• CONTACT
Manfred Michl, Manager of Technical Sales, Process Engineering
Competence Center, KHS AG, Bad Kreuznach
Tel: +49 (671) 852-2325, E-mail: [email protected]
Ludwig Clüsserath, Construction/Development Manager,
Process Engineering Competence Center, KHS AG, Bad Kreuznach
Tel: +49 (671) 852-2501, E-mail: [email protected]
Lothar Wilhelm, Manager, Process Engineering
Competence Center, KHS AG, Bad Kreuznach
Tel: +49 (671) 852-2372, Email: [email protected]
2
“One 4 Two”: New KHS system
for changing fittings
Fit for
1
Fittings
Until now, it has been a global problem to process kegs with
different fittings one after the other. Keywords: high investment
and changeover effort. This is now a thing of the past.
KHS, a world leader in keg system technology, presents a system
for a smooth transition between different fittings.
With no downtime.
Globalization is one of the big keywords in
the international brewing industry. That
doesn’t just mean that existing selections
must be integrated or reduced, but also that
technical solutions must fit together. In keg
line technology, it’s not at all unusual that
acquisitions result in kegs with different fittings being processed from one day to the
next within a brewing group. Hence, significant investment in corresponding connector geometries for washing and racking
heads, as well as higher retooling costs when
changing over to different fitting types. The
result: lower system effectiveness.
A job – a challenge – for the experts
at global keg market leader KHS. They have
developed and perfected a solution, which
eliminates these drawbacks: a technology
capable of processing two different fitting
types with no transition and thus with no
downtime at all.
*
*
The initial situation: When switching to
different fitting types, the line is down
for about an hour.
Let’s look at the matter in detail:
* The normal fittings are basket fitting
and flat fitting versions.
* Even for alternating fittings, washing
and racking heads always have to work
perfectly.
* That particularly applies to the centering cone, which grips the fitting and
centers it, along with the rod, which is
pushed into the fitting and opens or
closes the fitting valve.
*
*
Until now, cleaning and filling heads
were only capable of adapting to a single given fitting.
In the case of a fitting change, therefore, there was a need to exchange the
centering cone and fitting rod as quickly
as possible.
For that purpose, there are quick-change
systems, but for hygienic reasons CIP
cleaning was always necessary.
That significantly reduces the availability of the line. Rule of thumb from practical experience: at least an hour.
The solution: With “One 4 Two” from
KHS, the line simply continues to operate despite a change in fittings.
The new KHS development is called
technology+innovation °
46*47
“One 4 Two” is a newly developed KHS system which – when properly integrated into
the washing and racking heads – allows the processing of two different fitting types.
“One 4 Two”. When integrated into the washing and racking heads, it allows the processing of two different types of fitting.
And this is how the ground-breaking idea
works, in general:
* Two fitting rods are built directly into
one another – one for handling basket
fittings and the other for flat fittings.
* The rod geometries for flat and basket
fittings have been modified so that they
not only fit into each other, but that
all parts of the “One 4 Two” system are
also subjected to ideal rinsing and cleaning.
* In “One 4 Two” as well, gas and fluid
flow rates are sufficiently large to enable
ideal washing and racking.
* The system has two drives. Each controls one fitting rod.
* Two different half-shells provide the
necessary centering to the outer contour of the keg fitting. Each of the halfshells has a separate pneumatic outlet.
* When opened, the half-shells center
the dimensionally larger flat fitting,
and when closed, they harmonize perfectly with the smaller basket fitting.
So the deciding innovation in the “One 4
Two” system is thus that the processing
parts for two fittings have been fitted inside
one another. The geometry of the part that
opens the fitting is exactly the way it always
was. The rest of the design of the washing
and racking head is somewhat lighter than
the traditional systems, but the “One 4 Two”
technology is still extremely robust and
durable.
The system: Detects kegs perfectly even
when fittings change on the fly.
Fantastic: a continual on-the-fly change
between different fittings is possible. Kegs
no longer need to be presorted by flat and
basket fittings before being fed into the
system. The system spontaneously washes
and racks the keg it finds:
* identified, for instance, using a keg ID
carrier
* or identified using transponders
* or, equally as plausible, the installation of appropriate sensors before the
washing and racking processes.
If the system sorts the kegs by fitting type,
all you need to do is to press a button on
the operating terminal to inform the washing and racking heads about the new orientation required.
Example from the field: The options
clearly speak for “One 4 Two”.
In the typical example, a brewery has a keg
fleet of 500,000 kegs equipped with flat
fittings. Due to the acquisition of another
brewery, 300,000 kegs equipped with basket fittings are added, which cannot be
processed with the existing keg system
technology. What can be done?
1. New flat fittings. The company equips
all 300,000 basket fitting kegs with new
flat fittings. The result:
* Costs for the conversion of the kegs to
a standard fitting.
* Additional costs for the work.
* Additional costs for the fitting rods and
centering cones needed for the washing and racking heads.
* Additional follow-up costs for conversion and sterilization (system availability).
* Additional logistical costs for the presorting of kegs.
*
of conversion depend on the variant of
the racking and washing heads and on
the keg line technology.
Additional costs for the adaptation of
piping and the connection of the electrical systems (additional pneumatic
outlets for the rods, as well as for the
moveable centering geometry).
Also to be determined and integrated appropriately: Criteria for switching to the different fitting types. At the push of a button or on-the-fly changeover? All that must
be determined before the project commences. If the change will be on the fly,
either sensors or keg ID carriers – if not
already available – must be integrated into
the keg line.
Planning: “One 4 Two” for KHS and thirdparty systems, for inline or rotary
machines
The “One 4 Two” system can easily be integrated into existing KHS keg systems built
after 1995. For KHS systems built up to
1995 and for third-party systems, the existing equipment needs to be reviewed.
The “One 4 Two” system can easily
be integrated into keg lines or keg rotary
machines. Integration is even possible into
semi-automatic keg washing and racking
machines.
Alois Monzel, Manager, Keg Technology
Competence Center, KHS AG, Kriftel
fi
INFOBOX
2. “One 4 Two” system. The company con-
• WEBSITE www.khs.com
verts its washing and racking heads to the
“One 4 Two” system. The result: The costs
are signif icantly lower than the effort
involved for Option 1. In detail:
* Costs for the one-time change of the
washing and racking heads. The costs
• CONTACT
Alois Monzel, Manager, Keg Technology
Competence Center, KHS AG, Kriftel
Tel:
+49 (6192) 491-193
E-mail: [email protected]
Perfect ACF inspection technology
Playing IT Safe
Here, nothing, but absolutely nothing, goes unobserved. Here, everything, and
absolutely everything, is registered. And here, data can be accessed even
retrospectively. With aseptic cold filling, consumer safety is the first commandment of inspection technology Made by KHS.
Inspection equipment for aseptic cold filling (ACF)
must satisfy the most demanding requirements. This
goes without saying. This article is intended to clarify which inspection measures are to be considered
before and after filling, and how these are to be evaluated.
In practice, there is a choice of two ACF methods for bottles and caps. Firstly the new method of
dry sterilization, and secondly, the conventional, and
in the meantime almost traditional, wet process. Experience shows that both methods perform absolutely
identically from the safety aspect – and the inspection
equipment is also identical.
First of all, the caps are inspected by means of
image processing as soon as they have been separated
and before they reach the capper. When the container
has been filled and sealed, several inspection methods are available for checking the fill level and the cap
once more. These can be used in different situations
and must be assessed differently.
The results in advance: Image processing using
camera technology is recommended for the predominantly used transparent PET bottles for a number of
reasons.
A MUST: PERFECT MANAGEMENT
Of particular importance in ACF is a management system, which provides intelligently combined information in conjunction with the inspection equipment.
Example: A PET bottle is grossly underfilled – in this
case, it is possible to immediately identify the filling
valve used for this bottle. Action can be taken equally
quickly. It is also possible to associate fitted caps
with the appropriate capper head or to associate the
appropriate rinsing station with each inspected PET
bottle.
Another task of the management system is the
automatic taking of laboratory samples. For example,
the programmed line channels out a certain number
of PET bottles at certain time intervals and sends them
to the laboratory for examination. It is also possible
to channel out bottles that have been filled by a particular filling valve. Or bottles that have been sealed
by a particular sealing head. Or the general channeling out of every xth bottle. Anything is possible.
When channeling out – whether it be for laboratory purposes or for the channeling out of detected
“bad” bottles – the system achieves maximum accuracy by the so-called carrying over of the ejection signal by means of a clock-pulse generator, mounted on
the conveyor. This means that this clock-pulse generator measures the speed of the conveyor and passes it
on to the control unit in the form of pulses. Accordingly, it is possible to say, for example, that every bottle checked by the inspection system will reach the
reject station after a certain number of pulses. This
is stored in the system.
Important: is that full data relating to aseptic
operation is always stored ready for retrieval. The rinsing, filling, and capping process can therefore be exactly
reconstructed, like the inspection results, with reference to a code printed on every PET bottle. In addition, interfaces can be created between the inspection device and the system such as laser or inkjet printers. Exactly the right inspection technology for the
most demanding requirements.
Herbert Menke, Manager, Control Systems
Competence Center, KHS AG, Niederzissen,
CHARACTERISTICS
Situation
Method
What is inspected
How it is inspected
Special features
Benefits
Limitations
Recommendation
technology+innovation °
ACF INSPECTION TECHNOLOGY: A LITTLE PROCESS THEORY
PROCESS BEFORE
CAPPING MACHINE
48*49
2
PROCESS AFTER FILLING AND CAPPING
Cap inspection
Fill level check
After separation of the caps and
before they go for cap sterilization
before the capper
Fill level and cap check are further inspection steps located outside the ACF block and therefore after the rinsing, filling,
and capping processes. There is a choice of three different methods for measuring the fill level.
Cap monitoring is carried out exclusively using image processing.
Fill level and cap check
Image processing
* Roundness of the cap
* Accuracy of the cap dimensions
* Intactness of the cap area
* Inspection of the sealing ring for
perfect seal
1 High-frequency measurement
Area measurement of the fill level
2 X-ray check
Specific point measurement of
the fill level
3 Image processing
Fill level and closure
* Uniform lighting ensures
perfect camera pictures
* Ejection by blowing out with
air or mechanically controlled
ejector.
* Telecentric image
(high-quality lens)
* PET bottles pass through a measuring bridge, which has a measuring
head mounted above it.
* Electrodes register overfilled and
underfilled bottles
Adsorption value indicates overfilling of PET bottle
* Camera equipment positioned opposite a light field provides information about the fill level and the
seating of the cap
* Two cameras, which are offset from
one another by 90 degrees, are used
* Large inspection range due to combination of both images
* Any system that is not already
using it can be retrofitted with
image processing
* System detects proportion of
good and bad caps (grounds for
checking the conditions under
which the closures are stored, for
example, as increased pressure
on the closure material is often
the reason for deformation).
* Fully automatic adjustment to
new requirements when new caps
are used
The measuring head and measuring
bridge have a fixed alignment and
cannot easily be adjusted
* Official approval required
* A person responsible for radiation protection in the company
monitors the proper use of the
equipment
* The position of the X-ray tube
assembly must be aligned with
the PET bottle to be inspected.
* The information from the camera is
displayed on a monitor
* Use of online direct help possible
* Images to KHS headquarters
* Rapid help if service required
* Adjusts to different non-alcoholic
beverages and different conductivities without any problem
* Fully automatic changeover possible
for new type selection
* Measuring accuracy independent of bottle diameter and bottle size
* Can also be used for non-transparent and metallic containers
* Simultaneous inspection of fill level
and cap seating
* Can be used for widely differing
sizes and shapes of PET bottle
None
* Can be used for transparent and
translucent but not metallic containers
* Only checking of fill level possible
* Special image processing station
required for cap inspection
* Data available in numerical form
only
* Only checking of fill level
possible
* Special image processing station required for cap inspection
* Data available in numerical
form only
Only suitable for transparent
containers when checking fill level
Only image processing is normally
considered for cap inspection
before capping
* Can be used for transparent and
non-transparent containers
* Particularly suitable when the system only processes a single type of
PET bottle
Suitable for transparent, nontransparent and above all for
metallic containers
* Clear plus point of image processing: Filling level and cap are displayed visually
* This considerably simplifies quality
control
* Bottle tolerances can be compensated for by neck ring referencing
Light in the
Tunnel
New: Camera system guarantees quality in shrink process
The shrink packer is becoming increasingly important in packaging technology.
But, what’s happening to the film in the shrink tunnel? Until now, users were literally in the dark. But with immediate effect, clarity prevails, thanks to a beneficial
new KHS development. The viewable shrink tunnel, which can be monitored
down to the last detail thanks to a camera system and air curtains, is here.
In the past, a shrink tunnel would be equipped
with heat-resistant curtains in the infeed
and outfeed areas, which ensured that the
temperature was maintained. A clear disadvantage is that it is not possible to see
into the tunnel in order to monitor the shrink
process. This can only be checked from the
outfeed end – usually in the case of a malfunction – with a great deal of effort. The
consequence is considerable time expenditure and significant additional costs.
This in turn did not allow the KHS
development engineers to rest. Their objective: To permanently monitor the shrink tunnel. It was obvious that the conventional
hanging curtain solution was no longer suitable for this. A freedom from barriers was
required. Hence the idea of the air curtain
for the tunnel infeed and outfeed was born.
It works using the same principle as those
that have become familiar in the entrance
and exit areas of department stores: An uninterrupted flow of air circulates from the upper
area to the lower area and guarantees constant temperatures. Advantages are
* Permanent view into the shrink tunnel
* The packs are not subjected to mechanical contact (by curtains) in the infeed
and outfeed areas.
* No longer a risk of damaging the freshly
*
shrunk, still warm, and therefore particularly sensitive shrink packs at the
outfeed.
No longer a risk of contamination.
IDEAL: AIR CURTAIN PLUS CAMERA
The perfect combination: air curtains with
upstream camera equipment. The distance
between the camera and the shrink tunnel
outfeed can be matched to the particular
tunnel design. Usually, the optimum monitoring equipment is located between 1.50
and two meters from the shrink tunnel. From
here, the camera focuses on the first onethird of the interior of the shrink tunnel as
technology+innovation °
50*51
Left Instead of conventional hanging curtain
solution, air curtains allow an unobstructed
view into the shrink tunnel.
Right The perfect combination: air curtains
with upstream camera equipment.
standard, as it is in this area that the decisive – quality-determining – work steps are
carried out:
* Sealing the overlapping sections of film
underneath each pack,
* inflating the pack with temperature-controlled hot air and thus
* initiating the shrink process.
The camera can also be turned off. If the
Furthermore, if problems should occur unexpectedly in the rear section, the camera can
change its viewing angle immediately.
Up to nine heat-resistant lamps,
which illuminate the entire shrink tunnel,
are installed in the tunnel area in order to
obtain the optimum visual impression. The
images are displayed on a monitor in blackand-white or in color as required. If there
should be problems with the shrink process,
the operating personnel can respond immediately, and quickly readjust the temperature and air feed, for example. The result of
the correction is then shown directly by the
camera.
The camera system can remain in
continuous operation if required. However,
it is intended primarily for checking the
shrink-wrap process after a format change,
when new settings have been made, if the
film quality varies, etc. The general rule is
that whenever the shrink pack processing
requirements change, the camera should be
running (by pressing a button on the control desk).
THE MAIN HANDLING ASPECTS
Multi-lane processing is no problem. Two
and three-lane operation in the shrink tunnel can be monitored with the same accuracy as single-lane operation. If the shrink
pack formation changes, for example from
12-packs to 4-packs and therefore from two
to three-lane operation, the camera does
not have to be readjusted.
camera will not be needed for an extended
period, simply turn it off, cover the lens with
a protective cap, and leave it mounted on
the machine. The only maintenance that is
required is to clean the camera lens from
time to time.
Faster troubleshooting. Up to now,
if malfunctions occurred in the shrink process,
it would be necessary to contact KHS by telephone and verbally describe the formed shrink
packs and the possible source of error. In
future, modern camera equipment will make
it possible to add pictures to the words. It is
absolutely conceivable to forward recordings
of the shrink packs and the shrink process to
KHS online. Complying with the old saying,
“A picture speaks a thousand words”, KHS
will then not only be able to respond more
quickly, but also more precisely. Communication between the camera equipment and a
plant information system is also conceivable.
Shorter commissioning. The system provides significant help when commissioning shrink packers – both in the KHS
plant and also on-site at the company’s premises. The response of the shrink packer to
different pack formations and different films
can be seen immediately. It is therefore possible to act more quickly than before. The
commissioning phase is shortened considerably.
Retrofittable. On request, the equipment can also be retrofitted to existing shrink
packers with shrink tunnel widths of 700 mm
and 1000 mm without major modifications.
With other sizes, it depends on the individual case.
Extendable camera use. Additional cameras with appropriate monitors
and communications logistics can be used
throughout the system without any problems. And certainly not only statically. If
the bottle infeed is continuously monitored,
for example, the camera equipment can also
immediately be used for operations at the
film station. Everything is feasible.
What is more, modern camera equipment is also suitable for other packaging
machines such as tray packers, wrap-around
packers and carton packers for the optimum
monitoring of critical processing situations,
it contributes to quality assurance, and helps
to achieve an attractive product presentation at the point of sale. And ultimately,
that’s what matters.
Werner Oster, Technical Sales,
Packaging Technology Division, KHS AG, Kleve
fi
INFOBOX
• WEBSITE www.khs.com
• CONTACT
Werner Oster, Technical Sales,
Packaging Technology Division, KHS AG, Kleve
Tel:
+49 (2821) 503-152
E-mail: [email protected]
Without microorganisms for food processing, we would have no beer, no
wine, or many other products. But what is the nature of microorganisms,
and what do they look like? What characteristics do they have, and how
can they be identified? Diana Wolf, a specialist working in the KHS Beverage
Technology Department at Bad Kreuznach, provides answers.
Microorganisms:
Noble Knights
Humans have been using microorganisms
for food processing for thousands of years
before they were finally identified. Examples include beer brewing or wine fermentation by the ancient Egyptians. On the
other hand, humans have had eye-opening experiences with pathogens: Many
ancient civilizations have been aware of
the connection between inadequate hygiene
and diseases or even epidemics.
The Columbus of the world of microorganisms was Englishman Robert Hooke. In
1664, he identified the first microorgan-
2
almost no metabolic activity. Sporulation
is induced by nutrient deficiency, for example. If a spore reaches a good culture
medium, it can germinate again and multiply.
WHEN MICROORGANISMS GROW
BRIEF DIGRESSION: SPORULATION
Certain types of microorganisms can form
spores, which are very resistant against
external influences. In this situation, the
microorganisms form a thick cell wall, reduce
their water content to a minimum, and have
Growth conditions include a certain pH
range, a defined incubation temperature,
and correct nutrient supply. Most microorganisms are mesophiles, i.e. they require
temperatures of 20 – 45° C and therefore
grow well at room temperature, which can
BRIEF TYPOGRAPHY OF MICROORGANISMS
Microorganisms can be classified in the following groups: viruses / phages, yeasts,
molds, and bacteria. The characteristics are
briefly described below:
1. Viruses / Phages …
Avg. size: 0.1-0.5 μm
… are pathogens that multiply in living cells.
Viruses and phages have a special status among
microorganisms because they require a host
cell (human or animal) in order to multiply.
They cannot multiply in food or beverages and
cannot be identified with traditional microbi-
1
isms in vinegar with the aid of a simple lens
apparatus. The first functioning microscope was built by Dutchman van Leeuwenhoek in 1684. He realized that “Plaque contains more microorganisms than people in
a kingdom.”
Technical terms
in practice
2
ology techniques. For this reason, this species
is not described in more detail here.
2. Molds …
Avg. size: 3 – 5 μm
…are multicellular fungi growing on food. They
spread through formation of hyphae and spores
on spore carriers.
3. Yeasts …
Avg. size: 3 – 12 μm
…are unicellular fungi requiring oxygen to
grow. In the absence of oxygen, they can
3
switch to fermentation and produce carbon
dioxide and ethanol, while growth is strongly
reduced.
4. Bacteria …
Flagellated bacterium, avg. size: 0.1 – 1 μm
avg. length: 0.4 – 5 μm
…are spherically or rod-shaped unicellular
microorganisms. They multiply asexually
through cell division and may form endospores.
They may be flagellated and therefore able to
move.
4
technology+innovation °
lead to rapid deterioration of improperly
stored food.
Another important criterion is water
activity, i.e. the quantity of freely available
water. Salami and ham, for example, have
a long shelf life because they have a high
salt content. Salt binds water, so that the
’aw‘ value is reduced to such a low level that
microorganisms can no longer grow.
A further important growth condition is oxygen. Microorganisms that grow
in the presence of oxygen are referred to as
aerobic. Microorganisms growing in the
absence of oxygen are called anaerobic.
Micro-aerophilic microorganisms are somewhere in between – they require not too
much and not too little oxygen for growing.
HOW MICROORGANISMS BECOME
VISIBLE
How can microorganisms, which are too
small for the human eye, be captured and
made visible? The work of a microbiologist
resembles that of a detective: He has to
“capture” the microorganisms, identify
them, and determine whether or not they
are harmful. Different techniques are used
for this purpose, depending on which samples is to be taken where, what its characteristics are and what insight is expected
from the result.
Depending on the application, the
specialist uses different culture media for
incubation. The culture media provide optimum growth conditions for the microorganisms. Media can be liquid or solid.
A liquid culture medium, known as broth,
provides a purely qualitative result: If
microorganisms are present in the sample
that can multiply in the broth, after a few
days of incubation the broth will show typical characteristics such as hazing, a deposit,
or gas formation. This visually identifiable
2
52*53
HIGHLIGHTS: WONDER WORLD OF MICROORGANISMS
* Researchers have been able to isolate and multiply viable spores from the stomach
content of a bee entrapped in amber. The spores survived for 25 to 40 millions years.
* A bacterium takes up its own weight in nourishment every five seconds.
* A sugar-fermenting bacterium digests 1,000 to 10,000 times its own weight within
one hour; by comparison, if a person were to eat an amount of sugar equivalent to
1,000 times his body weight, it would take almost half his lifetime to digest it.
* A bacterium can move 50 times its body length per second – a swimmer would have
to swim at a speed of 90 meters per second to achieve this.
change indicates that microorganisms were
present in the sample (qualitative), but it
is not possible to determine how many
microorganisms the broth contained at the
time of sampling (quantitative).
By contrast, there are solid culture
media. These can have the same nutrient
content as liquid culture media, although
through addition of agar-agar, a polysaccharide extracted from algae, they are converted to a gel that solidifies at around 45°
C and liquefies again at 95° C. With this culture medium, any microbes will remain in
position and multiply in situ. Each individual microorganism will form a colony (also
referred to as a cell cluster) that after two
or three days will have grown sufficiently to
become visible for the human eye. A colony
count allows conclusions to be drawn about
the initial microbial population of the sample: Each colony corresponds to a microbe.
A culture medium can therefore provide both
qualitative and quantitative information.
WHY SAMPLES ARE SO IMPORTANT
Initially a sample has to be taken and
processed. How this is done depends on
the type of sample and the sampling location: liquid sample or swab sample.
1. Liquid sample: A liquid sample is transferred to a sterile bottle via special sterilizable sampling taps. The bottle is sealed
and taken to the laboratory, where further
processing will depend on whether the sample is cloudy or clear.
Clear sample. A clear sample is
generally filtered through a membrane filter with a pore size of 0.45 μm – naturally
under conditions that should be as sterile
as possible. This has the advantage that a
significant proportion of the sample can
be examined microbiologically (several milliliters or liters). The membrane filter containing the microorganisms separated from
the liquid is placed on a culture medium
contained in a Petri dish. The microorganisms take up nutrients through the pores
of the membrane and multiply.
Cloudy sample. If the sample is
cloudy (orange juice, for example) it cannot be filtered by a membrane filter, because
the pulp fibers, which are much larger than
the microorganisms, would block the membrane. This type of sample can be examined using the pour-plate method. Between
5 and 10 milliliters are taken from the sample using a sterile pipette and transferred
to a Petri dish. The culture medium, which
Technical terms in practice
Example of a bacteria colony
was previously liquefied and cooled to
approx. 45° C, is poured into the Petri dish
while it is still liquid. The sample is mixed
with the culture medium through gentle
rotary motion. The Petri dish is then left
to stand at room temperature until the culture medium has solidified. The problem
with this type of sample processing is that
only a few milliliters can be examined. However, since one germ is sufficient to spoil
a beverage, that germ has to be found in
a sample. If only 10 milliliters are taken
for analysis from a 1-liter sample, the probability of detecting a single germ is very
low. For cloudy samples, the specimen itself
is therefore usually pre-incubated for three
days, so that any microbes contained in the
fi
INFOBOX
• WEBSITE www.khs.com
• CONTACT
Diana Wolf, Beverage Technology Department,
KHS AG, Bad Kreuznach,
Tel: +49 (671) 852-2611
E-mail: [email protected]
sample can multiply. However, this means
that the result is once again purely qualitative.
2. Swab samples: The germ content of a surface can be analyzed using the
swab method. A sterile cotton swab is
moved across the surface to be analyzed.
This swab is contained in a sterile tube, to
which it is returned after sampling. In the
laboratory, the tube is filled with nutrient
broth, so that any microorganisms present
on the swab can multiply and therefore
become visible. Once again, the sample is
purely qualitative.
EXAMPLE ILLUSTRATING THE
SAMPLING EFFORT
For validating an aseptic line, the contractually specified quantity of bottles is filled
with clear, fermentable product (usually
apple juice) under validation conditions.
This bottling process serves the purpose of
microbiological system acceptance and may
involve 100,000 bottles. The bottles are
incubated for three weeks at temperatures
between 25 and 30° C. During this time,
any harmful germ contained in the bottles
would spoil the product. The effect would
become visible through clouding of the
product, mycelial tissue or other changes.
After three weeks, each individual bottle
is visually examined. This is important,
because from the contractually specified
batch a maximum of one bottle may show
signs of microbiological spoilage, which
means 100% inspection is required. There
is currently no economic alternative (based
on advanced techniques) to this procedure.
Commercially available equipment can
process and analyze samples automatically.
However, here too the samples have to be
pre-incubated for three days. A member
of staff then has to spend around two hours
preparing a batch of 48 samples (a tray)
and place it in the device. This system can
process one tray per shift, corresponding
to a maximum number of around 150 samples per day. Validating 100,000 bottles
would therefore take at least 660 days for
testing all samples. For validation purposes, it is therefore still far more economical to inspect the samples manually as a
team after three weeks; depending on the
number of employees involved, this takes
about 2 to 3 days.
RESULT:
Detection of microorganisms still remains
a challenge. Results take 3 to 5 days, a
considerable quantity of material is required,
and the effort and therefore staff costs
involved are significant. Several developments have led to advanced techniques that
can process and analyze samples automatically. However, these techniques are not
yet matured enough to be able to replace
traditional microbiology, although for analyzing cloudy products such system may
well become essential for routine checks,
because reliable results are available after
four days, and quarantine periods can be
reduced significantly compared with traditional microbiology.
Diana Wolf, Beverage Technology Department,
KHS AG, Bad Kreuznach
Guest at KHS °
54*55
Left Tradition …: Neues Schloss [New Palace] in the city center.
Right … and progress: Mercedes Benz Museum in Untertürkheim.
Welcome to
Stuttgart
Once upon a time, there was a city in Germany that had a dreadfully gray image. They roll up the sidewalks at 9 PM, some said.
You have to be able to speak Swabian, because the locals can’t
speak proper High German (a claim strongly denied by the Swabians), said others.
Don’t listen to such fairy tales. Stuttgart has – in the
meantime – become of the most interesting cities in Germany:
lively, international, and modern. So trendy, in fact, that some
travel guides particularly rejoice at the urban development superlatives made of glass, steel, and concrete. Undoubtedly, these do
exist. But the city is still strongly committed to tradition. And
this is no disadvantage.
Visitors can get a clear impression of this when they look
down from the television tower over the mélange of palaces, parks,
red-roofed town houses, modern glass-covered arcades, and hightech high-rise buildings in the valley.
Speaking of tradition: Did you know that Stuttgart’s television tower was the first of its kind worldwide? Perhaps you are
just looking over towards Esslingen, where Germany’s oldest champagne cellars, founded in 1826, stands at the banks of the Neckar
River. A visit to Kessler with its splendid profane buildings and
mighty vaults, where 1.5 million bottles of champagne are stored,
is well worth it.
Or why not enjoy bubbling refreshment at Europe’s second
largest mineral water system: Stuttgart has eleven spas. One of
them is Mineralbad Bad Cannstatt, bathed in light and an architectural treat with its large-span parabolic roof. Or, after leaving
the trade fair, you can stroll through Schulstraße, which connects
Königstraße and the market square and offers a range of fashion
shops, pubs, and restaurants. And by the way, in 1953 Schulstraße became Germany’s first pedestrian precinct. Calwer Straße
features handsome gabled houses and old timber-framed buildings with excellent shops.
If it rains, you can take a trip to Untertürkheim – towards
the star. There you can marvel at the Mercedes-Benz Museum,
designed by one of Europe’s most innovative architectural practices (UN Studio) and opened in 2003. On exhibit are more than
100 years of automotive history, including, of course, the world’s
first cars built by Karl Benz and Gottlieb Daimler.
If you feel more like amusement, how about a visit to the
Palladium for the “Mamma Mia” musical and the 22 greatest Abba
hits (every day except Monday). Here too, the focus is on the past
and its value for tomorrow’s luck. Perhaps a quick coffee before
the show? Kaffeehaus Stuttgart on Herderstraße is the place to
go, where the Hagen company operates one of Germany’s oldest
privately run roasting houses in the Bauernmarkthalle. Tradition
and good mood included.
And after the theater, you can visit one of Stuttgart’s many
Besenwirtschaften (wine taverns) that can be identified by a broom
hanging outside the door. After all: the tradition of winegrowers
serving some of their own wine in their own houses goes back to
Charlemagne granting permission more than 1 200 years ago. A
toast to tradition!
Walter Senft, Sales Manager for Wine, Champagne,
Fruit Juice, and Liquor Systems, KHS AG, Bad Kreuznach
30 1992-01-985/2 0407 GW
Adresses
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) 713-6901
Fax
+44 (121) 745-5306
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
GRAFIK
Konzeption+Design, Trawny / Quass von Deyen, Cologne
Layout: Yvonne Voss
CONTRIBUTIONS
Herbert Bartnick, Ludwig Clüsserath, Dr. Hartmut Evers,
Dr. Johann Grabenweger, Mike Herrmann, Herbert Menke,
Manfred Michl, Herman Miseur, Alois Monzel, Werner
Oster, Thomas Rams, Walter Senft, Matthias Stammer,
Andreas Steinle, Günter Unkrig, Hennie van der Graaf,
Andreas Waldscheck, Diana Wolf, Lothar Wilhelm
TRANSLATIONS
Fachübersetzungen CP MacKusick
PHOTOS/ILLUSTRATIONS
Friederike Arndt, Peter Arnold, Bosch Rexroth,
Alfred Buellesbach/VISUM, Wolfgang Burkart,
Bernd Euler/VISUM, eye of science/Agentur FOCUS,
F1 ONLINE, Hans Gronauer, Vincent Jung,
OKAPIA KG, Germany, Thomas Pflaum/VISUM,
Frank Reinhold, RhönSprudel, G.E. Kidder Smith/CORBIS,
Vario Press, voss water
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.