solutions KHS

Transcription

solutions KHS

Competence | 01.2010
30 1992-01-992/2 0510 SK
Competence
in Solutions
Focus on Solutions
Technology in Practice
Interview
Rhodius Mineralquellen:
keg line for slim kegs
The Big Five – what customers want:
InnoPET BloFill with plenty of new advantages
The wheels of change:
Hanni Rützler on food trends
FOCUS ON
QUALITY
KHS worldwide. For further addresses and contacts, visit
www.khs.com
Innocheck CCI crooked cap inspection for PET bottles:
safe, incorruptible, and precise right down the line,
this is high-tech with a sure eye for precision.
56 57
Trade Shows
_Novi Sad Agricultural Fair, Novi Sad, Serbia
May 15–22, 2010
_China Brew & Beverage, Beijing, China
September 7–10, 2010
_Beer, Sochi, Russia
_Fachpack, Nuremberg, Germany
May 19 – 22, 2010
_Interfood, Astana, Kazakhstan
_Japan Pack, Tokyo, Japan
May 27–29, 2010
_Iran Food & Bev. Tec, Teheran, Iran
May 30 – June 2, 2010
_Korea Pack, Goyang, Seoul, South Korea
June 1– 4 , 2010
October 5 – 8 , 2010
_K-show, Düsseldorf, Germany
October 2 7 – N ovember 3, 2010
_Asia Food & Bev Tech, Mumbai, India
October 29 – 31, 2010
_FISPAL, São Paulo, Brazil
_Pack Expo, Chicago, United States
June 8 – 11, 2010
October 31– N ovember 4, 2010
_Auspack, Sydney, Australia
_BRAU Beviale, Nuremberg, Germany
June 16 – 19, 2010
November 10 – 12, 2010
_Pro Pak Asia, Bangkok, Thailand
_drink technology India, Mumbai, India
June 16 – 19, 2010
November 18 – 20, 2010
_Expo Pack, Mexico City, Mexico
_EMBALLAGE, Paris, France
June 22–25, 2010
November 22–26, 2010
_ProPack China, Shanghai, China
_Propak Indonesia, Jakarta, Indonesia
July 14 – 16, 2010
December 8 – 11, 2010
Addresses
KEEPING YOUR LINE RUNNING IS WHAT WE STAND FOR.
Long lasting, safe, and efficient: Original spare parts from KHS.
KHS GmbH
Juchostrasse 20
44143 Dortmund, Germany
Phone: +49 (231) 569 - 0
Fax:
+49 (231) 569 -1541
Planiger Strasse 139 -147
55543 Bad Kreuznach, Germany
Phone: +49 (671) 852- 0
Fax:
+49 (671) 852- 2411
Enzingerstrasse 139
67551 Worms, Germany
Phone: +49 (6247) 97- 0
Fax:
+49 (6247) 97-3215
Ruwoldtweg 14
22309 Hamburg, Germany
Phone: +49 (40) 63703 -37100
Fax:
+49 (40) 63703 -37150
Boschstrasse 1-3
47533 Kleve, Germany
Phone: +49 (28 21) 503 - 0
Fax:
+49 (28 21) 26110
Kapellenstrasse 47-49
65830 Kriftel, Germany
Phone: +49 (6192) 491- 0
Fax:
+49 (6192) 491-144
KHS UK Ltd.
Unit 6 Monkspath Business Park,
Highlands Road, Shirley, Solihull
West Midlands B90 4NY, Great Britain
Phone: +44 (121) 713 - 6900
Fax: +44 (121) 713 - 6935
Email: [email protected]
KHS Asia Pte. Ltd.
25 International Business Park
# 3-15/19 German Centre
Singapore 609916
Phone: +65 (6560) 9313
Fax: +65 (6560) 9910
KHS Corpoplast Gmbh & Co. KG
Meiendorfer Strasse 203
Phone: +49 (40) 67907- 0
Fax: +49 (40) 67907-100
For further information, visit www.khs.com/service
KHS Competence
KHS Plasmax GMBH
Phone: +49 (40) 67907- 364
Fax: +49 (40) 67907- 353
KHS USA, Inc.
880 Bahcall Court
Waukesha, WI 53186, U.S.A.
Phone: +1 (262) 797-7200
Fax: +1 (262) 797- 0025
5501 N. Washington Blvd.
Sarasota, FL 34243, U.S.A.
Phone: +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
Phone: +61 (393) 35 -1211
Fax: +61 (393) 35 -1331
KHS Machinery Pvt. Ltd.
15, Madhuban, Nr. Madalpur Underbridge, Ellisbridge,
Ahmedabad - 380 006, India
Phone: +91 (79) 2644 - 0331
Fax: +91 (79) 2644 - 5146
Information for ordering
KHS Competence is published in German,
English, French, Spanish, and Russian. Those interested can order further copies of the magazine
at www.khs.com.
PUBLISHER
KHS GmbH, Dortmund
EDITORS
jj-media Cologne; Dr. Arno Lammerts;
Manfred Rückstein; Friederike Arndt;
mcpr – meiner corporate pr, Grafschaft;
pr+co., Stuttgart
GRAPHICS
Konzeption+Design, Trawny / Quass von Deyen, Cologne
Layout: Nicole Bock, Yvonne Voss
CONTRIBUTIONS
Alfons Abels-Rümping, Wolfgang Augel, Ludwig Clüsserath,
Harald Eisenacher, Ulrich Fischer, Partho Ghose,
Hennie van der Graaf, Frank Haesendonckx,
Clemens Hannen, Jürgen Herrmann, Heinz Hillmann,
Herman Miseur, Edgar-George Petsche, Dr. Felix Wagner
TRANSLATIONS
Fachübersetzungen CP MacKusick GmbH & Co. KG
PHOTOS / ILLUSTRATIONS
Friederike Arndt, beltsazar/shutterstock, Jürgen Eberl,
Caro/Muhs, Keith Naylor/shutterstock, Peter J. Obenaus,
Privat-Brauerei Heinrich Reissdorf,
Jörg Schwalfenberg Photography, Bek Shakirov/Corbis,
Teusser Mineralbrunnen/Löwenstein
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.
03
>>Closer to the Markets:
New Setup at KHS <<
Roland Flach,
Chief Executive Officer of KHS
Dear Readers,
John F. Kennedy (1917 – 1963),
35th president of the United States
The KHS Group is well prepared for the pending upswing. When the economy
took a downturn in 2008, the company drew up a restructuring process and a
cost-reduction program. With a reduced order volume, the group is now better
able to adjust its costs. In April, Sales globally adopted a new setup, bringing
KHS even closer to the customer with its system lines and services based on the
highest standards and thus making the company noticeably more powerful on
the market in the short term. How will customers benefit from this change?
»The Chinese use two brush
strokes to write the word
“crisis”. One brush stroke
stands for danger, the other
for opportunity.«
The new structure permits much improved, faster clarification and processing
of orders. Processes and procedures can be thoroughly systematized and fully
optimized systems can be ensured in the interests of the customer. The aim is
not only to offer each customer a solution individually tailored to meet his or
Vincent van Gogh (1853 – 1890),
her requirements with top technology and excellent service but to ultimately
Dutch painter
give the customer a competitive advantage as well.
Looking at the results for the first quarter of this financial year, KHS has
happily noted a turn for the better. A change in trend was immediately notice-
»Change is just as necessary as the
renewal of the leaves in spring«
able following the crucial drinktec trade show held in September 2009. The incoming orders for the first quarter of the current financial year roughly reached
the level of those for the year 2008. In developing economic areas, such as China
and South America, order volumes are noticeably picking up.
Within the new structural setup of the KHS Group and its parent company
Jan G. Carlzon (b. 1941),
Klöckner-Werke AG, the main shareholder Salzgitter Mannesmann GmbH an-
former CEO
nounced at the beginning of March that it would offer the minority sharehold-
of SAS Scandinavian Airlines
ers of Klöckner-Werke AG a suitable cash settlement. This will be decided on at
the general meeting of Klöckner-Werke AG on August 25, 2010. This measure
will also continue to strengthen the core of the KHS Group, making KHS' base
even more reliable for our customers. This in turn will enable us to make and
implement important strategic and company policy decisions with greater
speed.
Kind regards,
Roland Flach
»Authority and responsibility are in
fact linked to the individual: to his
wisdom, his knowledge, and his
way of dealing with people. All
this gives him an authority that
nobody can take away from him.
Ideally, employees should gain
their sense of security in dealings
with customers, that is, from
within.«
| Contents | 01.2010
12
| Focus on Solutions | 06
An Eye on
Quality
| Focus on Solutions |
Coca-Cola Hellenic
Austria | 08
Best practice inspection technology
Coca-Cola Enterprises | 12
Can line with an efficiency kick
Rhodius Mineralquellen | 18
Mega-flexible keg technology
Be it in the beverage, food, or non-food industry, at KHS
everything revolves around the customer. In this issue of
KHS Competence you will find three examples of customized systems from KHS for very different practical applications that fully meet all requirements.
04 05
32
50
54
| Interview |
| Market Report |
| In-house News |
The Wheels of Change | 22
Hanni Rützler, trend researcher and
Turnkey Keg Line for
Kölsch | 42
A Visit Says More Than
A Thousand Words | 52
bestselling author, on food trends
The Heinrich Reissdorf Microbrewery
On site in the Far East
in Cologne
| Technology in Practice |
Optimized Flows | 54
A Brief Introduction | 43
Process optimization at the KHS Kleve
Oettinger Brauerei / Derhim Industrial /
plant: processing time cut by 30%
The Big Five: What Customers
Want | 26
Coca-Cola Içecek / FoodCare /
Teusser Mineralbrunnen / Gramex2000 /
The Perfect Way | 55
InnoPET BloFill stretch blow molder/
Distell / Coca-Cola Enterprises
KHS relies on duality
filler system comes with many new
advantages
Perfect Partnership | 45
Compañía Cervecera de Puerto Rico,
Pallet Ballet | 32
| Service & Dialog |
Puerto Rico
Precision system integration
Perfect Sanitizing | 35
Premiere for 3-liter PET Bottles
with Recessed Grip | 48
Safety for all beverage types
Henkel Central Eastern
Competence for the
Next Generation | 56
Making the most of system production
Europe (HCEE), Vienna
Trade Shows | 57
Hygienic design in filling technology.
Joss in Shantou | 50
Addresses | 57
An overview.
Coca-Cola / Yanjing Guillin / Anheuser
Simply Simple | 37
Busch InBev / Heineken (China)
Focus on Solutions
Customers all over the world want ultimate systems. KHS supplies them – custom made
An Eye
on Quality
At KHS, everything revolves around the customer. Whether in the
beverage, food, or non-food industries, with their profound specialist knowledge the experts at KHS can come up with a tailor-made
system that fully caters for what the customer wants. This is what
counts in the long run, guaranteeing each and every company process optimization and a technological competence that has been
gleaned over decades, coupled with gains in efficiency and competitive advantages. In this issue of KHS Competence you will
find three examples of customized systems from KHS for very different practical applications that fully meet all requirements:
08Coca-Cola Hellenic AUSTRIA
Best practice inspection technology
12Coca-Cola Enterprises
Can line with an efficiency kick
18Rhodius Mineralquellen
Mega-flexible keg technology
06 07
Best Practice for
Top Quality
Coca-Cola Hellenic Austria uses the Innocheck platform for inspection // Consistent quality
assurance has top priority in the food and beverage industries. The KHS Innocheck
inspection platform installed at Coca-Cola Hellenic Austria in Vienna demonstrates how
this can be achieved in practice with up-to-the-minute technology and a strong focus
on the customer. The result is quality in abundance.
C
oca-Cola‘s success story began on the Austrian
brand products. This has proved successful; the great
market in 1929. Today, Coca-Cola Hellenic Austria,
importance the company has in the Alpine republic
a subsidiary of the Coca-Cola Hellenic Group
is, according to manufacturing manager for Coca-
based in Athens, is Number One in Austria for soft drinks
Cola Hellenic Austria Erwin Langela, partly attribut-
and mineral water. Each year the company‘s two pro-
able to the relationship consumers have built up with
duction sites and seven distribution centers supply around
“their Coca-Cola brands”. “In Austria, Coca-Cola‘s
50,000 customers in the hospitality and retail food trades
Cappy brand has become practically synonymous with
and thus up to 8.4 million consumers.
orange juice, for instance. And this is just one of many
Looking at their history, this is hardly surprising.
Over the decades, the chief objective of the manage-
examples that demonstrate just how closely consumers are tied to these products.”
ment has always been to honor and keep the uncon-
This may sound obvious and comparatively sim-
ditional trust of the Austrian consumer in Coca-Cola
ple, yet in practice the company constantly strives to
08 09
Spotlight: Coca-Cola Hellenic Austria
_Founded in 2000 as a 100% subsidiary through fusion of Coca-Cola Beverages
with the Greek Hellenic Bottling Company SA
_Austria's Number One producer of soft drinks and mineral water
_The plant in Vienna produces soft drinks, such as Coca-Cola, Coca-Cola
apply the highest standards of quality to raw materials,
the product, and its presentation on the market. At
light, Coca-Cola zero, Fanta, Sprite, mezzo mix, and the energy drink
Burn
Coca-Cola Hellenic Austria this starts with the suppliers,
_Römerquelle at the Edelstal site, integrated in 2003, bottles classic min-
all of whom have to keep to precisely stipulated qual-
eral water and health drinks based on mineral water with an innovative
ity standards. And, to cut a long story short, it ulti-
range of flavors that include pear and lemon balm, blackberry and lime,
mately ends with a merciless system of quality control.
This is where KHS comes in – with its cutting-edge inspection technology.
The choice of inspection equipment required for
a PET filling line at the plant in Vienna was made quite
specifically in favor of KHS. The exciting thing here is
that the newly installed Innocheck system is a KHS pilot
system with numerous features and advantages. First
and foremost is maximum ease of operation. “Our people have become familiar with the system within a very
short time,” enthuses Langela, “as the system‘s operator
prompting is particularly simple. Here, the line works
and also lemon grass
_Parent company Coca-Cola Hellenic is the second-largest bottler of brand
products for the Coca-Cola Company worldwide and the biggest in Europe,
with 80 production sites employing over 48,000 people in 28 countries.
Yearly sales volume: 2.1 billion unit cases (11.9 billion liters)
_Serves about 560 million consumers
_Established markets: Austria, Greece, Italy, Northern Ireland, Switzerland,
and Cyprus
_D eveloping
markets: Hungary, Croatia, Poland, and Slovakia, for
example
_Emerging markets: Russia, Romania, Serbia, Ukraine, and also the African
state of Nigeria, among others
for the operators and not the operators for the line
which, among other things, increases line efficiency.”
The components of the Innocheck
system in Vienna
To date, the Innocheck platform in Vienna includes
an Innocheck CUB control unit with a touch-screen
monitor for operation and visualization, an Innocheck
FHC fill level check, and Innocheck CCI crooked cap
inspection.
_ 1 Fill level check: precise and simple. After the filling and capping process, the PET bottles move on towards the Innocheck. A light barrier first checks the
presence of each individual bottle upstream of the fill
level checker (an Innocheck FHC). The Innocheck CUB
control unit then computes exactly how many conveyor
cycles elapse before the fill level is measured. The PET
bottles are tracked in real time. Fill levels are measured
within a high-frequency measurement bridge. The
control unit immediately receives and processes the
measurements. Fill levels that are not within the given
_ 2 Crooked cap inspection: CCD camera. A second
tolerances are recorded and signaled immediately to
light barrier checks the presence of the PET bottles be-
the rejection system. A pneumatically controlled pusher
fore they pass through the crooked cap inspection sta-
channels out any underfilled or overfilled PET bottles.
tion. This stage in the process prevents problems with
Maximum and minimum fill levels can be very easily set;
inspection during any line standstills. The chief com-
the operator simply has to open the fill level check set-
ponent here is a high-resolution CCD camera, built
tings menu on screen and enter the settings for the
into a protective stainless steel housing. Motorized
new measurement levels that are immediately stored
height adjustment enables the camera to be accurately
by the control unit.
adjusted to fit the size of bottle due for inspection. A
telecentric lens guarantees that the distance between
individual PET bottle, photographing caps starting at
the PET bottles and camera does not hinder the accu-
the neck ring within a given measurement window. Pos-
racy of the images. This means, for example, that any
sible discrepancies in height therefore do not affect the
inaccurately adjusted guide railings have no impact on
quality of the images. These settings can be easily
the results. Telecentric imagery and special LED light-
changed using the on-screen settings menu for crooked
ing provide perfect acutance in the image. Another
cap inspection. Incidentally, besides plastic closures the
great advantage is that the camera system is not influ-
Innocheck CCI is also able to perfectly inspect metal caps,
enced by parasitic light.
crown corks, and sports caps.
Another problem that needs to be solved is the
production-related, slight difference in heights of the
_ 3 The result: a perfect, self-learning system. The re-
PET bottles. Before taking an image, the camera system
sults of the fill level check and crooked cap inspection
thus scans the bottom edge of the neck ring on each
are finally processed and attractively presented on the
The Innocheck platform integrates an Innocheck CUB control unit with a touch-screen monitor for operation and visualization, an Innocheck FHC fill level
check, and Innocheck CCI crooked cap inspection.
10 11
Eco shrink tunnel also convincing
Coca-Cola Hellenic Austria recently invested in a new Innopack
Kisters TSP tray shrink packer equipped with a KHS eco shrink
tunnel. Here, too, the company now occupies a pole position
within the Coca-Cola Hellenic Group; as opposed to conventional shrink tunnels, the eco shrink tunnel
Innocheck platform screen. Whether measurement curves
caps or individual measurements of single PET bottles,
_Cuts energy costs by up to 50%, and
_Reduces CO emissions by 60%.
all this and even more can be individually prepared by
The reason for this is that gas is converted directly into heat. Due
the system. What‘s also important is the Innocheck tests
to multiple conversions of energy, electrical heaters always emit
itself by permanently carrying out plausibility checks at
a significantly higher rate of CO2.
showing fill levels or rejection rates caused by crooked
2
the light barriers. As a result, the system signals any
Manufacturing manager Erwin Langela is full of praise.
malfunctions immediately.
“When all's said and done, with these two innovative technical
Manufacturing manager Langela concludes, “With
solutions KHS has once again proved that we have a partner we
KHS‘ new inspection technology, utmost precision goes
can trust.”
hand in hand with maximum information and fast setting capabilities. At the same time we greatly appreciate
the high level of flexibility the system offers us, enabling
us to integrate additional inspection instruments into
the Innocheck platform in full accordance with our requirements.”
_ 4 Perspectives: filler management system. It is conceivable that in the future Coca-Cola Hellenic Austria
may expand the Innocheck platform to include an
additional integrated filler management system, the
Innocheck IFMS. The advantage of this system is that
each individual PET bottle is directly allocated to a filling
valve and capper head. A permanently underfilling filling
valve, for example, can be quickly pin-pointed by the
filler management system and the system can quickly
react, thereby increasing line efficiency.
This additional system would require that further
signals be communicated between the filler and capper
and the Innocheck CUB control unit, a light barrier be
integrated at the discharge of the filler/capper monoblock, and that light barriers be installed at the conveyor
transition points. Once this has been done, the required
to suit required individual standards and also the fill
software is simply activated and filler management can
level check and crooked cap inspection.
start. “Complexity is an alien concept as far as this system
is concerned,” says Langela.
The hardware is also well planned and can be
quickly and easily adapted to suit new operating conditions. If a computer module in the control unit reaches
Standard components of the Innocheck system
its limits of performance, all that is needed is to open
KHS‘ innovative inspection technology is based on a care-
the CUB terminal and plug in another module, for ex-
fully worked out modular concept. Coca-Cola Hellenic
ample. It just couldn‘t be easier to keep the focus on
Austria could thus easily integrate further inspection
quality.
features into the system, such as tamper-evident seal
inspection, leakage check, bottle alignment, labeling
inspection, or filler management, for example (see above).
Required measurement systems with upstream light barriers can be installed in series. The necessary standard
software is already installed in the Innocheck CUB control unit and once activated can be equally easily adapted
Jürgen Herrmann | KHS GmbH, Dortmund, Germany
Phone: +49 (231) 569 -10117
12 13
Efficiency and More
Turnkey canning line for Coca-Cola Enterprises: all customer requirements
fully satisfied // KHS has implemented a raft of ideas and refinements in
a special canning line at the Dutch CCE plant in Dongen. Referring to the
tasks involved, plant director Kris Moortgat commented, “With an all-in
engineering package, KHS managed to complete every aspect of the job
to perfection”. The secret is in the detail.
I
f a company expects more than 90% system efficiency
on average and then actually achieves 98.2%, this
represents, without doubt, a particularly successful
performance. How this came about and how, in a fa
vorable context, it was even possible, is illustrated step
by step in the example of Coca-Cola Enterprises (CCE).
The customer presented KHS with a large number of
tasks, some quite tricky, which had to be solved by a
team of experts.
It happened like this: CCE, the largest producer
and distributor of Coca-Cola products in the world, (see
Spotlight, page 14), first invested in canning at the
Dongen plant in Holland. CCE has been operating in the
country since 1993 when the Dongen plant was acquired,
now the largest in the Benelux countries and the secondlargest CCE plant on the whole of the European market.
Last year the company produced 450 million liters of
Coca-Cola products in various types of container here,
to date PET and glass bottles (and postmix). For the
Dutch market alone, Dongen processes about 250 different packaging units. And the site is further expanding as plant director Kris Moortgat briefly outlines. “In
2009 we achieved a significant plus. We are expecting
even more growth in 2010”. It was against this backdrop
that the new KHS canning line with its special features
was planned and installed.
Customer requirement: highly versatile plant e
ngineering in terms of capacity, containers,
product filling, and packaging.
Capacity. According to CCE figures, the current capacity
of the new KHS turnkey canning line is 90,000 0.33-liter
cans per hour. In line with planned growth, this should
be considerably more in future. From depalletizer to
filling system, the machines are already designed for
120,000 0.33-liter cans. An additional dry area will
ensure the necessary increase in capacity in packaging
Packaging. The new Advanced line of KHS packaging
and palletizing by the middle of the year.
machines includes both shrink packers and tray shrink
Problem solved.
packers. Thanks to the consistent development of its
modular design, the line offers maximum flexibility in
Containers. Besides the conventional 0.33-liter cans the
packaging systems as well as maximum safeguarding for
line also fills and packages 0.5-liter cans and 0.33-liter,
the future. Designed to be interchangeable, the func-
0.25-liter, and 0.15-liter slim cans.
tion modules can be used for any task. Thus the shrink
Problem solved.
packer can easily become a pad shrink packer or tray
shrink packer if necessary. Whether cans, plastic or glass
Product filling. In addition to carbonated beverages, the
bottles, or containers of very different shapes and heights,
electronically controlled Innofill DVD volumetric filler is
whatever needs packaging, the technology can cope.
also able to process non-carbonated beverages without
To be precise, in Dongen Innopack Kisters SP Advanced
difficulty. At present Dongen only fills carbonated Coca-
shrink packers and Innopack Kisters TSP Advanced tray
Cola brand products.
shrink packers are in operation. The line is able to make
Problem solved.
shrink packs and then take these shrink packs to either
the palletizer or the Innopack Kisters TSP Advanced. The
Customer opinion: Maurice Malchair, senior engi-
Innopack Kisters SP Advanced operates at up to 120 cy-
neering manager at CCE Dongen, says, “With our
cles per minute. It creates four-packs, six-packs, eight-
new KHS line we are well equipped to meet cus
packs, and twelve-packs. A leaflet inserter is also inte-
tomer demands now and in the future.”
grated into the system.
Performing up to 100 cycles a minute, the Innopack Kisters
TSP Advanced places the waiting shrink packs into 24-can
tray packs which are then wrapped in film and shrunk.
It is also possible to feed individual cans directly to the
tray shrink packer. In this case the cans are packed in
Spotlight:
Coca-Cola Enterprises (CCE)
24-can trays, shrunk if necessary, and then forwarded to
the palletizer.
Problem solved.
Customer opinion: Marc Adriaansen, engineering
_ CCE is the world's largest producer and distributor
of Coca-Cola products
_ Represented in 46 U.S. states and Canada; sole Coca-Cola
bottler in Belgium, France, the UK, Luxembourg, Monaco,
and maintenance manager at CCE Dongen, says, “We are impressed by the high degree of flexibility
of our new packaging equipment, the straight
forward operator-controlled format changeover,
and the top-of-the-line hygienic design.”
and the Netherlands
_ Produces approx. 42 billion units of Coca-Cola products
Customer requirement: maximum functionality
per year
and efficiency when conveying, blending, filling,
turnover
Conveying: The KHS line was not only to be highly flex-
_ Earns 16% of the Coca-Cola Company's total worldwide
_ Dongen plant (open since 1993) is the second largest CCE
production plant in Europe
testing, and packaging products.
ible, but functional as well. This starts even before the
cans are depalletized. A forklift loads empty can pallets
• Production in 2009: 450 million liters
in pairs onto conveyor belts moving parallel to one an-
• Key brands: Coca-Cola, Coca-Cola light, Coca-Cola zero,
other. If the conveying segment is fully loaded with
and Fanta
• 55% filled in PET bottles, 25% in cans, 10% each in glass
bottles as well as post-mix.
• The share of Coca-Cola products consumed
in the Netherlands is 80%
empty can pallets, this will still be enough for a production time of about 45 minutes.
Once the Innopal ASH bulk can depalletizer has supplied
the cans into the line, the system uses a vacuum bridge
to channel out any flawed cans. A special feature is the
S-shaped vacuum bridge that accommodates the
14 15
The Innopack Kisters TSP Advanced, here shown packing cans in trays of 24, which can also be shrink wrapped if necessary.
conveying height. An air conveyor takes the 'good'
Blending. In operation at Dongen is an Innopro Paramix
cans to the rinsing system positioned on an incline, and
C three-component dosing and blending system, which
separates them shortly before they enter the rinser,
KHS just recently launched to market. A special feature
where they are rinsed with water and air. Light scanners
of this is the horizontal position of both the deaerating
continually monitor the degree of conveyor use. If the
and finished beverage tanks. This means that they not
conv eyor belts are completely full, the empty can
only take up less space, but also have overall technical
depalletizer stops automatically.
advantages (for example, a more efficient deaerating
Problem solved.
process; less than 0.3 milligrams residual oxygen per
liter; discarding diluted syrup phases is no longer neces-
Customer opinion: Adriaansen says, “As is the sary; even shorter product changeover times; analog fill
case upstream of the rinsing system, spacious
level measuring in the buffer tank combined with recipe-
conveyor sections maintain a continuous flow of
controlled, fully automatic output control ensures uni-
cans throughout the line.”
form production conditions; additional consumption of
CO2 eliminated). All this results in increased line efficiency and targeted cost cutting as well as a tangible
From ring bowl to filling valve, passages throughout the
Innofill DVD are smooth.
improvement in the performance of the filling system.
Problem solved.
Filling. The core of the line is the electronically controlled
Innofill DVD volumetric filler equipped with 184 filling
stations. Electromagnetic inductive flowmetering ensures
a maximum filling accuracy. Tolerances for can capacities
from different manufactures are therefore no longer an
issue. For example, if a volume of 0.33 liters is programmed
into the system, the cans will then contain exactly 0.33
liters. When the can sizes are changed, the adjustment
is made at the push of a button, with values already programmed into the system. This saves time and increases
the versatility of the machines (only a change in can diameter entails the usual change of format parts).
Problem solved.
Checking. Before the filled cans arrive at the packaging
Rejection of incorrectly filled cans is integrated between
machines, the fill levels and caps must be checked, the
the filling and capping systems. Complete filler rounds,
cans turned upside down by an automatically driven
planned roughly every hour, can also be channeled out
turner, coded, turned back upright to their original po-
onto a separate conveying segment. The objective is
sition, and finally the fill levels and caps rechecked.
maximum microbiological safety. During checking, each
Problem solved.
Packaging. Additionally ordered Advanced series shrink
packers and tray shrink packers are increasing the capacity of the entire line to 120,000 cans per hour.
Problem solved.
individual can is allocated to the relevant filling valve and
capping head. This means immediate and, above all, appropriate corrective action can be taken if necessary.
Problem solved.
Packaging. Even Advanced packaging technology must
meet the highest standards of hygiene. Support systems
Customer opinion: Kris Moortgat notes, “Besides
for the function modules are made of painted tubes,
the planned increase in capacity, this further
permanently welded to the machines. The drainage
investment in KHS packaging technology and in
system for cleaning agents, rinse water, and any discharg-
another palletizer gives us even greater flexibility.
ing product has been optimized by placing newly de-
This means we can simultaneously produce differ-
signed drip trays underneath the function modules.
ent types of packaging in parallel.”
Problem solved.
Customer requirement: perfect hygiene in filling
Customer requirement: gentle handling and simple
and packaging.
operation in conveying, filling, and packaging.
Filling. From the ring bowl to the filling valves, passages
Conveying. After the system has automatically removed
are smooth throughout the Innofill DVD. The membrane
the plastic load-securing straps, the empty can pallets are
and sealing technology is, of course, aseptic. The filler/
conveyed smoothly to the Innopal ASH bulk can depal-
capper monoblock is completely enclosed. Filter units on
letizer where the pallets are lifted into the appropriate
the ceilings filter and clean the bottling shop air.
pushoff position in a pit enclosed on three sides. A pusher
system enclosed on four sides controls the centering of
every single layer during depalletizing, which is a prerequisite for the careful handling of sensitive can material.
The adjustment of the pusher framework centering
“Even when designing the line, our cooperation with KHS was an example of teamwork at its very best,” states Kris Moortgat, plant director of CCE Dongen (left back
row). Also pictured: Maurice Malchair, senior engineering manager of CCE Dongen
(center front row); Marc Adriaansen, engineering and maintenance manager
of CCE Dongen (right front row); Hennie van der Graaf, manager of KHS Benelux B.V.,
the Netherlands (right back row), and Herman Miseur, Sales KHS Benelux B.V.,
the Netherlands (left front row).
guides is motor-driven. In conjunction with the pneumatic pit wall adjustment used, the machine can switch
to a new format at the push of a button. Only the grippers of the steel framework must be adjusted manually,
which is quickly done. All the surfaces of the depalletizer
coming in contact with the cans are covered with plastic
sheeting to prevent damage to the cans. The machine is
equipped with two lifting devices. One of them grips the
steel cover frame, moves it to a parking position, and sets
it down on the pallet again after depalletizing. A light
scanner checks that it is set down in the correct position.
The automatic pallet liner lift-off conveys the pallet
liners into another magazine provided especially for this
purpose. The magazine is emptied automatically and
therefore extremely operator-friendly.
Problem solved.
Filling. When filling carbonated Coca-Cola products, once
the cans have been sealed against the filling valve, any
air present in the can must first be displaced by purging
it with CO2. The next step is to close the return gas
16 17
Process engineering unit: the dosing and blending system is synchronized with the capacity of the filling system.
passage whereas the gas passage remains open. The can
Customer opinion: summing up, plant director Kris
is then pressurized to a filling pressure based on the CO2
Moortgat says of the investment and the project,
content of the product. Once the desired pressure is
“Even when designing the line, our coopera-
reached, the fluid valve opens and radiates the products,
tion with KHS was an example of teamwork at
free of bubbles, gently down the walls of the can at a
its very best. KHS not only fulfilled our require-
constant filling speed. The gas in the can escapes into
ments perfectly in every respect; the company also
the pressurization channel. Once the magnetic inductive
contributed a great deal of additional expertise in
flow meter has registered the set filling volume, the fill-
implementing our ideas in a complete engineering
ing valve closes automatically, thereby ending the filling
package”.
process. Low-foam snifting follows next, which can be
done in two stages for beverages with a particularly high
foaming tendency.
Problem solved.
Packaging. An advantage of the operator-controlled
format changeover of the packaging machines is that
the machine's operator panel shows the operator exactly
where new settings must be made during a product
changeover and exactly what adjustments must be
made at each operator station. A special feature of
the I nnopack Kisters TSP Advanced is the longer
m agazine for the cardboard blanks that minimizes
operator involvement.
Problem solved.
Hennie van der Graaf | KHS Benelux B.V., Breda, the Netherlands
Phone: +31 (76) 572-3235
Herman Miseur | KHS Benelux B.V., Breda, the Netherlands
Phone: +31 (76) 572-3234
Classy Kegs
Pepsi partner Rhodius Mineralquellen opts for a very special KHS line //
At Rhodius Mineralquellen, once the first Pepsi franchisee in Germany,
KHS shows the customer, arm in arm, just what can be done with flexible,
creative, and individually customized keg technology. The result is a keg
line with class.
S
ome companies are surviving the crisis quite well.
and the great ease of operation. The container system
Rhodius Mineralquellen und Getränke GmbH &
previously in use here needed four people to operate it.
Co. KG in Burgbrohl in the heart of the Brohltal/
Now we only need one.”
Laacher See volcanic park is clearly one of these. In 2009,
This praise is all the greater when we consider just
Rhodius increased its output from 210 million to 260
how long the owner-managed Rhodius Group has been
million filled units. The sales volume climbed from 1.5
active on the market, how demanding, flexible, and
million to around 1.8 million hectoliters. A small team
creative it is, and what it traditionally expects from its
of specialists from KHS and the mineral water company
suppliers. It all began in 1827 with the manufacture of
is quietly proud of the fact that this growth is partly
flake white, a colored pigment used as an underpainting
attributable to the recently installed KHS keg line for
layer for oil painting. Rhodius later sold carbon dioxide,
10-liter and 20-liter slim kegs destined for the hospitality
minium, and lead oxide and was one of the first compa-
trade.
nies in Europe to start making high-speed grinding wheels
All those involved are just as pleased with the con-
in 1952. Today, Rhodius Schleifwerkzeuge GmbH is one
ceptual and technical implementation of the keg chal-
of the largest manufacturers of cutting and grinding
lenge set by Rhodius. Stefan Tönnesmann, managing
wheels in Germany, exporting to over 100 countries
director of Rhodius Mineralquellen, professes himself to
worldwide.
be extremely satisfied with the results when he says,
The company branched out into beverage produc-
“With our new KHS keg technology we now have a keg
tion purely by chance. In 1958 Manfred Rhodius, com-
racking and packaging system that leaves nothing to be
pany owner in the second generation, departed for New
desired. We are just as enthusiastic about the exception-
York to conclude contracts for his grinding tools in 1958
ally hygienic racking process that not only saves on prod-
– and by complete coincidence he also made contact with
uct but also on carbon dioxide as we are with the inno-
Pepsi. On his return to Germany, the entrepreneur had
vative robot palletizing and depalletizing technology,
a contract with the Pepsi Bottling Group in his pocket as
18 19
The benefits in brief
The KHS keg line gives the customer:
… Production startup within three weeks
… All the advantages of an extremely flexible keg racking system
… A robot capable of controlling up to 25 target positions in 8 functional units, adaptable to the situation in line
… An Innokeg Till TRANSOMAT 5/1 that cuts water, wastewater, and energy consumption by pre-washing
with mixed water
… A DFC racking system that is fast, precise, and reduces the consumption of carbon dioxide compared
to traditional racking systems by up to 40%.
the first franchisee in Germany commissioned with the
wine beverages, and Prosecco – in many types and styles
filling of Pepsi-Cola and later also other products in the
of container, ranging from cans, non-refillable PET, and
Pepsi range under license. It wasn’t until 1974 that the
PETcycle bottles to glass bottles and kegs. “This high
company began filling its own mineral water and other
degree of flexibility is what largely contributes to our
soft drinks under the Rhodius umbrella brand. Manag-
present success,” says Tönnesmann. And this has also
ing director Tönnesmann claims, “This was exactly the
literally reaped rewards. The DLG, for example, has pre-
right decision. We now have two strings to our bow in
sented Rhodius with three gold medals in the categories
our beverage sector: our own brands plus license and
Classic, Medium and Naturell for its magnesium-rich
contract filling.”
mineral water; at the Superior Taste Award, an interna-
In this capacity Rhodius fills a wide range of soft
drinks plus alcoholic beverages, such as beer, wine, mixed
tional competition ranking quality and taste, three stars
were awarded (the maximum number);
and the German magazine Öko Test graded Rhodius
mineral water “very good”. And that’s not all: sommeliers in the journal Alles zum Wein and Zenith Inter
national have confirmed that Rhodius Mineralwasser has
the best characteristics to complement wine.
Rhodius distributes its own brands on a regional
__ The stainless steel jacket of the keg prevents the
filled product from being exposed to the surround
ing air
__ Kegs are lightproof, tasteless, corrosion resistant,
and shockproof, and
__ Kegs allow the product to be stored for a very long
basis in the high price segment. The target group con-
period of time without any impact on the quality.
sists of active sportsmen and women of all age groups.
These advantages are also welcomed by PepsiCo
Rhodius mineral water is also enjoying increasing popu-
Deutschland GmbH, as Rhodius manager Tönnesmann
larity in the hospitality sector, where the company now
explains, “Our new top-quality KHS keg line is considered
sells 500,000 0.7-liter glass bottles as opposed to 100,000
a very positive addition by our licensing partner. The
five years ago. Figures for the 0.25-liter restaurant bot-
majority of our keg racking activities are currently focused
tle have tripled to around five million units. These good
on Pepsi brands.”
relations are likely to be promoted further by the new
KHS keg line. Kegs are now replacing the bulk contain-
Special features of the new KHS keg line
ers previously delivered by Rhodius to hospitality clients.
KHS installed the new keg line (160 kegs per hour) with-
“We have received nothing but positive feedback from
in just three weeks, when it was ready for operation and
hospitality businesses regarding the switchover,” declares
could begin production. The first and last station on the
Tönnesmann. “They especially like the easy handling
line is the Innopal RK 6 palletizing and depalletizing ro-
and the high level of hygienic safety that always comes
bot. What’s special here is that it can navigate up to 25
with the keg.”
target positions on 8 functional units at a workload of
In fact, there are many aspects in favor of racking
up to 240 kilograms, picking up two kegs at a time. It
soft drinks in kegs:
can also flexibly adapt to the current situation on the
__ The hospitality trade is very familiar with the keg
line. If, for example, the full keg segment is becoming
__ Kegs take up little space, are easy to handle, and
crowded, the robot will focus on palletizing full contain-
provide maximum hygiene
ers. If there are not enough empty kegs in the system,
Spotlight: Rhodius Mineralquellen
__ Founded in 1827
__ Production: 260 million fillings, 1.8 million hectoliters
__ Products: Rhodius mineral water (new: whey products Key and
Power Point in no-deposit cans), Rhodius soft drinks, contract
fillings for PepsiCo Deutschland GmbH, bottling of alcoholic
beverages
__ Filling distribution:
• 30% own brands, 80% of which is Rhodius mineral water
(60% Rhodius Medium, 35% Rhodius Classic, 5% Rhodius
Naturell), 10% apple spritzer, and the rest classic soda pops,
sports, and energy drinks and the Rhodius fruit juice Fructi
• 70% contract filling, 60% of which are Pepsi brands
20 21
Keg exteriors are washed over several zones in the Innokeg Till AK 1.
it will turn its attention to depalletizing empties. An
intelligent logic controller sets priorities.
Both of the two washing and racking segments of
the Innokeg Till TRANSOMAT 5/1 are equipped with one
racking station and five active washing and sterilizing
stations, plus one passive caustic soaking station. The
fact that the mixed water used in the pre-wash to remove
coarse soiling is salvaged from the last hot water spray
helps to specifically save on water, wastewater, and
energy consumption.
The DVF filling system stands for maximum filling
accuracy and high filling speeds. Its special feature is
that its reduces the consumption of carbon dioxide versus conventional filling setups – by up to 40%.
Rhodius initially intends to rack about 200,000
Stefan Tönnesmann, managing director of Rhodius
Mineralquellen und Getränke GmbH & Co. KG (right),
and Wolfgang Augel, Sales Germany, KHS GmbH,
practice cooperation and partnership.
kegs a year. Should the demand for soft drinks in kegs
continue to increase, “the figures for contract keg racking could grow in the next few years,” says Stefan
Tönnesmann. In this context, Tönnesmann admits that
they already have a new innovation in the pipeline – but
he’s not letting on any more than this. The mineral water
industry will have to watch and wait …
Edgar-George Petsche | KHS GmbH, Dortmund, Germany
Phone: +49 (231) 569 -1668
Wolfgang Augel | KHS GmbH, Dortmund, Germany
Phone: +49 (231) 569 -1635
Interview
Topical trends and tips: experts of world renown have their say
“The Wheels
of Change”
Hanni Rützler, trend researcher and bestselling author, on food trends // What are the
global megatrends in food and what do they signify for manufacturers and retailers
in the food and affiliated industries? In an interview with KHS Competence renowned
future food expert Hanni Rützler spills the beans.
KHS Competence: Ms Rützler, do you sometimes eat soured
his Noma restaurant in Copenhagen and again gave seasonal and
boiled rump, or Tafelspitz, to give it its Austrian name?
also regional vegetables pride of place on our plates.
Hanni Rützler (laughs): Yes! Why not?
Let’s keep to the basics for a minute. What do food styles
Because this traditional Austrian dish may taste delicious but
and food trends have to tell us in general?
it isn’t …
Food trends are reliable seismographs recording processes of
… really a future food? That’s true – and then again, it’s not.
change in our society. In these, new, creative, and unconventional approaches to current food issues become apparent. Food
Why?
trends are not only the result of technological innovation, such
Well, on the one hand the old-fashioned dishes our grandmothers
as gene and nanotechnology, or new methods of business, such
used to cook are increasingly being overshadowed by modern prod-
as e-business, but also answers to the great social frameworks
ucts. On the other hand, the trend for regional cuisine is causing a
that mold our lives. These include megatrends such as health,
renaissance of traditional fare. And the method of preparing Tafel-
globalization, neo-ecology, New Work, and individualization, ones
spitz, for example, namely boiling instead of frying the beef and
that often first manifest themselves in seemingly everyday ac-
serving it with steamed vegetables, is definitely more in line with
tivities, such as our eating habits.
the growing desire for lighter and healthier food.
In short …
Are Tafelspitz, potatoes with butter, and knuckle of pork thus
… food trends are often the wheels of change with which we can
the new future foods?
predict the future.
Yes and no (smiles). Simply digging out a few ancient recipes is not
enough to succeed on the extremely dynamic food scene. Tafelspitz
Why are food trends, as you describe it, also so important in
is also a pretty untypical example, as most traditional dishes don’t
other fields?
fit in half as well with our modern eating culture. They’re often too
Practically no other field is subject to such dynamic change as the
greasy and too calorific, and extremely time-consuming to prepare.
food industry. Its dynamism is immensely innovative and the in-
Yet a creative reference to regional custom can lead to exception-
dustry is not afraid to venture out into new areas of business. Be-
ally innovative, trend-setting cooking concepts. Just think of René
sides the immense pressure of competition, this is also down to the
Redzepi, for example, who revolutionized Scandinavian cuisine at
fact that consumers are becoming ever more experimental and
22 23
The interviewee
Magister Hanni Rützler, the founder and manager of futurefoodstudio in Vienna, is heralded as a pioneer of nutrition science.
The food expert, health psychologist, and author of reference
books and bestsellers has made a name for herself worldwide as
a consultant speaker on all aspects of our eating and drinking
habits. Rützler mediates between the theory and practice of
topics that include future food, food quality, consumer protection, regional food cultures, and healthy eating. Her expertise is
not only sought by food manufacturers and health politicians all
over the world but also by multinational concerns and big
system caterers.
Since 2004 Hanni Rützler has worked in the field of future food
(among others) as a trend expert and consultant speaker with
the Zukunftsinstitut (institute of the future) run by Matthias
Horx. The Zukunftsinstitut, founded in 1998, is considered an
influential think tank in international trend research and
futurology. Which changes, which trends and megatrends
dominate our present lives and which conclusions can be drawn
from these for the future of our societies, companies, and
ever keener to try out new products and recipes. With food, this
cultures? The objective of all research is to make companies and
is easier and less damaging to your wallet than with many other
developers fit for the future, to recognize opportunities – and to
products …
naturally exploit these to the full.
… which are then later subject to similar trends?
Yes. Altered eating habits, new foods and cooking techniques have
always been symbolic of a general change in society. Food trends
are thus also often indicators for developments in other fields. The
organic boom, for example, started with food and has subsequently
spread to many other branches and markets.
level of fitness. What’s referred to here is a maintaining of the balance between health, taste, and enjoyment in our stressful everyday
Do you have another concrete example?
lives. Making this easier for consumers through intelligent concepts,
The new trend for regional products that’s currently causing a stir
products, and services also gives the food and beverage industries a
in fashion, tourism, and design was also preempted by the food in-
promising chance.
dustry; Slow Food, the vins de terroir philosophy, and the trend towards regional cooking were the culinary forerunners of local chic.
In your talks and books you present detailed trends that
Not to mention the boom in Asian products.
product designers can put to good use in their work, depend
ing on their branch and product. Are there any overriding
What role does social change play in food and beverages?
megatrends that influence all sectors?
Over the past few decades this has massively increased the scope
By definition, megatrends have a long-term effect on all areas of
with which we can individually shape our lives. More and more
our lives and thus on all branches of industry. Take the megatrend
people believe their lives can be consciously organized and devel-
of globalization, for example. This is leading to an increasingly in-
oped rather than being determined by fate or social origin. More
tense exchange between all the regions on our planet. Products,
and more people are basing their choice of food on whether it’s
and also food and beverages, are being imported and exported
good for their personal physical and mental wellbeing. This trend
worldwide to an ever greater extent; growing networks and constel-
is characterized by the words “selfness” and “soft health”, both of
lations are in turn influencing our food cultures and also resulting
which involve much more than just keeping up your health and
in enormous shifts in our preferred tastes. Most recently it was the
| Interview |
» Food trends are reliable
seismographs recording
processes of change
in our society. «
economically booming countries of Asia that enhanced our taste
They only become an issue when they are no longer a matter of
buds. In the future we will also be confronted with new influences
course. And as food is the most ’intimate’ commodity we know, that
from Central and South America. Our ’western’ tastes and the nor-
is, these are products that we eat and that become part of our own
mative dominance of French cuisine are no longer the measure of
body substance, we are particularly sensitive in our reaction to
all things.
them.
Will regional food then drop out of the running?
The word ’authenticity’ is thus more than a welcome slogan
On the contrary. It was globalization, and especially the globaliza-
in marketing circles?
tion of food, that awakened our interest in regional produce and
’Authenticity’ primarily means that as consumers we also get what
helped to create regions with distinct culinary characteristics. The
we’ve been promised. Ideally, hand-produced food based on tra-
appreciation of regional cuisine is the direct result of the general
ditional methods of preparation and manufacture from specific
availability of foods and dishes from all over the world.
regions keeps this promise better. Authentic food products thus
also hold a promise of quality. And in the wake of our change in
What’s behind all this?
values quality has gained a new sense of status for the majority
Definitely not some romantic obsession with our native homeland,
of consumers.
as it might seem at a first glance. First and foremost, this trend is
backed by a consistent marketing logistics system that provides the
What are the specific effects of this?
confused and increasing insecure consumer with some answers. In
We have all often learned that cheap things can cost us dear! Just
view of the global range of produce on offer and the unprecedented
look at the food scandals in the last few years and decades. An
variety of foods we consume on a daily basis in our supermarkets,
economy that only concentrates on price neglects quality, safety,
restaurants, and take-aways/take-outs, the region has become a
and ethics. Due to our change in values the significance of these
helpful, measurable point of reference. It suggests authenticity,
will increase in the years to come and have a long-lasting effect on
transparency, safety, and trust.
our eating and drinking habits. The new motto is “better is more”.
We will consume less but place greater value on quality and enjoy
These are characteristics that were always important; will
what we consume more consciously. This will also result in our ex-
they become more so in the future?
pectations as to the aesthetics, design, form, packaging, and pres-
Strictly speaking, these words have only become significant in the
entation of products growing, as this conveys value and quality
wake of the industrialization and internationalization of our food,
better.
resulting in the consumer becoming alienated from the manufacturer and vice versa. In times when people largely supplied their
You’re talking about ’Ess-Thetik’ (eat-sthetics) here.
own food or acquired it locally, these traits were taken for granted.
Yes, that’s the relevant buzzword.
24 25
And organic? Is this still a sales argument? After all, any
recommendations for healthy eating, such as consuming more fish,
bright company is using this nowadays.
or heed ecological warnings, such as the threatened overfishing of
No company can afford to lose sight of the mega neo-ecology trend.
the world’s oceans.
Organic is thus still an important argument, especially with food.
Organic produce has set standards that premium products may no
You see the megatrends of feminization and singlization as
longer fall short of and which are increasingly becoming a measure
the pioneers of convenience food. Is the classic household
of quality in the discount sector. But just being organic will in the
dying out?
future not really be enough to set you apart from your competitors.
No, definitely not. However, old structures are being broken by
If you bet on organic plus a little bit more, however, you will stand
women achieving higher levels of education and how the allocation
a good chance of asserting yourself in future, with added social
of roles is changing between the sexes. New ways of living are evolv-
value, for example. The keyword here is Fairtrade. As well as that,
ing that require new structures in the home.
organic plus regional is the new dream team. More and more consumers are attaching value to products that are not climate killers
Which way are things going as a whole in the food and
but instead produced in their direct vicinity – and if possible are
beverage industries?
also a regional delicacy or specialty to boot.
Back to the center. The middle market segments that at the end of
the 1990s and the beginning of this millennium were threatened
Which dominant megatrends will continue to shape the
with annihilation by the discount and premium markets are the win-
manufacture of food and beverage products?
ners of the crisis. And they will continue to dominate the food and
As French sociologist Claude Hoffmann puts it, the megatrend of
beverage industries once the economy has recovered. In the fight
individualization has led to a double revolutionizing of our eating
for the new center it’s important to become clearly established, to
habits: firstly, the liberation of the individual from accepted norms,
define your market position, and to arm yourself with outstanding
with the result that we can allow our very personal sensory impres-
values. More than ever consumers are on the lookout for products
sions to run riot when eating and in our choice and preparation of
that are honest and authentic and that provide quality with a cost-
food; and secondly, an ongoing problematization, a necessity for
effectiveness that is absolutely transparent.
constant individual reflection on whether we’re “eating the right
thing” or not. On the one hand we have the continuing gourmet
And does this apply to Tafelspitz?
and pleasure boom, with luxury foods, award-winning restaurants,
Yes, of course, to this especially.
and magazines for food and wine connoisseurs. On the other there
are the political and individual health-conscious laments about obe
Ms Rützler, thanks for giving us an informative interview.
sity, food scandals, and food intolerances.
The interviewer was Jürgen Jacobs.
Is our health an increasingly convincing argument?
In Europe in particular, the mega health trend and an ethical awareness fuelled by the neo-ecology movement have permanently changed
the way in which we see food. It has forced not only the launch of
new products but also a change in consumer behavior to which the
retail trade is paying more and more attention. A selection of Fairtrade products is now almost standard in any better class of supermarket.
Bertolt Brecht saw things differently. He once said, “Food
Further information
first, then morals”.
Yes, when we’re starving we perhaps don’t always allow ourselves
www.futurefoodstudio.at
to practice morals. However, for decades we have had an excess of
www.zukunftsinstitut.de
food. Especially in the German-speaking countries of Europe, nutrition is thus a highly moral topic. We don’t have to drink coffee that
Recommended reading (in German):
farmers in Kenya or Columbia have been paid a pittance to produce.
FOOD CHANGE – 7 Leitideen für eine neue Esskultur, Hanni
We don’t have to eat eggs that have been ’manufactured’ in hen
Rützler/Wolfgang Reiter, Krenn Verlag, May 2010.
batteries. In addition, we also have to weigh up whether we follow
As a world market leader KHS is a specialist for efficient technology
26 27
The Big Five |
What Customers Want
1 Flexibility 2 Efficiency 3 Sustainability 4 Economy 5 Simplicity
InnoPET BloFill stretch blow molder/filler comes with many new advantages // The new
generation of the innovative KHS stretch blow molder/filler system sets new market standards. Systematic overview of the highlights of the InnoPET Blomax Series IV.
T
ravelers to Africa are constantly on
This is precisely what the KHS InnoPET BloFill
the demands of practical use, KHS has further
the lookout for the legendary Big Five.
stretch blow molder/filler monoblock recently
developed the InnoPET Blomax Series III gen-
Even if it’s just this once, they live in
introduced to the market is able to offer
eration of stretch blow molders to produce
hope of catching a glimpse of the elephant,
the beverage industry. This new develop-
Series IV, which is even faster, has a higher
lion, rhinoceros, buffalo, and leopard in the
ment marries the competence of KHS Corpo
capacity, and comes with a whole catalog of
wild. In a certain respect the African tourist
plast (high-speed stretch blow molders) with
advantages for the beverage industry. KHS
has much in common with the businessman
that of KHS GmbH (high-performance filling
Competence has tested the InnoPET Blomax
and engineer also hoping to bag the Big Five.
systems) that has evolved over many years.
Series IV to see if it can deliver the custom-
Their sights are set on a very different target,
The general advantages of monoblocked
ers’ Big Five, describing which technological
however, with quality, economy, and tech-
stretch blow molder and filling system tech-
aspects of the system are setting standards
nology in focus rather than ecology and bi-
nology (see KHS journal 1/2009) are that there
and what’s new to this generation. Many of
ology. To be more precise, their concern is
is no longer any need for an air conveyor
the innovations and refinements are perti-
that all machine systems that go into opera-
segment, costs for PET materials are reduced,
nent to several sections of the machine.
tion should fulfill the following five basic
the system requires much less space, and
criteria: they must be 1) flexible in their use,
costs for energy and staff are cut (see “Plus
2) operate efficiently, 3) manufacture with
points”).
1 Customer request: flexibility
an eye to sustainability and the environment,
But it hasn’t stopped here. The goal
4) operate at a minimum of cost, and 5) be
is to go on providing the customer with even
standard version of the modular system can
simply designed and easy to operate.
more competitive advantages. According to
now process PET bottle sizes of between
NEW Container more variable. The
The InnoPET Blomax Series IV with innovative preform handling: active mandrels, one of the main features of Series IV,
and a TouchGrip system offer reliable and exact guidance of preforms.
28 29
InnoPET BloFill: plus points
The key basic advantages of the
monoblock concept
_ Eliminates the need for an air conveyor
_ Reduces costs for PET materials
_ Uses less energy
_ Offers higher availability
_ Takes up less space
_ Decreases personnel costs.
Additional advantages of the new
InnoPET Blomax Series IV
The intelligent CLever-Loc blow stations used in Series IV enable a higher specific
bottle output, save space with their toggle lever locks, and are also compatible
with the molds in Series III.
_ Able to process more types of container
_ Servo motors optimize synchronization
_ Approx. 2/3 higher monoblock output
(up to 72,000 bph)
_ Approx. 22% higher output per blow
station (up to 2,200 bph)
_ More streamlined technology increases
efficiency (up to 98%)
_ Improved heating technology saves
more money and energy.
120 ml and 3 liters (previously 0.2 to 2.0 liters)
wheels and can be deployed on high-
of various design.
performance lines.
Suitable filling systems. Free-flow filling of
NEW Servo-motor-controlled stretching
non-carbonated beverages and pressure fill-
process. The stretching process in the blow
(such as the 0.5-liter PET) and occasionally
ing of carbonated beverages in a concept
stations is now controlled by servo motor.
also larger sizes (such as the 1.0-liter PET)
that does not require a front table, devel-
Until now, using a mechanical cam-controlled
on one monoblock system, KHS Corpoplast
oped in compliance with hygienic guidelines,
stretching process was standard procedure.
developed the half-load option. Although
is available for hot or cold filling. A mono-
In this type of stretching process it was pos-
this option did not involve replacing the
blocked long-tube filler can be used for the
sible to cut stretch blow molder capacity
stretch cam, it did call for other conversions,
low-oxygen bottling of beer or mixed beer
down to a maximum of 70% without affect-
such as changing over cam disks and grippers,
beverages in large PET bottles.
ing PET bottle quality – and without the need
for instance. The half-load system also did
for a complicated stretch cam change that
not function particularly well with PET bottle
Beverage-specific modules. If non-carbonated
could take several hours. If, in a monoblock
sizes that greatly differed from one another.
beverages are to be bottled, the PET bottles
system, 1-liter PET bottles were produced
Changing over from the 0.5-liter to the
are sent straight to the infeed star of the
and filled in addition to 0.5-liter PET bottles,
2.0-liter PET bottle, for example, still required
filling system after passing through the
the problem arose that a 70% reduction in
changing of the stretch cam due to the con-
airlock. If carbonated beverages are sched-
stretch blow molder output was not sufficient
siderably longer filling process required for
uled for filling, a third cooling segment mod-
for a filling system configured for the 0.5-liter
the larger bottle.
ule is integrated in the monoblock concept
PET bottle. (To elaborate here: a stretch
All of the aforementioned problems
between the airlock and infeed star. Two
blow mold system can make different sizes
have now been eliminated thanks to the
alternative modules are available here. The
of PET bottle within an almost identical time
servo-motor-controlled stretching process.
first has three transfer wheels and is designed
span. The filling system, however, needs more
The speed of the blow molder now per-
to handle an output of up to 30,000 PET bot-
time to fill larger PET bottles.) To assist bev
fectly adjusts itself to the settings of the
tles per hour; the second has five transfer
erage companies who fill both small bottles
filling system. Two-liter PET bottles can thus
be produced immediately after half-liter
spaced approx. 350 millimeters apart. When
made possible by the fact that the preforms
PET bottles – with the speed of the blow
processing 2.0-liter PET bottles, for example,
are now heated using near infrared radia-
molder reduced by 75% if necessary. Con-
the filling system requires a standard bottle
tion or NIR.
versions are no longer a necessity. The result
distance of 125 millimeters. A difference of
is more flexibility than ever before for the
225 millimeters must thus be accounted for.
NEW Shortened buffer area. The reduced size
of the heater segment means that the buffer
beverage company.
Identical airlocks. An identically designed
area between the monoblock and a down-
airlock ensures that the dry area of the blow
stream labeler can be shortened. For example,
molder is kept strictly separated from the
the InnoPET BloFill has to stop for a label
NEW Higher output. The monoblock
wet area of the filler, thereby eliminating
changeover. The usual procedure is to halt
concept now processes up to 72,000 PET bot-
the risk of corrosion in the blow molder. A
the preform infeed. To avoid loss, all preforms
tles per hour. Compared to Series III, this is
flow of filtered ambient air pumped into the
still in the heating element are blow-molded,
an increase in capacity of up to 28,800 PET
system from above ensures that there is a
filled, and buffered in front of the labeler.
bottles an hour.
constant slight positive pressure in the airlock
Because only half as many preforms are now
zone. Flexibility is also given in that the air-
in the heating element compared to the
NEW Higher bottle production. Extremely
lock unit can also be supplied with dry ster-
InnoPET Blomax Series III, the buffer area
compact blow stations are used in the new
ile air according to ambient conditions.
upstream of the labeler is reduced.
bottles per hour and blow station versus the
Precautionary cooling. A cooling segment
NEW Startup time reduced by almost 90%.
usual 1,800 PET bph.
module cools down the bases of the PET bot-
Faster preheating of preforms after each stop
tles for carbonated beverages from around
shortens the startup time considerably and
NEW Just one transfer wheel. After the stretch
75°C to approximately 55°C. The reason for
increases availability accordingly. Where
blow molding process, the standard practice
this is that pressurized PET bottle bases that
previously 2 minutes elapsed before the first
to date was to use one transfer wheel to re-
have not been sufficiently cooled bulge at
preheated preform entered the blow mold,
move PET bottles from the blow molder, a
the base or even burst during filling. This
now only 15 seconds are required.
second to turn the PET bottles, and a third to
and also the formation of stress cracks are
space the PET bottles. These three have be-
avoided.
2 Customer request: efficiency
series that are able to produce 2,200 PET
NEW Efficiency of at least 96%. Both the
InnoPET Blomax Series IV and KHS filling sys-
come one; removing bottles from the blow
station and adjusting the distance of finished
NEW Modified heating technology halves
tems are highly efficient. Considered indi-
PET bottles to one another according to the
heating time. A new heater has been inte-
vidually, each machine has an availability of
configuration of the filling system is now han-
grated in InnoPET Blomax Series IV machines
around 98%. The efficiency of the mono-
dled by just one modular transfer wheel. All
that approximately halves the time required
block system as a whole is at least 96%.
PET bottles leave the stretch blow molder
to heat preforms versus Series III. This is
3 Customer request: sustainability
Bottles & Shapes™: the complete carefree package
Low water consumption. The cooling
process uses a minimum amount of water.
KHS Corpoplast’s Bottles & Shapes™ program specifically boosts the competitive advantages
The principle here involves a system of noz-
of KHS customers. Bottles & Shapes™ is an all-inclusive consultancy service that is optionally
zles that spray fine drops of mist consisting
provided on customer request and offers advice on all aspects of each investment in the
of a mixture of water and air onto the bottle
InnoPET BloFill system. KHS Corpoplast provides a complete carefree package that covers all
bases. The consumption is virtually negligi-
areas of the process, beginning with the bottle design to selection of materials, preform de-
ble. A system with five transfer wheels uses
sign, savings potentials with lightweight PET bottles, bottle engineering, mold design up to
a maximum of nine nozzles, for example,
and including testing and mold trials. All stages of consultancy take into consideration both
with each nozzle spraying just one liter of
the filling technology used and the demands production, retail, and also end consumers make
water an hour. Despite the low consump-
of the PET bottles.
tion, even large and heavy bottle bases are
perfectly cooled.
30 31
The cooling process uses a minimum amount of water, with a nozzle system spraying fine drops of mist consisting of water and
air onto bottle bases.
NEW Compressed air savings. The amount
NEW Heating technology saves space and
deliberately modular. This has the advantage
of compressed air used in the blow molder
preforms. Shorter heating times (see “Effi-
of even greater simplicity and, as a result,
is even further reduced compared to the
ciency”) also mean that the space required
the monoblock system can be set up at the
previous generation. Depending on the
for the heater segment is only half as large
bottling operation much more quickly.
bottle size, 5 to 15% less compressed air is
as for the previous heater. In addition – and
used. This noticeably improves the energy
this is the crux of the matter – only half as
NEW Changeovers twice as fast. Blow sta-
efficiency.
many preforms are inside the heater element,
tions can be changed over in about half the
which means that only half as many preforms
time needed to date. What’s more, mainte-
need to be channeled out of the system if
nance procedures have also again been con-
an emergency stop is triggered within the
siderably simplified.
4 Customer request: economy
Minimized water consumption. The
monoblock.
Greater ease of operation. Monoblocking
low consumption of water (see “Sustainability”) is extremely economical. A water treat-
NEW Optimized use of materials. Regardless
the systems means that one operator can
ment plant is not required.
of the stretching speed, the servo motor (see
now keep an eye on both machines while at
“Flexibility”) ensures an optimum distribu-
the same time keeping tabs on the labeler.
Lightweighting makes big savings. Thanks
tion of material within the produced PET
Rapid access is of course provided when serv-
to the elimination of the air conveyor and
bottles. As a consequence, preforms can be
ice is required.
the extremely gentle transfer of finished
processed that have been optimized down
PET bottles within the monoblock concept,
to the last tenth of a gram of PET material.
lighter weight PET bottles can now be used.
This was not possible in the previous setup.
The weight of a 0.5-liter PET bottle, for
A reduction in speed meant that more ma-
example, is reduced by 2 grams. At an an-
terials were needed to maintain the desired
nual production of 100 million bottles, sav-
PET bottle quality.
ings of around €110,000 can be achieved.
In addition, this reduction in materials also
lessens the amount of compressed air and
heating energy required in the stretch blow
molder.
5 Customer request: simplicity
Modular systems. The monoblock
s ystems used in the InnoPET BloFill are
Frank Haesendonckx | KHS Corpoplast
GmbH & Co. KG, Hamburg, Germany
Phone: +49 (40) 6790 -7475
Heinz Hillmann | KHS GmbH,
Bad Kreuznach, Germany
Phone: +49 (671) 852- 2714
Pallet Ballet
Precision system integration // In mid-2008, Augustiner-Bräu in Munich decided to replace
their palletizing system. The age-old brewery is now making successful use of KHS conveyors
and the KHS Innopal RS3 palletizing robot.
W
hen the traditional meets the
modern, things usually start to
get exciting. Sights were set high
when the planning department at AugustinerBräu Wagner KG begin forming its first
ideas for a new palletizing system. The new
setup was to be both innovative and futuresafe, perfectly fit the shop floor, and at best
also give the internal logistics system a boost.
Not an easy task considering that Munich's
oldest brewery produces its popular beer in
the heart of the city where space is tight.
And to complicate matters further, the new
equipment was to be installed during production – in buildings listed as historical monu
ments. “The citizens of Munich and many
fellow beer drinkers have delighted in the
brewing skills of the Augustinians since 1328,”
says Werner Mayer, managing director of
Augustiner-Bräu Wagner KG, “and a lot of
manual work is still involved in the manufacture of our beer. Yet we also use modern
methods to maintain the high quality of
Augustiner beer. We do everything for topquality beer.”
Beneficial planning with 3D
measurement
When it came to their new palletizing system, the planners at the Augustiner brewery first sounded out the market. Which
manufacturer would be a possibility? Which
products seemed feasible? Who could put
together the best complete package? All
these are typical issues raised during the
decision-making process, the answers to
which usually take a long time to find. Not
so in Munich. “After intense comparison
of the various offers, the many merits of
The Innopal RS3 palletizing robot depalletizes at high speed and with the utmost
precision.
the tender made by KHS soon became obvious,” states Werner Mayer, “which is why
we were able to make a clear decision by
32 33
The Innopal RS3/RK palletizing robot:
the plus points in brief
_ P alletizing and depalletizing robot
_ P rocesses plastic beverage crates, low-wall crates, split boxes, kegs,
casks, cartons, trays, shrink-wrap packs, packets, individual small
packages, and bags
_ S uitable for returnable and non-returnable containers
_ N ominal output of up to 3,600 crates per hour
_ L oads of up to 450 kg (approx. 990 lbs)
_ W
orking radius of 180° (Innopal RS3) or 360° (Innopal RS3/RK)
_ A utomatic head changing for combined processing of returnables
the end of 2008.” Along with the various
technical and financial aspects, the brewery
was convinced by KHS' method of planning.
and non-returnables
_ E asy touch-screen operation
_ F eedback of braking energy to the power supply
_ M
inimum maintenance effort
_ M
odular, freely programmable control system
_ M
any statistics and diagnostic functions
_ L ittle space required
_ L ow cost of investment
For the first time in Munich, KHS made use
of its newly developed 3D technology, using 3D laser scanning to measure the
premises at Augustiner-Bräu. The advantage of this procedure is that empty production halls can be measured just as accurately as areas already equipped with
line technology. “Using the laser data we
were able to not only define an optimum
palletizing and conveyor system for
Augustiner but also to perfectly plan the
various stages of construction,” explains
Peter Barczewski, the KHS project manager
in charge of the project. All the advantages
and disadvantages of the possible placements of the various components were
checked out in advance using an on-screen
simulation program by KHS design engineers working together with the brewery
Grouped Innopal RS3 robots make optimum use of the available space and
enable short processing distances.
planners.
New concept convinces preservationists
Together with the project managers at
Augustiner, KHS developed the idea of putting
in a second floor for the palletizing system,
an Innocheck PKS pallet inspection unit, and
Optimized warehouse logistics reduce
concentrating all components in a compact
Innoline GTR and Innoline PTR conveyor belts
truck wait time
area. The advantages here were extremely
for pack and pallet conveying.
The first priority was to install the top floor
attractive but required the approval of the
In the meantime, detailed planning in
and reorganize pallet conveying, including
historic building preservationists before the
the KHS engineering department was going
the delivery and pickup of the beer pallets.
scheme could be put into practice. The latter
full speed ahead. Each stage of construction
Truck wait times during delivery and pickup
had very few objections; the new palletizing
for the third floor was defined jointly with
in particular were to be optimized by the new
concept, including the new conveying system,
Augustiner-Bräu and the building contractor.
process. The aim was to dispatch trucks
also convinced the authorities. Four Innopal
The first of six stages of installation began the
quickly and effectively; since modification,
RS3 column-type robots were to make up the
latter part of April 2009. “The decision to
this has been handled as described in the
core of the new palletizing and depalletizing
start this complex modification at the begin-
following. After unloading at one of the five
system. Various other components were also
ning of our peak season was undoubtedly an
newly positioned pallet infeeds in the empties
prepared for the job on Landsberger Strasse
unusual one,” says managing director Werner
warehouse, just a few feet further along
in Munich, including three Innopal SF pallet
Mayer, “but we were simply convinced by the
Augustiner beer trucks reload full bottles,
elevators, an Innopal MPH pallet magazine,
first-rate planning.”
crates, and pallets in the full container area.
Unloading and reloading trucks non-stop
a minimum amount of space; Innopal RS3
film wrapping unit and pallet labeler before
with minimum wait times is the perfect
machines are also able to combine processing
they are passed down to the full container
solution here.
of various types of pack by simply changing
storage area and the truck loading bays on
While the trucks are unloading their
the gripping mechanism – fully automatically
the ground floor by the pallet elevator and
cargo spaces, with the help of several turn-
if required. Equipped with state-of-the-art
conveyor belt. “Watching the RS3 robots
ing stations Innoline PTR conveyors whisk
robot technology and modular controls,
automatically load and unload pallets is like
the empties off to the new two-story pal-
t he Innopal RS3 guarantees high system
watching a carefully orchestrated ballet,”
letizing center.
availability, short cycle periods, and the
exclaims Sebastian Fegl from Augustiner-
lowest wear and maintenance effort. The
Bräu Wagner KG. He is particularly pleased
Versatile palletizing robots
fact that they are also freely programmable
that he can observe and monitor every in-
Two separate lines, each one equipped with
opens up c ountless options for use and
dividual step of the 'dance' – or individual
an Innopal RS3 column-type robot, depalletize
makes them future-proof.
processes in the system – on all touch-screen
terminals dotted along the line. “Switching
the pallets of empties layer by layer on the
ground floor. At present, the Augustiner
Convenient touch-screen operation
over to robot technology pays off every sin-
brewery uses Euro and Vichy honeycomb
Augustiner-Bräu also invested in versatile
gle day,” he claims enthusiastically. When
returnable containers; palletizing wooden
and reliable engineering for beer pallet load-
the traditional meets the modern, excite-
beer casks would also be an option. At the
ing, this time one floor up. After the crates
ment is not only guaranteed; the production
Oktoberfest in Munich Augustiner is the only
and bottles have been washed, refilled, la-
of the best possible Augustiner beer is also
brewery to tap beer from wooden barrels.
beled, and inspected, they are returned by
a sure thing.
Innopal RS3 robots shift a maximum load of
conveyor to the third floor of the palletizing
450 kilograms per layer up to 520 times an
center. Here, two Innopal RS3 robots work-
hour within a working radius of 180°. Should
ing independently of one another load the
this radius be too small, its sister model
pallets with packs of Augustiner beer layer
Innopal RK can turn a complete circle of 360°.
by layer. Innocheck PKS and Innocheck PKR
Both robots are equally distinguished by their
machines first check all pallets for damage
variety of variations and use. They are not
or protruding nails. Once fully loaded, the
only able to load and unload pallets within
pallets travel on to the nearby strapping and
Harald Eisenacher | KHS GmbH,
Sales Office Ulm, Germany
Phone: +49 (731) 184766 -72
Three questions for Werner Mayer, Dipl.-Ing.
Managing director of Augustiner-Bräu Wagner KG
Mr Mayer, the new KHS palletizers have been in operation
at Augustiner-Bräu for half a year now. What is your
impression so far?
Werner Mayer: Thanks for asking! We’re completely satisfied, as
the entire system is running efficiently and extremely reliably.
Which factors especially influenced your decision to go for
the KHS concept?
Mayer: The high quality of our traditional beers always has top
Is there one aspect of the implementation you are particularly
priority, and as we all know, Munich is the home of beer. How-
pleased with?
ever, we still have to produce beer economically. Besides the
Mayer: The entire planning process ran smoothly and harmoniously,
outstanding profitability of the investment, favorable operating
yet I was still pleasantly surprised to see that the various stages of
costs, high system availability and performance, and a well-planned
the commissioning process really did take place on schedule without
and efficient overall concept that included the redesigned pallet
disruptions in production. The excellent joint efforts of our plan-
infeed were decisive factors.
ning departments really paid off here.
34 35
Perfect Sanitizing
Safety for all beverage types // Customers expect top quality from beverage producers
at all times. However, high expectations such as these can only be fulfilled if production
systems are cleaned and sterilized regularly. KHS CIP-C series systems offer perfectly
coordinated cleaning procedures for this purpose.
H
ygiene and cleanliness require regular, thorough cleaning – which has
been a known fact in Stuttgart since
1492. Since the Middle Ages, the city's citizens have been required to keep their houses
and streets spotless by law under the stipulations of the famous Swabian Kehrwoche
(spring cleaning week). Cleanliness is also
top priority in beverage production. How
ever, the times when production equipment
was dismantled and cleaned by hand are
long gone. “Beverage production demands
ecologically and economically efficient sanitizing of processing systems,” explains Alfons
Abels-Rümping, product manager at the KHS
Ultra-compact installation: the KHS Compact CIP-C in a container design
GmbH Process Technology Competence Center.
He adds, “If beverage producers cannot rely
on the removal of product residue from production operation, of deposits and decay
products, bacteria and other impurities, they
speeds require intelligent processes to
and keg racking lines. Using hot and cold
cannot operate filling lines reliably and
maintain the microbiological safety of the
water, hot caustic, and individually dosed
successfully.”
operating components. KHS offers custom-
cleaning media, CIP-C units ensure the
ized solutions with its Innopro CIP-C series
m aximum hygiene of the cleaned com
Maximum hygiene with
cleaning systems. The compact components –
ponents during production. Based on elec-
CIP-C equipment
CIP-C stands for Compact Cleaning in Place –
trochemically activated (ECA) water, cold
Increased demands for consumer safety
optionally clean and disinfect the process
cleaning media and disinfectants also guar-
and, at the same time, ever higher production
components and filters, product lines, fillers,
antee microbiological safety.
Whether water, juice, wine, beer, or soft
Sanitizing to perfectly match
minimized mixing phases reduce the use of
drinks, Innopro CIP-C series cleaning systems
customer requirements
chemicals as well as costs; in addition, sepa-
are suitable for all types of beverage and the
CIP-C systems clean precisely in accordance
rate tanks ensure systems can be safely de-
widest range of production methods. These
with each cleaning task. Besides removing
coupled from the customer's water supply.
can be used equally effectively in aseptic
all residue, deposits, and impurities, the aim
A plate heat exchanger heats the clean-
ultra-clean or hot filling and conventional
is to sterilize internal surfaces to remove
ing agents by means of saturated steam or
filling systems. Combined with KHS fillers,
product-contaminating bacteria. The clean-
hot water, whereby the temperature is
mixers and flash pasteurizers, they can even
ing effect depends, above all, on the tem-
electropneumatically regulated. The installed
be designed as a total processing package.
perature, duration, flow velocity, and type
supply pump regulates the increase in the
“Apart from the power supply and the
and concentration level of the cleaning me-
corresponding cleaning pressure and the re-
r equired media, i.e. water, caustic and
dia used. Equipped with three separate tanks
quired circulation of the liquids between
cleaning agents, CIP-C cleaning systems are
for clean water, hot water, and caustic, as
systems. The current degree of contamina-
factory-equipped with all that is needed,”
well as a pneumatic dosing system, the clean-
tion of the cleaning liquids can be monitored
Alfons Abels-Rümping explains. All the
ing capacity of each CIP system can be indi-
by a conductivity meter with a temperature
c omponents, including pumps, valves,
vidually regulated and thus adapted to the
output, which simultaneously controls the
heaters, medium tanks, and control cabinet
different requirements of particular custom-
dosing of the added caustic or acid concen-
including the control are neatly arranged
ers and beverages when filling. Depending
trates. Alfons Abels-Rümping comments,
on a stainless steel frame, installed ready
on the level of expansion required, cleaning
“CIP-C systems ensure a cleaning perform-
for operation and already tested. According
capacities of up to 45,000 liters of cleaning
ance perfectly adapted to a particular bever-
to the product manager, “KHS calls this
agents per hour are possible. This means
age, as well as easily and flexibly modifiable
method Plug & Produce ®”. For the customer
fillers equipped with more than 150 filling
cleaning sequences and media parameters.”
this means extremely quick installation and
valves and their processing systems can be
While users are able to operate the base ver-
commissioning, as in: unpack, plug in, clean.
cleaned at the same time. Short piping and
sion model manually by pressing a lighted
button, fully automatic units are also optionally available. These models are controlled
by a touch screen monitor which also displays
Innopro CIP-C systems (Compact Cleaning in Place)
each of the cleaning processes. In this way
CIP-C systems ensure perfect hygiene and
cleanliness, with cleaning results which can
Cleaning unit for process components and filling systems
be reproduced at all times. In contrast to
for beverage production
the Swabian Kehrwoche however, KHS systems are absolutely flawless and reliable.
All advantages at a glance:
_ C ompletely installed, ready to connect, and tested
_ C leaning capacity: 20 m³/hr, 30 m³/hr, or 45 m³/hr
_ S upply pressure: 4 bar
_ S kid mounted batch tank (integrated into the main unit)
_ S eparate tanks for fresh water (1,000 liters),
hot water (3,000 or 4,500 liters), hot caustic (3,000 or 4,500 liters)
_ H eating media: saturated steam / hot water
_ T emperature regulation: electropneumatic / electronic (optional)
_ M
easurement of conductivity, return flow temperature, and media flows
_ O
peration: manual / automatic by touch screen monitor (optional)
_ P lug & Produce ensures quickest possible commissioning
_ R obust, durable design, CIP unit made entirely of stainless steel
_ E conomical, long intervals between maintenance
_ W
orldwide service
_ C ompact size and on-going operation
_ D imensions: suitable for shipping in a standard overseas container (20')
®
Alfons Abels-Rümping | KHS GmbH,
Bad Kreuznach, Germany
Phone: +49 (671) 852-2211
36 37
Simply Simple
Hygienic design in filling technology. An overview // Hygiene is top priority in the
food and beverage industries. Anything related to product processing must meet
maximum requirements in hygienic design. And the best solutions generally tend
to be simple rather than complicated.
C
ommon sense and also the market, legislation,
functions are as perfect as its hygienic design. The modern,
and industrial regulations demand that great
computer-controlled filling systems on the market today
emphasis be placed on maximum hygiene in the
satisfy very high requirements like these. Typically, they
production and processing of food and beverages. This
feature smooth, fairly simple surfaces, aseptic sealing,
particularly applies to all implemented machines, sys
easy access for cleaning and disinfecting procedures,
tems, and components. They must be designed in such
and an unobstructed runoff of liquids.
a way that contaminants and micro-organisms cannot
accumulate or can be easily removed from the surfaces
From mechanical to computer-controlled
of devices. This is the fundamental principle of hygienic
filling systems
design, the main goal of which is optimum safety for
But first, let's look back so that we can understand the
consumers and employees.
situation better. A few developmental stages in the his-
It goes without saying that producer competitive-
tory of filling technology were needed to achieve the
ness is also important. From the economic perspective,
perfect hygienic design of today. For example, in purely
hygienic design not only pays off because microbiologi-
mechanical filling systems the whole filling process
cal risks are eliminated, but also because it means ma-
was regulated by mechanical elements such as switch
chines and their components can be cleaned quickly and
levers, switch plungers, cams, and controllers which were
easily. Short cleaning cycles mean longer production
actuated by machine rotation. High complexity thus
times and an increased efficiency of line equipment
prevailed in the immediate vicinity of the products them-
which in turn means less cleaning media and lower en-
selves (critical zone A, see “European standard”), with
ergy consumption.
crevices and niches where beverage residue and micro-
Right from the start development engineers con-
organisms could accumulate. Consequently, time-
sistently take all these aspects into account when de-
consuming and costly manual cleaning procedures had
signing new machines. A firm rule is that, without a
to be carried out, even up to dismantling individual
holistic approach, there can be no such thing as perfect
components.
hygienic design. When developing a product, it is nec-
In first-generation pneumatic filling systems, switch
essary to ensure at each stage that machine functions
levers and plungers were replaced by pneumatic cylin-
are designed in accordance with the principles of hygi-
ders. Membranes and expansion joints transferred the
enic design and do not allow micro-organisms to form
force from the cylinders to the product area. As a result,
biofilms. It must be possible to sanitize and sterilize
components could no longer move from the outside
all surfaces quickly. The result is a machine whose
into the product area. However, there were still some
The membrane (right) simultaneously performs four sealing functions of the conventional rod seals in the gas
cylinders (left).
This results in the use of fewer components, and removal of the risk posed by gaps and carryover into the product
area (colored blue) through sliding seats.
38 39
Hygienic design in brief
According to the definition of the German Society for
Hygiene and Microbiology, hygiene is the “doctrine of
disease prevention and the maintenance and promotion
of health”. The concept of hygiene originally comes from
Greek and goes back to Hygeia, the goddess of health.
Nowadays, in issues concerning the highest standards
of hygiene, the prime focus is on the food production
industry. Practical application of these standards chiefly
entails implementing hygienic design in machine and plant
engineering. The main principles are
__ simple design rules,
__ easy access to all machine surfaces for cleaning,
disinfection, and inspection,
__ dispensing with machine surfaces wherever possible,
__ eliminating hidden areas where deposits and biofilms
can accumulate, and
__ the unobstructed runoff of liquids.
The KHS Innofill DRV filling system: many hygienic design components are combined in
this successful overall concept.
filling valve components, springs, and guide parts in the
during the heating and cooling phases thanks to the
beverage passages. Critical areas therefore still existed
comparatively smaller amount of material used versus
here, requiring more thorough cleaning.
the thick-walled rectangular container.
Finally, the
Modern, entirely computer-controlled filling sys-
lightweight construction of the tubular ring bowl les-
tems provide the optimum hygienic design solution, not
sens the drive forces necessary, which in turn reduces
only inside where the filling valves are located, but also
energy consumption and the cost of maintenance.
externally. An excellent example of this is the computercontrolled KHS Innofill DRV volumetric filling system
__2 Control concept with few switching elements. The
which can process the entire range of plastic bottle shapes
control concept has been kept simple and operates with
and sizes from 0.1 liter to 5 liters. This successful, all-
only a few switching elements. For example, only two
inclusive package features many of the components of
pneumatically controlled functions per filling valve are
hygienic design. The Innofill DRS probe filling system
needed for the traditional method of filling carbonated
for bottling beer and soft drinks in glass bottles is equal-
soft drinks. They control the entire filling process, inclu-
ly hygienically designed.
ding the pressing stroke and sealing the bottle mouth
against the filling valve. It is possible to use so few con-
The Innofill DRV filling system: three reasons
trol functions and dispense with a lifting element because
for perfect hygienic design
the energy resulting from pre-pressurizing and from the
__1
Tubular ring bowl with no corners and crevices.
filling pressure is transmitted directly to the neck ring
The filling system has a tubular ring bowl with filling
holder by expansion joints designed in accordance with
valves flanged to a separate valve support system out-
aseptic design criteria. There now no need for bottle-
side. The advantages are that there are no corners
lifting elements nor the associated components and con-
and crevices; liquids always flow to the deepest point,
trollers for supplying air and lubricants.
which is ideal for CIP and SIP processes. Another bene
The general principle is that the fewer the pneu-
fit includes lower costs since less energy is required
matically actuated membrane cylinders used, the fewer
Hygienic design: a European standard
European standard DIN EN 1672-2 (hygiene requirements for
food processing machinery) identifies different hygiene areas for
machines and systems which are exposed to food. Technical
solutions must be based on these standards. Most importantly,
hygienic design must be consistently implemented in zones A
and B.
__ Zone A: concerns the foods themselves, from where contaminated products could get back into the product mainstream.
In the beverage industry zone A could include piping and
tanks, in which products flow, or the area around the filling
valves in the immediate vicinity of open bottles or cans.
__ Zone B: the spraying area, from where products can no longer
get back into the product mainstream via a direct route.
However, since product sprays can also stimulate the growth
of microbes, there is a danger that germs will enter zone
A. Zone B includes, for example, machine cladding and star
shafts.
__ Zone C: this is the non-food zone outside danger zones A and
B. It includes, for example, the outer area of the filler housing, and also the bottle conveyors located in front of it.
The Innofill SV-ACF Capper has been specially designed for an aseptic process in which the fundamental separation
of capping movements into rotational cap and vertical bottle motions is a great advantage.
mechanical elements and hose connections required (al-
the plastic bottle. The benefit is that there are no radi-
ways located outside the hygienic area). Ideally, pneu-
ating elements protruding into the bottle.
matic pilot valves should also be placed outside the hy-
The gas passages are equally simple in their design.
gienic area in closed, easy-to-clean stainless steel housings
Gas cylinders with gapless sealing systems control the
– as in the case of the Innofill DRV.
filling process. The targeted cleaning of the process passages is also computer controlled.
__3
Filling valve with many advantages. The fill
As a result, all computer-controlled KHS filling sys-
ing valve has open rod guides for the neck ring holder
tems function in full compliance with hygienic criteria.
and smooth external surfaces and sloping surfaces on the
Both sealing systems and design principles comply with
gas cylinders, specifically designed to aid product run
the requirements of aseptic filling. This provides further
off. All the sealing systems inside are aseptic. There are
proof of the fact that, even with traditional technology,
no springs or guide parts inside the beverage passages.
KHS relies on hygienically optimized systems, thereby
A single seated seal opens and closes the filling valve.
consistently achieving the very best in hygienic design.
The advantages are that there are no spaces in which
deposits can accumulate; cleaning and sterilization are
Example innovations
kept simple.
__ Expansion joints
All the passages through the filling valve are short.
The individual elements integrated into the filling system
The advantage here is that very few parts and only small
must be reappraised time and again in terms of achiev-
surfaces are exposed to the product. Swirlers are used
ing the most perfect hygienic design possible. An exam-
to fill the product. The filling principle is that once the
ple of a new development further enhancing the hygiene
filling valve opens, the liquid flows down the walls into
of the Innofill DRV are the aseptically designed expansion
40 41
joints. This means the lifting elements and associated
allowing liquids to drain away. This prevent sumps and
peripheral elements can be completely eliminated since
deposits forming in the first place.
the expansion joints transmit the pressure through an
aseptic passage inside the filling valve to the bottle
__ From rinsing sleeves to switchover
pressing mechanism.
Humans are a source of contamination and persistent
The principle here is that the expansion joints are
danger, prompting us to continue to automate our proc-
made of PTFE, a special durable material which is highly
esses more and more. For example, instead of inserting
resistant to hot temperatures, fully resistant to clean-
rinsing sleeves manually before cleaning, the rinsing caps
ing media and disinfectants, and has a dirt-repelling
are now positioned automatically in plastic bottle filling
surface structure. Cleaning agents flow through the
systems; conversion to a new filling method, for exam-
expansion joints tangentially during CIP cleaning,
ple, from normal pressure filling to counterpressure fill-
thereby ensuring optimum dirt removal and discharge.
ing, now takes place automatically; switching between
This is verified both in practice and in numerous
bottles with different mouth shapes can be done at the
l aboratory experiments based on EHEDG (European
push of a button. All these measures not only result in
Hygienic Engineering & Design Group) specifications
maximum hygiene and optimized hygienic design; they
and simulating extreme contamination after applying,
also allow for increased system accessibility.
for example, beer concentrate or carrot puree to expansion
joints and then allowing it to dry.
The Innofill SV-ACF: maximum hygiene
The KHS Innofill SV-ACF screw capper ensures maximum
__ New probe solution
hygiene in the capping area. It was developed for use
Another example of a single development which now
with aseptic filling machines and is therefore predes-
ensures even greater hygiene is a new probe inside the
tined for use with all other hygienic processes. A crucial
KHS Innofill DRS filling system. Previously, complex ele-
factor is that even the capper guides and bearings have
ments and seals were needed for the necessary separa-
an open design, allowing free access for cleaning and
tion of the electric plus and minus poles of a control
disinfecting. Each capping spindle has a dedicated
signal. Now a stainless steel rod is implemented which
servo drive which adjusts the capping torque to suit
separates the poles by means of a permanently attached
individual caps, regardless of the machine speed.
insulation coating – completely gap-free.
Changeover is at the push of a button and there is no
need for mechanical intervention.
__ No machine front table
Another highly important factor in terms of enhanced
Effective hygienic design saves time and money
hygiene is that, today, filling can be done entirely with-
Above all, hygienic design means one thing: implement-
out the traditional machine front table. This is thanks
ing simple solutions which generally even lead to a cut
to servo technology with individual drives, which dis-
in costs. As a rule, the consistent, practical application
penses with the need for gearboxes, large gear wheels,
of hygienic design makes systems more efficient. On the
and joint shafts.
one hand, this is thanks to cleaning processes which can
be carried out more simply and quickly, on the other, to
__ Seals with no gaps
less complex technical solutions and therefore minimal
Seals or membranes are necessary everywhere: in filling
use of wear parts. Ultimately, these numerous benefits
valve connections, connections for pipe flanges and fit-
give the food and beverage industries a clear competi-
tings, and in tanks. Although normal O-rings act as seals,
tive advantage. This is a victory for common sense.
when they are inserted into traditional grooves, they
often leave gaps, creating the perfect niche for product
residue and microbes. This problem is solved by designing O-ring grooves in such a way that the O-rings slot
straight into them. There are then no more gaps.
__ Design principles
Smooth welding of pipes and sheet metal structures is
a must. Any uneven surface or misalignment conceals
the risk of contamination. An equally simple hygienic
design solution for the filling area is to slope surfaces,
Ludwig Clüsserath | KHS GmbH, Bad Kreuznach, Germany
Phone: +49 (671) 852-2501
Market Report
KHS technology successful across the globe
The Heinrich Reissdorf Microbrewery in Cologne
Turnkey Keg Line
for Kölsch
In the cathedral city of Cologne, everybody knows the market leader
machines. For example, if a 50-liter keg has a Bavarian-style tap, the
of Kölsch beers: the traditional Reissdorf microbrewery established
system recognizes this in the combined washer and cleans it using a
in 1894. KHS recently delivered and installed a complete turnkey
preset cleaning mechanism.
keg line at the company that in its own words has “continuity and
Because each keg is equipped with a transponder, keg histo-
a sense of what's really necessary”. The brewery opted for KHS as
ries can be stored in a database. Using this data, the kegs can be
its competent supplier as the company was able to install such a
monitored. The system transports the racked kegs on pallets with
complex system ready for use in the given operating environment.
the pertinent data to the fully automatic warehouse.
Technical dimensions. The keg line is capable of racking 700
Reissdorf employees thus always know which keg with which
kegs per hour and is used exclusively for top-fermented Kölsch beer.
transponder data is stored on which pallet with which number in
It processes PLUS kegs with a flat fitting and a Bavarian-style tapping
which warehouse bay.
system in 10-liter or Pittermännchen format, and in sizes of 20, 30,
A Plant Monitoring System (PMS) collates and processes any
and 50 liters. The empty kegs are conveyed in several layers on pal-
additional data. Remote diagnostics are possible via KHS' ReDiS
lets to the racking system. The machine destacks, washes, and racks
system (Remote Diagnostic Service). The company thus has a per-
the empties and then palletizes and restacks them. The pallets are
manent link to KHS. One new development is that line can now
then sent to a fully automatic, high-bay warehouse. The pre-washer
detect leaks in both flat fittings and Bavarian fittings. Rejected kegs,
and main washer are integrated in one machine as a combined unit
such as those with leaks or faulty transponder data, can be processed
that also cleans the side bung hole.
at the keg repair station. All work processes are stored in the data-
Special process engineering features. All processes can be
continuously tracked by transponders and antennas that have been
base. Before they are re-racked, the fittings on serviced kegs are
automatically retightened in addition to regular treatment.
systematically installed in the kegs and on the line. The antennas
read the data from the kegs and communicate with the relevant
www.reissdorf.de
42 43
Oettinger Brauerei, Oettingen, Germany
65,000-cph
Can Pasteurizer
At Germany's largest privately owned brewery, Oettinger Brauerei GmbH in Oettingen
in Bavaria, a KHS can pasteurizer with a can conveyor has now gone into operation
with an impressive peak capacity of 65,000 cans per hour. The old-established
brewery, the first written record of which goes back to 1333, has five locations in
Germany. Besides its headquarters in Oettingen, the company also brews beer in
Gotha, Schwerin, Mönchengladbach, and, since 2009, in Braunschweig (Brunswick).
All of the sites attach great value to making independent beers that are typical of
the area. These are then marketed and sold regionally by the company. Cuttingedge logistics and its own transport fleet enable Oettinger to deliver to over 10,000
points of sale in the country. With a production of over 6.4 million hectoliters, the
FoodCare, Zabierzów, Poland
Oettinger Group is one of the largest brewery groups in Germany.
Power for the
Tiger Drink
www.oettinger-bier.de
Derhim Industrial, Al Hudaydah, Yemen
Modern Times
FoodCare SP z.o.o. in Zabierzów, Poland, has taken de-
A bulk depalletizer and tunnel cooler/warmer for the canning line and a whole
Tiger energy drink, FoodCare has been the country's
range of modern equipment for existing KHS lines have now been supplied to
market leader in this segment since 2007. The system
Yemen's Derhim Industrial in Al Hudaydah on the Red Sea, one of the hottest
uses the latest in innovative technology and operates
places in the world. The company, with a workforce of around 1,000 employ-
with the highest standards of safety. On its website the
ees, has sworn by KHS quality for many years and is now boosting capacities
company stresses that less than 5% of all companies in
with its newly purchased machines. Derhim Industrial was founded in 1980
this industry worldwide use such advanced filling tech-
and is one of the most innovative companies in Yemen, specializing in soft
nologies. The installation of this line represents a very
drinks, fruit juices, mineral water, and energy drinks. Its best-known brands
important phase in the development of FoodCare and
are Dico, Rani, Tiger, Alrahma, and Hi 4 U.
also creates new job opportunities.
www.dico-ye.com
www.foodcare.pl
Coca-Cola Içecek, Elaziğ, Turkey
PET Right Down
the Line
Last year, Coca-Cola Içecek completed a new building project
on the greenfield site at Elaziğ. A new KHS CSD PET line recently went into operation here that can process either 24,000
2.5-liter bottles, 27,000 2.0-liter bottles, or 35,000 1-liter bottles per hour. A complete PET high-performance line, including an innovative InnoPET BLOMAX 20 stretch blow molder,
is now in operation at Elaziğ. Special features include a preform blowout facility in the BLOMAX, an air conveyor with
three-stage filtration, and a PET filler. Practically identical KHS
systems can be found at the CCI sites in Corlu and Kemalpaşa,
Turkey.
www.cci.com.tr
livery of a complete canning line from KHS designed to
process 48,000 0.25-liter slim-line cans per hour. With its
| Market Report |
Teusser Mineralbrunnen,
Löwenstein, Germany
It Had to Be KHS!
KHS has delivered a rinser/filler monoblock with a capacity of 22,000
PET bottles an hour to Teusser Mineralbrunnen Karl Roessle GmbH
& Co. KG in Löwenstein-Teusserbad. The KHS filler is monoblocked
with an Innofill DRV PET 60/15 capper and a KHS Innoclean PET-ZM
50 PET rinser designed for rinsing with two media. In the past,
various machines provided by different suppliers were in operation
at the mineral water company in Baden-Württemberg. Now the
company just wants KHS, as it requires extreme flexibility from the
new machines. For example, the new filler can process carbonated
and non-carbonated products both in a single-chamber and triplechamber filling procedure and also uses pressureless filling for noncarbonated beverages. Nitrogen dosing stabilizes the bottle for
pressureless filling. KHS has also met other requirements stipulated
by the bottling plant, namely the ability to apply flat caps and
Seaquist closures.
www.teusser.de
Gramex2000, Veresegyház, Hungary
Premiere for Dry ACF
Coca-Cola Enterprises,
Milton Keynes,
Great Britain
needed for the gentle production and filling of syrup and juice in PET bottles. The line has
90,000-cph
Canning Line
an output of 12,000 bottles per hour. Gramex2000 is a young, up-and-coming company with
A t t h e e n d o f l a s t y e a r, a c o m p l e t e
one of the most modern production lines in Hungary. In addition to contract filling for well-
90,000-cph KHS canning line went into op-
known European beverage companies, Gramex2000 also markets many of its own products.
eration at Coca-Cola Enterprises in Milton
www.gramex2000.hu
Keynes, England. The new line replaces an
Gramex2000 Ltd. is the first private company in Hungary to successfully invest in the dry aseptic process. The enterprise, situated in Veresegyház, has now been supplied by KHS with a
complete dry ACF line with a linear filler, including all the process engineering equipment
extremely reliable and well-used Holstein
& Kappert canning line from the beginning
Distell, Springs, South Africa
of the 1990s and has a maximum filling
Long Tube Number Two
capacity of 90,000 0.33-liter or 60,000
The Distell Group, South Africa's leading producer of fine wine, brandy, and cider with
now form packs of 4, 6, 8, 10, 12, and 15
4,200 employees worldwide has now installed a non-refillable glass line for cider from KHS
cans, for example. The site at Milton Keynes
at its plant in Springs. The line can fill 60,000 0.33-liter ACL bottles per hour. In the year 2000,
houses the second-largest Coca-Cola plant
Distell took delivery of a line with the same capacity for this plant. The company has
in Great Britain. From here, over a third of
thus decided in favor of KHS technology once again – complete with a long-tube filler.
all Coca-Cola products in cans are shipped
In addition, KHS also installed a new Innopro PARAMIX mixer including alcohol metering
to market throughout the whole of the
and a flash pasteurizer.
British Isles.
www.distell.co.za
www.cokecce.co.uk
0.5-liter cans per hour. With the extremely
flexible new KHS system, the company can
44 45
Compañía Cervecera de Puerto Rico, Puerto Rico
Perfect Partnership
Craig Hylwa, operations team leader at Compañía
last detail and are thus fully coordinated with one an-
Cervecera de Puerto Rico, comes straight to the point.
other. Hylwa says, “The key factor for us is German qual-
“We have a partnership with KHS that simply couldn't
ity standards. It's not without reason that German engi-
be better,” he says. And the man knows what he's talk-
neering enjoys a particularly good reputation world-
ing about. For recently KHS installed not one but three
wide.”
complete systems at his company:
_a glass line processing 60,000 non-refillable glass
bottles per hour,
_a can line handling 75,000 cans per hour, and
_a keg line with a capacity of 60 kegs per hour.
of production, to saving time, and to an increase in machine availability with maximum flexibility. Below are
just a few of the highlights of the filling systems:
The technology of all components on the lines is state
_The glass line operates with an Innofill DRS-ZMS
of the art. The machines used in the turnkey plant en-
equipped with 144 filling stations and a computer-
gineering by KHS come from both Germany and from
controlled, pneumatic pressure filling system that
KHS factories in Brazil and Mexico. They are thus as per-
permits an extremely low-oxygen filling process with
fectly attuned to one another as the quality of the tech-
the least possible use of CO2 (230 grams of CO2 per
nical systems.
hectoliter of beer; the O2 pickup is a likewise excellent
All KHS plants worldwide operate according to a
KHS seal of quality that has been honed down to the
The partners at Compañía Cervecera de Puerto
Rico attach great importance to the maximum quality
0.02 milligrams per liter).
_T he filling system gives the brewery the utmost
| Market Report |
flexibility when it comes to future developments (bottle
machine design. Flexibility is also writ large. The glass
sizes and shapes new to the market can be filled with
line fills 7-ounce and 12-ounce non-refillable bottles,
existing or newly developed qualities of beer or car-
equivalent to 207 and 355 milliliters. The canning line
bonated non-alcoholic beverages at any time).
currently only processes one type of container, the
when the product and/or bottle are switched, a high
other options. “The containers currently in use are by
degree of availability thanks to the central fill level
no means a permanent fixture. KHS engineering opens
adjustment, and a speed and standstill-independent
up many other possibilities for the future – both with
process. It can also adapt the filler output to the re-
regard to types of bottle and can and also new bottle
spective line capacity.
designs and extremely varied packaging options. We are
_The Innofill DRS-ZMS also has short changeover times
_T he heart of the canning line is the computer-
10-ounce or 206-millimeter can. However, Hylwa foresees
extremely well prepared.” All of these investments were
controlled, volumetric Innofill DVD filling system
part of a strategic investment plan instigated by the
equipped with 92 filling stations. The advantage of
traditional, family-run brewery that also included new
this machine is the pressure-controlled, low-foam
buildings, a new brewhouse, and new plant equipment.
snifting. A push of a button is all that is needed to
It is thus not without reason that the company,
changeover to other cans with the same can diameter.
founded in 1937, is considered one of the most modern
Carlos Agelvis, brewing team leader at Compañía
breweries in Latin America. Compañía Cervecera de
C ervecera de Puerto Rico, remarks, “What we
Puerto Rico is the second-largest brewery in the Carib-
particularly like about KHS filling technology is the
bean and is also one of the top ten U.S. breweries to
extremely low-oxygen filling process.”
boot. The group's biggest brand of beer is Medalla Light,
The team also manages to make considerable sav-
mostly sold in cans. This is a light, high-quality, expres-
ings in water and energy on both lines thanks to sev-
sive lager that has plenty of taste as it contains more
eral sustainable, ecologically-friendly refinements in
bitter substances than many other light beers. The company's other main brand, sold as a non-alcoholic alternative to beer, is Malta, usually marketed in non-refillable
glass bottles and widely available on many islands of the
Caribbean and in the United States. According to Craig
Hylwa, Medalla Light has all the makings of a good export product. The idea is that it should follow the example of the Puerto Ricans and make a name for itself
in the chief centers of the United States, such as New
York, Miami, Orlando, and Chicago. Hylwa claims, “If
all goes according to plan, we can continue to build on
our successes.” Among other things, this simply illustrates that this is a family-owned brewery that scores
additional points through its readiness to make decisions
and its high degree of flexibility.
The company began its steep rise to fame at the
turn of the millennium, when Carmen Amalia Valdes
became president of Compañía Cervecera de Puerto Rico
(previously Cervecería India). She is the oldest grand-
The Innopack Kisters WSP wrap-around shrink packer is highly flexible
when it comes to secondary packaging.
daughter of brewery founder Alfonso Valdes and his
wife Garcia Valdes, who took over the business on the
death of her husband. With the support of her husband
46 47
Flexible and efficient: like the Innofill DVD can filler, the Innofill DRS-ZMS glass bottler also
employs an extremely low-oxygen filling process.
Craig Hylwa, the new company director has since boosted
the island; 15% of it is also exported to many other Car-
the group's market share of the Puerto Rican beer market
ibbean islands and to the US. Medalla Light could follow
from 6% to currently about 30%. Sales figures shot from
in its footsteps.
400,000 hectoliters to 1.2 million hectoliters in 2008, with
“We are extremely pleased with our success at all
60% of this captured by Medalla Light and 40%
levels,” concludes Hylwa, and adds with a smile: “Of
attributable to Malta.
course, KHS technology also has a significant role to play
This success is no coincidence. Compañía Cervecera
as a bringer of good luck! Only extremely flexible line
de Puerto Rico has always placed great emphasis on qual-
technology can help us to keep all our options open –
ity, as demonstrated by the many awards it has received.
both for other types of bottle and can and also new bot-
At the New Zealand Beer Awards in 2007, the brewery
tle and packaging designs. We are thus well prepared
was presented with the gold medal for the best American-
for all imaginable future eventualities.”
style lager. In the same year it also picked up a few Quality
Medals at the Australian International Beer Awards.
The partners of Compañía Cervecera de Puerto
Rico must also be well prepared on all fronts. KHS, for
Another big success factor was undoubtedly the
example, needed a total of 86 large containers to ship
switch to distribution partner Coca-Cola in the year 2000.
all the equipment for the three lines over to Puerto Rico.
On the Latin American market, it is not unusual for manu
There wasn't enough space to store these on site, so that
facturers of soft drinks to also distribute brewery prod-
the brewery had to hire a separate plot for the contain-
ucts. The cooperation with Coca-Cola works extremely
ers. The lines were assembled and commissioned ex-
well. Another plus point was the marketing. Carmen
actly according to plan. “KHS also deserves a huge com-
Amalia Valdes took the helm here, promoting a number
pliment for its perfect logistical achievements,” enthuses
of new activities. Medalla Light beer is now well repre-
Hylwa. “We are well on the way to establishing a world-
sented in all of Puerto Rico's media – on TV, on the radio,
class brewery here in Puerto Rico.” And there doesn't
in print, on billboards, and on the Internet. The main
seem to be anything standing in his way …
target group is young adults between 18 and 24 years
of age. The malt beverage Malta is also very popular on
www.cerveceradpr.com
| Market Report |
Henkel Central Eastern Europe (HCEE), Vienna
Premiere for 3-liter
PET Bottles
with Recessed Grip
The Henkel plant in Vienna, Austria, is working very successfully with
whole range of advantages for us has been fully confirmed.” Those
a newly installed KHS Corpoplast, high-capacity, rotary stretch blow
responsible for the switch soon realized that:
molder with lots of extras. And now the key question: why does
Henkel in Vienna keep investing in KHS Corpoplast technology, with
five stretch blow molders from Hamburg now on site and 25 in operation throughout the entire concern? Like on any best-practice
storyboard, it's worth taking a brief look at this long-term relationship between the two companies.
_ 1. T he stretch blow molding process with preforms is much simpler than extrusion blow mold technology,
_ 2. stretch blow molders take up less space,
_ 3. make systems independent of converters,
_ 4. reduce process costs, and
_ 5. improve bottle aesthetics.
Martin Bachmayer, production manager at Henkel in Vienna, adds,
Visit to Vienna
“In the years of working with KHS Corpoplast we have learned to
The Henkel plant in Vienna began treading new ground in the mid
appreciate that in them we have a partner who not only makes top-
1990s. Prior to this, bottles were manufactured from polyethylene,
quality stretch blow molders but also has a wealth of expert knowl-
polypropylene, and PVC for all kinds of liquid products in an elabo-
edge on the design of PET bottles.”
rate extrusion blow molding process. Werner Rosenberg, then re-
The goal of the most recent project was not only to construct
sponsible for the control of liquid products at Henkel Central Eastern
a stretch blow molder that met Henkel's specific requirements but
Europe (HCEE), initiated the changeover to stretch blow molded PET
also to design a variety of PET bottles holding one to three liters
bottles. Wolfgang Hlavacek, HCEE's engineering manager, says,
that have a particularly user-friendly recessed grip. Bachmayer claims,
“Werner Rosenberg's assumption that PET bottles would have a
“The result is extremely satisfactory. We have been able to:
_ 1. cut manufacturing costs,
_ 2. plan production even more flexibly, and
_ 3. once again save a noticeable amount of space.
This is important for us; as a rapidly expanding company, we rely on
plant technology that operates extremely efficiently and also takes
up little space.”
The new generation: the InnoPET Blomax 8 CL PH
The new generation of stretch blow molders, the InnoPET Blomax 8
CL PH, is destined to make a contribution to the company's successful history. The machine has 8 blow stations that take up just 20
square meters (215 square feet) of space, producing 1-liter, 2-liter,
and 3-liter PET bottles at an output of 11,200, 10,400, and 8,000 bottles per hour. A 4-liter size also wouldn't pose a problem. Hlavacek
Wolfgang Hlavacek, engineering manager at Henkel CEE (left), Martin Bachmayer, production manager at Henkel in Vienna (right),
and Björn von Lengerke, general sales manager at KHS Corpoplast, in front of the InnoPET Blomax 8 CL (compact large), equipped with
blow stations for particularly large containers.
is enthused. “This machine allows us to not only produce large-size
PET bottles inline but also to introduce recessed grips to this size of
PET bottle for the first time ever. This is something Werner Rosenberg
thought about years ago. The technology that has now come into
play is, in our opinion, a great achievement.”
48 49
KHS Corpoplast blow-molding components tried and tested over
The new InnoPET Blomax 8 CL PH also contributes to the aspect of
many years have also been integrated into the new stretch blow
sustainability within the company. The Airback air return system
molder. And as in earlier projects, the experts at Henkel in Vienna
already included in other systems has now been improved upon by
and KHS Corpoplast mastered the challenges they were presented
adding a ring vessel. This salvages the compressed air that would
with together. In the 1990s, for example, a preferential heating
otherwise remain in the bottles and feeds it straight back into the
process was developed for the oval bottles traditionally used by
compressed air supply system. This is known as the Airback II air
Henkel, a procedure that guarantees the optimum distribution of
return system. “This system”, claims Bachmayer, “will help our sales
materials and uses as little material as possible to produce bottles
figures to increase and us to achieve our planned production target
of the best possible shape.
of 270,000 metric tons a year even faster.” In 2010 – and this is of-
It thus comes as no surprise to learn that within the Henkel
ficial – the Henkel factory in Vienna is planning to produce 230,000
concern, Vienna is heralded as a center of competence in the field
metric tons of goods, 150,000 of which are to be liquid products. In
of PET bottle production. Since the turn of the millennium, KHS
view of the further growth predicted for Henkel products on the
Corpoplast has been a constant partner to Henkel CEE in the design
Eastern European market, this seems perfectly feasible. These growth
of over 30 new variations on the PET bottle, from the initial idea to
figures, thinks Mario Altan, senior brand manager of Henkel CEE,
industrial manufacture. Here, KHS Corpoplast's special Bottles &
are largely contributable to the high level of investment shown by
Shapes™ program was put to good use (see page 30), also in the
Henkel, including innovations in both concept and packaging. “These
design of large PET bottles with recessed grips. The shape of the
innovations,” concludes Hlavacek, “will also be of great significance
container was developed using computer simulation. Samples (hap-
in the future to the increase in production flexibility brought about
tics and visual design) were then produced and finally the bottle
by the inline manufacture of PET bottles – and, accordingly, also to
went into production, at first just on a lab machine.
our partnership with KHS Corpoplast.” Competence | 01.2010
www.henkel.at
| Market Report |
Coca-Cola / Yanjing Guillin / Anheuser Busch InBev / Heineken (China)
Joss in Shantou
J
oss is an important word in the Chinese
One good example of a company with plenty
language, for it means “luck” or “hap-
of joss is the KHS plant in Shantou. Since the
piness”. And the Chinese don't leave
KHS Group strengthened its presence in
something as significant as this to chance.
China a few years ago by acquiring the ma-
To secure personal luck and happiness, they
jority interest in Chinese Guangdong Light
humor the gods and let sleeping dragons lie.
Industrial Machinery Plant 2 Ltd (GLM2), the
In the Chinese world of business, however,
company has written its own success story
concentration is more focused on the earthly
through systematic action, innovation, and
rather than the celestial. But here again,
quality. A key factor here was that KHS
joss is only assured those who leave nothing
Shantou realized it could win or keep well-
to chance …
known customers with suitable products and
50 51
individual systems catering for various branches
of industry. The following highlights the
achievements of the financial year 2009 and
outlines the perspectives for 2010.
The highlights of 2009: Coca-Cola Cofco
and Yanjing Guillin
In China, the start of 2009 was overshadowed
by the world economic crisis. A certain hesi
tation was noticed when it came to investment, meaning that orders were noticeably
depleted in the first half of the year. Yet in
the second half of 2009, the massive programs
of economic support launched by the Chinese
government reaped rewards. During the
course of the year the country performed a
Members of staff at KHS GLM2 Ltd. and plant manager Dr. Felix Wagner:
convincing customers with expertise and quality.
small miracle, boosting its economy by an
impressive 8.7%.
Chinese customers of KHS thus abandoned their reluctance to invest in the second
half the year and set course for an economic
upturn. This is mirrored in the overall annual success of KHS GLM2:
_It now has 70% of the market share for
beer lines in China;
_It has been working at full capacity since
July 2009; and
_It has a balanced net income/loss for 2009
despite the extremely quiet first halfyear.
The management and staff also put the slight-
output of 26,000 0.6-liter PET bottles per
The highlights of 2010: Anheuser-Busch
hour. The outstanding product advantages
InBev and Heineken
of a PET filler made in China are:
More products and projects are to follow this
_Tried-and-tested
KHS neck handling
throughout the entire machine
_Rinser with active 'no bottle, no rinse'
function
_Filler with an original KHS Innofill DMG-
year. KHS' Innopal palletizers and the Innoline
conveyor, that has proved its worth worldwide, are creating a vortex in the market.
Thus in the second quarter of 2010, the first
two Innopal AS1H glass bottle depalletizers
VF filling valve that permits a filling tem-
are to be delivered to Anheuser-Busch InBev.
perature of 15°C for soft drinks
And in the course of the Heineken Guangzhou
project, KHS was able to persuade customer
ly quieter periods to good use. They were
able to considerably improve processes and
Another very special product highlight for
Shanghai Asia Pacific Breweries (Heineken)
technologies, complete ERP implementation,
China in 2009 was the Innopas C pasteurizer.
to order two 24,000-bph glass lines from
and systematically rework the quality assur-
As it is already in very successful use in many
KHS.
ance setup. Together with the transfer of
other parts of the world, it seized the Chinese
expertise consistently geared towards the
market by storm – for two reasons in par-
The result. With a view to doing business
customer, all this has convinced Chinese cli-
ticular. Firstly, the excellent PU control beats
long term, KHS in China is building techno-
ents to opt for KHS. KHS GLM2 is thus now
the specifications otherwise typical for China
logically and economically sound systems for
the preferred supplier to the Chinese brew-
by a factor of ten, meaning that Chinese
its customers using both local and imported
ing industry for packaging systems.
breweries and beer drinkers can enjoy a much
products. We could call it systemized joss.
After equipping the mechanical beer
improved stability of flavor in the future.
As the old Chinese proverb goes, “No road
filler with an original KHS Innofill DMG filler
And secondly, the Innopas PIISC pasteurizer
is too long with a friend by your side.”
and capper system in 2008, as a consequence
is also convincing when it comes to consump-
the company began taking its first steps on
tion, this being so precisely configured that
the PET market last year. At Coca-Cola Cofco
it achieves considerable savings in electricity
in Nanchang in March 2009, the first Innofill
and water. KHS GLM2 has now sold 18 tun-
CZN PET rinser/filler/capper monoblock was
nel pasteurizers to customers throughout
successfully commissioned with a nominal
the country.
Dr. Felix Wagner | KHS GLM2 Ltd., Shantou, China
Phone: +86 (138) 2588 -7060
In-house News
News from the world of KHS
A Visit Says More Than
A Thousand Words
On site in the Far East // The KHS Supervisory Board and Executive Management Board
visited customers and KHS plants in China and India to see just how well their staff and
systems are performing in these boom regions.
A
journey of a thousand miles,” said
legendary Chinese philosopher Laozi,
“begins with just a single step”. And
this is just how the visit of a delegation from
KHS started – at their own plant in Shantou,
Guangdong. In February of this year, the chair-
inery
l Mach
dustria
In
t
h
ner,
ig
lix Wag
dong L
: Dr. Fe
Guang
t)
f
h
o
g
s
ri
,
st
ny
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, left to
h,
ng Zilia
(GLM2
nd Flac
ny, Wa
Plant 2
Iianno
n, Rola
n
g
a
n
e
h
rm
h
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g
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n
o
rg
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Heinz
r.-Ing.
Prof. D
ecker.
B
rd
a
rkh
and Bu
man of the KHS Supervisory Board Prof. Dr.Ing. Heinz Jörg Fuhrmann (also vice-chairman
of the Executive Management Board of
Salzgitter AG), the chairman of the KHS GmbH
Executive Management Board Roland Flach,
and KHS' CFO Burkhard Becker went to ex
amine the high achievements of the approximately 1,000 employees working at KHS GLM2
near the coast of the South China Sea.
KHS GLM2 Co. Ltd. (see also page 50)
is the newest of the eleven KHS production
Holdin
g deta
iled an
the ma
d inform
nagem
ative ta
ent of
lks wit
KHS G
h
LM2.
sites worldwide, with GLM2 standing for
Guangdong Light Industrial Machinery
Plant 2.
52 53
In an area of 105,000 square meters (over a
million square feet or about 15 soccer fields)
the plant chiefly manufactures filling systems,
pasteurizers, and packers for the Chinese
market according to global KHS standards
of quality. After a not entirely smooth start
a few years ago, the company has now long
convinced local customers with its optimized
Tourin
g the
site in
Burkh
Ahme
ard B
dabad
ecker,
Rolan
(left t
Prof.
d Flac
o righ
Dr.-In
h, G.S
g. Ma
t):
. Bhull
tthias
er, an
Niem
d Yan
eyer,
tindra
Sharm
a.
products and individual systems.
And it is precisely here that the second
stage of the journey to the Far East began,
with the top-flight delegation testing that
the above criteria were met at Kingway
Brewery (Shantou) Co. Ltd. in Shantou that
uses KHS systems in the production of its
well-known beers.
The managers of the joint venture partner, Zheng Iiannony and Wang Ziliany, gave
the German delegation a very warm welcome.
The KHS delegates were joined by the management of KHS GLM2, represented by Fei
Song and Dr. Felix Wagner. During an extremely stimulating round of talks a great
number of specific market-related and also
technical questions were discussed in the
traditional KHS manner – namely with the
focus on the customer.
Also in search of quality in India
Those who say “China” also have to say
“India.” Not long after its successful trip to
China, in March the top team from KHS, now
with KHS CTO Prof. Dr.-Ing. Matthias Niemeyer
mony
welcome cere
color: Indian
of
ot
of.
sp
Pr
a
d
ng
Addi
pervisory Boar
of the KHS Su
for chairman
ann.
z Jörg Fuhrm
Dr.-Ing. Hein
on board, paid the KHS production plant in
Ahmedabad in India a visit to inspect the
quality of production and the machines
manufactured there. The modern production
plant covering an area of 110,000 square
meters (over a million square feet) has been
in operation since 2007 and considerably
increased production capacities for KHS in
India. KHS has taken the growth potential
in this region into account, as well as the
t)
m righ
(2nd fro
eing
b
meyer
ie
ts
c
N
u
s
ia
rod
Matth
f the p
r.-Ing.
abad.
ality o
Prof. D
Ahmed
igh qu
h
in
e
t
n
th
g
pla
in
S
H
in
K
m
exa
at the
ctured
manufa
increasing demand on other Asian markets.
KHS India is also now strengthening ties to
and boosting support for its clients through
its KHS Academy, described as unique, where
Goblej site in Ahmedabad, where KHS had
the KHS delegation as to the astounding
business partner employees can complete a
recently installed a technologically pioneering
perspectives their company group has in
practical course of study as graduate engi-
PET bottling line with an output of 36,000
I ndia. Everybody parted on the best of
neer trainees or GETs.
bottles per hour. Coca-Cola India was very
terms and promised to meet again soon.
The journey came to a (customer-
pleased with both the quality and efficiency
For in India it is fittingly said that “A smile
orientated) close at Coca-Cola India at the
of the line in daily operation and informed
you send will always return”.
| In-house News |
Optimized Flows
Process optimization at the KHS Kleve plant in Germany. Processing time cut by 30% //
With the focus on customer requirements, the departments in charge of processing at the
KHS Kleve plant began an in-house campaign to optimize processes – with impressive results. Processing times have been cut by a third. The following tells the success story of
a successful team.
N
othing is so good that can't get better. This often-quoted
processing followed mid-2008. Plant manager Karl-Friedrich Böhle
saying could be, as it were, the guiding principle behind a
sums up their task as follows: “The project team had to analyze and
project that caused a stir at the KHS Kleve plant which spe-
optimize all production processes. No more, no less”. Timeline of
cializes in high-quality packaging machines. Wholly consistent with
the KHS company philosophy, “that the constant improvement of
the procedure.
processes and products is one of the most noble duties of a con
_1. Taking stock: processes and areas. Firstly, colleagues (they
sistently customer-oriented and quality-oriented group like ours”,
deliberately opted not to employ external management consul-
to quote Dr.-Ing. Johann Grabenweger, chief operations officer, the
tants) examined the current state of the production processes
project team from the Lower Rhine came up with some amazing
which had evolved over the years. An additional factor was the
results. This even surprised long-serving members of staff. Already
available space.
constantly improved over the years, production processing times
were further cut from about twelve weeks to a fantastic six to eight
weeks.
_2. Analysis: considerable potential for optimization. It very soon
became clear to the experts that the structures had not really kept
The whole project started way back in 2007. The financial
pace with the neck-breaking speed of market demand in previous
prosperity of those years and the fast-moving process of globaliza-
years. They were no longer appropriate in the contemporary
tion brought about a noticeable increase in customer demands for
situation and held great potential for optimization. At first, the
high-quality packaging machines at attractive prices and with short
challenge was to stop seeing the concept in terms of the existing
delivery times. The first step at the Kleve plant was to optimize
building structures and, instead, to think only in terms of the
workplaces according to the recognized MTM (Methods, Time, Meas-
processes.
urement) method. Mobilization of all departments involved in
54 55
KHS relies on duality
The perfect way
_3. Objective: compact, streamlined production. Using
Those familiar with German engineering terms and abbreviations
know that NIRO is synonymous with stainless steel. NIRO, however,
individually optimized workstations, the aim is to bring
also means something else. It also stands for Netzwerk Industrie
the production process and operating material flows
RuhrOst (Network of Industry in the Eastern Ruhr), a regional net-
as close together as possible. Materials of a suitable
work of 61 companies in the mechanical engineering, metal, and
quality and quantity should be stored directly at the
industrial electronics sectors. The goal of the partnership is to
component assembly site, dispensing with temporary
strengthen the competitiveness of the Eastern Ruhr as an industrial
storage as far as possible.
area at both a national and international level.
Within this alliance, NIRO member KHS is investing in the pro-
_4. Implementation: getting things moving. Having
motion of young talent. There are currently six trainees in mechatronics
started with plans for massive building extensions,
and two employees who have completed their training in mechani
when the project team took a closer, more critical
cal engineering at the Hessische Berufsakademie (Hesse University
look, they realized that the structure of the existing
of Cooperative Education) in the Unna district while continuing to
building would just about be adequate. In the end,
work. KHS is financing their studies which will lead to a Bachelor of
only a few smaller extensions and alterations were
Engineering after six semesters. The graduates intend to then work
needed in order to implement the project. The basic
as engineers, preferably at KHS.
principle was to keep the component moving onto the
Dr.-Ing. Johann Grabenweger, a member of the KHS GmbH
next assembly area in fixed intervals (cycles), therefore
Executive Management Board and a member of the Executive Board
ensuring completion by the time it reached the com-
of NIRO, feels dual training like this benefits both sides. ”The gradu
missioning section. This required a optimized logistics
ates don't only get their degree courses funded; they also have a
process, including the close integration of suppliers.
regular income and gain valuable professional experience. On the
This meant doing away with the central warehouse
other hand, the company training them has plenty of time to get to
almost entirely. A high level of standardization was
know the budding engineers and to integrate them into its systems,
prerequisite; here, previously modularized products
and they are usually subsequently hired. This is the ideal way to
greatly aided implementation from a design stand-
secure and keep a highly motivated, talented workforce.”
point.
_5. The result: optimum flow production. In an ideal
KHS is the company responsible for offering the special mecha
tronics course. According to Matthias Auferkamp, training manager at KHS in Dortmund, ”It was working together with other
scenario, the processing time of a standard machine
companies at NIRO which enabled us to get enough young people
is reduced from twelve weeks to about six or eight
together to be able to set up the first course of this kind in North
weeks since processes are now organized in a more
Rhine-Westphalia.”
targeted manner. The process begins with technical,
order-related issues. Parts of the required quality
More information | www.hessische-ba.de and www.ni-ro.de
must then be provided at short notice on site by the
suppliers. It culminates in a smooth-flowing production process located right at the end of the chain.
The temporary storage of semi-finished products
(components) has almost been completely eliminated,
thanks to processes which have been grouped together
in certain areas. Inventories have also been greatly
reduced. At the same time, heavily standardized
production processes and selective testing procedures
ensure high quality assurance in production.
Clemens Hannen | KHS GmbH, Kleve, Germany
Phone: +49 (2821) 503 -198
Good prospects when starting out as engineers with KHS: student trainees
Patrick Neitzel (left) and Raik Rose.
Service & Dialog
KHS working for customers all round the world
Competence for the
Next Generation
Making the most of system production // With a special graduate engineer trainee or
GET program, KHS India is training customer staff up in both theory and practice.
At the KHS Academy in India, 25 young engineers at Coca-Cola India have now successfully
completed a three-week training course.
At KHS, the emphasis has always been on a holistic approach to system design, closely geared towards the
interest of its customers. Worldwide. With this firm
promise in mind, in late fall 2009 twenty-five young
Coca-Cola engineers embarked on their graduate engineer training at the KHS Academy in Ahmedabad, India.
This was preceded by an order from Coca-Cola India to
KHS India for a 36,000-bph PET bottling line for the
Goblej site in Ahmedabad – a mere 40-minute drive away
from the KHS production plant.
At the KHS Academy, described as unique in India,
the graduate engineer trainees or GETs completed an
initial three-week course on the theory and practice of
Added value for the customer: GETs (graduate engineer trainees) and
teachers at the KHS Academy India during qualification.
beverage bottling and packaging. This stage in the training program (two more are to follow in 2010) is focused
primarily on
_the basics and principles of line and machine operation, from filler to labeler,
_pneumatic systems of all kinds, and
_further correlations between constructional elements,
software, and principles of operation.
“Our KHS Academy,” says Sharma, “gives our customer‘s
up-and-coming engineers plenty of positive, targeted
impetus for a qualified professional career. This will
also benefit KHS.” And G.S. Raghu, technical and quality
region manager at Coca-Cola India, praises “the extraordinarily positive feedback and great educational poten-
KHS sees the three-stage program, headed by experi-
tial” the GET program has already unleashed among the
enced KHS experts both at the training center and on
future quality elite at this initial and early stage. KHS‘
the running line, as a perfectly natural addition to the
holistic approach is obviously bearing fruit.
services it provides its customers with. A good two years
after the start of production at KHS India in Ahmedabad,
KHS Director Yatindra R. Sharma is pleased with the very
good general response to the trainee program, both
among the certified graduates and the top management
of Coca-Cola India (whose claim is “Little Drops of Joy”).
Partho Ghose | KHS Machinery Pvt. Ltd., Ahmedabad, India
Phone: +91 (79) 661- 00073
56 57
Trade Shows
_Novi Sad Agricultural Fair, Novi Sad, Serbia
May 15–22, 2010
_China Brew & Beverage, Beijing, China
_Beer, Sochi, Russia
_Fachpack, Nuremberg, Germany
May 19 – 22, 2010
_Interfood, Astana, Kazakhstan
_Japan Pack, Tokyo, Japan
May 27–29, 2010
_Iran Food & Bev. Tec, Teheran, Iran
May 30 – June 2, 2010
_Korea Pack, Goyang, Seoul, South Korea
June 1– 4 , 2010
October 5 – 8 , 2010
_K-show, Düsseldorf, Germany
October 2 7 – N ovember 3, 2010
_Asia Food & Bev Tech, Mumbai, India
October 29 – 31, 2010
_FISPAL, São Paulo, Brazil
_Pack Expo, Chicago, United States
June 8 – 11, 2010
October 31– N ovember 4, 2010
_Auspack, Sydney, Australia
_BRAU Beviale, Nuremberg, Germany
June 16 – 19, 2010
November 10 – 12, 2010
_Pro Pak Asia, Bangkok, Thailand
_drink technology India, Mumbai, India
June 16 – 19, 2010
November 18 – 20, 2010
_Expo Pack, Mexico City, Mexico
_EMBALLAGE, Paris, France
June 22–25, 2010
November 22–26, 2010
_ProPack China, Shanghai, China
_Propak Indonesia, Jakarta, Indonesia
July 14 – 16, 2010
December 8 – 11, 2010
Addresses
KEEPING YOUR LINE RUNNING IS WHAT WE STAND FOR.
Long lasting, safe, and efficient: Original spare parts from KHS.
KHS GmbH
Juchostrasse 20
44143 Dortmund, Germany
Phone: +49 (231) 569 - 0
Fax:
+49 (231) 569 -1541
Planiger Strasse 139 -147
55543 Bad Kreuznach, Germany
Phone: +49 (671) 852- 0
Fax:
+49 (671) 852- 2411
Enzingerstrasse 139
67551 Worms, Germany
Phone: +49 (6247) 97- 0
Fax:
+49 (6247) 97-3215
Ruwoldtweg 14
Phone: +49 (40) 63703 -37100
Fax:
+49 (40) 63703 -37150
Boschstrasse 1-3
47533 Kleve, Germany
Phone: +49 (28 21) 503 - 0
Fax:
+49 (28 21) 26110
Kapellenstrasse 47-49
65830 Kriftel, Germany
Phone: +49 (6192) 491- 0
Fax:
+49 (6192) 491-144
KHS UK Ltd.
Unit 6 Monkspath Business Park,
Highlands Road, Shirley, Solihull
West Midlands B90 4NY, Great Britain
Phone: +44 (121) 713 - 6900
Fax: +44 (121) 713 - 6935
KHS Asia Pte. Ltd.
25 International Business Park
# 3-15/19 German Centre
Singapore 609916
Phone: +65 (6560) 9313
Fax: +65 (6560) 9910
KHS Corpoplast Gmbh & Co. KG
Phone: +49 (40) 67907- 0
Fax: +49 (40) 67907-100
For further information, visit www.khs.com/service
KHS Competence
KHS Plasmax GMBH
Phone: +49 (40) 67907- 364
Fax: +49 (40) 67907- 353
KHS USA, Inc.
880 Bahcall Court
Waukesha, WI 53186, U.S.A.
Phone: +1 (262) 797-7200
Fax: +1 (262) 797- 0025
5501 N. Washington Blvd.
Sarasota, FL 34243, U.S.A.
Phone: +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
Phone: +61 (393) 35 -1211
Fax: +61 (393) 35 -1331
KHS Machinery Pvt. Ltd.
15, Madhuban, Nr. Madalpur Underbridge, Ellisbridge,
Ahmedabad - 380 006, India
Phone: +91 (79) 2644 - 0331
Fax: +91 (79) 2644 - 5146
Information for ordering
KHS Competence is published in German,
English, French, Spanish, and Russian. Those interested can order further copies of the magazine
at www.khs.com.
PUBLISHER
KHS GmbH, Dortmund
EDITORS
jj-media Cologne; Dr. Arno Lammerts;
Manfred Rückstein; Friederike Arndt;
mcpr – meiner corporate pr, Grafschaft;
pr+co., Stuttgart
GRAPHICS
Konzeption+Design, Trawny / Quass von Deyen, Cologne
Layout: Nicole Bock, Yvonne Voss
CONTRIBUTIONS
Alfons Abels-Rümping, Wolfgang Augel, Ludwig Clüsserath,
Harald Eisenacher, Ulrich Fischer, Partho Ghose,
Hennie van der Graaf, Frank Haesendonckx,
Clemens Hannen, Jürgen Herrmann, Heinz Hillmann,
Herman Miseur, Edgar-George Petsche, Dr. Felix Wagner
TRANSLATIONS
Fachübersetzungen CP MacKusick GmbH & Co. KG
PHOTOS / ILLUSTRATIONS
Friederike Arndt, beltsazar/shutterstock, Jürgen Eberl,
Caro/Muhs, Keith Naylor/shutterstock, Peter J. Obenaus,
Privat-Brauerei Heinrich Reissdorf,
Jörg Schwalfenberg Photography, Bek Shakirov/Corbis,
Teusser Mineralbrunnen/Löwenstein
This information is non-binding. Only the technical
specifications of our quotes are determinative with
regard to design and scope of delivery.
Subject to design modifications.
30 1992-01-992/2 0510 SK
Competence
in Solutions
Focus on Solutions
Interview
Rhodius Mineralquellen:
keg line for slim kegs
The Big Five – what customers want:
InnoPET BloFill with plenty of new advantages
The wheels of change:
Hanni Rützler on food trends
FOCUS ON
QUALITY
KHS worldwide. For further addresses and contacts, visit
www.khs.com
Innocheck CCI crooked cap inspection for PET bottles:
safe, incorruptible, and precise right down the line,
this is high-tech with a sure eye for precision.

solutions KHS

Transcription

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