08.495 KHS Journal 02_08 engl_US.qxd

Transcription

KHS journal
2° 2008
English
New Belgium Brewery:
Premiere in the U.S.A
Strong Partners
Asahi Group: 27 Filling Systems from KHS
Beer for the World
Coca-Cola Içecek
Dry ACF for Coca-Cola
Precise. Flexible. Future Proof.
Perfect Pouchers
VALUE ADDED BOTTLING
TURNKEY PET LINES
KHS Offers Customers Complete Competence
editorial
Valentin Reisgen,
Chief Executive Officer of KHS AG
THE KHS PORTFOLIO IS COMPLETE:
VALUE ADDED BOTTLING IS A STRONG PLUS.
Dear Readers,
Earlier this year the media reported that Salzgitter AG, the majority shareholder of the KHS parent company Klöckner Werke AG with a share of around 86%, acquired SIG Beverages, a worldwide leading specialist for PET blow
molding technology (slogan: value added bottling). Today I would like to tell you about the state of the cooperation and in particular about opportunities for KHS.
Right from the beginning, it was clear that the merger provided the KHS Group with outstanding PET expertise
that will enable KHS to offer complete systems from one source in the dynamically growing market for plastic
bottle technology. This includes a transparent, uniform market presence. Accordingly, the individual companies
have since been renamed to KHS Corpoplast (stretch blow molding technology), KHS Asbofill (aseptic filling of
sensitive products), KHS Plasmax (barrier coating), and KHS Moldtec (mold production). At the present time,
our teams are additionally coordinating their sales activities, laying the foundations for close technical cooperation and dealing with a wide range of other integration issues. This process is carried out in a cooperative and
constructive manner. Although the focus is on joint advancement of the strengths of all companies involved,
our customers will continue to have access to existing contacts and persons they know.
A key factor is that KHS is now able to offer all customers – around whom ultimately everything revolves – complete solutions from one source, because the expertise gained in development, production, barrier coatings, and
aseptic filling in the PET segment over three decades essentially completes the KHS portfolio. World-renowned
KHS competence for filling and packaging meets unique competence in the field of PET. The Group is thus able
to offer customers even more sophisticated, interface-free, environmentally and economically sustainable solutions over the entire product cycle of the machines. I am convinced that value added bottling is a strong plus
for the future of KHS and will quickly make a positive contribution to the continuing success of the group.
In conclusion, the results of the KHS Group for the previous financial year 2007 are certainly impressive: a significant increase in sales of 32.4% led to revenues of almost 1 billion euros, incoming orders exceeded the
already successful previous year by a further 7.8%, and the operating profit reached around 39 million euros. In
a word: 140 years after the company was established, KHS remains a solid and successful trusted partner.
Yours truly,
»
World-renowned KHS competence for filling and
packaging meets unique competence in the field of PET.
«
contents ° 2°2008
people+markets
04
07
news
Customers, Know-how, and Contacts
04
Focus on:
10
Value added bottling: Comprehensive PET expertise from a single source
Turnkey PET Lines
10
dossier
14
Pouch filling and packing: KHS offers everything from one source
Perfect Pouchers
dialog+opinion
18
Interview mit Dr. David Bosshart
“Globalization Enters a New Phase”
22
The Asahi Group now operating 27 filling systems from KHS
Beer for the World
26
Coca-Cola Içecek relies on new technology
30
Anton Hübner, provider of innovative health products,
labels perfectly
Stick-to-it-iveness
33
Kumbok-Ju relies on soju – and KHS
Traditionally Progressive
36
Karlsberg Brewery invests in highly flexible KHS system technology
Made to Measure
39
New Belgium Brewery in Colorado places trust in KHS
Strong Partners
42
Kulmbacher Brewery: Focus on quality and environment
The Beer Experts
46
Brauerei Hacklberg combines tradition and innovation
Firm Roots
48
Innofill NRS: Worldwide new principle for bottling convenience drinks
Focus on Wellness
50
For non-alcoholic beverages: Now integrated hot-fill version for PET
Hot Stuff
53
Product line harmonization at KHS:
Packaging technology for the future
As Flexible as the Alphabet
56
Technical terms in practice: Don’t be afraid of statistics (Part 1)
Magic Numbers
18
task+solution
39
42
technology+innovation
59
48
stopover
Don’t miss the opportunity
59
02*03
Left Logistics Day at TU Dortmund: Volker Till, Chief Technical Officer, KHS AG, announces the endowment of a professorship for filling and packaging processes. Right Discussion session: (from left) Volker Till, Dr. Volker Paetz (CEO ThyssenKrupp Materials International), Michael Brockhaus (CEO Rhenus AG), Norbert Przystupa (Managing Director of forty-five Personalberatung).
KHS ENDOWS PROFESSORSHIP FOR FILLING AND PACKAGING PROCESSES AT TU DORTMUND
OPPORTUNITIES FOR YOUNG TALENT
“The purpose of endowing a professorship
for filling and packaging processes at the
Institute for Intralogistics and IT as a center for scientific research into technical
logistics is to contribute toward promoting consistent basic research,” said KHS
CTO Volker Till at a press conference during the Logistics Day on 17 April 2008 in
Dortmund. The new KHS endowment for
TU Dortmund, which will initially run for a
five-year period, will focus on integrated
networking of technology and IT in logistics processes.
KHS sees this as a contribution to
the expansion of logistics expertise at Dortmund, with the intention of engaging with
key topics in research and education. Volker
Till: “By working together on research projects relating to filling and production
processes we intend to strengthen the
robustness and performance of our products, speed up the formation of know-how,
and promote specific project ideas.” Prof
Michael ten Hompel, Chair for Conveyor
and Warehouse Systems at TU Dortmund,
Managing Director of the Fraunhofer Institute for Material Flow and Logistics IML at
Dortmund, and founder of the new Institute, emphasizes, “KHS is contributing a
wealth of expertise in filling and packaging engineering, process design and organization and logistics for modularly interlinked, integrated production systems.”
This is an ideal basis for successful joint
research and development projects.
In this way, KHS promotes young talent by
providing high-quality academic education
while gaining access to bright graduates and
scientists who research, study, and work at
the new Institute as part of international
activities. For Volker Till, student programs,
dissertations, theses, site visits, and traineeships therefore represent important potential links: “The international outlook of the
Institute offers scope for recruiting suitably qualified individuals into our team.”
Praise for KHS: Professor Michael ten Hompel, TU Dortmund (second from left)
people+markets ° news
04*05
KHS DRY TECHNOLOGY AT GEHL FOODS, INC., U.S.A.
FDA ISSUES LETTER OF NON-OBJECTION
The U.S. Food and Drug Administration (FDA) who responsibilities
include protecting the public health by assuring the safety of the
nation’s food supply, has issued Gehl Foods, Inc., Germantown, WI,
U.S.A., approval (letter of non-objection) for a high-performance
ACF bottling machine from KHS. The technology of the Innofill
ACF is based on a special aseptic filling system developed by KHS
that operates with hydrogen peroxide according to the principle
of fully automatic dry sterilization and offers numerous production
and cost benefits (see page 26).
Gehl Foods, Inc. is a leading, widely diversified dairy facility in the U.S. that has pioneered in the production and packaging of shelf-stable dairy products and since 1970 has successfully
relied on aseptic cold filling. This KHS line (600 8 – 14-oz. bottles per minute) increases the number of low acid product lines in
operation at the company to a total of 16. The cutting-edge filler
meets the growing demand for non-refrigerated dairy products and
features a unique, re-sealable cap that avoids the foil seal method.
John Gehl, CEO of Gehl Foods, charts the future direction of the
company: “With the rising cost of refrigerated distribution, we are
seeing even more desire for non-refrigerated products. Gehl’s plans
to take advantage of that demand and remain the preferred leader
in our industry.”
KHS PROMOTES VLB BERLIN
Close ties with KHS since 1958: Jörg Wallmüller (center) with KHS CEO
Valentin Reisgen (right) and Helmut Weber, Chairman of the Joint Works Council.
KHS IN-HOUSE
JÖRG WALLMÜLLER 50 YEARS AT KHS
Antoine de Saint-Exupéry believed “Being true to others means
being true to yourself,” long before Jörg Wallmüller joined KHS.
Wallmüller, now a sales engineer in the Central Logistics / Purchasing Dept., began his training as a machinist on April 1, 1958 with
a company to which he has remained loyal for 50 years. On completion of his training, Jörg Wallmüller (born in 1943) worked
first in the chain construction final assembly department and
then the packer and palletizer construction departments. In 1965,
he attended a private engineering night school for three years in
addition to his full-time job. Now a construction technician, he
was then promoted to a position as a technical employee in 1968
and worked as an administrative assistant in the packer spare parts
department. Wallmüller, who has been working as a sales engineer
with a wide range of tasks since 1973 is respected and well-liked
by both colleagues and customers. The Executive Board and the
employees of KHS AG thank Jörg Wallmüller for his commendable
commitment to his KHS over past half-century.
MINI PASTEURIZER FOR RESEARCH
In May this year, the Research Institute for Brewing and Malting
Technology, Berlin (VLB Berlin) put a test Innopas C pasteurizer
into operation donated by KHS. This is an investment in the
future for KHS and intensifies its cooperation with VLB regarding
research and development in the field of PET pasteurization. The
Berlin-based institute is involved in trend-setting research in this
field. Because of the ever-increasing market demand for PET bottles for biologically sensitive beverages, the researchers are striving to optimize the temperature-time profile and develop bottles
capable of withstanding the conditions prevailing in tunnel pasteurizers. This is very well possible with the test pasteurizer from
KHS which is able to reproduce the complete pasteurization process
on a footprint of only about two square meters while providing
the same flexible functionality offered by its big bother of the
Innopas C series.
WWW.KHS.COM/INDIA
SPECIAL WEBSITE FOR INDIA
Because customers need to be well informed at the regional level
as well, the KHS team has developed a special website for the booming subcontinent of India after completing a special website for
the U.S. This website provides information on the incorporation
of the country into the company group as well as special knowhow in India. Including among other things information and
facts on the location, points of contact, services, customer events,
trade fairs, and news. For KHS, the Indian site Ahmedabad is an
important strategic location for other Asian markets as well. A new
plant was recently opened in Ahmedabad in 2007 according to KHS’
globally applicable quality standards. Look for the India website
under Quicklinks on the KHS homepage or click on
www.khs.com/india.
FLASHBACK: KHS AT THE INTERPACK 2008
ALL-ROUNDER FOR POUCHES
KHS has just recently introduced a far-reaching innovation to the
market for pouches. By integrating ExpertPack into this sector,
KHS has now become a complete and turnkey supplier now offering a product line that includes everything from form / fill / seal
machines, to pouch packaging systems, up to and including a cartoning and palletizing program.
As the many visitors to KHS’ booth saw for themselves at
this year’s Interpack in Düsseldorf (2744 exhibitors, 179,000 visitors), the focus was on innovative technical solutions for processing pouches, a new version of the modular packer for disposable packaging, and the wrap-around packer especially designed
for the entry and medium capacity ranges. In brief,
The new Innopouch K series poucher combines the functions of manufacturing pouches and filling them with product in
one work step. Special features: The system processes either flat
rollstock or fills pre-made fin-seal or stand-up pouches in a wide
range of sizes at speeds of up to 105 packs per minute in single
mode. The horizontal motion mode of operation ensures maximum
leakproofness of the fin seals even for the most sensitive of products (see page 14). What’s more, the innovative KHS packer concept provides exceptionally gentle pouch handling coupled with
plenty of flexibility.
With its Innopack Kisters TSP tray shrink packer, KHS
presented a completely redesigned, and in many aspects further
developed, packaging machine in the modular product series featuring outputs ranging from 35 to 135 cycles per minute. Harmonizing the product range makes future conversions even easier
and faster (see page 53).
Lastly, KHS presented a new generation of shrink tunnels that in addition to electric operation can also be heated with
gas, which is not only more economical but also sensible from an
ecological standpoint. Depending on the installation location,
users can save up to 50 percent on energy costs and reduce the
CO2 output by up to 60 percent (see KHS journal 1/08).
The new Innopack Kisters WP 030 wrap-around packer
is designed especially for the entry to medium output ranges in the
food, beverage, and non-food sectors. Special features include outputs of up to 30 cycles per minute optionally for wrap-around or
tray packaging. The operator friendly machine flexibly processes
cans, jars, glass and PET bottles, and pre-wrapped packaging.
A great deal of interest in innovative packing technology was shown by
the visitors to the KHS exhibition booth.
CORNERSTONE LAID
NEW ASSEMBLY SHOP AT KHS WORMS
On June 6, 2008, KHS COO Dr. Ing. Johann Grabenweger
together with Lord Mayor Michael Kissel and Jens Guth, member of Rhineland Palatinate’s parliament, laid the cornerstone for a new assembly shop at KHS’ plant in Worms. The
shop is to be equipped with a 20-ton crane rail, will occupy
and area of nearly 2500 square meters, reach an impressive
height of 14.4 meters, and will be used to manufacture packing and palletizing machines. KHS’ competence center for
packing and palletizing technology is thus making a lasting
investment in the future. Dr. Ing. Johann Grabenweger, “Our
intention is to achieve a breakthrough and increase our efforts
in the food and non-food sectors in addition to the beverage industry.” Plant manager Peter Müller sees substantial
potential worldwide particularly in the area of palletizing.
“By expanding this plant, we want to be well prepared. And
that includes providing 20 new jobs.” The assembly shop is
planned to go into operation by the end of August. Incidentally, the stainless steel capsule sealed in the cornerstone
during the ceremonies was made in KHS’ apprentices’ training shop. Tradition meets technology.
Laying the cornerstone (from left to right): Michael Kissel,
Lord Mayor of the city of Worms, Dr. Ing. Johann Grabenweger,
Chief Operations Officer KHS AG, and Jens Guth, member of
the Rhineland Palatinate state parliament.
06*07
KHS AROUND THE WORLD
CUSTOMERS, KNOW-HOW, AND CONTACTS
KHS has been represented in world markets by its engineering and the proficiency of its employees for
140 years. The company stands for absolute customer-orientation, problem-solving competence of its
high-tech experts, and the know-how of a consulting staff that contributes expertise on economic
issues. The KHS team demonstrates this worldwide day after day.
COCA-COLA IÇECEK, TURKEY
ELDE CANNED FOODS, ZACHOW
NEW LOCATION – NEW LINE
QUALITY OF SERVICE ALSO
COMPELLING
The order placed by the renowned bottler Coca-Cola Içecek (CCI) for its new
mega plant in Elazig in southeast Turkey was bitterly contested. A number
of suppliers wanted to install the first line at this site. KHS, who has had
good business relations with CCI for many years, was awarded the contract.
For this high-performance system as well, the bottler once again placed its
confidence in the perfect project management and robust machines from
KHS. The line fills all five bottle types including 1.0-, 2.0-, and 2.5-liter
contour, straight wall, and Fanta Splash bottles and is optionally capable of
processing the 0.45-milliliter type of packaging in the future as well. The
line is comprised of:
* A BLOWMAX 20 blow molder from KHS Corpoplast that feeds bottles to the
filler inline directly over an air conveyor.
* An Innofill DRV 162 VF/N filler (also suitable for non-carbonated products)
equipped with a sanitary room enclosure complete with HEPA filters that
has been designed with adequate space to accommodate an ionized air
rinser later.
The
two-lane dry area – comprised of two Innopack Kisters SP shrink
*
packers, two robot grouping stations, two palletizers, and two pallet stretch
wrappers – includes a compensating distributor so that production can be
run from packer 1 to palletizer 2 and vice versa.
BOSTON BEER COMPANY, PENNSYLVANIA, U.S.A
HIGH-TECH MEETS THE TRADITIONAL
Boston Beer, the largest and leading brewery for craft-brewed beer in the
United States, is receiving from KHS a complete new 280 keg-per-hour Till
TRANSOMAT 5/1 keg racking line for its plant in Miscellaneous Allentown, Pennsylvania. This turnkey line includes robots for palletizing and depalletizing.
The Allentown brewery took over Boston Beer from Diageo to position this
brand it as its flagship for traditional brew.
For the first time, ELDE Konserven in Brandenburg’s
Zachow near Parchim has decided in favor of KHS by
ordering two rotary Innoket ROLAND 8/ 4 labeling
machines, each designed for an output of 6,000 jars
per hour. The more than 100-year-old still active producer of high-quality canned foods is convinced by
the high quality of KHS machines and the comprehensive service provided by KHS that also includes unproblematic spare part procurement. Here, “KHS has the
leading edge.” With a workforce of currently 170 employees, the company produces approx. 30,000 tons of raw
goods on 4 production lines operating on a floor space
of 7,000 square meters. Forty percent of ELDE Konserven’s sales are realized in other European countries.
HOCHWALD, THALFANG, GERMANY
PACKER FOR “BÄRENMARKE”
Hochwald Nahrungsmittel-Werke is receiving an Innopack Kisters
TSP 050 tray shrink-packer for its plant in Weiding (Mühldorf) to
process cans and jars of “Bärenmarke”, its internationally wellknown brand of condensed milk. The system processes all variations of the variety of packaging at an output of 500 cans per minute
(30,000 per hour) on one or two lanes depending on the formation and output. This is Hochwald’s first decision in favor of packing machines from KHS. The extremely high level of flexibility and
the forward-looking technological concept of the system were the
decisive factors. Hochwald saw for itself the great potential of
the packing machine on inspection tours and at the open house
exhibition celebrating the 50th anniversary of KHS’ Kisters plant
in Kleve.
CROWN BEVERAGES, UGANDA
PREMIERE IN KAMPALA
The internationally renown Pepsi franchise bottler CROWN BEVERAGES LIMITED of Kampala, Uganda has made a first-ever decision
in favor of a KHS turnkey bottling line. The line is designed to fill
0.3-liter refillable glass bottles with Pepsi products and tonic water
at 40,000 bph. The components: Innopack PPZ crater / decrater
(24-bottle plastic crates), Innoclean KW crate washer, Innoclean
DM double-end bottle washer (with extra long treatment and submersion periods), Innopro CMX Paramix, Innofill DMG VF filling system, fill level checking, and manual palletizing.
COCA-COLA ENTERPRISES, BELGIUM
ROBOT CREATES FLEXIBILITY
KHS is installing an Innopal RK 6 palletizer with robot
grouping for crates at the Ghent plant of Coca-Cola
Enterprises, Belgium. After the bottles are sorted,
the system conveys the production bottles to the filling system and then segregates the filled bottles (three
types) and packs them in crates. The crates are fed over
three crate conveyors to the KHS palletizer with robot
grouping where the crates are put into formation and
loaded on a separate pallet. This ensures maximum
flexibility with the advantage that complete layers of
crates can be palletized on three separate pallets and
not palletized crate by crate. As an articulated robot,
the Innopal RK provides a large 360° working radius on
a minimum footprint, has no dead spots, and thus allows
a high degree of freedom when planning conveying system projects.
08*09
NORTHERN BREWERIES, SABMILLER, ZAMBIA
DEL MONTE FOODS, PLYMOUTH, INDIANA, U.S.A.
42,000-BPH REFILLABLE GLASS LINE
COMPLETE CONVEYING SYSTEM
For the first time, Northern Breweries (1995) PLC in Ndola, Zambia, KHS’ longstanding business associate is taking delivery of a complete KHS refillable
glass bottle line for carbonated beverages. The company is a member of the
SABMiller Group. The line processes 0.3-liter (crown corks) and 1.0-liter bottles
(screw-on caps) at 42,000 and 21,000 bottles per hour, respectively. The 0.3liter bottles are packed in twenty-four bottle crates while twelve-bottle crates
are used for 1.0-liter bottles. The line is equipped with automatic palletizing and
depalletizing, a crater and decrater, a bottle washer, a crate washer, an Innofill
DPG VF filler, and an Innopro CMX Paramix.
KHS has installed a complete conveying system at the
headquarters of world famous and heritage-rich Del
Monte Foods in Plymouth, Indiana. After the successful startup of the system, Del Monte Manager John
Matthews praised the installation as the best ever in
his 30 years of working for the company.
CARLSBERG, DENMARK
KEG LINE FOR TUBORG BEER
Carlsberg Danmark AS in Fredericia has ordered a complete, 310 keg-per-hour turnkey keg line for Tuborg
Bryggerierne.
KOMPANIA PIWOWARSKA, POLAND
ALL GOOD THINGS COME IN THREES
KHS is now delivering the third 100,000-cph canning line to the well-known
Kompania Piwowarska brewery group in Poznan, Poland (another 50,000-cph
line is also operating successfully). The line ordered is designed to process 0.5liter cans. The company is a subsidiary of SABMiller and with an output of approx.
14 million hectoliters (2007), is the leader of the Polish market (breweries: Browar
Dojidy, Lech Browary Wilkopolski, and Tyskie Browary Ksiazece). By sales volume, the key brand Tyskie is one of Europe’s top ten best selling brands of beer.
NAFCA, LÜNEBURG, GERMANY
WHERE QUALITY PREVAILS
Lüneburg-based Nafca GmbH, a company committed
to offering only high quality products has ordered a
rotary Innoket ROLAND 10 H labeling machine (10,000
bottles/hr) and an Innoket VARIANT 1 labeler designed
for an output of 6,000 bottles per hour. The top quality of KHS products was the reason for the company’s
first-time decision in favor of KHS.
UNILEVER CR, CZECH REPUBLIC
PALLETIZING TECHNOLOGY AT ITS FINEST
Unilever CR located in the Czech town of Nelahozeves is expanding its
previously installed KHS lines by adding cutting-edge palletizing technology. The machines in detail: one Innoline pack conveyor, Innoline
pallet conveyor, Innopal handling robot each, and two Innopal LH
palletizers, each with a capacity of maximum 1500 packs per minute.
Unilever in the Czech Republic thus relies for the first time on palletizing technology
from KHS in addition to the simple as well as economical technology of the new LH
palletizer. Both palletizers are used for the Knorr wellness product “VIE”. An Innopal
handling robot supplies both palletizers with the necessary cardboard slip-sheets.
With this solution, Czech Unilever is cutting the cost of palletizing significantly.
focus °
Value added bottling: Comprehensive PET expertise from a single source
Turnkey PET Lines
A valuable addition to Klöckner-Werke AG took place on April 2, 2008:
The KHS Group, together with the four former SIG Beverages companies, have
now combined their complementing PET expertise under the slogan
“value added bottling” and now comprise the field of packaging solutions.
KHS customers will benefit from this newly acquired PET knowledge
by way of an attractive offering: Turnkey PET lines
The companies of the former Beverages Division – Corpoplast, Plasmax, Asbofill, and Moldtec – are known
around the world for their many years of proficiency
relating to all aspects of high-quality plastic bottle solutions. Their comprehensive service package, Bottles &
Shapes™, takes into account all aspects of a complete
bottle development – from the first design proposals
to industrial production, while complying with the
defined specifications. Corpoplast manufactures stateof-the-art stretch blow molding machines, Plasmax is
a specialist for barrier coatings, and Asbofill supplies
linear aseptic filling technology.
These companies have long since not just seen
themselves as machine builders, but have been very successfully active as modern service providers for PET packaging solutions. All individual packages, like the interplay under the “value added bottling” promise, have a
single objective: calculable added value coupled with
maximum availability and precise production resulting
in minimum overall operating costs for the customer.
BOTTLES & SHAPES™: OVERALL PRODUCTION
PROCESS IN FOCUS
What characteristics must a bottle have in order to
provide optimum protection for the product, to be able
to be filled safely during production and, at the same
time, effectively assist its marketing? The answer to
this is given by the Bottles & Shapes™ service product. A brief summary of the core philosophy:
* As early as the bottle design stage, bottle designers, PET experts, and line specialists take into
account the entire process that the bottle goes
through on its way to the point of sale.
* Even the most sophisticated bottle design must
result in a lightweight and at the same time stable
bottle, which can be produced, filled, labeled, and
transported efficiently.
* The PET specialists take into account all influencinfactors:
– At what points can easily less material be used
without affecting the stability?
10*11
CORPOPLAST: Precision stretch blow technology with maxi-
PLASMAX: Wafer-thin, crystal clear barrier to
mum availability and minimum energy consumption.
protect sensitive products.
– How can the stretchability of the PET material be
optimally utilized in order to decrease heating
energy and air consumption?
– How do the bottles behave during filling, on conveying systems, and on pallets?
When all aspects have been taken into account, the customer is presented with an optimum bottle tailored to
BOTTLES & SHAPES™: Lightweight
packaging solutions for plastic bottles with
perfectly matched characteristics.
his requirements. High-precision blow molds are developed and manufactured in parallel with the bottle design.
Because of the high demands on perfection and availability, the molds are made by Moldtec in Essen.
CORPOPLAST: LIGHT WEIGHTING AND PRECISION
PRODUCTION
An example of the Bottles & Shapes™ approach: In order
to keep the overall operating costs as low as possible,
cost-cutting measures include minimizing the use of
materials. In times of skyrocketing oil prices and intensive competition, one thing is becoming more and more
important especially in the water sector: Light weighting – reducing the bottle weight. When manufacturing 100 million bottles, only one gram less weight leads
to a saving of 120,000 euros in material costs alone.
At the same time, the bottles must continue to
be stable enough to enable customers to produce and
transport them in a continuously repeatable process
with maximum efficiency. Finally, the optimized plastic containers are manufactured on the standardized
BLOMAX Series III modular high-speed blow molding
machines from PET pioneer Corpoplast. These machines
mean optimum process reliability, maximum availability, precise production, and minimum energy and spare
parts consumption.
PLASMAX: LIGHTWEIGHT AND CRYSTAL CLEAR
FOR OPTIMUM PRODUCT PROTECTION
Plasmax provides a special barrier solution for bottling in plastic bottles for the complete range of sensitive products including fruit juices, beer, and wine.
For optimum shelf life and quality of these products,
Plasmax has developed a unique process that coats
focus ° Value added bottling
ASBOFILL: Innovative filling systems for
sensitive products – linear, aseptic, flexible.
the inside of the PET bottle with a crystal clear, pliable, and completely inert layer of silicon oxide (SiOx).
This wafer-thin PLASMAX coating gives the lightweight
plastic bottle the barrier characteristics of glass that
protect the contents against oxygen pick-up – just like
a glass bottle. The PLASMAX coating protects the product against CO2 loss, a decisive criterion particularly in
the case of small containers. An additional plus is that,
unlike alternative barriers such as multi-layer or blends,
PLASMAX-coated bottles are 100 percent recyclable.
This reduces preparation costs and protects the environment.
ASBOFILL: INTEGRAL ASEPTIC ZONE FOR MAXIMUM
SAFETY WITHIN A MINIMUM AMOUNT OF SPACE
Asbofill completes the value-added bottling chain with
a reliable, aseptic filling method for microbiologically
sensitive non-carbonated products. The ABF 610 and
ABF 710 linear aseptic fillers from Asbofill provide an
absolutely safe filling process for low and high acid
products such as fruit juices, liquid dairy products,
and neutraceuticals while taking up a minimum amount
of space. The compact, integral aseptic zone of the
filler with only 0.9 cubic meters not only increases the
aseptic safety but at the same time also cuts investment
and operating costs. In addition, a non-contact filling process provides increased protection.
requirements of their lines, whether it be for high-speed
rotary fillers or linear, aseptic filling systems. What is
more, the combined expertise will enable new projects
to be implemented even more quickly in the future. The
experts in the company group are working at full speed
on the development of monoblock stretch-blow bottling lines. Two ongoing projects are scheduled for
installation this fall.
The result: Together with the “value added bottling” experts Corpoplast, Plasmax, Asbofill, and Moldtec,
KHS is the ideal PET turnkey partner for the beverage
industry as well as the food and non-food sectors. In
the future, the “value added bottling” promise will supplement the KHS motto “Filling and Packaging – Worldwide” for any type of PET line – from the first bottle
design idea to the ready-to-deliver product range coupled with minimum operating costs.
Matthias Damm, Marketing & Communications, KHS Corpoplast
fi
INFOBOX
• WEBSITE www.valueaddedbottling.de
SYNERGIES BRING ADVANTAGES FOR CUSTOMERS
The recently acquired PET expertise now makes it possible for KHS to offer PET lines as turnkey projects for
the first time. In doing so, customers benefit not only
from machine and conveying know-how, but also from
a plastic bottle that is adapted and designed to suit the
• CONTACT
Matthias Damm, Marketing & Communications,
KHS Corpoplast, Hamburg
Tel: +49/40/679 07 350
E-mail: [email protected]
12*13
Pouch filling and packing: KHS offers everything from one source
Perfect Pouchers
The pouch boom is continuing unabated. With the
new Innopack CMP packaging machine and the proven
Innopouch K pouching machine, KHS now offers all
sectors a complete range for a widest variety of pouch
types. The modes of operation of the systems are
consistently practice-oriented: precisely, flexibly,
and with an eye to the future.
There are trends that take time to become established worldwide.
And there are trends that virtually zip around the world. Above
all, the flat pouch is the current trend in the filling and packaging industry. Or, more precisely, the trend toward fin-seal bags,
stand-up bags (also referred to as Doypacks or pouches), blockbottom bags, or flow packs. The food and beverage industries as
well as the non-food industry are selling more and more products
to the customer in this kind of pouch. Today, anyone Googling for
the term Doypack will find around 128,000 entries – just two
years ago, there would have been only 88,600 hits.
Experts are accordingly forecasting worldwide growth rates
for the popular pouch of more than ten percent per year. Because
when attractively and eye-catchingly printed, they initially signal
added value for the product they contain. Furthermore, they perfectly suit the lifestyle of the customer: as single or family pack
and with convenience attributes such as special sealing systems
and maximum ease of opening. And lastly, pouches take up hardly
any more space than that occupied by the filled product itself.
Thousands of companies are therefore now saying that the pouch
is a must, instead of the classical can, bottle, or carton.
With the newly designed Innopack CMP pouching machine
and the group’s existing cardboard box and palletizing know-how
complementing the successful Innopouch K poucher in the marketplace (see Page 16), KHS now offers a complete and comprehensive range.
PRECISE. FLEXIBLE. FUTURE PROOF.
dossier °
14*15
Top Cartridges: In the closed conveying position and in the open
loading position. The fins suspended between the pouches compensate for different pouch thicknesses. Bottom Innopack CMP:
View of the machine outfeed. Display boxes packed with stand-up
pouches leaving the packer.
INNOPACK CMP: WIDE CAPACITY RANGE
The Innopack CMP processes 60 to 250 pouches per minute depending on type and design. Pouch sizes may range from 90 mm wide
and 100 mm high up to 200 mm wide and 250 mm high. Other
package sizes can be processed without difficulty. Cartons can be
filled with pouches at a maximum output of up to 30 cartons per
minute.
INNOPACK CMP: HIGH FLEXIBILITY
Maximum flexibility is important for the pouch type of packaging.
KHS is therefore prepared for all eventualities. Regardless if pouches
arrive horizontally with the wide side first, horizontally with the
narrow side first, or upright – the system responds accordingly. If
pouches enter the packaging system with the narrow side first,
they are turned 90 degrees by a corner turntable, and those that
are not exactly in line are perfectly re-aligned.
Horizontal pouch packs pass to an uprighting module with
the wide side first. The machine handles packaging and product
extremely gently. What happens, however, if the contents shift,
as in the case of powdery and chunky products? The system then
equalizes the pouch contents in an upstream vibration segment
to save space later in the carton. This is all done with minimal
pressure without harming the product or damaging the pouches.
INNOPACK CMP: EXACT POSITIONING
Whether powdery, chunky, pasty, or liquid products, all pouches
pass horizontally conveyed by two vertical parallel belts (feed unit)
directly into the packer designed in the form of a carousel. The
belt system not only conveys less sensitive liquid and pasty products accurately into the cartridges provided, but at the same time
also equalizes the pouch contents. The feed unit is always configured exactly to suit the type of pouch to be processed. Spindles are used to make adjustments for product and package
changeover.
The system now pushes the pouches into cartridges that
are comprised of several vertically arranged plates. While the outer
PRECISE. FLEXIBLE. FUTURE PROOF.
Left Horizontally conveyed pouches are continuously uprighted before entering the
packing cartridges. Top Pouches held in cassettes, synchronized over an open display
box, and placed in the box.
2
POUCH FILLING: ONLY WITH INNOPOUCH
More than 55 years ago, KHS already recognized what the market was demanding more than ever and has already installed more
than 3,900 horizontal form / fill / seal machines. With the Innopouch K model range, a generation of machines entered the world
market that combines the experience of the company with the specifications of big-name multinational customers. It was the users
and operators of such machines that defined the requirement specifications for the development of these machines. In a nutshell:
KHS answers all issues relating to filling with the Innopouch K
• liquid products such as soups, sauces, ketchup, and juices,
• pasty items such as marzipan or puree, and
• dry products, ranging from instant soups to baking powder
The Innopouch K product range processes either from flat rollstock
or filled pre-made pouches. The operator can quickly switch to the
appropriate mode. Here the distinguishing characteristics of the
machine in brief:
by-side metering stations as standard equipment / Optional feature: sealing of pouring spouts and adapters and top seam sealing with ultrasound. Modularity also means that the machine produces and fills pouches both from the flat rollstock and also, after
changeover, processes pre-made pouches fed from a magazine.
1. Broad spectrum. Fin-seal and stand-up pouches 80 to 350
4. Reliable control. Double gripper system receives the pouches
COMPACT PRESENTATION: THE SIX HIGHLIGHTS
mm long and 80 to 360 mm wide / 105 pouches per minute in
single mode.
They remain in a linear arrangement up to the pouch outfeed
station / Reliable control at all times.
/
2. Exceptionally well sealed. The new pouch forming method
5. Flexible filling / dosing. Up to four dosing stations can be con-
enables the sealing pressure to be applied linearly, while the servo
motor direct drive enables processing of both very thin and very
thick wrapping materials. The sealing parameters are displayed
reproducibly on the operator panel and are monitored by the control system. A form / fill / seal machine, which is also suitable
for producing so-called retort pouches, is available for the first
time. These are pouches made of materials that allow them to
be sterilized after filling at temperatures ranging from 121 to
128 degrees Celsius. The sealed seams meet maximum requirements for leakproofness. This is particularly important when filling sensitive liquid products.
nected in series as standard / Dosing and filling are both volumetric and gravimetric. Servo motor-driven filling nozzles or
hoppers increase the standard machine output capacity by up to
1.4 times, depending of course on the characteristics of the product to be filled and the rollstock.
3. Modular concept. Individual machine design according to the
processed product / Fin-seal and stand-up pouches made from
all common hot-sealable packaging materials / Up to four side-
6. Fast cleaning. No corners or crevices of any kind underneath
the gripper systems / Extremely short cleaning times.
THE MARKET GETS WHAT IT NEEDS
All in all, the KHS Innopouch K poucher is a technology that the
market demands. In short: The modular design allows maximum
flexibility and individuality complemented by maximum production reliability with consistent clean design in addition to maximum
convenience in operation, cleaning, and changeover.
PRECISE. FLEXIBLE. FUTURE PROOF. PRECISE. FLEXIBLE. FUTURE PR
dossier ° Pouch filling and packing: KHS offers everything from one source
16*17
Indexed into the packer: Pre-made
display boxes still open at the top.
plates are stationary, the adjustable inner plates can be exactly
matched to the packs to be processed in each instance. When all
cartridge compartments have been filled, the cartridge is conveyed
to the carton packer by a friction drive.
At the carton station, the carton blanks are erected, glued,
and indexed simultaneously. Servo technology positions the cartridge directly above the ready and waiting carton. The cartridge
then moves parallel to the continuously forward moving carton into
which it is lowered and then retracted. The upright positions of
the equalized pouches save space and improves the display effect
versus horizontally packed pouches.
INNOPACK CMP: MIXED PACKS POSSIBLE
The trade is increasingly demanding mixed packs. The KHS packer
is prepared for this eventuality. The system feeds two or even three
pouches per compartment into appropriately designed cartridges.
A plate distributor located ahead of the corner turntable or uprighting module ensures that the various types of pouch pass to the
machine in the required order. Important: When processing mixed
packaging, the pouches are fed from a storage or buffer area to
ensure that the packer is continuously supplied with the correct
type of pouch in each case. Faulty pouches are very simply ejected
out of the system by a flap mechanism contained in the cartridge
conveyor.
INNOPACK CMP: MODULAR DESIGN
The continuously rotating carousel accommodates up to seven
cartridges. The modular system design is particularly suitable for
those customers who are just starting with pouches and are not
yet able to foresee their success. The slogan: Start with a few cartridges and simply upgrade with increasing success. If all available
cartridges are exhausted, the modular concept enables users to
integrate additional stand-alone carousels into the pouching system.
INNOPACK CMP: PERFECTLY INTEGRATED
The Innopack CMP is directly coupled to the KHS machinery installed
upstream and downstream. There are no interface problems – the
speed is controlled automatically. Not least because of its small
footprint, the system can be perfectly integrated into existing technical solutions. In short, a technical solution that meets the market demand.
Thomas Matheyka, Product Management Pouching Machines, KHS AG
INNOPACK CMP: HIGHLY FUTURE-PROOF
Not only mixed packs point to a flexible future. The packing system can also be adapted to new requirements at any time without
difficulty. Case 1: As long as there is no change in the number of
pouches in a carton, the plates in the cartridges can be adjusted
by means of spindle to adapt taller, wider, heavier, or lighter weight
pouches. A spindle adjustment is also used to adjust the infeed
area. Only the carton erector needs a new set of format parts. Case
2: If the number of pouches to be packed in each carton changes,
a new format set is implemented simply by changing cartridges. A
quick-release lock makes for rapid removal and installation. If an
increase in capacity is planned, additional cartridges can be incorporated into the system. Each new format is stored in the controller by adapting the software. Thus, when changing formats,
all that is necessary is to select the appropriate format on the display screen.
fi
INFOBOX
• WEBSITE www.khs.com
• CONTACT
Thomas Matheyka, Product Management,
Pouching Machines, KHS AG, Kriftel
Tel: +49/61 92/4 91 – 123
ROOF. PRECISE. FLEXIBLE. FUTURE PROOF. PRECISE. FLEXIBLE. FUT
“Globalization is entering
a new phase”
Interview with Dr. David Bosshart,
CEO of Gottlieb Duttweiler Institute, Switzerland
The Migros founder, Gottlieb Duttweiler, shaped Swiss economic
history with a genius for business, tenacious fighting, bold ideas,
and a strong sense of social responsibility. This description is
taken from the GDI website (Gottlieb Duttweiler Institute, Switzerland). Gottlieb Duttweiler established this independent research
institute in 1962 at the age of 74. To this very day, the institute’s remit includes monitoring of developments in global markets and registering of trends and counter-trends that are relevant for the economy and society. As set out by Gottlieb Duttweiler, and in keeping with the guiding principle of “Focus on
people, not capital”, the Gottlieb Duttweiler Institute is today
regarded as one of the leading European think tanks for economy and society. Reason enough for KHS journal to ask CEO Dr.
David Bosshart which factors will decisively shape the global economic and social development in the future.
KHS JOURNAL: The Gottlieb Duttweiler Institute is a global
household name and has a reputation for identifying developments at an early stage. In its Agenda 2008, GDI states that
“Globalization is entering a new phase”. Which new phase will
this be?
DR. DAVID BOSSHART: We are seeing a drastic increase in the number of issues that are relevant for companies. Let’s look at the
financial markets, for example. Over recent years, we have seen
a great many innovations, and private equity has become increasingly important. The banks have taken a leading position in the
economy, while the influence of politics has been declining.
This led to a growing gulf between the economy and politics.
Recreating a balance in this area is a demanding task. In addi-
tion, through today’s wealth of information sharing options we
have reached an unprecedented level of communication. Take
India, for example: Within the last few years, 350 million people, who previously had never even seen a conventional landline
telephone, obtained cell phones and access to the Internet. On
the one hand, this is progress, of course, but on the other hand,
this progress has dynamic effects that are increasingly difficult
to predict. After all, more information and more communication
invariably also always means more potential for conflict. All in
all, for me the new phase of globalization looks positive from an
economic perspective, because globally, wealth is increasing,
but on the other hand the political controllability is decreasing,
and risks for companies in relation to production and the financial markets are increasingly difficult to narrow down.
° What exactly does this situation mean for small, medium,
and large companies?
* The question of the right company size and the envisaged distribution area is becoming increasingly important in the future.
This means that even for large companies it may not necessarily
be beneficial to aim for global player status. Manageability,
controllability, and risk reduction will become increasingly important, and it may well be advantageous to concentrate on markets offering high planning reliability.
° What criteria should companies use as the basis for selecting
suitable markets?
* In the past, many companies felt they had to have a global
presence, not least for prestige reasons. In reality, a rush towards
dialog+opinion °
18*19
Dr. David Bosshart is CEO of the Gottlieb Duttweiler Institute in Rüschlikon,
Zurich. The independent institute for economic and social studies is engaged in
worldwide research activities. Speakers and guests who have shaped the GDI
over the years include famous figures such as Ludwig Erhard, Friedrich Dürrenmatt, Václav Havel, Albert Alessi, Daniel Bernard, and many more. Dr. Bosshart
has been CEO of the GDI since 1999. His work focuses on the future of consumption and social change, management and culture, globalization and political philosophy. He has written numerous international publications and is a multilingual
expert and sought-after keynote speaker in Europe, U.S.A., and Asia.
global presence is often not necessarily beneficial. Companies
should examine the countries in which they are or want to be
active from a long-term perspective. For the envisaged markets,
the focus should not just be on current growth potential. Instead,
companies should closely examine all stability indicators, including the prevailing value systems.
° In this context, do you expect competition between the world
markets to increase further in future?
* Competition is definitely increasing. However, the real conflicts will take place in the area of supply. In my view, it is clear
that, if we don’t get to grips with agriculture and energy at a
global level, it will be impossible to sort out industrial issues. In
theory, we can live without cars, but not without food and water.
With increasing world population, these issues will become increasingly pressing. “From the region for the region” could be a guiding principle, which the food retail sector is already beginning
to pick up, particularly in the developed countries. In addition,
we need products that take proper account of environmental
aspects, such as CO2 emissions.
° This sounds like a redefinition of values.
* Exactly. In the future, competition will increasingly concentrate on a competition of values. Consumers will ask which products offer which values. In the developed countries, this has already
started to happen. The Swiss Coop retail chain is a good example.
Consumers for whom price is the key value will chose “entry-level
products” labeled with a blue dot, which, although produced according to government regulations, do not incorporate values such as
“organic” or “produced locally”, etc. Consumers seeking additional
values can choose more expensive products with different labels.
° You mentioned the risk of future food and energy shortages.
This would mean rising prices. Doesn’t this mean that we will
reach a point when the price will once again become the
decisive value for consumers?
* This is indeed the case in developing countries, where the
focus is on meeting basic needs. In the developed countries, on
the other hand, the basic needs are covered, and health is becoming one of the key values for which consumers are willing to pay
more. Let’s take a brief look into the past: About 100 years ago,
50% of income was still being spent on food in developed countries. Today this figure has fallen to 9% in Switzerland. Consequently, the last few generations have experienced an almost continuous reduction in food prices. This trend cannot and will not
continue.
° Does this mean that companies from the beverage and food
sectors would be well advised to continue moving towards
health and to focus marketing campaigns more on product
quality?
* Of course. More and more consumers are seeking quality and
values associated with quality such as transparency, decency, and
confidence. They want to know where their food, drinks, and
other consumer goods come from, what they contain and under
what conditions they were produced. In the new phase of globalization, consumers, the retail industry, and production companies will be called to account even more strongly than in the past.
“The small are the most resilient, vital, and in a
democracy, the strongest.”
In this context, another key factor incidentally is the increasing
responsibility of companies and the retail industry in terms of
quality assurance at several levels. We need excellent product
quality, service quality and innovation quality – in other words,
we need quality as a whole. We need to look at the entire life
cycle of each product, starting from design right up to disposal.
° Which role do packaging and design play in this holistic scenario?
* Packaging and design are key aspects. It goes without saying
that the aesthetics of products and their attractive appearance
also represent values, although this doesn’t mean that packaging
has to be elaborate. The key is to omit anything that is superfluous, especially those things that don’t serve to highlight product
quality from a consumer standpoint. The question is: How can I
combine abstention and hedonism in a pleasurable way?
true
long term, although it is clear that we will see more and more
interlacement. For example, acquisitions in the field of participation financing are likely to provide access to European creativity and European know-how. In this context, the recent takeover
of the British carmaker Jaguar by the Indian car manufacturers
Tata Motors had an almost symbolic character, because it could
be regarded as a process of “reverse colonialization”.
° “Focus on people, not capital” is a guiding principle of the
Gottlieb Duttweiler Institute. Will this guiding principle
become more significant in a new phase of globalization?
* The focus will no doubt increasingly shift to social responsibility as a value that reaches into all activities of a company. A
company generating a large proportion of its added value in a
defined home market, reinvesting there, and ensuring sustainable job creation will place even greater importance on this than
in the past.
° For many companies, ensuring quality at several levels is only
possible if suppliers provide top quality. Is cooperation with
suppliers therefore likely to become an even more important
factor than it is already?
* Absolutely. Cooperation with suppliers who have the same
mindset is vital. Long-term cooperation on a firm basis results
in win-win-win situations. Vertical cooperation will therefore
undoubtedly become increasingly in future.
° How will the relationship between employees and companies
change?
* Employees will increasingly seek good employers offering
maximum advancement. The times when job hopping every
two years was fashionable are over. Employees who can identify with the corporate culture and see scope for advancement
will stay.
° How important will creativity and innovational spirit be for
business success in future?
* Creativity and innovational spirit are decisive factors, particularly in Europe. Asian countries such as China have traditionally focused on cheaper production and copying. I consider America as particularly strong in marketing and in the field of hightech. It is difficult to predict how the picture will change in the
° How would you envisage a corporate culture that attracts
good people?
* I feel we need a variety of different corporate cultures. Employees will choose the corporate cultures that suit them, because in
the future good people will tend to choose their employer rather
than the other way round. All corporate cultures should give
employees a high degree of responsibility. Each individual should
dialog+opinion ° Interview with Dr. David Bosshart
make a significant contribution to the company’s success, and
each individual employee can expect something in return.
° What exactly do you mean by “something in return”
* I’m particularly referring to respect, integration in a positive
corporate atmosphere that is characterized by mutual trust, and
performance-related pay. Additional benefits such as company
cars, daycare centers, etc. will automatically be part of a functioning corporate culture.
° The role of women in the world of employment is being discussed worldwide. How will this role change?
* We are seeing this change already today: In countries where
women don’t play a significant role in the economy, growth is
automatically inhibited. It is quite easy to prove that women are
generally better able to cope with complex tasks than men. We
therefore need teams comprised of both men and women, particularly for complex projects. In my view, the role of women in
the world of work will continue to gain in significance, both in
developed as well as in developing countries.
° Currently, we are still distinguishing between developed markets and markets in development. Is it possible to predict
when market development will have converged?
* In my view, the main aspect in a global scenario is peace.
Progress is only possible if peace prevails. Progress should be
steady, and never too fast. If the gap is too wide, the middle class
will not be strong enough. A stable middle class is imperative
for orderly growth, because middle class essentially means hope
for a better life for the family. If the middle class dies off, hope
also dies off. It is difficult to provide a general answer to the
question of the time period for the convergence between developed and developing countries. Nevertheless, I think that, based
20*21
on an optimistic forecast, China as the largest Asian country may
have reached the economic level of the United States by 2020,
although in this scenario certain questions will no doubt gain in
significance, such as: Will China be affected by overaging? Will
there be enough healthy people in gainful employment in 2020?
These aspects indicate the importance of investment in health
and education in developing countries.
° What is your view on a convergence of lifestyle habits in Europe?
* Basically, I would like to state that it is good to have an economically strong Europe, although a cultural Europe must always
be considered in addition to an economic Europe. One can’t
exist without the other. In terms of cultural development, there
are tremendous differences within Europe, which can’t simply be
swept away over a few decades of prosperity. I see Europe as an
experiment, and I have no doubt that genuine growing together
will take longer than another generation. Incidentally, the process
of growing together of European countries is very different from
the situation in the United States, where the focus is on the “American way of life”, i.e. independent, success-oriented individualism. The key question long-established citizens and migrants
alike are asking themselves is how they can implement the “American way of life”, and this is a strong integrating factor.
° Can we conclude from your example that the history deserves
close examination when companies enter new markets?
* Of course. Both the political history and the culture are key
criteria. I can’t stress this often enough: Companies who only
take a cursory look at economic aspects when they enter new markets are taking a big risk. What counts is a holistic view of a
market based on a carefully planned market entry strategy.
° Dr. Bosshart, many thanks for this interview.
BEER
The Asahi Group now operating
27 filling systems from KHS
FOR THE WORLD
The Japanese Asahi Group has ambitious aims: The company intends to
become one of Asia’s leading suppliers to the beverage, food, and
health sectors, and is well on its way to achieving this goal.
Outstanding product quality and KHS technology play a significant role.
The Japanese love their traditional cuisine. An extensive choice of beverages complements the wide range
of local rice and fish dishes. One of the big players
in the Japanese beverage market is the Asahi Group,
which started off as a brewery. It is the undisputed
market leader in the beer sector. Based on this success, Asahi is well on its way to becoming an established force in the Japanese food and health industry. The Group has a long-term growth strategy for
these areas. Hitoshi Ogita, President and COO of Asahi
Breweries, Ltd., has a clear concept: “We intend to
make the Asahi Group the market leader in the bev-
erage, food, and health sectors in Asia.” In the past,
the focus has been on alcoholic drinks, as evidenced
by sales figures. 2007: 69.1%, while non-alcoholic
beverages had a share of 20.5%. The strongly growing food and health sector made a 4.6% contribution
to Group sales. Around 6% of sales originated from
areas such as logistics and restaurant management.
An important aspect for the success of the company is its wide range of products. Asahi offers something for every taste. Take beer, for example, where
Asahi has its roots: Established in 1889, the Osaka
Beer Brewing Company received its first Grand Prix
task+solution °
Left Very popular in Japan: guided tours of Asahi breweries.
Right KHS PU control: a key quality factor for the modular Innopas C pasteurizer solution.
award for Asahi beer as early as 1893 at the World
Fair in Chicago and again a few years later.
During its long history, Asahi has repeatedly set
new trends. For example in 1900, when the company
presented Japan’s first bottled draft beer. Or in 1958,
the year when Asahi was the first Japanese brewery to
start filling beer in cans. In 1987, the company revolutionized the Japanese beer industry with the introduction of Asahi Super Dry, the first Japanese dry beer.
TOP SUCCESS WITH TOP BRANDS
Twenty years later, Asahi Super Dry still has an impressive 70% share of Asahi Breweries’ beer, Happoshu and
New Genre sales. But the company never relied only
a single brand: In addition to Asahi Super Dry the product range includes Jukusen, Asahi Stout, Asahi Black,
Kohaku no Toki keg beer and Kita no Shokunin, while
Asahi also fills Miller Special and Löwenbräu under
license and sells imported Bass Pale Ale, Tsingtao Beer,
and Bellevue Kriek.
Happoshu and New Genre beverages are specialties in the Japanese beverage market. Happoshu
is a beer-like beverage produced with very low malt
content, while no malt at all is used for New Genre.
The Japanese love these new varieties. One reason for
their huge success is the fact that in Japan beer tax
is based on the malt content, among other parameters, so that the new beverage types are cheaper than
conventional beer. Happoshu has a 12.3% share and
New Genre a 6.1% share of total Asahi sales, with
further strong growth expected. Asahi’s total sales
figure for 2007 was nearly 24 million hectoliters, equiv-
alent to a market share of 49.4%. In Japan, the Group
has been the market leader since 2001.
Asahi not only has ambitious aims for the
domestic market, it also has a strong presence abroad.
Asahi Super Dry is now regarded as one of the ten
main beer brands worldwide. Internationally the company relies on a license production strategy, which
offers advantages in terms of short routes, reliable
partners, and local production. According to Noriyuk
Karasawa, Director and Executive Officer, Senior General Manager Production Headquarters Asahi Breweries, Ltd., outside Japan Asahi will focus predominately on the growing markets in China and SouthEast Asia in future: “In China we expect significant
growth, not least against the background of the 2008
Olympics.” Asahi has already been active in China
since 1994 with four joint ventures, brewing Chinese
brands as well as Asahi Super Dry. In 2006, the four
partner companies produced around 6.37 million hectoliters of beer. Further important foreign markets
are Thailand (licensee: Boon Rawd), the UK (Sheperd Neame), Czech Republic (Staropramen), and Canada
(Molson Breweries).
Asahi sells around 63% of its beer in cans with
a wide range of sizes between 135 milliliters and 1,000
milliliters. Glass bottles in sizes between 334 and
1,957 milliliters have a market share of 20%. A special highlight is that Asahi is one of the few breweries offering beer in aluminum bottles, which enabled
the Group to attract a fine circle of connoisseurs.
Around 17% of total sales are filled in kegs (5 to 30
liters) for the catering trade.
22*23
Left Noriyuki Karasawa, Director and Executive Officer, Senior
General Manager Production Headquarters Asahi Breweries,
Ltd.: “Besides the high quality of the technical solutions
offered by KHS, we value the company’s know-how as a global
player. Center Aluminum bottle. Right canned beer: The big
seller for Asahi.
2
THUMBNAIL PORTRAIT: ASAHI
* Nine production facilities in Japan
* Market leadership with a 49.4% share of the market
* History
1889 Osaka Beer Brewing Company is founded
1893 First award for Asahi beer the World Fair in
Chicago
1900 Market introduction of draft beer in Japan
1958 Market introduction of canned beer in Japan
1987 Asahi presents the first dry beer in Japan.
* Strong brands Asahi Super Dry (68% share of turnover), Jukusen, Asahi Stout, Asahi Black, Kohaku
no Toki keg beer, Kita no Shokunin
PROVEN TECHNOLOGY PARTNERSHIP
Asahi and KHS have been brewing technology partners for decades. The partnership began in the early
1960s. At the time, the company invested in mechanically controlled filling systems: “We were and continue to be very satisfied with these systems, although
as a modern and innovative brewery new investments
naturally focus on state-of-the-art equipment,” says
Karasawa. Take electronically controlled filling systems, for example. This was relevant when investment
in new technology was recently required at two locations: At the Fukushima brewery Asahi required new,
gentle filler-rinser equipment, while at the Ibaraki
brewery both an efficient filler solution and pasteurizer equipment with optimum hygienic performance
were required.
Today a total of 27 KHS filling systems are in operation at Asahi breweries in Japan, 14 of which are used
for cans, 8 for glass bottles, 4 for kegs, and 1 for aluminum bottles. Karasawa emphasizes, “In addition to
the high quality of the technical solutions offered by
KHS, we value their know-how relating to different
markets as a global player for filling and packaging
technology.”
RINSER-FILLER AT FUKUSHIMA:
GENTLE AND FLEXIBLE
The rinser-filler monoblock at Fukushima operates with
a mechanically controlled Innoclean FR-EM singlechannel rinser and the computer-controlled volumetric Innofill DVF pressure filling system. The bottomup filling method with long filling tubes is particularly gentle and reduces oxygen pickup to a minimum.
The flexible and future oriented solution system is
already prepared for processing PET bottles in future.
The only retrofit that would be required is a neck
handling system for conveying the PET bottles.
FILLING SYSTEM AT IBARAKI:
EXACT AND EFFICIENT
The new Innofill DVD can filling system installed at
the Ibaraki brewery offers an optimum solution with
regard to filling accuracy. The electromagnetic induction flowmetering system integrated in the computercontrolled volumetric filler ensures maximum filling
accuracy. With conventional filling level systems, fill
level variations were experienced in some cases when
cans from different manufacturers were used. Karasawa is impressed by the new filling system: “The
system offers high line efficiency, a factor that is very
important for us. And in addition, this filling system
task+solution ° Asahi Group with 27 filling systems from KHS
also offers scope for new can developments within the
brewery group, which means we are already equipped
for the future today.”
PASTEURIZER AT IBARAKI: MODULAR AND
PRECISE
Ibaraki also invested in KHS pasteurizer technology
and installed an Innopas C double-deck pasteurizer.
Thanks to its modular design, the pasteurizer is able
to meet all customer requirements down to the last
detail. The system calculates the dynamic temperature profile for all products to be pasteurized and the
respective packaging. This ensures the correct temperature and PU values and the associated heat consumption levels. Director and Executive Officer Noriyuki
Karasawa sums it up, “With KHS pasteurizing equipment we are once again on the safe side when it comes
to quality.”
The highlight of the system is the KHS PU
control with automatic program changeover integrated
in the Innopas C. If there is a product or can
changeover, the pasteurizer automatically detects the
last container from the old batch and the first container from the new batch. It then creates a gap
between the old batch and the new batch and adapts
the process as required without interrupting the pasteurization. Mechanical pushovers at the pasteurizer
infeed and outfeed regulate the necessary separation of products. “It leaves nothing to be desired,
especially since, as usual, KHS integrated Japanese
control technology into the overall package as
requested,” says Karasawa.
State-of-the-art KHS technology was recently
also installed and commissioned at the Asahi plant in
Suita (Osaka), including a combined unit for pre-wash-
ing and main washing, an Innokeg Till CONTIKEG CKHR
32/32 and an Innokeg Till CONTIKEG CFK 20/20 filler
with a capacity of 1,100 kegs per hour, based on 19liter kegs. Key criteria for Asahi Brewery’s decision
to use advanced KHS technology were the DCF system
for optimizing the filling volume and the field satellite technology with minimum cabling effort and faster
availability for production due to minimum installation and commissioning times.
Oliver Schneider, Sales Manager, Business Area
Far East/Australia, KHS AG
Hideo Suzuki, President, KHS Japan Corporation
fi
INFOBOX
• WEBSITE www.asahibeer.co.jp
• CONTACT
Oliver Schneider, Sales Manager, Business Area
Far East/Australia, KHS AG, Bad Kreuznach
Tel: +49/6 71/8 52 – 26 23
Hideo Suzuki, President, KHS Japan
Corporation, Osaka
Tel: +81/6/49 60/47 11
24*25
Coca-Cola Içecek relies on new technology
Coca-Cola Içecek (CCI) is number ten among the Coca-Cola bottlers worldwide. The Turkish company is the first Coca-Cola bottler to receive an ACF line with dry sterilization from KHS as non-carbonated beverages play a major role in the company plans. CCI has also ordered a PET line for carbonated drinks. A company that continues to grow.
With six production locations, Coca-Cola Içecek in Turkey is the undisputed market leader
for both carbonated soft drinks and noncarbonated, alcohol-free beverages. And
the company is looking for new challenges
in Eurasia and the Middle East. The idea is
to further expand the Turkish market and at
the same time to focus on interesting countries such as Kazakhstan, Azerbaijan, Kyrgyzstan, Turkmenistan, Tajikistan, Jordan,
Syria, and Iraq. After all, CCI is today already
one of the ten Coca-Cola bottlers with the
highest sales worldwide.
The Corlu plant, located on the outskirts
of the mega-metropolis Istanbul with
around 20 million inhabitants, is the company’s most important site. Here, CCI bottles Coca-Cola brand products and produces
PET preforms and PET bottles. As a producer of PET preforms, Corlu ranks as one
of the largest plants in Europe and supplies the other CCI plants with a wide variety of packaging types ranging from the
0.33-liter to the 2.5-liter family-size bottle, which is extremely popular on the Turkish market.
Coca-Cola is clearly the leading product followed in second place by Fanta. Other carbonated brands in the range include Sprite,
Schweppes, and Sen-Sun. But CCI is also
strong when it comes to non-carbonated
beverages. Fruit beverages such as Cappy,
tea drinks such as Nestea, sports drinks such
as Powerade, spring water such as Damla –
all are included in the wide range of products. CCI boasted 2-digit overall growth
rates the previous year and the upturn is
expected to continue due to the rapid
increase in buying power in the Turkish mar-
task+solution °
2
THUMBNAIL PORTRAIT: COCA-COLA IÇECEK
* Market leader in Turkey for carbonated and non-carbonated alcohol-free beverages
*
*
*
*
26*27
One of the top ten Coca-Cola bottlers worldwide
Six locations: Ankara, Bursa, Corlu, Izmir, Mersin and Mahmudiye
Wide range of varieties and containers
Two-digit international growth rates
Left Turkey: Still CCI Group’s strongest market. Largest of six
production facilities is Corlu.
Center Mini-isolator technology: Keeps the clean room volume
within the ACF monoblock as small as possible.
Right Rinser-filler-capper monoblock of the “classical line”: The
rinser cleans bottles with ionized air.
ket. High-priced non-carbonated beverages
in particular have a great future.
*
*
It retains the natural taste, flavor, and
color of the beverage
We can safely do without preservatives
COMPELLING ACF TECHNOLOGY FROM KHS
With an innovative technical solution, CCI
is now well prepared to cope with the boom
in non-carbonated beverages: the first ACF
(Aseptic Cold Filling) line in the Coca-Cola
Group worldwide working with dry sterilization has been put into operation at the
Corlu site. Praise from Ahmet Nuri Yilmaz,
Operations Manager at the CCI plant in Corlu:
“For us, all aspects of the process are impressive. And we have assured ourselves of the
highest quality with the latest ACF equipment from KHS.” According to Yilmaz, the
decisive factor was initially the basic advantages of the ACF process:
* It is suitable for the most sensitive beverages
* It provides outstanding microbiological
safety
In addition, dry sterilization scores further plus points versus the conventional but
likewise completely microbiologically safe
wet ACF process:
* It saves rinsing water for bottles and
caps and therefore cuts costs
* It takes up considerably less space (15
instead of 65 cubic meters of clean room
volume)
Selim Mizrahi, CCI Engineering Service Manager, sums it up, “KHS was attractive as
the first supplier of this technical solution
to the Coca-Cola organization worldwide,
because we think KHS probably has the most
comprehensive experience in the industry
when it comes to the ACF dry sterilization
process.”
As a brand name producer, Coca-Cola not only
relies on a wide variety of products and different bottle sizes, but also on differently
shaped PET bottle styles. The dry sterilization process is particularly suitable for this
purpose. The sterilization medium for bottles and caps is hydrogen peroxide (H2O2).
Bottle surfaces and caps treated with this
medium are always completely wetted. The
process even reaches any undercuts, edges,
and angles, such as those found on ribbed
bottles, and even sports caps. The stations
of the line are described briefly below.
Sterilization. The non-refillable
PET bottles are conveyed by air conveyors
to the ACF monoblock and then over an
infeed plate that requires no format parts,
to the sterilizer / activator area for internal and external sterilization with H2O2.
Vaporized H2O2 is distributed evenly on the
bottle surfaces by condensation. The
appearance of condensation on all the inter-
Ahmet Nuri Yilmaz, Operations Manager of the production facility in Corlu (left), and Selim Mizrahi, CCI
Engineering Services Manager, agree: “With KHS technology, we believe we’re playing it on the safe side.
In KHS, we are dealing with a trusted partner.”
nal and external surfaces of the bottle means
that the condensation process is also very
easy to check visually. The actual sterilization process starts as soon as warm air flows
into the plastic bottle in an activator area
connected to the sterilizer. The H2O2 displaced by warm air generates free radicals,
which immediately attack the cells of
microorganisms. At the same time, the H2O2
dries without leaving any residue. Two activators are used at CCI Corlu to ensure that
this is absolutely the case for all conceivable filling situations.
Filler. After sterilization, the PET
bottles pass directly to the pressureless freeflow filler. Depending on the product, the
line fills volumetrically in one or two steps
by means of electromagnetic inductive
flowmetering for exact fill volumes. Other
benefits: no time is lost for changeover when
changing bottles types (data are stored electronically) and the central filler control is
fully automatic. The result is process reliability at the press of a button – with the
AIS plant information system.
Capper. Both classical plastic
screw caps and sports caps are used. The
caps are sterilized in separate units. Special features include separating the capping motion into the rotary movement of
the cap and the vertical movement of the
bottle. Each capping spindle is equipped
with its own servo drive. The stations operate entirely without lubricants for maximum microbiological safety.
Mini-isolator. To keep the clean
room volume within the ACF block as small
as possible, KHS uses so-called mini-isolator technology. The basic principle of the
compact isolator technology involves containing only the PET bottle guide elements
in the sterilizer and activator as well as
the filling valve bells in the filler carousel
and the capping heads in the capper. All
moving parts are kept outside the sterile
clean room. The system operates under
clean room class 100 conditions only in
the mini-isolator zone. HEPA (high efficiency particulate air) filters provide a constant supply of sterile air. An important
aspect is that during antiseptic operation,
the system measures and stores all actual
process values, which can be called up as
required at all times. A code on every PET
bottle provides information relating to the
rinsing, filling, and capping process as well
as the inspection results should there be
any queries from the consumer.
Check. Fill levels and caps are
checked outside the ACF block using
advanced camera technology. Squeezers
are used to check for leaks.
Labeler. Two labeling machines
feed the PET bottles alternatively with rollfed or shrink-sleeve labels.
Packer / Palletizer. The bottles
then pass to the Innopack Kisters SP shrink
packer. The six-axis Innopal RK 6 articulated robot palletizes the packs (a roller carpet head handles the shrink packs with care).
As this is the first ACF line with dry
sterilization within the worldwide Coca-Cola
Group, Ahmet Nuri Yilmaz expects many visitors in the near future. CCI Corlu could
almost set a good example and serve as ACF
training center. “Because,” says Selim
Mizrahi, “we assume that there will be further investment in this new technology over
the next few years – both in Turkey and
worldwide.”
task+solution ° Coca-Cola Içecek relies on dry ACF
28*29
Left Labeling: a roll-fed labeling machine in the carbonated soft drinks line. Center Packing: shrink packs in both the ACF line
as well as the “classical line”. Right Shrink tunnel: Temperatures are adapted to the film quality and pack size.
CLASSICAL PET LINE
While the ACF line was being commissioned,
CCI ordered yet another classical PET line
from KHS to bottle carbonated soft drinks.
Yilmaz says, “KHS has been our trusted partner since the production facility was set up
in 1997. We are so satisfied that CCI Corlu
has literally become a KHS stronghold.” And
indeed, the Corlu plant is nearly exclusively
equipped with KHS system technology – six
lines in all are currently in operation. Mizrahi
adds, “Although the ACF line is something
special because of its novelty value, we are
equally satisfied with our new soft drinks
line, especially since it also offers many special features.”
A very special rinsing system is used
in the newly installed KHS line for carbonated soft drinks, for instance, which once
again emphasizes the company’s high environmental friendliness. The computer-controlled Innoclean FR-ER single-channel rinser
uses ionized air as the rinsing medium. The
basic principle involves blowing out the bottles with ionized air to electrostatically discharge and clean them. Air serves as a carrier medium for ions that produce a con-
trolled neutralization of the electrostatic
charge in bottles. Once the electrostatic
charge is neutralized, any particles clinging to bottle walls are removed. The main
advantages of the system:
* It saves precious water
* It saves time
* It can be implemented in rinsers that
are half the size
* It does not burden the product being
bottled with remaining water
* It ensures that the statically neutral bottles do not attract particles in the ambient air while being transferred to the
filler
The new KHS line for carbonated soft drinks
is used primarily to fill the 2.5-liter PET family bottle. Yilmaz says, “To achieve the highest possible system efficiency, we pursue a
strategy of switching bottle and product
types as little as possible for all of our lines.”
A strategy that pays off.
Erhard Magin, Director Business Area Africa,
Middle East and Southern Europe, KHS AG
Hubert Schiffer, Sales Africa, Middle East and
Southern Europe, KHS AG
fi
INFOBOX
• WEBSITE www.cci.com.tr
The rinser is contained in a monoblock
together with the computer-controlled
Innofill DRV volumetric, pressure filling
system that operates with exceptional precision without filling tubes using electromagnetic inductive flowmetering. Another
highlight is the Innoket RF labeling
machine. Each of the two labeling units
is equipped with a double reel stand for
fast reel changing to minimize machine
downtime.
• CONTACT
Erhard Magin, Director Business Area
Africa, Middle East, and Southern Europe,
KHS AG, Bad Kreuznach
Tel: +49/6 71/8 52 – 26 75
Hubert Schiffer, Sales Africa, Middle East and
Southern Europe, KHS AG Bad Kreuznach
Tel: +49/6 71/8 52 – 26 71
Especially manufacturers of health products must be able to rely
on perfect results in packaging. The technological keywords are
flexible, gentle, durable, strong. That is why Anton Hübner
relies on KHS labeling quality.
Stickto-it-
iveness
Anton Hübner, provider of innovative health products, applies labels perfectly
Since time immemorial, human beings have relied on the power of
herbs to fight disease. One of those people was the Black Forest
priest Hurst, who in 1920 was looking for an effective way to fight
respiratory disorders. At that time, manual workers suffered from
these diseases, especially those in the domestic textile industry.
Paging through a book of herbal remedies, Hurst stumbled across
an herbal medication recipe written by his ecclesiastical counterpart Sebastian Kneipp.
Hurst continued the development of that recipe, adding
special Black Forest medicinal herbs. In the mid-1920s, Hurst joined
forces with the pharmacist Eduard Hiepe to launch this natural cold
remedy to market, under the name of “Tannenblut”. Its healing
power was soon well-known, piquing the interest of businessman
Anton Hübner, who purchased the license for Tannenblut in 1936
and started industrial production of the medication. For about 25
years, Tannenblut remained the only product of Anton Hübner GmbH.
2
THUMBNAIL PORTRAIT: ANTON HÜBNER
Eventful history …
In 1968, the company gradually expanded its product line when
Tannenblut was joined by new brands, such as Original silicea Balsam® and denk fit!. By the end of the 1990s, the company had
changed hands several times, before Nordzucker AG took it over in
2000.
… with high-quality brands …
Over the years, the silicea brand has become the company’s best
selling product now representing about a third of Hübner’s total
sales. The core of the brand is the Original silicea Balsam®.
… with a unique silicic acid gel …
One of the success factors of the silicea products is silicic acid gel
that Hübner produces without preservatives using one of the world’s
most unique sterile processes. The company utilizes the circumstance that the ingredient silicon turns into silicic acid gel when
combined with water. Used externally, the gel helps to sooth sunburns, as well as minor skin injuries. But used internally, silicic
acid reveals its beneficial effects, encouraging controlled nutrient transport to the skin cells, for instance.
… with strong distribution channels through health food stores …
1920
1936
1968
1988
2000
2008
Tannenblut cold remedy is developed
Anton Hübner acquires Tannenblut license
Operations taken over by Wilhelm Oberle and product line expanded
Acquired by Wella AG
Acquired by Nordzucker AG
About 200 products, with a strong distribution channel through health
food stores. Export to about 30 countries
Marketing silicic acid products is equally as unique as the company’s
production process. Hübner sells its products in Germany primarily through health food stores with silicea as the single most-sold
product in these stores. Sebastian Ott, Production and Engineering Manager at Anton Hübner GmbH & Co. KG, explains, “Hübner
has grown up with health food stores as a distribution channel.
In Germany, we’re sticking with that distribution route. Since there
is no comparable health food store structure abroad, our sales activ-
task+solution °
30*31
Top Perfect labeling results: For Hübner, the main reason to decide
on KHS labeling technology.
Bottom Advantage of cam control: The lower chucks oscillate to
ensure optimal brush-on label application.
Perfect results
* Gentle package handling
* Short product changeover
A brief glance at the most important features of the Innoket ROLAND
10 H labeler.
*
HIGH PERFORMANCE: 9,000 BOTTLES PER HOUR
ities are oriented to each market entirely on a case-by-case basis.”
Even today, Anton Hübner realizes nearly one third of its sales in
more than 30 countries – and with an upward trend.
… and a broad product range
Today, Hübner offers an assortment of nearly 200 different products, ranging from nutritional supplements to cosmetics, and
even numerous medications. All products must meet the same high
quality requirements. That starts with the selection of high-quality raw materials, continues with gentle processing, and ends with
perfect packaging quality.
LABELING TECHNOLOGY FROM KHS
Keyword packaging: Hübner’s decision in favor of KHS labeling technology was not coincidental as Sebastian Ott explains, “The label
is our first communication with the consumer at the point of sale.
Exactness is our uppermost principle. With KHS technology, we’re
staying on the safe side.” The labeling solution must meet the
following requirements to satisfy these high expectations:
* High performance
The new labeler should also be prepared for future production expansion. The KHS Innoket ROLAND 10 H labeler fulfills that requirement perfectly. It is designed to label up to 9,000 bottles per hour.
Today, Hübner labels about 13,000 bottles per day. That leaves
plenty of room for growth. Ott says, “Growth, which would exhaust
any conceivable labeling performance is absolutely possible here
at Hübner in the medium term.” For more than 20 years, KHS and
Hübner have been technology partners in the field of labeling. The
old labeler was only retired because its performance could no longer
keep up with the demand for increased performance.
PERFECT RESULTS: NEARLY NO RANGE OF TOLERANCE
Ott mentions another reason for the partnership: “KHS labeling
technology offers us – and this point was decisive – the precision
we need for applying each and every label.” The labeler is currently
being used to apply adhesive pressure labels to 200- and 500-milliliter silicea plastic bottles. One labeling field is provided for
each front and back label and virtually no range of tolerance to
apply them. A slight bulge in the bottle surface designates the
labeling fields. Ott says, “The label itself is designed so that on
the left and right, and the top and bottom there is exactly two
millimeters of clearance in the labeling field. Since we place primary emphasis on an attractive appearance, the range of tolerance
is next to none.”
Anton Hübner applies labels perfectly
Sebastian Ott, Production and Engineering Manager (center) and Branislav Krznar, responsible machine technician (left) agree: “The kind of technical solution a growing company like Hübner needs.” Also pictured: Jan-Wilhelm Brückel, KHS AG, Hamburg.
fit labeling of square shaped plastic bottles. Of course, this system can be retrofitted later. Should Hübner decide to expand its
variety of bottles in the future, KHS will provide appropriate bottle plates for the Innoket ROLAND 10 H.
IDEAL BRUSH-ON APPLICATION: CAM-CONTROLLED
LOWER CHUCK
MAXIMUM FLEXIBILITY: VARIETY OF 54 DIFFERENT LABELS
The adhesive pressure process offers quick changeover of dressing
to ensure maximum flexibility. An especially important item for
Hübner as the company uses a total of 54 different film label styles.
With such a wide variety, the adhesive pressure process has genuine advantages over the wet glue process, since there is no need
to change glue segments, label hoppers, and when changing over
to another label style, all that is necessary is to change label
reels.
GENTLE HANDLING: NO ACCUMULATION PRESSURE
In addition, the labeler must handle the plastic bottles particularly
carefully. Which means, with as little accumulation pressure as possible. Two bottle flowgates prevent the build-up of accumulation
pressure in the first place. The first bottle flowgate is directly
upstream of the labeler while a second bottle flowgate is integrated
into the feed screw.
In the labeler carousel, there are two adhesive label units for the
front and back label. Cam control drives the lower chuck in the
carousel, setting it into an oscillating movement after the labels
are applied. This allows the labels to be optimally brushed on.
After labeling, the bottles reach the outfeed star that can be equipped
with an additional labeling assembly, opening up further label application options for Hübner such as lid or closure labels.
SHORT CHANGEOVER: CLEARLY ARRANGED AND ACCESSIBLE
The Innoket ROLAND 10 H reveals itself as being particularly efficient when it comes to changeover. When switching bottle types,
format parts can be changed within a minimum amount of time and
production can be quickly resumed. Sebastian Ott says, “Not only
is the labeler compact, it also has a clearly arranged layout and is
outstandingly accessible. For the limited amount of space we can
provide for the labeling machine, that’s exactly the solution we
need now and in the future.”
Jan-Wilhelm Brückel, Marketing Manager, Labeling Machines, KHS AG
EXACT POSITIONING: LONGER FEED SCREW
KHS has designed the feed screw so that it is ideally suitable for
sensitive plastic bottles. Because it is longer than normal feed
screws, it is able to space the containers particularly gently and
distribute them perfectly. The centers of gravity of the bottles to
be labeled vary depending on their composition. The position of
the feed screw can be adjusted horizontally and vertically just as
exactly.
PERFECT LABELING: RECESSED LOWER CHUCK
An infeed star feeds the bottles into the labeler carousel where
lower chucks and centering bells hold the bottles and lock them
in place. These chucks have recesses to ensure perfect, custom-
fi
INFOBOX
• WEBSITE www.anton-huebner.de
• CONTACT
Frank Huckfeld, Product Support, Labeling Technology,
KHS AG, Hamburg
Tel: +49/63 70 33 71 17
task+solution °
32*33
Left Attractive labels: For perfect product presentation at the point of sale.
Right Innofill UMG filling system: Extremely precise filling process.
Tried-and-tested and high-tech do
not have to be mutually exclusive.
The South Korean soju manufacturer
Kumbok-Ju combines both with
the utmost success – and an
exceptionally high-performance
line from KHS also plays its part.
Kumbok-Ju relies on
soju – and KHS
Tradition, so it is said, is not preserving the
ashes but passing on the flame. This view
of things is admirably confirmed by the
South Korean beverage company KumbokJu. For many decades, the company has
specialized in the production of soju,
Korea’s national drink. Soju – a light liquor
distilled from the main ingredient rice in
combination with wheat, barley, or sweet
potatoes – has been enjoyed by the Koreans for several hundred years. Kumbok-Ju
has succeeded in passing on the flame of
this tradition – with new soju brands and
a modern product appearance.
Kumbok-Ju was founded in 1957 as
Samsan Co. Ltd., and began by producing
among other things brandy, gin, and wine.
The soju production began a year after
the company was established. In 1963
came the hour of the soju brand KumbokJu, and in 1975 the entire company was
renamed after the successful drink. The
main source of sales today is still soju, of
which the company manufactures several
styles under the Charm brand name with
an alcohol content ranging from 19.7 to
23 percent.
Traditionally
Progressive
There is also a lighter version: The Blue
brand with only 17.9 percent alcohol.
Younghue Shin, Vice President of the Kumbok-Ju group of companies: “We focus our
two new soju developments particularly on
the young generation and the female target group.”
As the per capita consumption of
soju in Korea is already very high, the overall market is not expected to grow at a
significant rate. However, Kumbok-Ju is
relying on an increasing market share of
one percentage point per year.
For all this, the quality of the products must always be right – an important
guarantee for highest product quality is
the right filling and packaging equipment.
The management decided on innovative
solutions from KHS. According to Shin,
“KHS plant equipment gives us production
and product reliability, and for the first
time makes future success possible in the
form that we want.” The company has
recently invested in a new KHS high-performance line with a capacity of 60,000
360-milliliter glass bottles per hour.
Installed upstream of the line are an
Innopro COSMOS horizontal mesh filter
and an Innopro ORION sheet filter.
DEPALLETIZING STATION WITH
INNOPAL PE AND DECRATING STATION
WITH INNOPACK PPZ
The crates are depalletized in the line by
an Innopal PE. The machine lifts the entire
stack of crates stacked in layers on the pallet to remove the empty pallet from the
system. It then destacks the individual
layers of crates from the bottom. The capacity of the depalletizer and the Innopack
PPZ decrater is 100,000 bottles per hour
each. This calculated overcapacity is nec-
Bottom Innopal RS2 column-type robot:
Right All from one source: Besides the filling and packaging
Stacks supplied crates in a crate magazine
equipment, KHS has also supplied the processing engineer-
with 1,680-crate buffer capacity.
ing equipment such as the Innopro COSMOS horizontal mesh
filter… left … and the Innopro ORION sheet filter.
2
THUMBNAIL PORTRAIT: KUMBOK-JU
* Founded in 1957 as Samsan Co., Ltd.
* 1958 Start of soju production
* 1963 Introduction of the Kumbok-Ju soju brand
* 1972 Founding of Kyong-Ju Beob Joo Co. who produ-
ces the rice wine of the same name
* 1975 Samsan renamed Kumbok-Ju Co., Ltd.
Soju
* Company’s share of the market: around 10 percent
* Main sales region: Gyeongsangbuk-do Province with
90 percent market share; Export markets: Japan and
China soon to be followed by the U.S.A. and Europe
* Charm brand with an alcohol content ranging from
19.7, 20, 21, and 23 percent
* The Blue brand, 17.9-percent alcohol content
* Andong premium brand
Left Younghue Shin, Vice President of the Kumbok-Ju
company group: “We take our
responsibility towards
Rice wine
* Share of total sales: 15 percent
* Kyong-Ju Beob Joo and Hwanrang brands
consumers very seriously.”
essary, because the returned crates contain around 40 percent foreign and unusable bottles and bottles with screw caps.
After sorting the bottles, the calculated
60,000 bottles are left for further processing.
Because of its high decrating capacity, a buffer table is incorporated immediately after the Innopack PPZ to ensure
that the bottles are gently conveyed onward
and to make optimum use of the available
working area. When the bottles enter the
buffer table, a patented chain guide separates the stream of containers into two
sub-flows and feeds them past a stationary plow tip without contact. Multiple
drives ensure an optimum scaling down of
the conveying speed and a low-pressure
transfer of the glass bottles onto the buffer
system outfeed. Here, camera equipment
is used to check the bottles themselves and
their discharge onto one of the three conveyor lanes in the system.
The first conveyor line guides foreign bottles and flawed bottles directly out
of the system. The second line conveys
those bottles with screw caps to the decapper from where they are conveyed further
to the bottle washing machine. Since it is
important that there be no safety rings
on the threads of the bottle, the system
uses a camera monitoring system to check
that there are none. Only flawless bottles
pass directly to the Innoclean DM doubleend bottle washing machine over the third
conveyor segment.
BOTTLE WASHING STATION WITH
INNOCLEAN DM
Reasons for using this type of machine
include optimum hygiene values achieved
by keeping the dirty bottles consistently
separated from the clean bottles. Treatment times can be controlled individually
by combining three in-line caustic baths.
Heat insulation and heat recovery units
also reduce energy and fresh water consumption. Environmentally friendly disposal of broken glass, labels, and waste is
handled by special discharge systems.
The Innoclean DM in operation at
Kumbok-Ju is equipped with a special prewashing facility to ensure that even heavily contaminated and dirty bottles are perfectly cleaned. After draining any remaining liquids, two rotating tubes spray the
bottles internally at high pressure enabling
discharge of coarse impurities with outstanding efficiency. This in turn increases
the service life of the caustic in the downstream caustic baths. In the caustic baths
themselves, Kumbok-Ju relies on a combination of rotating and stationary sprays
task+solution ° Kumbok-Ju relies on soju – and KHS
automated full bottle inspection system.
With this system, Kumbok-Ju has adopted
a pioneering role in South Korea. In the
past, only visual inspection was used in
high-capacity bottling lines. Now automatic full bottle inspection systems are
guaranteeing top quality standards for the
first time.
LABELING STATION WITH
INNOKET KL 2080
to further increase the cleaning effect.
Shin says, “KHS bottle washing equipment
leaves nothing to be desired. We are more
than pleased with the results.” An empty
bottle inspection system checks the cleanliness of the bottles using triple side wall
inspection, bottle base inspection, and bottle mouth inspection, and additionally
inspects the threads and checks for residual liquids.
FILLING STATION WITH INNOFILL UMG
The 360-milliliter soju bottles and their
narrow neck areas require a precision filling process, as even the smallest variations
in height would give the impression of inaccurate filling at the point of sale and detract
from the uniform presentation of the product. The mechanical Innofill UMG vacuum
filling system ensures perfect filling results.
The specified fill levels can be exactly determined by means of a return gas tube and
a gas lock. The filling process ends as soon
as the soju reaches the return gas tube.
The drip-free filling process also prevents
loss of product. The filling valve has only
a few moving parts, which minimizes wear,
reduces maintenance costs, and increases
machine availability.
A clamping star system at the filler
outfeed feeds freshly filled and sealed bottles into the two-lane outfeed and to the
Bottles that have passed this quality inspection now travel over a buffer table to the
Innoket KL 2080 labeling machine. Integrating buffer tables at key strategic points
in the line ensures a disruption-free system flow. KHS has solved this problem at
Kumbok-Ju in an extremely space-saving
way.
The labeling machine operates with
two wet glue stations to apply shoulder and
back labels. I. H. Kim, Engineering Manager of the Kumbok-Ju company group,
says, “KHS has also provided top-level technology when it comes to labeling equipment. We are greatly impressed with the
Innoket KL 2080.” An Innocheck ETI inspection machine checks that the labels are
perfectly seated and optimally applied.
palletizer without processing. The robot
is able to process the empty crates without difficulty with its two tables; one for
palletizing empty crates and one for palletizing full crates or for palletizing wraparound packs. A truly integrated logistics
solution, which allows parallel handling of
full and empty crates as well as cartons.
A further highlight is the integrated
crate magazine with a maximum buffer
capacity of 1680 crates. The Innopal RS
column-type robot stores the supplied
crates. Equipped with additional centering devices in the head area and holding
devices, it is also able to stack slightly
deformed crates perfectly without any problems.
Shin says, “We are exceedingly satisfied with KHS system technology. In retrospect, our decision in favor of this highquality technical solution has proved to be
exactly right.” Hyun-Pal Ha, Managing
Director of the Kumbok-Ju group, adds,
“The efficiency of the line is outstanding.
We are working a two-shift operation at
94-percent efficiency.” And finally Kim,
“It is also of great importance to us that
KHS has supplied everything from one
source.” The fire of tradition continues
to burn at Kumbok-Ju.
PACKING STATION WITH INNOPACK
PPZ AND INNOPAL RS3 BGN
COLUMN-TYPE ROBOT
The crates washed by the KHS Innoclean
KW crate washer and the bottles merge at
the Innopack PPZ crater. An Innopal RS3
BGN column-type robot palletizes the preformatted layer patterns using a clamping device. The three-axis robot works
according to the SCARA principle, i.e. exclusively with horizontal and vertical movements.
A special feature: As an alternative
to packing the bottles in crates, the line
can also be combined with a wrap-around
packer. In this case, empty crates pass
through the Innopack PPZ packer to the
34*35
Rainer Hilgert, Director Business Area
fi
INFOBOX
• WEBSITE www.kumbokju.co.kr
• CONTACT
Rainer Hilgert, Director Business Area
Tel: +49/6 71/8 52 – 24 62
H. W. Kim, President KHS South Korea, Seoul
Tel: +82/2/5 18/59 06/8
MADE TO MEASURE
Karlsberg Brewery had more than half a dozen special requirements for the new filling line from KHS. And major parts of the previous system were to be connected to
it. Order completed to the customer’s satisfaction.
At Karlsberg Brewery, everything concerns the future: “Do today
what others think about tomorrow,” is the motto at the traditional Homburg-based company, which in the meantime is managed by the fourth generation of the family. Karlsberg has almost
always gone its own way and has many times shone as an innovation leader and trendsetter. For instance, it is the only brewery
within the German-French sales region to have been filling beer in
cans since 1953. Or in 1968 when Karlsberg introduced the socalled giant can to the market. The 3.8-liter and 5-liter size cans
then celebrated gigantic success at the parties of the 1970s.
Today the Karlsberg Brewery is an important nucleus of
the Karlsberg Association, which is active in numerous business
areas. The international multi-channel company provides widely
differing beverages and services well beyond the beer sector – from
fruit juices, soft drinks, and hot beverages through transport and
event services to sandwiches and snacks. The group thus occupies
future-oriented and success-oriented areas on the way from a
regional brewery to internationally successful beverage and service association.
Regional roots and international alignment are no contradiction for Karlsberg. “Someone who does not know where he comes
from will not understand where he is going to. Provenance is the
future,” so says Dr. Richard Weber, Managing Partner of Karlsberg
Brauerei KG Weber, on the occasion of the company’s 125-year
anniversary in 2003. Since that year, Karlsberg has been cooperating with Heineken and Brau Holding International in the domestic beer sector. Today, the Karlsberg Association ranks among the
top ten beverage manufacturers in Germany. Furthermore, the
Association is the seventh largest export brewery in this country.
CLASSIC AND INNOVATIVE PRODUCT RANGE
New products and containers representing the spirit of the age
are continuously being added to the classic beer range, which
includes Karlsberg UrPils, Gründel´s Alkoholfrei, and Zischke. With
Karlsberg MiXery, the Homburg-based brewery has opened up a
new segment in the beer market. At Karlsberg, mixed beer drinks
have a continuously growing share, currently 20 percent. Dr. HansGeorg Eils, Engineering and Logistics Director, puts it in a nutshell: “For a company that is as innovative as the Karlsberg Brewery, the technical solutions must of course also be innovative and
flexible to meet the high demands imposed by our quality products.”
It is no wonder that Karlsberg and KHS have been working
together on a basis of mutual trust for decades. The latest project is a new bottling line for glass bottles at the Homburg site that
offers maximum flexibility. The line processes refillable and non-
task+solution °
36*37
Left Innofill DRS-ZMS: Bottles with low oxygen pick-up, saves CO2. Center The
Innoclean EE single-end bottle washer, for example, which like all KHS
machines, has a special noise-insulated housing. Right Container conveyor:
hygienically designed. Large photo right Filling system: Operates with fill level
probes after triple pre-evacuation and double purging with CO2. Bottom Quickly
relocated from an existing outdated line to the new line: The Innopas C
double-deck pasteurizer with the crate magazine on top to save space.
2
THUMBNAIL PORTRAIT: KARLSBERG
* Founded: 1878
* Location: Homburg
*
*
*
*
Collaborations: Heineken, Brau Holding International
Positioning: One of the top ten beverage manufacturers in
Germany
Range: Includes Karlsberg UrPils, Gründel’s, MiXery, Desperados
Philosophy: Do today what others think about tomorrow
refillable bottles for the complete product range and currently
fills refillable 0.33-liter as well as 0.5-liter glass bottles. Capacity: 60,000 bottles per hour. Of course, the line also handles
other sizes of bottle as well as all possible innovative products.
Praise from Tobias Sohns, Bottling Shop Manager at the Karlsberg
Brewery, “The new line exactly meets all our expectations in every
respect.” This also includes a few special tasks, which the company gave to the KHS experts.
fore handles the task of packing filled bottles in prepared crates
at the end of the KHS line.
TASK 2: REDUCE CHANGEOVER TIMES
Both Innopack PPZs are fitted with a fully automatic KHS format
changing system. At the press of a button, the decrater replaces
the previously used packing head and centering frame with new
components. In addition, the crater controls the fully automatic
lane switching. The only manual intervention required is connecting and disconnecting the power and air supply hoses. Parking stations for additional format part sets can be installed later at any
time.
TASK 3: REDUCE BACKGROUND NOISE
Noise reduction wherever feasible – this was the requirement.
KHS achieved this not only with the crater and decrater, but also
with all other machines. Special housings are designed so that
the noise-insulating ceiling essentially absorbs the noise.
TASK 1: MERGE THE OLD AND THE NEW
Among other things, a concept for connecting the existing depalletizer and palletizer as well as the sorting area to the new line.
Solution: The existing equipment operates in the basement of the
brewery building and the new machinery on the ground floor.
Bottles and crates arrive segregated by type at the Innopack PPZ
decrater located on the ground floor. The Innopack PPZ is extremely
flexible and is outstandingly suitable for use both as a decrater and
as a crater. The logical decision at Karlsberg Brewery was therefore Innopack PPZ times two. Another modern cyclic crater is there-
TASK 4: SAVE SPACE
The Innoclean EE single-end bottle washer saves space versus the
double-end machine and operates with Triple-i-Drive technology.
Another special solution is the crate magazine, which is built directly
onto the pasteurizer. Sohns, “An excellent idea! We have space
for temporarily storing more than 600 crates.”
TASK 5: OPTIMIZE ENERGY CONSUMPTION
The integral patented energy-saving carrier with reduced carrier
ing situations, whether new bottle shapes and sizes or innovative
beer or mixed beer beverages. Even soft drinks are no problem.
The monoblock filler system currently includes a crown cork capper. The mechanism for integrating an additional screw capper is
already in place.
TASK 8: INTEGRATE THE EXISTING PASTEURIZER
Left Innopack PPZ: Cog belts for freedom from maintenance and reduced background noise. Right Praise from Dr. Hans-Georg Eils, Engineering and Logistics
Director (right) and Tobias Sohns, Bottling Shop Manager (center), “The new
KHS line is a sophisticated system concept right down to the last detail that
offers plenty of future potential.” Also pictured: Wolfgang Augel, Sales, Germany, KHS AG.
weight permanently reduces energy and fresh water consumptions and at the same time reduces the heat and caustic carryover
thereby using 10 to 15 percent less heat and 15 to 20 percent less
water.
TASK 6: MAXIMIZE HYGIENE
The bottle washing machine disposes of extracted labels through
a pipe directly into a receptacle provided for this purpose. Maximum hygiene is the keyword. Hans-Georg Eils, “Modern KHS bottle washing equipment is perfectly in line with our hygiene requirements and its design is extremely environmentally friendly. Both
aspects are of great importance to the Karlsberg Brewery.”
The line conveys bottles from the bottle washing machine
to the filler over easy-clean conveyors with welded components
(no dirt pockets). The single-lane, hygienically designed container
conveyor is equipped with an integrated interior and exterior sanitizing system. What is more, incoming and return chains are separated from one another. Other hygienic components include
special aseptic gear motors to prevent air turbulence.
The microbiological filler front table with its geometrical
shape ensures the selective run-off of product residue, foam, water
and glass fragments out of the biologically critical area of the
filler thereby providing a high degree of microbiological safety.
TASK 7: FLEXIBLE BOTTLING WITH LOW OXYGEN PICK-UP
The Innofill DRS-ZMS computer-controlled pneumatic pressurized
filling system is ideally suited for the low-oxygen bottling of beer
in glass bottles. Furthermore, it is designed for all conceivable fill-
The Innopas C is a double-deck pasteurizer dating back to 2003
that was previously incorporated in a line, which was to be dismantled because of its age. The pasteurizer was broken down into individual modules, transported in sections to the new line where it
was reassembled by KHS and modified by adding a section to match
the higher line capacity. KHS’ PU control system also makes it
possible to program subsequent product specification changes and
new products at any time.
Director Eils sums up: “The new KHS line is a sophisticated
system concept right down to the last detail.” Tobias Sohns adds,
“Regardless of the product consumers may want in the future, we
are already equipped for this today with new KHS technology.” Such
as the company’s latest new development: Gründel’s fresh – a
non-alcoholic cocktail of apple and beer. “With Gründel’s fresh,
the Carlsberg Brewery is also applying its innovative strength in
the non-alcoholic beer segment,” comments Alle Ypma, General
Manager of Karlsberg Brewery on this product. It’s looking into
the future that counts.
Günter Unkrig, Director, Central European Business Area, KHS AG
Wolfgang Augel, Sales, Germany, KHS AG
fi
INFOBOX
• WEBSITE www.karlsberg.de
• CONTACT
Günter Unkrig, Director, Central European Business Area,
KHS AG, Dortmund
Tel: +49/2 31/5 69 – 16 02
Wolfgang Augel, Sales, Germany, KHS AG, Dortmund
Tel: +49/2 31/5 69 – 16 35
task+solution °
38*39
STRONG
PARTNERS
New Belgium Brewery in Colorado
places trust in KHS
The New Belgium Special Brewery in Fort Collins, Colorado brews unique beers and is growing at a
tremendous pace. Although striking and typically American, the history of this young company
began in a basement and not a garage. The partnership between New Belgium and KHS is also
developing extremely dynamically with a new filling line that is unexcelled in the United States.
During a bike trip through Europe on his
old-fashioned bicycle, Jeff Lebesch had no
idea that his life was about to change dramatically. For after returning home, the
electrical engineer from Fort Collins, Colorado began brewing beer in his basement
in the finest Belgian tradition that he had
learned to love during his bike trip. Both
of his first two creations, Abbey and Fat
Tire, quickly earned a reputation among
family and friends for their remarkable and
well-balanced taste. People were now
drinking delicious Belgian beer in a form
that could otherwise only be enjoyed
abroad.
Together with his wife, Kim Jordan,
Lebesch gradually expanded the brewing
activities in his basement and officially
opened for business in 1991. Kim took care
of marketing and sales and even delivered
beer herself in the family station wagon.
In 1995, the team expanded further and
moved to a railroad depot. But they soon
outgrew this second location and consequently the built their first real brewery
shortly thereafter. Today, the New Belgium
Brewery with headquarters in Fort Collins,
Colorado is the third largest specialist brewery in America and has a whole line of
unique beers in its assortment of products.
2
THUMBNAIL PORTRAIT: NEW BELGIUM
* Founded: 1991
* Headquarters: Fort Collins, Colorado, U.S.A.
* Positioning: Third largest specialist brewery in
the United States. Owner managed.
* Sales: 476,100 beer barrels (@ 31 U.S. gallons)
It is fantastic how sales of 476,100 beer
barrels (@ 31 U.S. gallons) have developed
from an experiment in the basement. What
is more, Jeff Lebesch is expecting a further 9-percent increase in production for
the current year. And so to the equipment.
New Belgium’s earlier systems consisted of
two filling lines with a capacity of 300 bottles per minute and 120 half-barrel kegs
(@ 15.5 U.S. gallons) per hour. The company then introduced a new organic beer
(Mothership Wit) and as a result of substantial growth rates was forced to make
further investments in the plant in order
to keep everything up and running.
for the construction of a new filling and
packing shop. Discussions were then held
with five possible suppliers with particular attention being paid to maintenance,
operational procedures, and engineering.
When making their assessment, New Belgium placed particular emphasis on the following items:
* Customer service
* Availability of parts and support
* State of the art
* Services
* Customer satisfaction and training
* Reputation in the brewing industry
… LEADS TO KHS …
THE SEARCH FOR THE RIGHT PARTNER …
First of all, the management put together
basic criteria and building specifications
The decision was made quickly and clearly.
KHS USA based in Waukesha, Wisconsin was
the first choice. “KHS scored well with
regard to engineering, technology, and
innovation, and has an outstanding reputation in the brewing industry,” summarizes Jim Spencer, New Belgium’s Engineering Director. With the latest technology,
KHS was able to come up with exactly what
the company required. “Innovation has
always been valued highly by the company
founders, Jeff and Kim,” explains Spencer,
“and KHS is absolutely in the lead as far
as technology is concerned.”
… AND TECHNOLOGY PREVIOUSLY
UNKNOWN IN THE U.S.A. …
KHS has provided New Belgium with technology that until now was unknown in the
U.S. (including a new bottling machine, a
wrap-around packer, and a robot palletizer),
which in the meantime is in operation at
task+solution ° New Belgium Brewery places trust in KHS
40*41
Left View of the bottling shop: Investment volume of 20 million US dollars. Top The filler: Precise filling
accuracy and minimized oxygen levels for optimum beer flavor and longer shelf life. Bottom Wrap-around
packer: With partition inserter – an innovation in the U.S.A.
the new production plant (total area over
5,000 square meters). The plant expansion with an investment volume of at least
20 million US dollars includes numerous
environmentally friendly design elements
and technologies, one example of which is
the KHS filler with reduced CO2 consumption.
… WITH FOCUS ON FILLING …
The electronic Innofill DRS-ZMS filler – an
innovation in the U.S. brewing industry –
made a particularly strong impression on
the New Belgium employees. Like most of
the European beer manufacturers, New Belgium retains the quality of its beers by
not pasteurizing them. Filling valves with
probes are used in the KHS filler to guarantee exact fill levels and minimize the
oxygen pick-up in the bottle during filling.
Low oxygen content protects the flavor of
the beer and increases the shelf life.
“The filler improves fill level accuracy and CO2 and water consumption,”
praises Spencer. “It provides high flexibility for product changes, and we are all
extremely impressed by the technology and
each of the structural elements.” New Belgium’s previous bottling line operated at
an output of 300 bottles per minute. The
new KHS filler has increased the capacity
of the bottling plant to more than 700 bottles per minute. The brewery now has a
capacity of 850,000 beer barrels per year.
… AND THE LATEST PACKAGING …
Perfection is also the name of the game
when it comes to packaging. The new KHS
Innopack Kisters WP wrap-around packer
is an innovation in the U.S.A. and exactly
matches New Belgium’s efficient and flexible packaging line. “The machine provides
an innovative solution for packing bottles,”
explains Spencer. “At the same time, the
KHS solution takes up less space, provides
higher efficiency, and is very attractive
overall”.
In the past, the brewery purchased premade cartons. The new system produces
cartons directly from cardboard blanks while
the bottles are being packed. At the same
time, the cartoner erects the partitions
then aligns and slides them between the
bottles. It then folds the carton, wraps it
around the bottles, and applies adhesive
to an inside flap.
… AND PERFECT LABELS …
The KHS Innoket KL cold glue labeling
machine now enables New Belgium to apply
back labels to the bottles as well. “A back
label is a special way of attracting the consumer’s attention to the product,” Spencer
asserts. Throughput has increased to over
800 bottles per minute while labels with a
length of up to 170 mm can be applied to
the front of the bottle.
… AND THE MOST FLEXIBLE ROBOT
TECHNOLOGY
The KHS palletizer robot also delighted New
Belgium with its capabilities of handling
widely differing designs of container and
pallet layouts. The robot arm, another first
for the States, aligns the containers in layers, and stacks them on top of each other.
The wrapped packs go straight from the
palletizer to the waiting truck. This system makes palletizing more precise and
reduces the work effort.
2
THE ABCS OF BARRELS
* One beer barrel equals 31 U.S. gallons
* One half beer barrel equals 15.5 U.S. gallons
* A US gallon equals 3.785411784 liters
what tipped the balance in KHS’ favor was
the support that we could expect from KHS,”
recalls Spencer, and praises, “we are highly
impressed with the commitment during our
ongoing collaboration and partnership.”
Furthermore, the KHS team obviously also
made an impression during commissioning. Spencer sees it this way: “During this
phase, KHS spared no effort to ensure that
the system worked as quickly as possible
in accordance with our requirements.” His
summary in brief: “KHS showed great commitment and great dedication.”
During the acceptance tests, the
new line ran with an average efficiency of
98 percent and therefore noticeably
exceeded New Belgium’s expectations.
There is hardly any doubt that the new line
will quickly reach the strived return on
investment. What a strong partnership.
Colby McLean, Western Regional Sales Manager,
KHS USA, Inc.
fi
INFOBOX
THE SUCCESS STORY CAN CONTINUE
• WEBSITE www.newbelgium.com
New Belgium chose KHS as a partner not
only because of the highly sophisticated
equipment and future-oriented technology, but also above all because the company values greatly the high motivation
and dedication of KHS’ staff. “Ultimately,
• CONTACT
Colby McLean, Western Regional Sales Manager
KHS USA, Inc.
Tel: +01/425 – 522 – 4215
The German Kulmbacher Brauerei AG is undoubtedly a company steeped in tradition
that understands the art of brewing. The Group has been pursuing an exemplary
strategy for a long time, focusing on values such as quality and resource conservation.
A new filling and packaging line from KHS with several innovative features fits the bill.
task+solution °
42*43
Kulmbacher Brewery: Focus on quality and environment
The Beer Experts
The first sight visitors to Kulmbach in Upper
Franconia, Germany, will see is the picturesque Plassenburg. Other prominent
features of the townscape include the hoods
of the malt drying kilns, brewery buildings,
hotels, and restaurants. It has been like
this for as long as anyone can remember,
because beer has always had a strong influence on the life of the people in this region.
Kulmbach Bierwoche is an annual event
that starts on the last weekend in July.
Two numbers indicate the significance of
the event: Population: 30,000, visitors:
120,000.
And finally, a 3,000-year-old beer
amphora was discovered some time ago in
the “secret beer capital” as the oldest evidence of the German art of brewing. There
is strength in unity. On this note, the
previously independent breweries Reichelbräu, Sandlerbräu, Mönchshof, and EKU
joined forces under the name of Kulmbacher
Brauerei AG back in 1996. The Group also
includes the traditional breweries Sternquell and Braustolz in Saxony, Würzburger
Hofbräu, Scherdel, Hof, and the non-alcoholic division of Bad Brambacher Mineralquellen.
UNIQUE PRODUCT RANGE …
Accordingly, the Group offers a wide range
of no less than 28 styles of beer, including famous brands such as
* Kulmbacher – national premium brand
with a leading role in northern Bavaria.
The group’s best selling product is Kulmbacher Edelherb, a full-bodied, palatable Pils.
* EKU – for traditional beer connoisseurs.
* Mönchshof – small, fine specialty,
undisputed top seller among clip-lock
bottles in Bavaria and nationally well
on its way to becoming number one.
* Kapuziner Weissbier – the number two
Left High-performance-line: fills up to 50,000 bottles per hour. Top Innopal PE: Depalletizes
empties crates layer by layer. Right Innovative bottle infeed for single-end Innoclean EE bottle
washer: The bottles enter the machine with minimum pressure and noise over smooth
pushover points. Openings in the conveyors ensure broken glass is discharged properly.
in northern Bavaria. Among the top
ten wheat beers in Germany.
The company uses an elaborate three-tank
beer production process. All beer ingredients come from – who could expect otherwise – the region.
Around 80% of all products are sold
in glass bottles (mainly refillable), around
20% in kegs and a small proportion in cans.
The range of bottle types and sizes used
includes traditional brown glass bottles
and clear glass bottles in 0.33 and 0.5-liter
sizes and all common bottle shapes including NRW, long neck and clip-lock.
… IS THE BASIS FOR SUCCESS
During the 2007 financial year, the Kulmbacher Group achieved a total output of
3.6 million hectoliters (2.4 million hectoliters of beer and 1.2 million hectoliters
of non-alcoholic beverages). Sales totaled
223.5 million euros.
Experts honor the fact that quality is a fundamental pillar of the corporate
strategy, covering all aspects of the Group’s
activities. At the recent 2008 DLG Beer
Test, for example, all seven beers submitted by Kulmbacher were awarded gold
medals. This was a strong endorsement for
the brewmasters and illustrated that continuous investments in quality benefit consumers. The company has long since been
active outside its core market. Kulmbacher
2
THUMBNAIL PORTRAIT: KULMBACHER BREWERY
* Founded: 1846
* Structure: Merger (1996) of Reichelbräu, Sandlerbräu, Mönchshof und
EKU. Further companies: Sternquell, Braustolz, Würzburger Hofbräu,
Brauerei Scherdel, Bad Brambacher Mineralquellen
* Beer brands: Kulmbacher, EKU, Mönchshof, Kapuziner Weissbier (a total of
28 styles of beer)
* Output 2007: 3.6 million hectoliters (of which two-thirds is beer)
* Sales 2007: 223 million euros
Conveyors: Easy clean design meets maximum demands.
beer has been popular in central and northern Germany and abroad for more than 150
years. In 1900, the company already
exported 733,000 hectoliters of beer.
Today, brand name beers are represented
particularly strongly in Italy and France;
EKU traditionally also in Asia. “EKU is
well known in Asia. Like all Kulmbacher
brand name beers, it conveys a feeling of
Bavarian life to consumers,” says Dr. Helga
Metzel, Director of Corporate Communications.
THE SPECIAL FEATURES OF THE
KHS LINE
The new high-performance filling and packaging line with a capacity of 50,000 bot-
tles per hour processes 0.33 and 0.5 liter
glass bottles and is used for a wide range
of Kulmbacher beer varieties. Kulmbacher
decided to use KHS as turnkey supplier,
because KHS equipment meets the demand
for flexibility while taking into account
environmental aspects and offering perfect filling and quality results. In addition,
the line design is top of the range when it
comes to hygiene. The special line characteristics in terms of energy and environment are described below.
* Heat consumers such as the bottle
washer and the process equipment are
fully insulated. This reduces the energy
consumption significantly.
* The bottle washer was designed for max-
*
*
imum energy efficiency. A unique innovative feature the Kulmbacher brewmasters came up with is to use natural gas
as heat source. This saves energy costs
and reduces CO2 emissions.
At the infeed of the single-end Innoclean EE bottle washer, the chains are
routed to ensure that the bottles enter
the machine with minimum pressure
and noise. Upstream of the main caustic bath, the bottles are presoaked and
sprayed under high-pressure. The labels
are thus largely removed before the
main caustic bath, resulting in reduced
contamination of the main caustic bath
and lower chemical consumption.
The energy-saving bottle carriers used
task+solution ° Kulmbacher Brewery: Focus on quality and environment
44*45
Left Innoclean EE with environment-friendly gas
heating for reduced energy costs and CO2 emissions.
Center Innopack PPZ: Crater and decrater with fully
automatic format changeover system. Right Innopal
RS 3: Palletizes filled crates and at the same time
manages palletizing of excess empty crates.
*
*
*
*
*
*
to convey the bottles through the
machine save 10 to 15% heat and 15
to 20% water.
The control system automatically
switches off empty conveyors thereby
reducing the power consumption
noticeably.
The PMS Plant Information System from
KHS is based on the latest Weihenstephan standard and makes consumption data, quality, process sequences,
and cost structures transparent. Intervention into the ongoing process is possible at all times. In the long term,
this protects resources and ensures that
the line, which, incidentally, is connected to the KHS Remote Diagnostic
Service (ReDiS), operates efficiently.
The filler area is located in a separate
room, which is under positive pressure and is continuously supplied with
filtered air.
Equipped with 144 filling stations, the
highly versatile Innofill DRS-ZMS filling system ensures top beer quality
with its extremely low-oxygen filling
process coupled with low CO2 consumption.
The easy-clean conveyors require little
maintenance.
The infeed and outfeed conveyor at the
single-lane filler is designed based on
*
*
*
strict hygiene standards (housing with
raised slide strips, incoming and returning chains are separated). Advantage:
This allows any product residue to drain
off at the side. The returning chain is
not exposed to overflowing product.
Other features include a microbiologically beneficial filler front table with
controlled and fast drain-off of all product residue, foam, and water.
Special KHS buffer systems are integrated between individual machines.
Optimum decoupling of the individual
units saves space and improves system
efficiency.
Two Innopack PPZ double-axis gantry
robots for packing and unpacking are
equipped with the fully automatic KHS
format changing system that requires
fewer resources during changeover.
The Innopal RS 3 palletizer features a
gripper head and is able to compensate differences in crate dimensions.
This results in perfect layer patterns,
gentle product handling and high overall stability of the pallet load.
Stefan Simon, Director of Production Engineering at Kulmbacher Brewery, sums it
up: “The line features sophisticated design
details that enable us to offer our consumers exactly the quality they ask for.
In addition, it meets the high environmental standards laid down by Kulmbacher
Brewery.” After all, beer is everything in
this region.
Günter Unkrig, Director,
Central European Business Area, KHS AG
Frank Fretwurst,
Sales Manager, Southern Germany, KHS AG
Frank Schneidermann,
Sales, Germany, KHS AG
fi
INFOBOX
• WEBSITE www.kulmbacher.de
• CONTACT
Günter Unkrig, Director, Central European
Business Area, KHS AG, Dortmund
Tel: +49/2 31/5 69 – 16 02
Frank Fretwurst, Sales Manager,
Southern Germany, KHS AG, Dortmund
Tel: +49/2 31/5 69 – 17 96
Frank Schneidermann, Sales, Germany,
KHS AG, Dortmund
Tel: +49/2 31/5 69 – 11 04
Hacklberg Brewery combines tradition with innovation
Firm Roots
Since 1618, the Hacklberg Brewery has supplied the Lower Bavarian countryside around Passau
with high-quality beer. While many brewing operations have recently suffered sales losses,
the cult brand of Hacklberg is doing fine. For this line of 42 products, KHS is now providing
highly flexible system technology.
This is real tradition: The Thirty Years’ War
– in 1618 to be exact – was the time when
beer was first brewed at the Hacklberg Brewery in the prince-bishopric of Passau. In
the 19th century, the company became property of the Elector, advancing to the status
of royal brewery. Soon thereafter, private
parties purchased the operation, but in 1897,
it reentered the ownership of the church.
Stephan Marold, Director of the brewery,
puts it this way, “Within the region, Hacklberg is sometimes compared to a well-rooted
2
oak. People say, Everything changes, except
one thing – Hacklberg.”
According to Marold, that continues to bring security and substantiality, as
well as a successful combination of the traditional and the modern. “The decisive point
for what we do is our need for high quality,” says Marold. And customers reward
that with consistent brand loyalty. The company has a distribution share of 90% in the
brewery’s core market, which is within a
radius of about 70 kilometers.
THUMBNAIL PORTRAIT: HACKLBERG
* Founded: 1618
* Turnover: 300,000 hl
* Product range: 42 styles of beer and soft drink
* Production: 180,000 hl of beer, 120,000 hl
of soft drinks
LEADER IN LOWER BAVARIA
With a production of 300,000 hectoliters
per year, the brewery is currently number
two in Lower Bavaria (in 2007, 180,000 hectoliters of beer and 120,000 hectoliters of
soft drinks). But while many Bavarian breweries have suffered sales losses in the past
few years, Hacklberg has stood its ground
with regard to beer sales. The company
offers three brands of soft drinks: Sonnenland, Frizz, and Dachsbergquelle. The Sonnenland line includes a total of 14 different products. The top-selling soft drink is
a cola mix, with a 40% share of sales followed by orange soda pop, apple spritzer,
and table water.
In all, the product line includes 42
different styles of beer and soft drinks. The
company fills this broad spectrum of products with a wide variety of bottle types in
eight returnable glass bottles, ranging from
the classical 0.5-liter NRW and 0.33-liter
task+solution °
46*47
Left/center Innoclean EE: Stainless is the key. Top The computer-controlled, pneumatic pressure filling system Innofill DRS-ZMS stands for a gentle, low-oxygen filling process. Bottom Stephan Marold, Director of the Hacklberg Brewery (right): “Our experience with KHS has been very good
in the past. Once again, we just couldn’t pass up KHS quality when it came to the hearts of the new line.” Also pictured: Frank Fretwurst, Marketing Manager, Southern Germany, KHS AG.
longneck bottles for beer, to the 0.7-liter
GDB and the 0.75- and 0.25-liter gourmet
bottle for soft drinks.
FLEXIBLE NEW SYSTEM TECHNOLOGY
FROM KHS
Recently, the brewery invested in new bottle washing, filling, and blending technology. Their trusted supplier was KHS.
Stephan Marold says, “Our experience with
KHS has been very good in the past. For
the main components of the new line, there
was just no getting past KHS quality again.”
The location of the new filling and
packaging line is Hutthurm, only a few kilometers away from Passau. There, in 1998,
after only six months of construction, the
Hacklberger Beverage and Logistics Center
(HGL) was built. To date, four filling and
packaging lines in three locations have been
delivering to this logistics center. With this
new line, which is replacing all existing lines,
both the logistic center and the filling and
packaging technology are now centrally
located in Hutthurm. However, the brewery will continue to remain loyal to the Passauer neighborhood of Hacklberg. Marold
says that this is mainly because that is where
the company’s roots lie.
With this variety of products and bottles,
the new system technology must be especially flexible. That starts with the KHS
Innopro PARAMIX CMX blending system,
expanded with additional dosing segments.
Supplying beer and thus blending beer mixed
beverages inline is just as easy as dosing
minimal amounts of flavoring or other additives. The dosing accuracy for syrup is about
0.05° Brix, and for CO2 it is approx. 0.2 g
of CO2 per liter. All product data is stored
in recipe memory ready for retrieval by the
operating crew at the push of a button.
The computer-controlled pneumatic
Innofill DRS-ZMS pressure filling system has 108 filling stations and processes
up to 40,000 0.5-liter bottles per hour. There
is both a crown corker for beer and a screw
capper for non-alcoholic beverages. A microbiological filler front table, optimized bottle guide parts, and hygienically designed
filling valves ensure sanitary conditions in
the filling area. The glass enclosure for
the filler / capper area provides maximum
transparency. The system is driven by the
latest in servo technology.
Director Marold is full of praise, “The
KHS filling concept is convincing right down
the line including the so very essential low-
oxygen filling process. At the same time,
we’re talking about the extremely hygienic
design, a high degree of user friendliness,
short changeover times, and maximum flexibility.” The fully insulated Innoclean EE
bottle washer made entirely of stainless
steel is equally compelling. Marold says,
“That increases the service life and together
with the energy-saving carriers, minimizes
power consumption.” And with Triple-i-Drive
technology, the widest variety of bottle
shapes and sizes can be processed with the
shortest of changeover times. Marold says,
“With the new KHS bottle washer, positive
aspects go hand in hand, mutually reinforcing each other. In comparison with the bottle washing equipment we have used in the
past, we’re referring to 30% lower water
consumption. And power savings are similar.” From the region, for the region –
and always following the motto that the
Hacklberg Brewery has always called its own:
Reliability earns customers.
Günter Unkrig, Director,
Central European Business Area, KHS AG
Southern Germany, KHS AG
fi
INFOBOX
• WEBSITE www.hacklberg.de
• CONTACT
Günter Unkrig, Director, Central
European Business Area, KHS AG,
Dortmund
Tel: +49/2 31/5 69 – 16 02
Southern Germany, KHS AG, Dortmund
Tel: +49/2 31/5 69 – 17 96
Innofill NRS: Worldwide new principle for bottling convenience drinks
Focus on Wellness
The new KHS Innofill NRS processes small plastic containers for non-carbonated
products, hot or cold, without the use of lifting elements. What advantages
does this have and what else does the technology have to offer?
Health and correspondingly oriented convenience drinks are the major trend of the
time. Consumers are increasingly questioning how carefully or hygienically the product has been processed. Manufacturers must
meet these requirements – but at the same
time, they want simple and economically
optimized filling systems. Problem solved,
the new Innofill NRS from KHS focuses very
specifically on filling small plastic containers with non-carbonated products using
a worldwide new principle, which involves
less wear and therefore provides higher availability. But more of that later. First a few
important parameters relating to the use of
the filling system.
between-meal snacks usually vary between
100 and 500 milliliters. Of course, somewhat smaller or slightly larger containers
can also be filled. The basic principle: The
system flexibly adapts to the customers’
requirements.
WIDE PRODUCT RANGE
A world innovation: With the Innofill NRS,
the filling level probe only lowers fully automatically into the container once it is positioned directly below the filling valve. This
has never before been the case in this form.
WIDE MOUTHS
The consumer wants convenience. The
Innofill NRS fills containers with mouth
diameters of at least 20 millimeters. The
basic principle: Due to larger mouths, the
system above all allows convenient and rapid
consumption of highly viscous products.
THE 10 TECHNOLOGICAL ADVANTAGES
1
The consumer demands variety. As a computer-controlled isobarometric pressure probe
filler, the Innofill NRS processes a comprehensive product range: classical and viscous
juice drinks, juice-vegetable or pure vegetable
drinks or mixed dairy products with cereals
and much more. The basic principle: The system fills everything that is flowable.
LIGHTWEIGHT CONTAINERS
Top Innofill NRS: Processes a comprehensive product range. Bottom After filling,
optimized capping: Different alternatives
for snacks in plastic containers with
aluminum cap or classical screw cap
The consumer demands convenient containers. For this reason, the Innofill NRS is particularly designed for the flexible filling of
lightweight plastic containers in a variety
of sizes and shapes. Such containers for
2
Filling without lifting elements
Non-contact filling
When the container has been positioned
in the neck ring holder and below the filling valve, the filling valve opens and the
probe moves fully automatically into the
container. Non-contact filling using the
free-flow principle provides microbiological safety – there is no longer a need to
press and seal the container mouth against
the filling valve.
technology+innovation °
48*49
Left Filler specialty: Small plastic containers with noncarbonated products. Right Filler range: Classical viscous juice, juice-vegetable or pure vegetable or mixed
milk drinks with cereals – and much, much more.
3
Filling with uniform fill levels
The filling valve closes as soon as the filling level touches the tip of the probe. The
probe moves fully automatically out of the
container. This ensures uniform fill levels.
4
Filling in one or two stages
The single-stage filling process is common
for smaller containers. Two-stage filling is
possible with the Innofill NRS depending
on the product and the container used. The
second stage is recommended for large-volume containers, particularly when foaming occurs: fast fill phase in the cylindrical
part and then low-foam slow fill phase in
the narrower container neck.
fi
INFOBOX
5
Non-drip filling
Single-stage or two-stage: both must be
drip-free. This is ensured by a gas lock in
the product outlet. This also allows a defined
proportion of solids to pass through, which
is decisive with products containing fruit
pulp or cereals.
6
Filling with return flow
The filling valves are connected to a partially filled ring bowl. If the line should
come to a stop, the heated product circulates through the ring bowl.
7
Filling with optimum hygiene
From ring bowl to filling valve – smooth
paths everywhere with aseptic membrane
and sealing technology within the filling
valves and for all product-conducting channels and paths.
• CONTACT
Ludwig Clüsserath, Manager, Process
Engineering Competence Center,
KHS AG, Bad Kreuznach
Tel: +49/6 71/8 52 – 25 01
Walter Senft, Manager,
Wine, Champagne, Juice and Spirit
System Sales, KHS AG, Bad Kreuznach
Tel: +49/6 71/8 52 – 23 80
8
Filling with simplest possible
cleaning
CIP sanitizing is simple and extremely
hygienic. Rinsing pans are positioned underneath the filling valves for CIP circulation.
Cleaning media enter the ring bowl. From
here, they pass through the intended CIP
channels before entering the rinsing bowl
through the free-flow filling valves. Finally,
the cleaning media are returned to the cleaning media tank through the circulation pump
and the catchment tank.
9
Hot or cold filling
The Innofill NRS is intended for hot filling.
However, non-carbonated products can also
be processed cold.
10
Filling with infeed plate
The system guides the containers over an
infeed plate that has no format parts, into
the rinser-filler-capper monoblock where it
passes them on accordingly after each station. Focus on simplicity.
Optimized capping follows filling.
Here, KHS offers various alternatives. Both
the aluminum cap and the classical screw
cap are possible for snacks in plastic containers.
The bottom line: With the Innofill NRS, KHS
provides a filling system that not only fulfils the demands of the market, but also
goes a long way toward satisfying future
requirements. The system gives the beverage and food industries the opportunity of
(further) pursuing the health and convenience trend consistently and objectively.
Ludwig Clüsserath, Manager, Process Engineering
Competence Center, KHS AG
Walter Senft, Manager, Wine, Champagne,
Juice and Spirit System Sales, KHS AG
Hot Stuff
*
Hot filling – like aseptic cold filling with isolator
technology – also provides microbiological safety
for non-alcoholic beverages in plastic bottles.
As a trendsetter, KHS provides innovative hot-fill
versions that leave simply nothing to be desired.
This is the future: The trade is more and
more frequently wanting to hot-fill microbiologically sensitive non-alcoholic beverages in plastic bottles. The reason is that,
in this way, clean room equipment and significantly increasing hygiene management
can be avoided, even if the costs associated
with hot filling are higher. At the same time,
the trade basically wants simple filling systems that are tailored highly flexibly to
the ever-wider variety of products. Problem solved: The KHS DRV-VF/NH is here – a
system that fills hot or cold, processes carbonated as well as non-carbonated beverages with different degrees of sensitivity,
and can be operated with or without pres-
sure. But for orientation, first a brief glance
at the family of Innofill DRV fillers from KHS,
all of which are the latest computer-controlled volumetric systems with the major
advantage of simple control concepts.
* Version 1: DRV-VF exclusively bottles
carbonated soft drinks and water. Only
two pneumatic functions control the
entire filling process – including the
lifting operation and sealing the bottle mouth against the filling valve.
* Version 2: DRV-VF/N allows the pressurized filling of carbonated soft drinks
and the pressureless filling of still water
and similar products. A further control function is included, which quite
*
simply manages the operating mode
changeover from pressurized filling to
pressureless filling for all filling valves
in a machine at the same time.
Version 3: DRV-VF/DN additionally provides the option of always pressurizing
more microbiologically sensitive carbonated refreshers, such as apple spritzer,
with freshly filtered gas using the triplechamber process. The system then also
works with a high proportion of inert
gas when filling thereby reducing the
oxygen pickup. The changeover from
classical pressurized filling using the
single-chamber principle to triple-chamber pressurized filling for carbonated
beverages and also the pressureless
mode of operation is achieved at the
push of a button.
Version 4: DRV-VF/NH, which along with
single-chamber pressurized filling and
pressureless cold filling, now also allows
hot filling.
The following contains a summary of possible future frequently asked questions about
the Innofill DRV-VF/NH.
HOW MUCH EFFORT IS INVOLVED IN
CHANGEOVER?
All filling valves can be changed over from
pressurized to hot filling at the push of a
50*51
Left Innofill DRV-VF/NH for PET: Bottles carbonated and non-carbonated beverages under pressure and pressureless cold and hot. Right Innofill NV-H for
PET: Bottles only non-carbonated, non-alcoholic beverages cold or hot.
button by means of pilot valves. A likewise
centrally controlled membrane cylinder triggers the beverage circulation within the
filling valves in standstill phases during
hot filling. In the case of a filler with 100
filling stations, this type of control saves
up to 297 solenoid valves, which reduces
the complexity with potential savings in
service and maintenance. The operator
selects the required operating mode at the
monitor. The changeover is menu controlled.
HOW IS THE SYSTEM BROUGHT UP TO
TEMPERATURE?
When filling hot, the first thing is to bring
the filler up to temperature. This is done
by circulating hot water through the filling valves and ring bowl directly after the
sterilization process. When the whole system has been heated to a specified temperature, the water is removed. The heated
product is now initially circulated from the
tubular ring bowl likewise through all filling valves. The filling process does not start
until the product return temperature
matches the required filling temperature.
The process is the same as with pressureless filling. The product is now no longer
circulated within the filling system. Heated
product is supplied to the filling valves
directly from the tubular ring bowl.
WHAT TEMPERATURES ARE POSSIBLE?
The filling temperature is always determined
by what the product demands with regard
to the necessary pasteurization units and
is the basis for the heat stability of the plastic bottles used. Filling temperatures of
up to 95 degrees Celsius are always possible. When defining the temperatures, KHS
is not only available to give advice but can
also carry out practical tests in advance in
the KHS Technical Center. This additionally shows whether the intended plastic bottles are suitable for the particular application.
IS MICROBIOLOGICAL SAFETY
ALSO ENSURED DURING FILLING
INTERRUPTIONS?
Shortage of bottles, backup at upstream
machines – there are many reasons for interruptions in filling. In such cases, the system again circulates the product through
the filling valves and tubular ring bowl. This
prevents cooling below the required pasteurization temperature. Hot product is
always ready at the valve seat. Tubular ring
bowl and valves are at the correct temperature to ensure microbiological safety. Hot
filling can therefore be resumed at any time.
This contributes to the high availability of
the filling system. Circulation of the product avoids phase separation in the case of
products containing pulp or fibers. The quality of the product entering the plastic bottle is therefore consistent at all times.
ARE THERE ANY SPREADERS?
As with all versions of the Innofill DRV, the
liquid film in the Innofill DRV-VF/ NH is
formed using a swirler. This is decisive for
hygiene. In this way, there are no spray elements protruding into the bottle. A further
plus point is that using a swirler ensures
high flexibility. Widely differing shapes and
sizes of bottle can be filled by means of a
swirler without any previous changeover
work – within the possible bottle capacities
specified by the system ranging between
0.1 and 3.0 liters.
HOW IS SANITIZING DONE?
With the Innofill DRV generation of fillers,
the CIP sanitizing process has also been
solved in an extremely advantageous way.
So-called CIP plates are either inserted manually or moved fully automatically over the
mouths of the filling valves. The same principle of pressing bottles against the filling
valves during pressurized filling is used for
the CIP sanitizing process. In this case,
however, the filling valves are sealed by the
pressure of the rinsing solution – fully automatically and exactly adapted to the internal pressure.
With the Innofill NV-H, the non-contact filling of plastic bottles by means of a free-flow filling valve represents the highest microbiological and hygienic safety. Free-flow filling for
the sensitive non-carbonated, alcohol-free beverages intended for hot filling is always carried out in two stages. Only the liquid seat is energized while the filling process is running
thereby reducing the cost of individual control elements for each filling station.
eration in the future, but who opt for Innofill
DRV filling technology, should invest in the
Innofill DRV-VF/NH version. The additional
costs are reasonable – with the highest possible flexibility in the future. The hot-fill
option can be easily retrofitted to existing
systems.
WHAT IF ONLY STILL NON-ALCOHOLIC
BEVERAGES ARE TO BE FILLED HOT?
WHAT ADVANTAGES DOES THE TUBULAR RING BOWL OFFER?
The tubular ring bowl of the DRV generation
of fillers is considerably lighter in weight
than the classical angular ring bowl solution. There are no corners or edges – this
ensures maximum hygiene. And the lightweight construction requires less drive force.
Furthermore, significantly less energy is
required for heating and cooling.
WHAT OUTPUTS ARE POSSIBLE?
When hot filling, the Innofill DRV-VF/NH
processes up to 60,000 bottles per hour.
When filling fruit beverages, the fruit/pulp
content in the beverage can be up to 8 percent. The system even processes fibers up
to 5 millimeters long and up to 1.5 millimeters in diameter.
HOW HIGH ARE INVESTMENT COSTS?
Even if those who are not certain today
whether hot-filling is likely to be a consid-
In this case, consideration is given to the
Innofill NV-H, the hot-fill option of the
Innofill NV developed by KHS. Special features: Fruit drinks can have longer fibers
with lengths up to 10 millimeters and diameters of 2 millimeters. The Innofill NV-H
can also process small pieces of fruit. It is
able to fill up to 60,000 0.1 to 3.0-liter plastic bottles per hour – and in special cases
up to 5.0 liters. Non-contact filling using
a free-flow filling valve makes the highest
microbiological and hygienic safety possible. Free-flow hot filling of sensitive noncarbonated alcohol-free beverages is always
carried out in two stages. Only the liquid
seat is energized while the process is running. This cuts the cost of having individual control elements on two solenoid valves
for each filling station. During interruptions in the filling process, the central return
valve opens and the product recirculates.
The passages are such that the heated external stainless steel areas keep the product
at the correct temperature even within the
gas lock. And different mouths can also
be processed.
RESULT
With these newly developed hot-fill options,
KHS is once again acting as a pioneer in the
market. In particular, the combination filling systems very clearly show that simple
functionality and a high degree of future
proofing with maximum flexibility of a filling system do not have to be mutually exclusive. On the contrary, they complement one
another.
Ludwig Clüsserath, Manager, Process Engineering
Competence Center, KHS AG
fi
INFOBOX
• CONTACT
Ludwig Clüsserath,
Manager, Process Engineering Competence Center, KHS AG, Bad Kreuznach
Telefon: +49/6 71/8 52 – 25 01
E-Mail: [email protected]
52*53
KHS sets an innovative milestone with
a comprehensive product line harmonization for
modular packaging technology solutions.
This realignment now also benefits packaging
equipment in the entry and medium capacity range.
As Flexible as the
The market is demanding individual solutions, particularly when it
comes to the increasingly important packaging technology. This
is exactly what KHS has been offering for some time in the form of
high-performance, modular packaging equipment. Customers from
the beverage, food, or non-food sectors can configure function
modules for shrink packers, tray shrink packers, pad shrink packers, and wrap-around packers to form optimize systems for the
respective task. After the product line harmonization, KHS now
also offers modular solutions for packaging systems with smaller
and medium capacity, so that medium-sized companies, too, can
benefit from maximum flexibility.
Alphabet
Product line harmonization at KHS:
Packaging technology for the future
Adjustment points with spindle adjustment: A central controller supplies the
new target position for format changeover. The Accu-Drive unit receives the
target position via an infrared interface.
Product line harmonization will make future changeovers even simpler, faster, and above all more versatile. The technical solution
can simply grow with user requirements, and not just in terms of
packaging type or performance increase. Integrating equipment
such as the leaflet inserters, film perforators, partition inserters,
or tray stackers is just as feasible as converting existing equipment
to new areas of application.
servo motor models. A master controller in the control cabinet controls these MI servo motors. A single connecting line between the
control cabinet and the first servo motor in respective packer segment is sufficient for perfect communication. Up to twenty ultracompact servo drives can be connected in series via a hybrid cable.
Numerous previous cable connections are no longer required, the
control cabinet can be much smaller, and the lack of control units
means that cooling equipment may no longer be required. The
servo motors and the individual functional units are connected via
plug connectors. This simplifies replacement of servo motors and
commissioning of the packaging machine.
ADVANTAGE NO. 2: UNITS BECOME TRANSPARENT
ADVANTAGE NO. 4: NEW DESIGN – SIMPLE AND HYGIENIC
The function modules are self-contained units that can easily be
removed from or integrated into the overall system. Interfaces can
be clarified quickly. Individual functional units become transparent for the user, making the respective packaging solution more
comprehensible. The principle: The technology is more manageable and maintenance is simplified.
The revision of the packaging machine design led to a cubic machine
frame. Together a new protective hood design, this offers machine
operators even better insight into the ongoing packaging process.
Access for the purpose of operation and maintenance has also been
optimized further. Easy to clean assembly support systems were
integrated for hygiene reasons. Together with the newly designed
catch pans for cleaning agent, rinse water, and possible product
leaks located below the function modules, this ensures maximum
hygiene. Any protruding parts such as bolts or bars for fastening
adjustable guides are now hinged or no longer required. Wherever possible, the new product line uses low-noise cog belts with
simple design and maintenance-free operation.
ADVANTAGE NO. 1: SOLUTION GROWS WITH REQUIREMENTS
ADVANTAGE NO. 3: IDENTICAL SERVO MOTORS
Identical servo motors are used for all functional units. This simplifies spare-parts stocking, among other benefits. The innovative servo motors feature integrated servo controllers offering
further improvement in communication compared with previous
KHS packaging technology for the future
ADVANTAGE NO. 5: FULLY CUSTOMIZABLE
The modular system enables simple mechanical, semi-automatic,
or fully automatic adjustments. This is particularly important for
food processing companies wishing to use the same packaging
machine for a variety of formats, for example. Clamping levers are
used for manual changeovers. Alternatively, operator-controlled
adjustment units based on electronic displays with acknowledgement function can be used for format changeovers. Manually maintained hardcopy lists are therefore no longer required, and the error
rate drops to a minimum. A modified cordless screwdriver makes
handling of operator-controlled adjustment units even more convenient. The cordless screwdriver communicates directly with the
central controller via a field bus system. This ensures maximum
precision, even for fully automatic changeovers. For fully automatic format changeovers, the adjustment units are equipped
with drives that have to be activated sequentially via graphical
menu-driven operating at the monitor.
ADVANTAGE NO. 6: EVEN MORE VERSATILE PRODUCT
GROUPING OPTIONS
The product grouping function module offers even greater flexibility. In the past a sectioning unit with two servo drives was used
2
that was designed for the largest product formation expected to
be processed with the system. This meant that smaller units had
to be conveyed with substantially higher speed, resulting in suboptimal utilization of the packaging machine. With the new sectioning unit up to four servo motors with speeds that are precisely
adapted to the respective type of packaging can be used. Each
servo motor has its own sectioning tool allocated. Outputs of up
to 120 cycles per minute are now also possible for PET bottles.
The data for optimum sectioning are stored in the system for each
individual product formation.
THE ADVANTAGES OF PRODUCT LINE HARMONIZATION
COMPONENT
SPECIAL FEATURES
ADVANTAGE
Drive
Identical servo motors in all functional units
Wiring
Machine frame
Wiring of up to 20 servo motors via a hybrid cable; cable
connections in the control cabinet with contact strips
Cubic design, new assembly support system
Drive transmission
Machine cladding
Cog belt
New safeguards
Guide rails
Suspension from above
Product formation grouping
Up to four servo motors, individually
scalable for any task
Easy to service, better spare parts management,
faster troubleshooting
Less space required in the control cabinet, simple wiring,
plug connections, error avoidance
Greater clarify, better access, optimized hygiene,
suitable for retrofitting
Less noise and maintenance
Optimum process monitoring, convenient handling,
vertical-lift doors as standard, optional sliding doors
Simplified format changeover, laterally protruding bars
are eliminated
Optimum speed for each product configuration,
higher speeds
Film cutting station
• Feed system
• Packaging material
Variable width, larger width, cog belt
drive
Thinner films can be processed
• Cutting tool
• Design
• Feed belts
Film wrapping
Shrink tunnel
Drive with servo motor, cog belt drive
Gap dimensions reduced, fewer guides
Antistatic, improved hole pattern
Height-adjustable, electronically controlled curve
Eco shrink tunnel, optional gas heating
Flexible adaptation to the position of different film
widths, greater format range, noise reduction
Increased range of films for processing, cost reduction for
packaging material, longer service life
Maximum cutting precision, low wear
Efficient operation
Increased film feed reliability
Perfect positioning accuracy, high degree of flexibility
Low energy consumption, very exact temperature control,
shorter heating phase
54*55
Left Cubic machine frame, integrated control elements, vertical-lift or sliding doors, optimum process
monitoring, hygienic design. Center Automatic guide rail adjustment via direct drive. Right Electronic
displays with acknowledge function guide the operator through the format changeover.
ADVANTAGE NO. 7: VERY THIN FILM IS POSSIBLE
A new film cutting and conveyor system enables processing of thinner films. Added to this: The new film cutting station is bigger,
offering greater flexibility in terms of film width. A servo-driven
cutter cuts the film with maximum precision and minimum cutter
wear. Within the film cutting station, the gap dimensions at transitions and the number of guides have been reduced significantly.
The film conveyor system has special coatings and new, conductive conveying belts. This reduces the risk of the film sticking,
winding, or tearing. In conjunction with an additional antistatic
system, it offers maximum conveying stability, even for very sensitive film types. The feed rollers are hinged for improved access
during maintenance and to facilitate film threading.
in the required packaging machine. Not to forget: All function modules not only contain the latest technical achievements, but are
also based on extensive KHS experience with packaging applications. This is exactly what the market needs.
Norbert Pastoors, Manager,
Packaging Technology Competence Center, KHS AG
Werner Oster, Product Support Manager,
Werner Ageling, Product Management Manager,
ADVANTAGE NO. 8: SHRINK TUNNEL OPTIONALLY
WITH GAS HEATING
The shrink tunnel can either be operated with conventional electric heating, or the new KHS eco-shrink tunnel with gas heating
can be used. This reduces the running costs by up to 50% and CO2
emissions by up to 60%. Both shrink tunnel versions feature the
familiar hot air nozzle arrangement in the shrink tunnel cover. It
goes without saying that the innovative format changeover solution can also be used in the new shrink tunnel. The shrink tunnel
section can be complemented with modular components such as a
cleaning facility, cooling fans, or advanced camera technology for
monitoring the shrink process.
THE RESULT: HARMONIZATION BEARS FRUIT
Overall, the expanded KHS range of modular packaging equipment in conjunction with the new product line offers numerous
benefits over the whole capacity range for the beverage, food,
and non-food industries. The crucial factor is the future proofness of the technology. The new system is highly versatile. Function modules can be removed or added; packing output can be
increased or decreased. Modular components can quickly be installed
fi
INFOBOX
• CONTACT
Norbert Pastoors, Manager, Packaging Technology
Competence Center, KHS AG, Kleve
Tel: +49/28 21/5 03 – 2 21
Werner Oster, Product Support Manager, Packaging
Technology Competence Center, KHS AG, Kleve
Tel: +49/28 21/5 03 – 1 52
Werner Ageling, Product Management Manager,
Packaging Technology Competence Center, KHS AG, Kleve
Tel: +49/28 21/5 03 – 2 37
Technical terms in practice:
Don’t be afraid of statistics (Part 1)
MAGIC
NUMBERS
The word “statistics” alone makes some people turn away or tremble with awe. After
all, it has to do with mathematics and mysterious symbols. But then again, statistics
are all around us on a daily basis: We have all heard of the Dow Jones Index and have
seen population statistics. We are therefore much more familiar with numbers than we
think. Let’s try to discover this secret language step by step.
The bon mot “There are three types of lies:
lies, damned lies and statistics” is attributed to the politician Benjamin Disraeli
(1804-1881). No one is quite sure about
the origin, but it indicates the significance
of improper use of statistics. If someone
has something to hide, they use a statistical trick and hope that no one will notice
the hidden numbers. You think you won’t
fall for this? No, you are set straight every
day. No one is safe from misinterpretations.
There are people who deliberately
select lottery numbers that haven’t been
drawn for a while, in the hope that “Surely
they’ll have to appear at last.” Unfortu-
nately, lottery balls have no memory and
no conscience. It is irrelevant how often or
infrequently they have appeared in the past.
They appear based on the laws of statistics,
and with the same probability for each lottery player. For your information: The probability is around 1:14 million. Accordingly,
you would have to play over 14 million times
to get six matching numbers. Let’s approach
the basics of statistics in consecutive stages.
STAGE 1: THE MEAN VALUE
The mean value is probably the best-known
statistical parameter. It is also known as
the average and plays a significantly greater
role than is generally assumed. The calcu-
lation is simple, and for small numbers it
doesn’t require a computer. Simply add up
the numbers and divide the result by the
number of individual values.
Example 1: Several people buying
drinks want to find out how many bottles
they buy on average.
Person 1 = 3 bottles
Values added: 3+6+20 = 29 bottles.
The total divided by the number of persons:
29/3 = 9.7 bottles
The formula means: Add up all values x,
starting from the first (i=1) until the last
value (n) is reached, and divide the result
by the number (n) of values.
The layman is surprised by the result, and
the expert can pretentiously explain that
the spread in the population is already relatively large. This gobbledygook means that,
if the individual values are very different,
averaging is not very meaningful. It is similar to saying, "If I eat two geese and you
eat none, on average, we’ll have eaten one
goose each.”
Nevertheless, the average often has
an almost magical effect and people often
forget that it is merely a guide for the order
of magnitude, rather than a prognosis for
an individual scenario. Therefore, the mean
value is only meaningful for a large number values or for situations where the individual numbers are more similar.
How can I nevertheless solve the
dilemma if I want to know the approximate
mean number of bottles in example 1? This
is what the median is for.
STAGE 2: THE MEDIAN
More magic? The median is also referred
to as the middle number or central value
in any given set of numbers or values. The
median for the first example is 6. The situation would be as simple as that if we always
had to deal with an odd set of numbers.
Unfortunately, we also have even sets of
numbers, and in addition they are usually
unordered. The sets therefore have to be
sorted in ascending order to find the middle value.
But that’s not all. There are several statistical options for calculating a mean value,
depending on the problem. It also requires
a certain understanding of the situation,
because there is no infallible means and
no infallible mean value. For the sake of
completeness, it is worth at least mentioning these other options without further elaborating on them: They are the harmonic
mean, the geometric mean and the weighted
mean.
STAGE 3: STANDARD DEVIATION AND
VARIANCE
it is helpful to reflect on the problem in
order to glean meaningful information about
the population of values. At the same time,
it is clear that the spread of values is important, but at this stage, we don’t know how
to get a more precise feel for it. Once again,
statistics can help solve this dilemma. It
offers the standard deviation as a measure
of dispersion. Sometimes the term variance
is used, which is directly related to the standard deviation, i.e. the variance is the square
root of the standard deviation, or in mathematical terms:
Let’s move on to another big issue that
causes many doubts about statistics: the
standard deviation and the variance. Both
are closely related, as we’ll see shortly.
Example 2: A so-called original list
contains the incomes of 25 families in a city,
let’s call it Rich City.
Income
1,200,000
150,000
86,000
37,000
35,000
32,000
29,000
26,000
24,000
60,000
51,000
49,000
20,000
18,000
18,000
18,000
16,000
16,000
45,000
42,000
38,000
14,000
13,000
11,000
10,000
The arithmetic mean value gives us a result
of 82,320 euros but it totally distorts the
picture, because the single millionaire family earning more than all others together
dominates the figures. The range isn’t helpful either in this case: It is the difference
between the lowest and the highest value,
i.e. 1,190,000 euros. But this doesn’t really
help either. Looking at the numbers in the
original list, it is clear that mean earnings
must be in the region of around 30,000
euros. This is where the median comes in,
i.e. the middle value from an ordered list,
in this case 29,000 euros. As you can see,
56*57
where
var = variance
xi = measured value at point i
_
x = mean value (read as: x bar)
n = number of measured values
s = standard deviation
Technical terms in practice
What exactly is the standard deviation? It
is a measure for the spread of the individual values. Let’s look at a target as another
example. If a number of shots are fired, the
holes will be scattered around the center.
If they are at the center or close to it, they
came from a marksman. If the shooter was
less skilled, the holes will be further apart.
A simple example can illustrate the calculation if the standard deviation.
The results after two shooters have
shot at a target are as follows:
Shooter 1
7
8
9
Mean value 8
Shooter 2
1
10
13
8
Anyone can see that one shooter shoots
more precisely than the other. While the
mean value is the same in both cases, the
spread of the results can provide additional
information. Let’s calculate the distance,
i.e. the difference of the results from the
respective mean value, and put the values
in a table:
Shooter 1
Result
7-8
8-8
9-8
Shooter 2
Deviation from
mean value
Result
-1
0
1
1-8
10-8
13-8
Deviation from
mean value
-7
2
5
It wouldn’t make sense to simply add up the
negative and positive deviations, but a mathematical trick called squaring makes them
all positive.
Shooter 1
Shooter 1
Deviation from Square of Deviation from Square of
mean value the deviation mean value the deviation
-1
0
1
Total
1
0
1
2
-7
2
5
Total
49
4
25
78
The difference in the sum of squares between
78 and 2 is very significant. The greater the
distance from the mean value and more individual results are added, the greater the
sums. We therefore have to take into account
the number of individual results by dividing the calculated sum by the number of
individual values. This is known as the variance, and the square root of it is the famous
standard deviation.
Variance
Standard
deviation
Shooter 1
2 / 3 = 0.67
fi
INFOBOX
• CONTACT
Priv.-Doz. Dr.-Ing. Hartmut Evers,
Laboratory and Technology Center
Manager, KHS AG, Bad Kreuznach
Tel: +49/6 71/8 52 – 2252
Shooter 2
78 / 3 = 26
It is immediately obvious that the shots from
the first shooter have a lower scattering
range than those from the second shooter,
and that he is therefore the better marksman.
The variance is a common theme in statistics, right up to the distant heights of variance analysis. The mathematical/statistical significance of the variance is tremendous: It eliminates negative values and at
the same time highlights larger deviations.
If one arranges the shots along a line, the
spread becomes clearly evident.
statistical function can be used to prove
this. The coefficient of variation (CV) indicates the relationship between the standard
deviation and the mean value.
The mathematical expression for the
variation coefficient is
We calculate as follows:
Shooter 1
Shooter 2
Shooter 1 = yellow fields
Shooter 2 = blue fields
Mean value = red
1 2 3 4 5 6 7 8 9 10 11 12 13
-1 +1
-7
0 +2
+5
A rule of thumb says that a CV of more than
30% indicates strong inhomogeneity of the
individual values. In our case, this means:
Shooter 2 is not concentrated enough, and
the shots scatter too far. While we had
already suspected this, we now have statistical proof.
Priv.-Doz. Dr.-Ing. Hartmut Evers, Laboratory and
Technology Center Manager, KHS AG, Bad Kreuznach
In one case the spread is less than 1, in
the other it is more than 5. While two of
the shots from the second marksman were
closer to the center, the scatter between
the individual shots was high. An additional
stopover ° Don’t miss the opportunity
58*59
DON’T MISS THE OPPORTUNITY
STOPOVER
KHS customers are active on all continents.
Their work takes them to many countries around the
world to call on customers, to attend meetings and
trade fairs. Such trips sometimes offer a welcome
opportunity for interesting excursions. Here are
a few tips for different stopovers.
LAS VEGAS, U.S.A.
CHER’S COMEBACK AT CAESARS
MUMBAI, INDIA
Almost three years after her farewell tour, the American pop icon Cher returned
to the place where her career started in the mid-sixties: The singer will be
appearing four times a week at Ceasars Palace in Las Vegas until her probably
last show in 2011. Cher has sold more than 100 million sound carriers and is
the only artist worldwide to have had Number One hits or Top Ten hits in each
of four decades. Tickets: www.ticketmaster.com or www.bestofvegas.com
ELEPHANT PARADE
In February 2009, the Elephanta Festival will take place
on Elephanta Island in the Indian state of Maharashtra, only ten kilometers from the port of Mumbai. Traditional music, dance, regional delicacies, and a varied cultural program presented by renowned national
artists or local fishermen make the festival an unforgettable experience. The illuminated Maheshmurti cave,
the largest of the 1000 year-old caves on the island,
which are home to the god Shiva, is a unique spectacle. Take the ferry from the Gateway of India at the port
of Mumbai. Information and dates: www.maharashtratourism.gov.in
SYDNEY, AUSTRALIA
HIGHLIGHT DOWN UNDER
The Sydney Festival, which first began in 1977 as an annual event
held at the beginning of the year, offers superlative cultural entertainment, and is the highlight of the Australian cultural calendar. In around
80 individual events over a three-week period (ranging from pop concerts to classical evenings in the world-famous opera house) more than
500 artists will perform to an audience of several million people. Further information about the 2009 Festival (10 to 31 January) will be
available over the coming weeks at www.sydneyfestival.org.au.
ZURICH, SWITZERLAND
MUNICH, GERMANY
WHISKY & CIGAR FESTIVAL
BURNT PUNCH XXL
The legendary Whiskyship & Cigar Festival will start on Swiss
Lake Zurich for the tenth time at the end of November (27
to 30). With round 850 different malt whiskies and 300
select cigars from the finest portfolios available it is the
biggest event of its kind. Nine ships, fifty exhibitors, and
dozens of organizers will be participating in the event. Info:
www.whiskyship.ch
From mid-December 2008 to early January 2009, the world’s biggest
burnt punch will be simmering at Munich’s historic Isartor. The preparation alone is a spectacle in itself: After dark, giant sugar loaves are
flambéed over a specially made, two and a half meter high, 9000liter capacity copper kettle. The legendary classic film “Die Feuerzangenbowle” starring Heinz Rühmann complements the scenario.
Insights: www.die-kessel-gbr.de
30 1992-01-988/2 0908 GW
Adresses
KHS AG
Juchostraße 20
D-44143 Dortmund, Germany
Tel +49/2 31/5 69-0
Fax +49/2 31/5 69-15 41
E-Mail: [email protected]
Planiger Straße 139-147
D-55543 Bad Kreuznach, Germany
Tel +49/6 71/8 52-0
Fax +49/6 71/8 52-2411
Enzingerstraße 139
D-67551 Worms, Germany
Tel +49/62 47/97-0
Fax +49/62 47/97-32 15
Ruwoldtweg 14
D-22309 Hamburg, Germany
Tel +49/40/6 37 03-3 71 00
Fax +49/40/6 37 03-3 71 50
Boschstraße 1-3
D-47533 Kleve, Germany
Tel +49/28 21/5 03-0
Fax +49/28 21/2 61 10
Am Kirchfeld 3
D-34454 Bad Arolsen, Germany
Tel +49/56 91/89 09-0
Fax +49/56 91/89 09-15
Kapellenstraße 47-49
D-65830 Kriftel, Germany
Tel +49/61 92/4 91-0
Fax +49/61 92/4 91-144
Industriegebiet Scheid 16
D-56651 Niederzissen, Germany
Tel +49/26 36/9746-0
Fax +49/26 36/9746-45
KHS CORPOPLAST GMBH & CO. KG
Meiendorfer Straße 203
D-22145 Hamburg
Tel +49/40/67 907-0
Fax +49/40/67 907-100
Masthead
KHS UK LTD.
Unit 6 Monkspath Business Park,
Highlands Road
Shirley Solihull, Great Britain
West Midlands B 90 4NY
Tel
+44/121/713-6900
Fax
+44/121/713-6935
KHS USA, INC.
880 Bahcall Court
Waukesha, WI 53186, U.S.A.
Tel
+1/262/797-7200
Fax
+1/262/797-0025
5501 N. Washington Blvd.
Sarasota, FL 34243, U.S.A.
Tel
+1/941/359-4000
Fax
+1/941/359-4043
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
KHS ASIA PTE. LTD.
25 International Business Park
# 3-15/19 German Centre
Singapore 609916
Tel
+65 6560-9313
Fax
+65 6560-9910
KHS MACHINERY PVT. LTD.
15, Madhuban, Nr. Madalpur Underbridge
Ellisbridge, Ahmedabad - 380 006, India
Tel
+91/79/2644-0331
Fax
+91/79/2644-5146
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
GRAPHICS
Konzeption+Design, Trawny / Quass von Deyen, Cologne
Layout: Yvonne Voss
CONTRIBUTIONS
Werner Ageling, Wolfgang Augel, Jan-Wilhelm Brückel,
Ludwig Clüsserath, Matthias Damm, Priv.-Doz. Dr.-Ing.
Hartmut Evers, Frank Fretwurst, Rainer Hilgert, H. W. Kim,
Erhard Magin, Thomas Matheyka, Colby McLean, Werner
Oster, Norbert Pastoors, Hubert Schiffer, Oliver Schneider,
Frank Schneidermann, Walter Senft, Hideo Suzuki,
Günter Unkrig
TRANSLATION
Fachübersetzungen CP MacKusick
PHOTOS / ILLUSTRATIONS
Friederike Arndt, Allgäuer Alpenmilch GmbH, Timo
Beylemans, Asahi Brewery, Bundesvereinigung Logistik
(BVL), GOLDBECK West GmbH, Burkhard Hellwig, Elde
Konserven, Unilever, shutterstock (Kasia, Artifan)
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.

08.495 KHS Journal 02_08 engl_US.qxd

Transcription

Similar documents

1_innopas pi/iisc modular tunnel pasteurizer

September 2011 - Kalida Local Schools

Kempner High School - Academy Publishing, Inc.

flexible solutions for pouch packaging

solutions for the wine, champagne, and spirits industry

October 11, 2015 - St. Michael Catholic Church

Water Xylophone - Abu Dhabi Science Festival

Sport 2014 - Kamo High School

FREE SAVE on BEER CAN KOOZIE

27 - The Center for North American Herpetology